THICKENERS AND FILTERS
to changing feed conditions to meet moisture targets and throughput requirements .
Overall , FLSmidth emphasises its complete flowsheet portfolio up to the largest designs , process knowledge , testing and piloting including ability to scale up from bench-scale , experience and references . Over the long term with FLSmidth ’ s advances in grinding and coarse particle flotation , applications could see further flowsheet capex and opex optimisation , resulting in differing or simplified concentrate and tailings dewatering solutions .
Diemme ’ s Domino effect
In the world of super sized filter presses , which will play a crucial role in global dry stacked tailings projects at the largest copper , iron ore and other mines , Diemme Filtration , part of Aqseptance Group , took a major step forward with the launch of its GHT5000F Domino model in late 2021 . It has a plate size of 5 x 5 m and a single unit is capable of handling over 8,000 t / d . The first unit is now with the launch customer , a Peruvian copper mining company which is to use it as part of a major new tailings project , first in a pilot trial but later , assuming that is successful , as part of a much larger bank of up to 9 or 10 of these presses for a total capacity of over 80,000 t / d . IM can also reveal that a second unit has now been ordered for a major copper mining operation in Chile .
On the apparent willingness of major miners to invest in super large filters and the Domino in particular , Diemme ’ s Director Marketing & Communication Andrea Pezzi told IM : “ It is something of course we started a few years back , but there has until now been some industry reluctance to take big steps due to perceived risk and of course the investment required . But with the industry focus on moving to dry stacked tailings , and the new ICMM Global Industry Standard on Tailings Management there are now people in key positions who are ready to quickly move to piloting stage and beyond to full installations of larger filter presses , recognising the economy of scale in these big tailings projects requiring throughput of 80,000-100,000 t / d or more .”
Pezzi further talked about filter press developments in Brazil which represents a market where there is huge potential and where Diemme has already had significant success . “ Brazilian mining is making major investments in dry stacked tailings projects , but Diemme Filtration as a company is also growing in the country as we are expanding our facilities there , both in Sao Bernardo do Campo in the state of Sao Paulo ; as well as in Belo Horizonte in Minas Gerais . This includes larger service teams , pilot facilities and spare parts warehousing .” Additionally , Diemme is expanding its main
Diemme filter presses installed at a customer site in Brazil
manufacturing facility in Lugo , Italy , in view of the increased manufacturing of multiple types of filter presses with increased sizes .
The two big filter press markets in Brazil in mining are in iron ore and bauxite ( alumina ) processing where they are transforming how alumina refineries manages bauxite residue – a byproduct of the alumina refining process that is primarily made up of red mud . Alcoa Brasil ’ s Filtro Prensa project at its Poços de Caldas alumina refinery , which is supplied by a captive nearby bauxite mine , is set to open late 2022 . It has three overhead beam GHT2500P filter presses with customised characteristics for Alcoa ( such as valves , electricals and components ). They have 100 plates each but are expandable to 130 . There is also the potential for further projects with Alcoa as it has additional refineries in São Luís ( MA ) and Juruti ( PA ).
Another bauxite related project in Brazil with a different customer which involves three GHT2500P18 filter press units that are being shipped from Lugo . These are going to an operation in Sao Paulo state . Plant start up is expected mid-2023 . The filter cakes will be placed into the old wet tailings dam which will enhance safety and extend the life of the TSF .
In iron ore , there is a new dry stack tailings project that has already been running since Q1 2022 in Minas Gerais – it has two GHT2500F filter presses – which are processing about 8,000 t / d of iron ore tailings and have been achieving about 15 % residual moisture . Particularly , this operation had been shut by authorities due to the condition of the TSF and the filter press introduction was instrumental in an operational restart being permitted . A second , larger project in iron ore , also in Minas Gerais , is worth € 15 million and involves four GHT2500F units with delivery scheduled for mid-2023 .
“ We know how important these installations are for our customers and for many of them it is a ‘ new ’ technology . So we support clients fully from Day 0 until they are able to run the plant themselves .” Pezzi said that this approach is helping cement its reputation in countries like Brazil and has led to new orders . In addition ,
most new large filter presses now leaving the Lugo factory are IIoT ready , equipped with its AIDA system for remote control , management and optimisation .
Metso Outotec invests in plate capacity
Metso Outotec is of course another full flowsheet player with a wide range of thickener and filter solutions . It recently announced it is investing in establishing its first polymer filter plate production unit in Mexico . With this investment , Metso Outotec says it is responding to global market demand by increasing its capacity to deliver high-quality polymer filter plates for its mining customers ’ filter presses . The company expects to invest a total of around € 28 million to acquire the land and develop the production facilities by 2025 . The construction work will begin as soon as the acquisition of the land and the planning of the facility have been completed . The construction of the new factory is expected to begin in 2023 and reach full capacity during 2025 , following a gradual rampup .
On thickeners , Metso Outotec in 2021 launched the Metso Outotec Reactorwell™ , a new generation feedwell for maximising thickener and clarifier performance while minimising flocculant consumption and bringing significant operational cost efficiencies . The feed system features high solids retention and mixing efficiency . It also eliminates feed short-circuiting and offers low shear for ideal floccule growth and even discharge symmetry , the company said . Brian Berger , Vice President , Thickeners and Clarifiers at Metso Outotec , said : “ The Reactorwell enables a big leap forward in thickener and clarifier performance as it utilises maximum settling area due to its high exit symmetry . It also provides improved overflow clarity as well as higher underflow density . Additionally , the Reactorwell allows better thickener operability with an improved response to process changes .” Berger additionally told IM : “ We have several operating Reactorwell™ feed systems which are performing well in their applications . Additionally , since the launch last year , we have sold approximately 40 new units that are in various stages of design , manufacture , and installation .”
ANDRITZ ’ s bespoke offering
Another company leading in both thickener and filter supply is ANDRITZ . Thanks to the thickener ‘ s innovative , modular design , ANDRITZ says it is able to offer a wide range of thickeners and clarifiers with diameters from 1 to 80 m . " Along with an extensive range of construction materials , efficient dilution systems , and optimised flocculation options , this means we can provide a customised solution . Its
20 International Mining | OCTOBER 2022