Tag Archives: mineral separation

Bunting ups the design ante with new Permanent Crossbelt Overband Magnet optionality

Comminution of minerals, Mining equipment, Mining services, Sustainable mining, , , , , ,

Bunting says it has developed three designs of Permanent Crossbelt Overband Magnet (PCB), with different magnetic polarity, to suit an ever-expanding range of applications.

Overband Magnets are mounted over conveyors to separate ferrous metal from non-magnetic material and are commonly used in industries, including mining.

The magnetic field of a Permanent Crossbelt Overband Magnet (PCB) is generated by charging ferrite or rare earth magnet blocks mounted inside a stainless steel box with a steel back bar. The steel bar back forces the magnetic field to propagate through and out of the bottom of the magnet box, which would be down towards a conveyor transporting bulk materials. Although all three designs operate under this basic principle, that is where the similarities cease.

The magnetic field of the three designs of PCBs is defined as being either a ‘Single Pole’, ‘Twin Pole’ or ‘Tri-Pole’.

The Single Pole design (PCB Single Pole) is the simplest and most common design of PCB. Constructed with a single magnet block and steel back bar, the north pole sits on the back bar with the south pole at the bottom of the block. The field runs vertical, from north to south, projecting out from the south pole and into material being transported on a conveyor. The Single Pole design removes general tramp metal from a range of products in various applications.

A Twin Pole (PCB Twin Pole) configuration uses two separate magnet boxes, mounted side by side on a single steel back bar, each with a different magnetic pole. The magnetic field flows from south to north (from one box to the other) producing a deep magnetic field that projects away and down from the magnet faces.

The enhanced separation performance of the PCB Twin Pole enables capture of smaller ferrous particles. The twin pole configuration has the advantage of lifting longer and thinner tramp ferrous metal, typically steel rebar, in a flat orientation which aids discharge and reduces belt wear. This characteristic of the Twin Pole occurs due to the different poles of the two magnet boxes attracting opposite ends of the ferrous metal rod, forcing it to remain flat in the field. The Single Pole design attracts one end, resulting in one end striking the belt or face of the magnet box.

The Tri-Pole Permanent Crossbelt Overband Magnet (PCB Tri-Pole) has two additional steel side poles mounted either side, with a gap, of a single central magnet box. Each of the side poles has a magnetic north pole, with the centre of the box being south pole (ie three poles). This generates two magnetic fields running from the box to the steel sidepoles. The sidepoles reduce flux leakage and concentrate the magnetic field downwards toward the product.

The greater depth of magnetic field generated by the PCB Tri-Pole results in a higher suspension height of the Overband Magnet, which is ideal for deeper troughed conveyors and higher burdens of material, Bunting says. The Tri-Pole model captures smaller ferrous metals that are difficult to separate with a PCB Single Pole.

An added advantage is that the shape and direction of the magnetic field limits any magnetisation of the Overband Magnet frame.

Metso teams up with Anglo American to develop ‘breakthrough hydrocyclone technology’

Comminution of minerals, Mineral processing, Mining equipment, Sustainable mining, , , , ,

Metso says it has launched a “breakthrough hydrocyclone technology” in the form of the MHC Hydrocyclone Curved Bottom (CB), a cyclone designed for superior particle separation with increased unit capacity and coarser cut sizes while minimising the fines bypass.

The MHCTM CB hydrocyclone is ideal for grinding circuit classification – from primary to fine grinding – and for a full range of mineral types, according to Metso. It is highly compatible with dewatering and desliming applications, and relevant to both greenfield and brownfield projects with a design that makes it easy to retrofit into existing hydrocyclone clusters.

Ben Klein, Product Group Manager of Hydrocyclones at Metso, says: “The design of the MHCTM CB is based on the proven MHCTM Hydrocyclone but upgraded with new innovative features, making it a true breakthrough technology for the classification process. Thanks to this unique patented design, the new hydrocyclone offers higher unit capacity compared to standard hydrocyclone technologies. The MHCTM CB is also capable of producing coarser overflow products for a given hydrocyclone size, allowing for greater flexibility in classification and especially beneficial to new coarse particle flotation circuits. Finally, it provides enhanced classification efficiency by minimizing unwanted fines and water in the underflow.”

The solution was developed in partnership with Anglo American, which has worked with Metso since the onset in investigating improvement in hydrocyclone classification, according to Klein.

“Anglo American has provided support with both large-scale laboratory and pilot testing to prove the technology,” he explains. “Imperial College has also provided support in bringing this concept to light and in confirming the validity of this new technology as a third party.”

Metso is promoting this product for a variety of applications including, but not limited to, lithium, gold, aggregates, nickel, magnetite, hematite, limestone, aluminum, zinc, molybdenum and silica.

Thanks to its energy efficiency and reduction in CO2 emissions compared with similar wet classification technologies, the MHCTM CB hydrocyclone has been approved as part of Metso’s Planet Positive offering.

Eriez packs more strength into smaller footprint suspended electromagnets

Comminution of minerals, Mineral processing, Mining equipment, , ,

Eriez® has announced the launch of its new SEV series of Suspended Electromagnets, representing, it says, a significant advancement in suspended electromagnet design.

These units feature stronger magnets housed in smaller enclosures, reducing overall weight and installation costs while optimising performance efficiency, the company says.

Integrated into the Eriez SE7000 line, the new SEV models leverage cutting-edge wire and conductor technology to energise the magnet circuit, also requiring less coolant for operation. The new wire configuration, boasting an ultra-thin anodised insulation layer, provides superior thermal conductivity, ensuring high heat dissipation within the circuit for improved magnet performance. Despite the compact size, these magnets deliver performance that surpasses larger counterparts, guaranteeing consistent and reliable operation, Eriez says.

Dave Heubel, Eriez Global Magnetics Product Manager, said: “As part of our commitment to continuous improvement, we’ve succeeded in packing more magnet strength into a smaller footprint, thereby lowering costs and boosting productivity for customers through streamlined installations and more stable, dependable performance.”

Eriez also offers self-cleaning versions of all SEV models. Additionally, a variety of options are available, including dust hoods, coils derated for elevation, high fire point coolants, armour-clad belts and numerous other customisable features for every unique application.

Bunting develops UK’s ‘largest DC impulse industrial magnetiser’ at Redditch facility

Comminution of minerals, Mineral processing, Mining equipment, Mining services, Steel and iron ore, , , ,

To meet the increased demand for magnetic separators following a sustained period of sales growth, Bunting has redesigned and refurbished the industrial magnetiser at its Redditch manufacturing facility in the United Kingdom. The enhancements make this DC impulse industrial magnetiser the largest in the UK, outside of academia, it claims.

Bunting is a leading designer and manufacturer of magnetic separators, eddy current separators, metal detectors and electrostatic separators. The Bunting European manufacturing facilities are in Redditch, just outside Birmingham, and Berkhamsted, both in the UK.

At the Redditch manufacturing operation, Bunting’s industrial magnetiser charges permanent magnet assemblies used in overband magnets, drum magnets and pulley magnets. The magnet assemblies are built in an uncharged state and then placed within the magnetiser for charging to create a focused and specific shape of magnetic field. The nature of this created magnetic field dictates how the magnetic separator will separate ferrous metals and magnetically susceptible materials from non-metallic materials as in the recycling, mining and quarrying sectors.

Bunting’s operations team continually review manufacturing processes for improvement opportunities and highlighted key benefits of upgrading the industrial magnetiser. These included significant operating efficiency improvements, which would support the continued sales growth.

The extensive refurbishment involved a complete mechanical and electrical overhaul. However, production demands dictated the time allowed for the refurbishment was limited to a maximum of 10 days.

The Redditch impulse industrial magnetiser is rated at 50 kW, drawing a continuous amount of DC current from the mains power. Each energising phase lasts for only 10 seconds and generates approximately 500 kJ of energy. The 12 t magnetiser stands 1.5-m tall on a 3 x 2-m footprint.

Since the upgrade, magnetisation of a magnet assembly requires significantly less ‘magnetic hits’, reducing the energy consumed by the magnetiser by over 30%, Bunting explains. The quicker magnetising process results in freeing production resource, accommodating the extra demand creating through sales growth. The size scope of chargeable magnet assemblies has also increased up to 2,000 x 1,400 x 400 mm, weighing approximately 5 t.

Adrian Coleman, Bunting’s European Engineering Manager, said: “Magnetising is a key stage within our manufacturing process and with the magnetiser refurbishment we are able to magnetise quicker and more efficiently than previously. The result is increased manufacturing capability and the ability to magnetise larger magnet assemblies.”

FLSmidth out to optimise closed-circuit grinding operations with KREBS SmartCyclone tech

Automation, Comminution of minerals, Mineral processing, Mining equipment, Sustainable mining, , , , , , , , ,

Efficient operation and minimal downtime are crucial for maintaining productivity and profitability in grinding circuits and, to address these challenges, many operations are opting for the KREBS® SmartCyclone™ technology from FLSmidth, according to the OEM.

Abrie Schutte, Senior Applications Engineer at FLSmidth responsible for the KREBS pumps cyclones and valves product business line, says this innovative technology combines advanced monitoring and automation features to optimise closed-circuit grinding operations.

“SmartCyclone integrates various components and software to provide a comprehensive solution for grinding circuit management, and significantly incorporates roping sensor technology, wear detection technology, a wireless controller system and ECS/ProcessExpert® process control software,” Schutte says. “End-users have found that by leveraging these elements, maintenance planning is enhanced, wear reduced and there is an overall improvement in grinding circuit performance.”

The wear detection technology of SmartCyclone employs specialised sensors to monitor the wear status of cyclone components. This real-time information enables operators to proactively plan for part replacements and schedule maintenance activities, minimising unexpected downtime caused by component failures.

Schutte further explains that an automated monitoring system is a key feature of SmartCyclone.

“This is important as it allows operators to detect wear and troubleshoot issues from a centralised control room, eliminating the need for manual equipment inspections with a reduction in associated risks,” he says.

By promptly identifying and addressing potential problems, process disruptions are minimised, ensuring optimal performance of the grinding circuit.

The SmartCyclone system also includes a roping detection feature, which identifies and corrects disturbances known as “roping”. Overloaded cyclones or those experiencing roping can lead to increased bypass of coarse solids to the overflow and greater particle size variation.

“This accumulation of slurry can adversely affect downstream equipment, such as flotation cells,” Schutte says. “By monitoring and detecting roping, operators can confidently operate the plant closer to its limits, thereby increasing production capacity and improving mineral recovery.”

By integrating SmartCyclone with ECS/ProcessExpert software, the grinding circuit’s performance can be further optimised, according to FLSmidth. The system dynamically adjusts variables such as water addition, pump speed and the number of operating cyclones based on real-time data from SmartCyclone sensors. This continuous optimisation enhances particle size distribution, maximises mineral recovery and improves the overall efficiency of the grinding circuit, it says.

SmartCyclone offers a comprehensive solution for closed-circuit grinding operations, FLSmidth says. By leveraging advanced sensor technologies, automated monitoring and process control software, this system empowers operators to enhance maintenance planning, reduce wear and optimise the performance of their grinding circuits.

Schutte concluded: “With its ability to detect early warning signs, troubleshoot potential issues and dynamically adjust variables, SmartCyclone sets a new standard for smart and efficient grinding circuit management.”

Multotec spirals helping assess heavy minerals potential in Cameroon

Comminution of minerals, Energy minerals, Mineral processing, Mineral project development, Mining equipment, Mining services, , , , , , , ,

Exploring for heavy minerals in Cameroon, a multinational mining company is gaining valuable results and insights through the use of an on-site pilot plant from South Africa-based process equipment leader Multotec.

The pilot plant was designed and assembled at Multotec’s extensive design, manufacturing and testing facilities at Spartan near Johannesburg, South Africa, and shipped to the remote site in central Africa last year. The containerised plant includes a range of Multotec’s own equipment including screen panels, cyclone rig and spiral rig.

According to Faan Bornman, Technology Manager: Research and Development at Multotec’s Technology Division, drill samples from the prospect area are passed over the screen to remove oversized material, with undersize going into a sump to be mixed with water to the correct density. The undersize material reports to the cyclone for desliming – the removal of very fine particles – delivering an underflow with an optimal size range of between 38 microns and 1 mm. This is fed to the spiral rig for concentration, with the spiral delivering a concentrate, middlings and tailings. The process allows the project to assess its economic heavy minerals portion, which is concentrated towards the inner section of the spiral.

“Multotec’s HX5 and 117HM spirals were employed to suit the customer’s requirement, with the new 117HM spiral showing great recovery in mineral sands,” Bornman says. “With the HX5 handling up to 5.5 t/h and the 117HM 2.3 t/h, these spirals also offer different recoveries and grade in the various heavy minerals.”

The equipment in this pilot plant is vital to achieving an accurate assessment of the deposit’s viability, but the results also give the customer important insights into how the full-scale plant should be designed if exploration proves results provide positive, according to Multotec.

“To ensure that the customer receives optimal value from the pilot plant, we sent a process engineer to site to commission the system,” Bornman says. “During the several weeks that he spent there, he also conducted training with local staff on how to run and maintain the plant.”

Metso Outotec highlights magnetic separation expertise

Comminution of minerals, Mineral processing, Mining equipment, Mining services, Steel and iron ore, , , , , , ,

Metso Outotec has introduced a magnetic separators portfolio that, it says, caters to a wide variety of applications with the separators’ flexible modular design enabling superior separation selectivity and improved recovery of fine and ultra-fine particles.

Metso Outotec High Gradient Magnetic Separators are designed to recover weakly magnetic material from non-magnetic matter and can be used for many applications including the processing of iron ores, rare earths and other weakly magnetic minerals, which are not normally treatable by ordinary magnetic separators.

The Low Intensity Magnetic Separators, which are designed to recover magnetic material from non-magnetic matter, are part of Metso Outotec’s Planet Positive product offering. The separators use physical separation and require no chemicals in the process. The Low Intensity Magnetic Separators feature modular design with several frames and process tank designs and use a common magnetic drum for ease of selection of the best machine for each individual application, the company says.

Metso Outotec’s offering also includes the SLon® Vertically Pulsating High-Gradient Magnetic Separator, which processes fine, weakly-magnetic minerals. The units are wet, high-intensity magnetic separators that use a combination of magnetic force, pulsating fluid and gravity to process minerals.

Jan Jirestig, Product Manager, Magnetic Separators, Metso Outotec, says: “We have a long history in magnetic separation, and we delivered the first separator back in the 1890s. Since then, we’ve developed and delivered thousands of magnetic separators worldwide. We are continuously developing our products, securing our position at the forefront of the magnetic separation industry.”

MBE Minerals ready to boost coal processing efficiencies in South Africa

Coal technology, Comminution of minerals, Mineral processing, Mining equipment, Mining services, , , , , , , ,

As South Africa continues to work hard to contain the cost of its coal-fired power generation, MBE Minerals SA is stressing the importance of efficiencies throughout the value chain – not least in beneficiation.

The continuous improvement in coal beneficiation technology and regular equipment upgrades in plants will become more important, according to the company’s Managing Director, Johannes Kottmann.

MBE Minerals, which has over a century of experience in the coal sector, has built up a wide footprint of vibrating screens in Africa for sizing, scalping, dewatering and media recovery. It also provides destoning solutions to customers.

“Among the company’s innovations is the side plate mounted drive, a much lighter option to using vibrator motors,” Kottmann says. “The screens can also be supplied with vibrator motors, if necessary, while resonance screens offer the added benefit of lower power consumption.”

All types of screening surfaces can be accommodated, with each screen incorporating mechanical design features such as vibration dampening, side plates, cross members and the appropriate feed and discharge chutes.

Kottmann highlights that MBE Minerals is actively engaged with developments in coal beneficiation technology through its international network, including the MBE Coal and Minerals’ Research and Development Centre in Cologne, Germany.

“This centre consults with customers globally in terms of optimum processing solutions, with the support of an in-house laboratory and pilot test work facilities,” he says. The centre also offers customer training, which can range from general mineral processing to maintenance of MBE Minerals’ equipment.

In addition to designing, engineering and supplying equipment, MBE Minerals conducts projects on a turnkey or engineering procurement and construction basis, he notes. The company can also operate complete coal processing plants.

MBE is well known for its BATAC® jig technology, which, the company says, delivers high separation efficiencies and improved product quality, as well as high availability and throughput. This technology’s ease of operation, robust design and economical maintenance cost have also been important factors in its success.

The company developed the BATAC jig to overcome the limitations of early stratification technologies, which achieved separation either by moving the entire jigging bed screen or through water pulsation generated in an air chamber beside the jigging bed.

“The separation accuracy of BATAC jigs is due to electronic control of the air pulse generator and sensing of the thickness and densities of the material layers being separated,” Kottmann says. The under-bed pulsated BATAC jig has proved ideal for coarse applications from 150 mm down to fine coal in the 10 to 0.5 mm size range, with throughput rates of between 100 and 1,200 t/h, the company claims.

MBE Minerals has also developed a solution for destoning raw coal – the ROMJIG® – which has produced impressive results in extensive testing around the world, it says. It achieves an overall reduction in the stone handled, Kottmann says, and there are indications of a lower percentage of refuse in the washery feed.

“This allows costs to be saved in a number of areas, such as reduced wear on machinery and transporting equipment, less grain degradation, and less dust and slurry,” he says. “It also means that flocculation consumption is reduced, along with flotation agents in downstream fines recovery circuits.”

The range of vibrating screens manufactured by the company includes dimensions up to 3.6 m in width and 6.75 m in length; they come in single or double deck configuration and with either circular or linear motion. They have been operating in the African mining industry for the past 40 years.

“We ensure that each application, whether greenfields or brownfields, is carefully assessed in conjunction with the customer, during a comprehensive engagement process to determine the optimum solution,” Kottmann says. Services available include detailed engineering, feasibility studies, raw material testing, financing concepts, erection and commissioning.

Components – as well as automation and process control equipment – can be supplied and installed for complete plants and systems. Measures to modernise plants or improve capacity can also be proposed. The company’s scope of services includes personnel training, along with pre- and post-sales services and support.

Flowrox expands Central Europe reach with German subsidiary

Comminution of minerals, Mineral processing, Mining equipment, Mining services, Water management, , , , , ,

Finland-based Flowrox has strengthened its operations in Central Europe by opening a new subsidiary, Flowrox GmbH, in Ratingen, Düsseldorf, Germany.

Jukka Koskela, President & CEO of Flowrox, said the new subsidiary was of strategic importance to the flow control, process automation, environmental and solid-liquid separation technology specialist.

“For years we have been operating in Central Europe through representatives,” Koskela said. “Our offering has recently expanded, and we also provide complete industrial solutions. That is why we feel it is crucial to be close to customers in this major market. By setting up a local operation in Central Europe, we can better support our customers and representatives with local projects, sales and services.”

Dirk Otto has joined Flowrox as Managing and Sales Director, Central Europe. Otto has a strong background in process technology and solid-liquid separation, according to Flowox. Before joining Flowrox, Otto worked with leading companies  in the field such as Larox, Clear Edge Filtration and Ipsen International.

With the opening of this new branch, Flowrox now has 10 subsidiaries located in Australia, Chile, China, Finland, Germany, Peru, Russia, South Africa, Sweden and the US, as well as more than 230 sales representatives in over 80 countries.

Weir Minerals strives for unmatched hydrocyclone performance with release of Cavex 2

IoT, Mineral processing, Mining equipment, Mining services, Sustainable mining, Water management, , , , , , , , , , , , ,

Almost 25 years after the original Cavex® hydrocyclone came into the classification market, Cavex 2 is set to introduce a step-change in performance and sustainability, with water and energy savings, according to Weir Minerals.

The launch of Cavex 2 marks a new generation of hydrocyclones, Weir says. Like the original Cavex hydrocyclones did more than two decades ago, Cavex 2 introduces new geometric features to offer performance unmatched by any cyclone in operation today, the company claims.

Debra Switzer, Global Product Manager for Hydrocyclones at Weir Minerals, said: “Our Cavex 1 design set an industry benchmark over two decades ago with its unique 360° laminar spiral inlet geometry, which significantly reduced turbulence. This design was so successful and desired by the market that it was widely replicated by competitors.

“Following years of research, development and trials, we have improved upon this design with the creation of LIG+™ inlet and chamber design. This unique design produces a more stabilised flow pattern, further reduces turbulences and friction throughout the hydrocyclone and provides up to 30% additional capacity.”

The advanced LIG+ design (patent pending) enables the Cavex 2 hydrocyclones to classify up to 30% more feed slurry, while occupying the same footprint as competitor hydrocyclones, according to Weir. This allows operators to achieve more throughput with fewer operating hydrocyclones, reducing the upfront capital expenditure.

The new design has taken into consideration the shape and angle of the hydrocyclone to ensure particles report to the correct stream, Weir says. This reduces recirculation and misclassification, further improving separation efficiency.

“Cavex 2 allows our customers to do more,” Switzer says. “A more sustainable circuit, with lower energy and water requirements. Expand the capacity of their existing circuits, without increasing the footprint of the cyclones or clusters. It’s the kind of generational engineering leap that will change the way circuits are designed for decades to come.”

Cavex 2 takes advantage of Weir Minerals’ Synertrex® IIoT technology, which enhances the overall performance of the hydrocyclone. Armed with this technology, operators are automatically alerted to roping or blockage conditions ahead of time, ensuring the hydrocyclone runs under the most optimal operating conditions.

“To minimise the amount of bypass that is produced in any hydrocyclone, it is favourable for it to operate in the semi-roping condition,” Switzer said. “This is often difficult to do continuously because any upset in the hydrocyclone’s feed conditions could move it into the roping condition, but, with Synertrex, this balancing act can be closely managed.”

Cavex 2 hydrocyclones can be customised to suit almost any application, according to Weir, with a variety of spigots, vortex finders and liners. Liners are available in a range of material options, including Weir Minerals’ proprietary R55® rubber compound or Linatex® premium rubber, both of which have been proven to outlast competitors elastomers in similar applications, Weir says. Liners can be replaced via a ‘snap-in’ system requiring zero adhesive, while smaller models (400CVD and below) are available with moulded fibreglass housings, the company says.

Switzer concluded: “Every stage of the Cavex 2’s design has been guided by the needs of our customers. As a consequence, it has been tested in multiple mining applications throughout the globe. These tests revealed outstanding results of up to 30% additional capacity.

“Decreasing ore grades and increasing need to reduce both water and energy usage have created the need for a low maintenance, highly efficient hydrocyclone, which can be readily retrofitted into existing circuits to increase throughput and maximise returns.

“I can’t wait for our customers to see what this new range is capable of.”