Ote White Paper Debottlenecking of Thickeners
Ote White Paper Debottlenecking of Thickeners
White paper
DEBOTTLENECKING OF THICKENERS
IN A CHANGING ENVIRONMENT
Brad Parker, Thomas Rivett, Paul Backeberg, Andrew McIntosh, Sherif El-Masry and Alex Heath
Dewatering, Minerals Processing, Outotec Oyj
Abstract
Thickeners are utilized in mineral processing for the purpose of solid-liquid separation (dewatering). Thickeners separate
an incoming feed slurry (i.e. water with solid particles of either product or tailings material) into two distinct streams; one
consisting of clarified water and the second stream being a slurry concentrated with solids.
Thickeners, like most processing technology utilized in minerals processing, are fixed geometry equipment designed for
a specific throughput and duty. During the course of the thickeners’ life cycle, in excess of 20 years, they are commonly
called on to perform to new process requirements due to changing mineralogical circumstances, revised plant
performance criteria and external changes in the operating environment. In addition, aging equipment requires increased
levels of maintenance to prevent unplanned shutdown from occurring.
To meet these changing conditions, the operator has an option to upgrade, or modernize, the thickener to ensure it
continues to provide the required outcomes efficiently and sustainably. This white paper will discuss the modernization
options available for thickeners.
After a brief introduction to the thickening process we move on to discuss the global external pressures on mine
operators to give context to the discussion and elucidate the need for efficient resource use.
Next, we look more specifically at how these external influences impact the operator, then we briefly review the
options available to overcome these challenges, and we discuss the owner’s decision process: “Modernize or buy new
equipment?”
2
In assessing the decision to modernize, we consider the elements of an upgrade and the advances in thickening
technology that allow operators to meet new challenges.
Finally, we will discuss the process of modernizing a thickener so as to achieve the client’s stated outcomes. This includes
identifying the issues, working through an investigation process, testwork, and engineering prior to the delivery and
implementation of the modernization.
Key words
Thickener, modernization, dewatering, upgrade, tailings thickening, concentrate thickening, feedwell
1 Overview of the Thickening Process effectively predetermined as the available surface area
Thickening technology utilizes the principle of depends on the thickener’s diameter.
sedimentation as a cost effective method of solid-liquid
separation. Hence, while better control and operation is able to
improve the average performance of an existing thickener,
Sedimentation is used to thicken an incoming feed stream the ultimate performance is limited by the ability of the
to produce two phases: feed system to promote faster settling of the material and
so allow for more aggressive ‘sizing parameters’ – solids
• Overflow - a stream containing minimal solids loading and rise rate.
• Underflow - a stream containing minimal liquid
Consequently, improvements in thickener process
This is accomplished by a number of means inside the performance typically include efforts directed at improving
thickener: the feed system, from upstream of the thickener through
to the feedwell. How far upstream this takes place will
• Settling under the force of gravity depend on the plant itself, taking into account the effect of
• Addition of reagents such as flocculants, which are feed properties, combined streams and elevation changes.
mixed with the incoming feed to enhance gravity Any components not optimized will affect the efficiency of
settling such that it occurs faster or at a higher rate the settling in the thickener and therefore its capacity and
• Bed compression due to self-weight of material in the performance.
settled bed
• Mechanical raking to release water trapped in the
settled bed
2 External Influences
Compared to alternative technologies, sedimentation Business owners globally are facing macro forces that
using thickeners is capable of processing high volumes of affect their planning and daily operations and mine
slurry at a relatively low cost. owners are not immune to these trends. These external
challenges impose upon mine operators a new paradigm
During operation the two outputs, overflow and underflow, to ensure they meet society’s requirements to not only
are rarely prioritized simultaneously. The duty of the provide the raw materials for global growth, but also the
thickener will determine which of the two is prioritized. increasing demands to do so in an environmentally and
socially sensitive manner.
In tailings applications where recovery of water and
minimal-sized tailings storage facilities are desired, Thickeners in an operating mineral processing plant play
underflow will be targeted to the detriment of overflow a vital part in the context of these external influences,
performance. assisting operators to meet growing demand efficiently
and sustainably while offering investors a suitable return.
Conversely in a typical concentrate application, overflow As a key piece of equipment in the dewatering phase,
clarity is an important requirement: otherwise the the impact of thickener performance on overall plant
valuable mineral would be returned to the concentrator operations should not be understated.
with loss of recovery and additional process costs in the
form of reagents and maintenance. 2.1 Demand Growth
Further considerations in thickener performance targets Driven by demand for more minerals in recent years,
are determined by downstream equipment and processes, capacity expansion plans have consistently featured
and upstream where the returned water enters the in the strategies of mine owners. Even in a climate of
process. declining demand and prices, expansion plans are still
under consideration, whether to position for future
Critical to thickener performance are two parameters:
growth or maintain capital efficiency and thereby reduce Societal awareness of mining activities is also driving
unit production costs. An analysis of expansion projects decisions by owners and operators. In an SEC filing from
presented in Figure 1 provides some context for the February 17, 2016 Newmont Mining reported in relation
importance of plans to expand operations, even at a time to the Conga Project that it “will not proceed with the full
of low metal prices and uncertainty. The analysis data lists development of Conga without social acceptance, solid
over 280 plants with expansion plans across all mineral project economics and potentially another partner to help
types. (SNL Metals & Mining 2015.) defray costs and risk; it is currently difficult to predict
when or whether such events may occur.” The filing
The benefit of expanding existing plants over greenfield further reported “Under the current social and political
development is clear. As ore body knowledge increases environment, the Company does not anticipate being able
over the operating life, technical risk is reduced and the to develop Conga for the foreseeable future.”
capital efficiency of the existing plant is increased as it is
extended beyond its original life or capacity. The processes of obtaining and maintaining a social
license to operate are playing an increasingly important
2.2 Water Scarcity and Social Impacts role in decision-making among mine operators
worldwide.
From an environmental and social perspective, efficient
thickener performance is becoming increasingly
important. Operating licenses are progressively more
onerous, requiring strengthened assessment and
mitigation of the likely impact on the local environment
and communities. In particular, access to water is more
tightly regulated due to increasing awareness of scarcity,
motivating operators to look for new and sustainable
sources of water.
10,000
Tailings
7,000
Water Lost
1,400
Water Saved
400
Large City Use
1.6
Higher prices enable
lower cut-off grades
New projects mining
1.4
higher grade during
Copper Grade Cu%
early years
Higher grade
1.2
underground mines
ramping up
1.0
0.8
Figure 3. Grade trends weighted on payable copper - including probable projects (Wood Mackenzie 2015).
60 2500
40
1500
30
1000
20
10 500
0 0
Figure 4. Changing throughput impact on performance and typical outcome of increasing the solids loading (SL) and changing
the ore to an existing thickener.
Figure 4, representing a typical copper tailings thickener, Even for greenfield plants, there are cases when the
shows that increasing the throughput of a thickener of fixed actual conditions will have changed from those used in
diameter (by increasing solids loading) reduces underflow design when many assumptions will have been made
density and consequently increases the amount of water based on limited knowledge from small sample sizes of
sent to tailings. drill results. If changes are significant modernization of
components may be required to deliver performance.
Similarly, changing ore characteristics, such as particle size
distribution (PSD), can also negatively affect the underflow
density and water sent to tailings as shown in Figure 5.
Water to tailings - m3/hr %w/w
40 600
US Denisty - %w/w
30 500
400
20
300
10
100
0 0
13 32 86 130 140
Figure 5. Particle size affect. The typical outcome of reducing the P80 PSD to an existing thickener without any other changes.
3.2 Aging Equipment in its capacity by the stage in the process with the lowest
efficiency, reliability, and availability. De-bottlenecking is
Beyond the process-based sedimentation challenges the term used to identify and overcome these capacity-
facing operators, extending the capacity and life constraining steps.
of existing equipment also requires a focus on the
mechanical components of a thickener. The capital- Additionally, obsolete parts, items with long lead times,
intensive nature of minerals processing plants motivates and parts that must be manufactured as “one-offs” can
owners to pursue capital efficiency, measured by be disruptive to the operations of any plant.
throughput and operating availability. Modernizations are
an ideal route to achieve this outcome. Thickeners are low-maintenance, designed as critical
equipment, and generally have no duty standby installed.
Recently there has been a sharp growth in the number As they age, more focus must be placed on them to allow
of minerals processing plants as the world’s population continuous operation.
both expands and becomes increasingly affluent, driving
demand. As these plants age, supporting their continued
operation will become increasingly vital.
35 600
30 500
25
400
20
300
15
200
10
5 100
0 0
1554
1900
1913
1924
1929
1933
1938
1949
1954
1957
1960
1963
1966
1970
1975
1978
1981
1984
1987
1990
1993
1996
1999
2002
2005
2008
2011
2014
Figure 6. Existing minerals processing plants and the year of establishment (SNL Metals & Mining 2015).
17,500,000
Annual Water to Tailings m3/hr
17,000,000
16,500,000
16,000,000
15,500,000
15,000,000
14,500,000
14,000,000
50 51 52 53 54
Underflow Density
Water Saving
3.3 Water Recovery upstream and downstream equipment such as valves and
pumps, and direct costs in process water tank cleaning
In previous sections, we discussed the environmental as the solids finally settle in this tank. It is reasonable to
and social focus on mineral processing operations. As expect 90% of the lost material from tanks and dams to be
a water recovery system, thickeners can be targeted to recovered. However, the last 10% (200 ppm) can represent
meet new requirements in the recovery and reuse of an economically significant stream, so investments in
water, ultimately reducing water consumed from the improvements generate easy returns.
environment.
For most counter current decantation circuits a valuable
This environmental imperative can be met by increasing component is present as a salt in solution. Any solids
the underflow density of current thickeners. An increase in the overflow may result in a decrease in the grade of
in underflow density of 1% or 2% can return significant the final product, and can add a large additional cost in
volumes of water to the operating plants. In Figure 7, each solvent extraction (SX) plant maintenance or the need
increase of 1% in underflow density reduces the amount for additional filtration prior to the SX plant. Underflow
of water to tailings by around 500,000 cubic meters per density from each stage directly influences circuit washing
year. efficiency and if the washing efficiency is not optimized
then valuable metal will be lost to the underflow stream of
3.4 Mineral Recovery the final thickener in the circuit.
The challenge of increasing capacity and changing • Will the proposed process parameters allow
ore may require replacement or parallel plants to be solids loadings and rise rates that provide suitable
constructed. In cases where ore changes require not only performance properties with the expected feed
increased capacity but different processes this may be the material?
only option. Ore can change when the oxidized layer of the • Is the condition of the tank and structure conducive to
pit is exhausted and mining progresses into sulphide ores, an additional 5, 10 or even 20 years of life and the higher
or for other, less common, reasons. The benefit of parallel loads expected?
plants is that the original plant continues to be fully
utilized providing no interruptions to customer deliveries. Assuming the tank diameter and condition are suitable
for increased loads, upgrades are possible to all other
When a capacity increase or changing ore can be elements. Sidewall height can be extended, overflow
processed by the existing plant, new equipment can be capacity can be increased with new launders and/or
considered to address any identified bottlenecks. For new overflow boxes, floor angle can be increased, and
thickeners, this is most often the outcome in cases where underflow arrangements can be modified.
the existing tank size is not suitable when judged against
thickener design rules (solids loading and/or rise rate). At this point, moving forward can become an economic
Alternatively, the age or condition of the thickener may decision and a cost comparison between replacement
mean that re-use of the tank and its support structure is and modernization can be made. In this comparison the
no longer viable. considerations are:
For an operating plant, expansion by “bolt on” equipment • time available for work — lost capacity during this stage
may seem an attractive option and considering the remote can have significant cost implications
location of some plants, it would seem that footprint is not • social and regulatory licenses relating to land use
a significant issue. Two factors frustrate this assumption: • cost of service provision to new thickeners
1. Installing new equipment at another location will entail Modernization becomes an attractive option because it is
changes to process flow, piping and electrification, encapsulated inside the plant boundaries and does not
which can significantly add to the project cost. require new services, maximizing the use of existing plant
so capital efficiency is maintained or even improved. This and control the elements required for good thickening
provides operators with an appropriate solution to their to occur. Feed pipe size, elevation changes and dilution
changing process and plant requirements. requirements all need to be considered in upgrading a
thickener feedwell.
DRIVE
• HPU
FEED SYSTEM • Drive Head
FEEDWELL
• Gearbox
• Breaktank • Control Panel • Feedwell
• Feedpipe • Floc Box
• Feedtank • Feed dilution
MECHANICAL
•
•
Bridge
Launder
FROTH CONTROL
• Overflow Box • Boom and Spray
• Bolt on Blades • Boom and Beach
• Underflow • De-aeration Tank
2. Introduce dilution (if required) into slurry for In recent years some thickener technology suppliers
optimal flocculation have developed various new feedwell design concepts to
meet the requirement of modern thickener feed system
3. Provide time for flocculant design discussed above. The Outotec Vane Feedwell™
design, shown in Figure 11, was launched during 2008
4. Provide low shear conditions for flocculated and has been at the forefront of developments in modern
aggregates to grow thickener feedwell design. It incorporates all of the
necessary elements to optimize flocculant efficiency and
5. Distribute the flocculated feed evenly into the improve thickener performance.
body of the thickener
7.2 Feed Tanks
designs. In addition, multiple streams may be delivering Installing a properly designed feed tank can result in
feed to a thickener. The best designs currently combine greatly enhanced thickener performance. The tank can
flows into a single entry to the feedwell at a controlled act as the collector of multiple streams so that only a
velocity to provide the best flocculation conditions. An single pipe takes feed to the thickener. Baffles, shelves,
example of feed tank design can be seen in Figure 12. tangential feeds and inverted outlet pipes are all used in
innovative feed tank designs. These designs complement
Critical to designing an appropriate feed tank will be a process improvements to allow a smaller-volume tank
thorough understanding of all potential streams, volume to be used, reducing the structural capacity required for
and solids loads, elevations, and the pipe layout prior to installation.
the tank.
Feed /
slurry entry Directional
AutodilTM ports
Directional
AutodilTM ports
Flocculated slurry
evenly dispersed
7.3.2 De-aeration or Break Tank As already discussed above, the trend of mining
lower-quality ore bodies is resulting in finer material
Recognizing the importance of receiving thickener in thickeners. These particles have a higher surface
feed at the correct velocity and with minimal aeration, area (per unit mass of solids) than coarser particles
and a lower solids concentration within the feedwell is 7.4.2 Forced Dilution
required to provide free particle settling and thus efficient
flocculation. In certain circumstances, it may not be possible to achieve
the dilution requirements for a particular application
Systems utilizing external dilution pumps, pipes and using directional auto dilution systems.
valves have now been replaced with less costly and more This includes applications where:
efficient internal dilution systems. In these systems, the
clarified liquor on the thickener surface (also known as 1. the specific gravity differential between the feed slurry
supernatant) can be directly utilized to dilute the feedwell and the overflow liquor is low, due to:
slurry. There are several thickener feed dilution systems
currently on the market. • the particles in the slurry having a low specific
gravity
7.4.1 Automatic Dilution • low feed concentrations
Automatic feed dilution systems were first introduced 2. high volumes of feed dilution flow are required to
during the 1980s. When the bottom of the feedwell is bring the incoming feed to the required density. This
largely closed off, the fluids on both sides of the feedwell is commonly demonstrated when a high differential
wall remain at different specific gravities. As they are exists between received slurry density and diluted
hydraulically coupled, the pressure equalizes and a density.
geometric level difference exists between the supernatant
liquor outside the feedwell and the feed slurry inside the To provide the necessary dilution in these cases,
feedwell as shown in Figure 14. In this system, gravity mechanical means are required. Figure 15 shows the
forced dilution principle. Additionally, when the feed
has a very high density, such as a thickener underflow,
Driving Head
and feedwell mixing becomes inadequate, additional
Outotec Directional Autodil™ Overflow mixing energy is required. Forced dilution can provide
both dilution for flocculation and the energy required
Feed Clarified liquor
1.1 1.0
for mixing. Forced feed dilution systems have the
Slurry
disadvantage of requiring a power supply and adding
Fluidized bed some mechanical complexity. Fortunately, there is
1.5 negligible wear on the rotating parts in such a low head
Typical SG
pumping application.
Thickener underflow
Values
Only
Driving Head
Outotec Turbodil™
Overflow
Fluidized bed
1.5
Typical SG
drives the dilution flow through openings in the feedwell Thickener underflow Values
Only
as the slurry level inside is at a lower geometric level than
the liquor outside of the feedwell.
Additionally, the thickener geometry and use of the The best forced dilution systems incorporate a design
hydraulic head differential allows the degree of dilution to optimized for low head applications to minimize power
be naturally varied according to fluctuations in the density requirements, shroud the impeller to ensure solids
and flow rate of the feed. Hence, the best systems are are not drawn into the feed, and introduce the dilution
able to buffer feed density variations, producing favorable liquor in a direction conducive to the flow in the feedwell,
flocculating conditions over a range of feed conditions. assisting the mixing of flocculant with feed slurry in the
feedwell.
7.5 Flocculant Delivery The age and condition of mechanical parts can be cause
for an upgrade, or at least replacement of the affected
When using flocculant, the preparation and delivery parts. Many thickeners operate in harsh conditions, with
method must be carefully selected. Just as there is an salt and chemical attacks common, as well as general
optimal solids dilution, the flocculant must also be diluted exposure to the environment.
to the correct level, which is typically 0.01-0.025%w/v.
However, transporting diluted flocculant is challenging When drive-line items reach the end of their life-spans,
as any shearing effect greatly degrades the polymer replacement with the latest technology is the best option.
chains. Best practice is to dilute to around 0.5%w/v at the Notable among these are gearboxes, which have a design
flocculant plant, pump with a low shear pump, and then life of 10+ years. When the mine life is extended, even
provide secondary dilution as close to the feedwell as these durable components should be modernized in
possible. a planned way to coincide with other thickener works,
rather than waiting for unplanned downtime.
The inclusion of bridge-mounted secondary dilution
equipment can greatly increase flocculant efficiency, Expansion, capital efficiency, and environment concerns
leading to reduced costs and improved settling. Properly often dictate that thickeners are required to provide a
designed secondary dilution can include static mixing, higher underflow density in addition to increased capacity.
an open box for operator visibility and discharge lines Even in cases with the same underflow density target,
optimized to prevent blockage. additional torque may be required due to rheological
changes in the material. Drives up to 14.5 million Nm can
now be installed when required.
Figure 16. Old column design before the upgrade. Figure 17. Column and half-span bridge replaced with full-span bridge.
In many cases, a reinforcement plan can be produced. an underflow cone scraper. It must be able to provide this
Adding additional elements, such as braces, gussets or duty for any new conditions.
boxing in open sections, can provide the strength and
rigidity required for a bridge to carry the loads of new Rake arms and blades help to move thickened slurry
equipment introduced for the modernization. inside the tank to the underflow cone and assist in
dewatering. Underflow density is increased by gently
When bridges must be replaced, some innovative shearing the bed to release water from individual
approaches have been taken. Full-span bridges can flocculants and, on a coarser scale, opening up paths for
be replaced and installed according to the existing trapped water, now liberated, to rise through.
arrangement. However, in some cases it has proven a
better solution to mount the new bridge on external Advances in design incorporating low profile arms, bolt-on
support. These circumstances may include: rake blades, rotating pickets, bolted underflow scrapers
or sectional steady pin and bearing arrangements, can all
a. reorientating the bridge to meet a changed plant be included in the modernization project.
layout
b. reducing the cut-over time of the installation 8.3 Drive and Power Supply
c. suiting the current tank structure conditions
Drive units are required to apply torque to the mechanism.
Modern bridge design allows some thickener upgrades They typically consist of a multistage planetary gearbox,
by replacing an outdated center column with a full-span a power supply (hydraulic or electric) and a rake lift
bridge. This has the added benefit of reducing the cost of mechanism.
the mechanism, drive, and operational maintenance.
In all gearboxes, high pressure is created inside each
Figures 16 and 17 show an upgrade where an old column meshing stage. This high pressure gradually removes
design was replaced with a reorientated full-span bridge. metal from the meshing surfaces. The replacement life of
these components can be predicted by regular oil analysis
A section of the column can also be used as a steady pin, and inspections. However, the availability of spare parts
reducing the scope and cost of the upgrade in relation to for components that are 10 or even 20 years old may be
underflow cone changes. A typical arrangement is shown the decisive factor in demanding a modernization.
in Figure 18.
Whether these drives are powered directly by electric
8.2 Mechanism motors or hydraulic power packs, the need for high
reliability and availability will provide justification
The mechanism delivers rotational force from the drive to consider replacing the power supply, either as a
and consists of a shaft or cage, rake arms and blades, and standalone upgrade or part of a broader upgrade strategy.
HPUs provide a reliable, low-cost power source as well as As with the overflow considerations, the installed
a simple way of monitoring torque. underflow nozzle(s) should be reviewed against the
upgrade criteria for adequacy of sizing, considering the
A system to lift the rakes can be included in the drive impact of slurry velocity and pressure loss in the pump
unit to assist in managing high torque loads from the suction or gravity discharge.
mechanism rotating in a thickened slurry. Raising the
rake mechanism to bring the rake tips out of the mud, If underflow nozzles are undersized, it may be necessary
where most of the torque is generated, will provide to cut out existing nozzles and replace them with a
temporary torque relief and additional time for operators suitably sized nozzle. Inline reducers are the simple
to take action to reduce torque load and avoid thickener response if smaller nozzles are required. Beyond the
downtime due to “rake bogging”. Triggered by torque underflow cone and nozzles, the new slurry characteristic
readings, rake lift can be powered by the same hydraulic may necessitate a comprehensive review of the underflow
power unit or an additional electric motor, depending on arrangement through to the final destination. Sizing of
the primary power source. all components, pipes, control valves and pumps must be
included in the review.
Upgrades must involve reviewing the drive unit and it is
vital to know the installed torque in order to assess the
changes required to ensure the thickener is suitable for
its new duty. When increased torque is needed, some 9 Electrical and Instrumentation
drive modernization will be required. The electrical components of a thickener are also subject
to modernization, with replacement or upgrading to
8.4 Overflow ensure ongoing reliability and operational performance.
Increasingly, the trend is toward more automatic control
Overflow lip and launder systems draw supernatant liquor of thickeners, and upgrading by installing modern PLC
evenly from around the thickener and collect it in a single and higher-level control can produce demonstrable
pipe. This uniform draw minimizes high, local rise rates improvements in stability and performance.
and helps to provide a clean overflow.
Installed instrumentation should also be reviewed to
Where a new duty has a higher volumetric loading, sizing ensure it is suitable for the process. The general operation
of the installed launders must be reviewed to ensure that and condition of the instrumentation, calibration,
they have capacity to manage any increased flows and cleaning, and correct installation should all be checked.
remove the overflow liquor. If not managed, the liquor In many cases control of the thickener will be improved
level may back up around the launder resulting in flooding through installation of newer technology such as bed level
and poor thickener performance. In extreme cases, there instrumentation or a settling rate measurement device for
is a risk of uncontrolled liquor losses from the tank. control of flocculant dosing.
There are a number of options to remedy this scenario. 9.1 Control Panels
In nearly all cases, the simplest solution is to install
a second overflow nozzle. This will be located at 180 Control panels are vital for ensuring that operators can
degrees from the existing overflow nozzle, provided interact with the thickener. Historically, many functions
launder depth is equal around the circumference of the of the drive unit were controlled using the local panel,
thickener. whereas newer practice uses the plant’s distributed
control systems (DCS) for machine automation – the local
Alternatively, the launder depth can be increased by panel functions as a marshaling panel only. Still, most
extending the weir plate allowing the thickener to run at control panels are not able to modify process variables,
a higher level. This can be best achieved when adequate but are used only to run the drive. Modernizing the control
tank freeboard is available, although the tank wall can panel, either as part of a broader upgrade plan or stand-
also be extended as required. alone measure, ensures that the control panel meets
current site standards and that all electrical components
(such as PLCs) are still supported by their Original
Equipment Manufacturer (OEM).
8.5 Underflow Handling
9.2 Bed Mass
The underflow cone and nozzles are the final withdrawal
point for the thickened slurry. Removal can take place Thickeners accumulate solids to create the bed pressure
by gravity, which is common in South America where necessary to achieve dewatering. To establish this
elevations permit, or by slurry pump. solids inventory it is necessary to operate with the solids
withdrawal rate below the solids feed rate for some period the efficiency of the dewatering of the thickener. Manual
during start-up. Then, during steady state operation, the measurements are suitable in some applications but
solids withdrawal rate should match the feed rate. To online measurement is generally recommended and can
achieve this steady state of operation, it is desirable to then be used in automated thickener control.
measure both flows with a high level of accuracy, or to
measure the solids inventory in the thickener tank. While a range of instruments are available for this
application, gamma radiation based instruments are
Accurate mass flow reconciliation between inflow and the industry standard and are widely available. During
outflow is difficult due to instrument error, leading to modernization, a review of the suitability of old radioactive
uncertainty. Fortunately, inventory can be indicated sources is warranted as detector sensitivity has increased
through a conversion of the output of a pressure so that even old sources can be reused.
transducer mounted on a purpose-built flange near the
underflow withdrawal point of the thickener. Best practice Density instruments are commodity items and
has the sensor flush mounted to the inside of the tank. instrumentation sales personnel may lack process
Any build up of solids forming a barrier between the bed understanding for thickener applications so during
and the sensor will reduce the accuracy of the reading. modernization support can be provided by the OEM.
10 Automation
The control of a thickener includes the measurement of the desired operation point in varying situations and
variables outside of the thickener footprint. Underflow quality targets not being consistently met.
pumps and flocculant dosing pumps must be manipulated
as shown in Figure 21. Whilst some classical techniques can handle these
situations, regular operator intervention is required. The
Typically, thickener controls are implemented as single tuning becomes difficult, typically requiring high-level
loop controllers in DCS/PLC systems. These systems are experts to remain onsite. Another challenge is in allowing
challenged by long response dynamics and interaction for process constraints and the desired prioritization
between variables, leading to difficulties in maintaining between controlled variables.
FLOCCULANT DOSING
UNDERFLOW
3650SIC011
DENSITY
AND FLOW
3420DI013A
3420DI013B
3420FI016A
3420FI016B
3420-PPP-45A
3420PIC801 3420-PPP-45B
CONCENTRATE FILTER
TANK FILTRATE
TANK
Figure 21. Underflow pumps and flocculant dosing pumps must be manipulated to control the thickener.
CONTROL ROOM
ACT HMI
REMOTE Introducing Automation Control Tools (ACT) overcomes
(DW PLANT) WORKSTATION
INTRANET
the inability of Proportional, Integral, Derivative (PID)
INTERNET loops to handle slow response dynamics and cross actions
EXTENDER
between controlled variables. An appropriate control
system architecture is required and an example is shown
AUTOMATION ROOM
(DW PLANT) in Figure 22. Here, the advanced control calculations
FIREWALL can take place on an Higher Level ACT system that sits
ACT CLIENT OPC SERVER
above the site’s process control system (PCS). A similar
architecture is used across a range of advanced control
FIREWALL
SWITCH ACT SERVER solutions. Separating advanced control from sequences
and the general human machine interface (HMI) on
PROCESS CONTROL SYSTEM (PCS OR DCS)
the PCS makes both systems easy to maintain and
troubleshoot.
PROCESS AREA Figure 23 shows the results that have been achieved after
installing ACT-based advanced control on a concentrate
FLOCCULANT
thickener. Of interest is the fact that the tuning period was
DI FI FC completed within only 1 week of onsite step tests. This
TORQUE
SLURRY
WC
compares favorably with PID based approaches that can
THICKENER take many months to fine-tune to an acceptable level of
performance.
TURBIDITY
QI PC DI FI
OVERFLOW UNDERFLOW
10 %
9%
8%
7%
6%
% of time
5%
4%
3%
2%
1%
0%
1,6 1,7 1,8 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6
Figure 23. Relative distribution of underflow density after installation of ACT on a concentrate thickener.
11 Outotec Solution and the physical assets available. The more work and
commitment in the early stages, the better the quality of
Designing and executing modernizations to a thickener to the outcome.
meet new process and plant conditions requires deep and
thorough investigation. The impact of process conditions Outotec works closely with the customer to identify
must be considered holistically for the impact on each the success criteria of the planned modernization.
element of the thickener. Testwork and process or even Understanding the key requirements of the upgrade –
plant audits may be required. In addition to confirming the “what and why” – will ultimately ensure a successful
operator requirements, these broader studies may also outcome for all parties.
highlight complimentary or alternative actions that are
required to achieve the process requirements. Audits Using a suite of tools including site audits, testwork,
often reveal that feed delivery routes and filtration plants engineering studies and the latest design programs, a
require further investigation. thorough information-gathering exercise is undertaken.
The specifics of the original equipment design, both
In some cases, the result of an investigation may reveal mechanical and process, are captured for the current and
a wholly different solution. Where filter performance is future requirements of the thickener.
tightly coupled with thickener performance, installing a
suitable filter feed tank to decouple the unit processes 11.1.1 Desktop Review
may offer a more effective solution than a thickener
modernization. Information is critical to the success of an upgrade.
To begin the process, the thickener performance
Outotec began upgrading thickeners in 1989 and has requirements must be known. A desktop review of the
successfully managed over 140 major upgrades globally. process is then conducted to determine the suitability of
The timing of these upgrades is shown in Figure 24. the thickener tank for the required duty.
18 160
16 140
14 120
12 100
10
80
8
60
6
40
4
2 20
0 0
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1999
2000
2001
2002
2003
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Upgrades Cummulative
Figure 25. Outotec test rig Figure 26. Outotec test rig is designed to be easily carried on site.
The outcome of this stage may include: tested at optimal loading conditions and comparatively at
conditions expected in the existing tank. These may not
1. a report of findings be the same due to the fixed diameter of the existing tank.
2. preliminary scope of options This information is vital for the operator to understand
3. price indications what can be expected and how this influences plant
4. firm pricing for testwork, site inspections and throughput and design. It can directly contribute to the
engineering studies if required decision to purchase new equipment or modernize
existing equipment.
11.2 Testwork
The test results provide information for feed system
Accurate characterization of the settling properties of design requirements, such as the optimal solids
thickener feed is best achieved with thickener-specific concentration at which material flocculates. This is
testwork. Outotec has developed a method of conducting important for designing the feedwell and dilution system
dynamic thickener testwork using a lab-scale thickener and establishing the flocculant dosing rate.
that, compared to traditional cylinder settling tests, is
more representative of the conditions present in a full- Satisfactory testwork results are also used as the basis
scale thickener. This includes the effects of a rotating of any process performance guarantees that may be
rake mechanism as well as the continuous up-flow of required for the upgraded equipment.
liquor inside the thickener. It is also possible to withdraw
samples of thickened underflow to measure their Once this has been done and outcomes agreed, work
rheological properties. The test rig is shown in Figures 25 moves forward to establish the final scope. At this point,
and 26. access to detailed information on the existing thickener
design is required.
A benefit in brownfield plants is that representative
ore is more likely to be available than during testwork 11.3 Engineering Review
for greenfield development. This ensures a more
accurate understanding of the settling and thickening An engineering review collates the available mechanical
characteristics of the material. Testing can also be carried information, proposed process changes and thickener
out on-site alongside an operating thickener. information to establish broad parameters for detailed
engineering and drafting to commence. An engineering
This on-site testing yields particularly valuable review will typically allow a firm price to be provided.
information when a site is auditing or troubleshooting
thickener performance. Carrying out the testing on-site There is often some difficulty in collecting the required
also provides benefits in applications where aging of level of engineering detail. Old drawings may be
material during transport and handling can render the inaccurate, lacking complete information, or they may
sample unrepresentative. On-site testing can also make not exist at all, necessitating an engineering survey.
it easier to test under a variety of conditions as in reality This can be conducted by either the client or Outotec.
many operations will receive run of mine (ROM) ore from Developments in laser scanning can replace some of the
multiple locations (Bickert 2012). survey requirements, enabling a faster time to realization
of the necessary detailed information.
Testing provides an indication of the thickening
performance that would be achieved with the material
During the engineering review, consideration of the Modernizations allow the owner to continue to operate
mechanical components is paramount. To upgrade a thickeners beyond their initial design parameters or life
thickener for improved process performance but then in a capital-efficient and environmentally sustainable
have it constrained in performance by a mechanical manner.
limitation would be undesirable. The customer needs to
have a clear understanding that changing or introducing Depending on the stage of the cycle and the specific
new elements to meet the process requirements can plant requirements, upgrades may focus on processes,
require enhancement of the mechanical elements. As mechanics, electrics or automation, or a combination of
detailed earlier, both static (mass loads) and dynamic these.
(torque) requirements can increase when a feedwell is
upgraded. An engineering review will provide the plan As a pure economic exercise, there is no doubt primary
to address these needs and allow for firm pricing of the motivation will be plant capacity increase, followed by
prerequisite work. changes in thickener feed (changing ore conditions).
In some locations, water utilization alone can provide
11.4 Design Considerations economic sense if the water cost is in the range of USD
1–3 per cubic meter.
At this stage, consideration must also be paid to
interfaces with any existing equipment. If the current Modernizing a thickener to accommodate process
bridge support structure is sufficient for the new feedwell, changes or to provide improved performance centers on
for example, how will the new feedwell and other items installing the latest in thickener feedwell technology.
attach?
Modernizations centered on mechanical or electrical
The design consideration would also include: needs ensure that thickeners can continue to operate
reliably and efficiently, providing risk mitigation
• transport windows and continuity of service. Automation upgrades can
• seismic and wind loads directly contribute to plant efficiency and bottom-line
• localized material and electrification requirements performance with greater control over the equipment.
References
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at: http://www.bhpbilliton.com/investors/news/bhp-billiton-approves-escondida-water-supply-project [Accessed April 2,
2016]
Bickert, G. (2012). Mechanical dewatering of tailings – an update with case studies, in Mathewson, D. (Ed), Proc. 14th
Australian Coal Preparation Conference and Exhibition, Canberra, Australian Coal Preparation Society, pp. 94–103
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Processing Congress, Brisbane 6–10 September
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Nguyen, T., Heath, A.R. & Witt, P. (2006). Population balance – CFD modelling of fluid flow, solids distribution and
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