MINERAL SEPARATION cyclone output the technology will also allow you to monitor fluctuations in the different size fractions. FLS sees this as a highly significant development with regard to mineral processing plants achieving true automation, including in relation to AI-based control.
FLS has already extensively tested the technology at minesites in the US Canada – and has two orders going to clients in West Africa and South America. Baah also highlighted the fact that for the value it brings, the CAPEX involved is low in terms of the initial install of the instrumentation itself, with the spare parts, software etc covered by a subscription model. This also means FLS is responsible for troubleshooting and performance monitoring – which is often neglected with sensor-based systems. KREBS ® OSA is also real time and not based on a batch process. Testing has shown it to have an accuracy of 95-99 %..
Weir’ s CAVEX ® 2 cyclones deliver for Dragon Mining
Many years of research, development and trials have gone into the creation of Weir’ s CAVEX ® 2 hydrocyclone. The improved design, shape, angle and proportions of the CAVEX ® 2 high-efficiency cyclone ensure that fine particles( 8-500 microns) pass through to the correct stream, rather than being returned for further processing. This optimises plant recovery by reducing the quantity of misclassified particles by an average of 10 % and improving fines bypass by an average of 15 %. Its LIG + ™ advanced laminar spiral inlet and size of the feed chamber reduce turbulence and allow the hydrocyclone to classify up to 30 % more feed slurry, while occupying the same footprint as the original CAVEX ® or competitor cyclones. Weir says this enhanced performance is unmatched by any known hydrocyclone in operation today. Its customers can now achieve more throughput with fewer operating hydrocyclones, reducing the upfront capital expenditure and resources.
Dragon Mining is a concentrator plant that has been producing gold since 2008, continuing operations from a former lead and zinc mining project. The underground mine produces ore from depths of 340 m, feeding two parallel circuits— flotation and gravity. Dragon Mining concentrates gold at a ratio of K = 60, resulting in 60 times reduction in the ROM mass before shipping product to Sweden for final recovery.
Dragon Mining faced a persistent challenge: ageing mills with limited power draw were creating a bottleneck in the grinding circuit, restricting throughput and impacting recovery. While investigating the bottleneck, Weir observed that the existing cluster of two CAVEX ® 400CVX10 hydrocyclones was operating close to roping conditions. Any fresh feed exceeding 40 t / h triggered roping, which compromised separation efficiency. A larger spigot wasn’ t an option to prevent roping, as it would increase circulating load and compromise the target P80.
Reducing circulating load while maintaining the desired P80 presented a significant classification challenge, typically linked to hydrocyclone efficiency. The site required a solution that could lower the circulating load without sacrificing classification performance. To improve classification efficiency and unlock additional capacity in the mill circuit, Weir specialists conducted a detailed performance assessment at Dragon Mining’ s operation. The team identified a retrofit opportunity that would deliver measurable gains without requiring major infrastructure changes. Weir:“ We collected performance data from the existing CAVEX ® 400CVX hydrocyclones. A process simulation revealed that replacing them with a CAVEX ® 2 CVD hydrocyclone of the same size could reduce the circulating load and increase classification efficiency, enabling lower throughput to the mill and improving overall circuit performance. The simulation showed potential to increase plant capacity from 41 t / h to 45 t / h, a 10 % improvement. Based on these findings, Dragon Mining agreed to trial a CAVEX ® 2 CVD hydrocyclone, confident in the projected performance uplift and operational benefits. Our service team retrofitted the new CAVEX ® 2 400CVD hydrocyclone into the existing footprint, ensuring minimal disruption to operations.”
Following commissioning and operational adjustments, Dragon Mining saw immediate and measurable improvements in plant performance and gold recovery. The trial exceeded expectations and led to a full-scale implementation of the CAVEX ® 2 CVD hydrocyclones on site. Operating at the same throughput as the previous setup, Dragon Mining achieved a 3-4 % increase in gold recovery. This uplift was significant enough for the site to adopt the new configuration as its standard operating mode. The initial trial demonstrated a maximum plant capacity of 47 t / h, a 14.6 % increase over the original 41 t / h, exceeding the 10 % improvement predicted by simulation.
Daily reports showed that the 3-4 % recovery increase could deliver Dragon Mining an additional US $ 1-2 million per year, based on a gold price of US $ 1,850 / oz. The investment in upgrading both hydrocyclones to CAVEX ® 2 400CVD model paid for itself within just four days, far surpassing expectations.
How Casa Berardi reimagined its grinding circuit with Metso MHC™
Metso says its MHC™ Series hydrocyclone design represents the next generation of hydrocyclones. Equipped with worldclass technology and several innovative features, the new range of hydrocyclones offers significant product advantages in comparison to other hydrocyclones. MHC™ hydrocyclones are built to provide a solution to diverse needs, a balanced grinding circuit and overall plant performance.
The inlet head design was developed in coordination with simulation and modeling scientists using the latest CFD-DEM
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