Tag Archives: MissionZero

FLSmidth takes gravity separation to a new level with Knelson GX Concentrating Cone

The latest innovation in semi-continuous gravity separation from FLSmidth is delivering a key breakthrough in performance that increases recovery and cuts maintenance downtime, according to the OEM.

For decades, Knelson gravity concentrators have been recognised for their recoveries of gold and precious metals, but the development of the new Knelson GX Concentrating Cone is set to take this performance a step further.

The new patented GX Cone delivers impressive recovery enhancements due to enhanced water distribution within each ring, according to the company.

FLSmidth explains: “As water enters from the base, it flows through zone separator nozzles for a customisable fluidisation profile. This allows for even distribution of water in each ring; the new design also significantly increases the active recovery surface area. The result is a step change in overall coarse and fine gold recovery.”

Test data shows that gold recovery in all size fractions, from course to fine, improved significantly with the GX Cone, according to the company.

By incorporating an advanced distribution of fluidisation water across the entire concentrating cone, the Knelson GX facilitates the highest possible recovery of coarse and fine gold. At the same time, balanced water distribution across the concentrating cone allows for a significant reduction in fluidisation water requirements while improving recovery.

The third major benefit of the Knelson GX is easier maintenance. Because it is made of a customised, abrasion-resistant and durable polyurethane compound, maintenance frequency and operational costs are significantly reduced, FLSmidth says.

Mike Lefler, Head of Global Product Line Manager for Precious Metal Recovery at FLSmidth, said: “The new Knelson GX Concentrating Cone is the culmination of over 40 years of research and operational experience and is exciting news for our customers. It delivers a win-win-win scenario: better recovery, less water use and less downtime due to easier maintenance.

“In short, it helps customers produce more with less resources – a central tenet of our MissionZero ambition to cut water and energy waste in mining by 2030.”

FLSmidth to deliver dry-stack tailings solution at Hindustan Zinc’s Rajpura Dariba mine

FLSmidth has been contracted to deliver an integrated dry-stack tailings solution and a paste fill plant to Hindustan Zinc’s lead-zinc mine in Rajpura Dariba, Rajasthan.

The solution will ensure environmental sustainability and significant process water recovery, as well as reduce the footprint of the tailings storage facility, the mining OEM said.

The new order, which was booked in the December quarter, includes design, engineering, procurement, supply of equipment and the commissioning for integrated dry tailings and stacking along with tailings paste fill plant. FLSmidth will also supply two Automatic Filter Presses (AFP-IV™, pictured), two E-Disc filters and one 26 m diameter High-Density Thickener as the main pieces of equipment. The project is expected to be completed by February 2022.

This new order follows a previous tailings-related order for Hindustan Zinc at its Zawar mine site in 2018.

Hindustan Zinc operates beneficiation plants at Rajpura Dariba and Sindesar Khurd, which both discharge tailings to the same tailings pond. The tailings dam was reaching capacity for conventional wet tailings deposition and so Hindustan Zinc needed a way to resolve this issue, FLSmidth said.

The solution the company required would involve creating a small dry-stack tailings area with minimal environmental and physical footprint and also a method to backfill the mine by using an adjusted dry filter cake mix.

By choosing FLSmidth’s hybrid technology – a combination of the E-Disc filter and the AFP-IV Automatic Pressure Filter – Hindustan Zinc will now be able to achieve this and recover around 85% of process water, according to FLSmidth. This recovered process water can be reused by the process plant located at the mine site with minimum operating and capital expenses.

The cake from the E-disc filter will contain below 16% moisture and can be used for mine backfilling, while the cake from the automatic filter press, with below 12% moisture, can be stacked on the surface in a safe and compact manner, FLSmidth says.

“The solution will also significantly reduce industrial water consumption, something that is of heightened importance in water-scarce areas, such as Rajasthan,” the company said. “The site will also have zero effluent discharge, further boosting its sustainable mining goals.”

Manfred Schaffer, Mining President, FLSmidth, said the order was another strong “proof point” for the quality and flexibility of the company’s technology for filtration and engineering solutions for tailing management.

“This project resolves the customer’s challenge through optimum utilisation of available space and ensures the paste backfill requirements are met with the lowest possible operating and capital costs,” he added. “Importantly, it also secures a high level of reusable water for the mine site, which helps their sustainability efforts and supports our own MissionZero ambition.”