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Ø16m High Rate

Thickener

Description of Equipment
Doc. No. P2383-T30-C004, English 2017

Project Name: Cobre Panama


Customer Name: Minera Panamá S.A.
Equipment Name: 16m High Rate Thickener
Concentrate Filter Area Settler
Equipment Number: 712-TH-9001
Purchase Order Number: 1824-0014
Date of Order: 21 May 2014
Vendor Reference Number: P2383 T30
Vendor Contact Details: Outotec (Perth)
40 Kings Park Rd
WEST PERTH WA 6005 AUSTRALIA
Tel +61 8 9211 2200
Fax +61 8 9211 2201
Website: www.outotec.com
Email: services.seap@outotec.com
Ø16m High Rate Thickener Description of Equipment

This document is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This document is intended for the use of Outotec's customers only for the purposes of the
agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the document shall be used, reproduced, translated, converted,
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without the prior express written consent of Outotec.

Customer understands and accepts that the information in this document is subject to any change without notice. It is the customer's responsibility to determine whether there have
been any such updates or amendments.

The document has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every
effort has been made to ensure that the information in this document is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the
accuracy or completeness of the document. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort
or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation incidental, special, direct or
consequential damages arising out of or in connection with the use of the document. Outotec's liability for any errors in the document is limited to the documentary correction of
errors.

Outotec logo is a registered trademark of Outotec Oyj.

Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only.

Copyright © Outotec Oyj 2017. All rights reserved.

Outotec Oyj

Address: Rauhalanpuisto 9, PO Box 1000

FI-02231 Espoo, Finland

Telephone: +358 (0) 20 529 211

Fax: +358 20 529 2200

Internet: www.outotec.com

B J Long 04/07/2017 S Gillam 04/07/2017 S Gillam 04/07/2017 Update of front cover to include Equipment Name, Equipment Number, Purchase
Order Number, Date of Order, Vendor Reference Number & Vendor Contact details.
A J Long 07/03/2017 S Gillam 07/03/2017 S Gillam 07/03/2017 Client Review
Rev Name Date Name Date Name Date Revision Text
Prepared Checked Released
Status: Original Size:

Customer: Project Phase: Site No.:


Minera Panamá S.A.
Project Name: Customer Document ID:
Cobre Panama
Replaced by: Replaces:

Document Title:
IOMS MANUAL

Ø16M HIGH RATE THICKENER


CONCENTRATE FILTER AREA SETTLER
Equipment No: Item No:
712-TH-9001
DESCRIPTION OF EQUIPMENT

Original instructions Translation of the original instructions

Language: EN

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Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Outotec Document ID:
P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

Contents

Contents ............................................................................................................................. 3 

1  Product identification ............................................................................................. 5 

2  Process Description ................................................................................................ 6 


2.1  Solid-liquid separation ................................................................................ 6 
2.2  Gravity sedimentation ................................................................................ 6 
2.3  The thickener process ................................................................................ 6 
2.4  Concentrate thickening .............................................................................. 7 
2.5  Flocculants ................................................................................................. 8 
2.5.1  Coagulants ............................................................................................ 9 
2.6  The high rate thickener ............................................................................ 10 

3  Main components .................................................................................................. 11 


3.1  Tank and support structure ...................................................................... 11 
3.1.1  Support structure ................................................................................ 11 
3.1.2  Tank .................................................................................................... 11 
3.1.3  Bridge .................................................................................................. 12 
3.1.4  Vane feedwell ..................................................................................... 12 
3.1.5  Flocculant Delivery Box (Floc Box) ..................................................... 12 
3.1.6  Deflector cone ..................................................................................... 13 
3.1.7  Overflow launder ................................................................................. 13 
3.2  Rake and rake drive equipment ............................................................... 14 
3.2.1  Hydraulic powerpack........................................................................... 14 
3.2.2  Rake drive ........................................................................................... 14 
3.3  Rake arms ................................................................................................ 15 
3.3.1  Auto lifting/lowering mechanism ......................................................... 15 
3.4  Thickener control...................................................................................... 16 
3.4.1  Control panel....................................................................................... 16 
3.5  Instruments .............................................................................................. 18 
3.5.1  Torque measurement.......................................................................... 18 
3.5.2  Gearbox oil level switch ...................................................................... 18 
3.5.3  Powerpack oil level switch .................................................................. 18 
3.5.4  Temperature switch ............................................................................ 18 
3.5.5  Torque trip switch................................................................................ 18 
3.5.6  Rakelift limit switches .......................................................................... 18 
3.5.7  Bed level detector ............................................................................... 18 
3.5.8  Bed mass transmitter .......................................................................... 19 
3.5.9  Rake height indicator .......................................................................... 19 

4  Technical data........................................................................................................ 20 


4.1  General data ............................................................................................ 20 
4.2  Process details ......................................................................................... 20 

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

4.3  Tank ......................................................................................................... 21 


4.4  Mechanism ............................................................................................... 21 
4.5  Hydraulic Powerpack ............................................................................... 22 
4.6  Feedpipe and Feedwell ............................................................................ 22 

5  Product modifications .......................................................................................... 23 

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Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Outotec Document ID:
P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

1 Product identification

This manual refers to the Ø16m high rate thickener equipment number 712-TH-9001.

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

2 Process Description

2.1 Solid-liquid separation


The majority of minerals processing steps involve the use of water. Therefore, there
must be a stage where water is removed from the solids so that the final concentrate
can be transported and processed, or so that the water is recycled back into the plant's
process. The basic purpose of thickening is to remove or recover as much water from
slurry to achieve a thick underflow, and a clean/clear overflow. The slurry is usually
thickened for a subsequent processing step such as filtration or drying.

2.2 Gravity sedimentation


All particles in slurry tend to be charged and particles having identical charges will repel
and stay in suspension until the force of gravity causes them to settle and concentrate.

Sedimentation is a cost effective method of solid-liquid separation. When the density of


the liquid and solids differ significantly, the settling of solid particles over time results in
a clear liquid distinctly separate from a layer of thickened slurry. The rate at which
particles settle is dependent on the size of the particle: very fine particles settle very
slowly, where larger particles settle faster.

The function of a thickener is to accelerate this process of sedimentation. The desired


end product determines how the thickener is designed and operated.

In minerals processing, the mineral ores are ground to liberate the valuable minerals.
Separation processes are used to produce a high grade mineral concentrate. After the
separation process, the thickener is used to remove as much water as possible from the
concentrate or the tailings. The water can then be re-used.

2.3 The thickener process


For hydraulic flow in a thickener, see Figure Fluid flow in a thickener.

1. Feed slurry enters the feedwell via the feedpipe.


2. Flocculant is added to the feed slurry at optimal locations in the feedpipe and/or in
the feedwell.
3. Vanes in the feedwell promote mixing of the flocculated feed slurry and allow an
acceptable residence time (approximately 40-45 seconds).
4. With the mixing energy dissipated, the feed exits the feedwell and is injected
through the deflector cone and across the top of a deep fluidized bed.
5. The particles then settle to the bottom of the thickener, while the clear water rises to
the top.
6. The clear water at the top spills over a notched weir into a launder located around
the circumference of the thickener.
7. Constantly rotating rakes draw the underflow towards the centre of the thickener.
8. The underflow solids are then withdrawn from the thickener out of the underflow

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

pipe. Flow is regulated using pumps or valves.

1. Feed 6. Overflow
2. Feedpipe 7. Underflow
3. Flocculant 8. Deflection plate
4. Driveshaft 9. Rake arms
5. Feedwell

Figure 1. Thickener process overview

2.4 Concentrate thickening


The concentrate thickener processes the concentrate that contains the metal to be
extracted. It is therefore important to obtain as thick an underflow as possible for cost
effective transport and refining. In some cases the concentrate thickener underflow is
put through a filter to remove further liquid.

Concentrate thickeners are often prone to froth problems due to the solids loading,
presence of reagents and air from the flotation circuit and the hydrophobic nature of the
concentrate minerals.

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Ø16m High Rate Thickener Description of Equipment

1. Concentrate 3. Concentrate solids ready for transport for further processing


2. Liquor recycled to plant

Figure 2. Concentrate thickening

2.5 Flocculants
The most critical part of a thickener operation is flocculation. Flocculants are added to
the slurry to increase the rate of sedimentation. Flocculants provide faster settling rates,
better clarity and homogeneous solids collection.

Flocculants are long chain polymers (hydrocarbons) with charged groups attached -
very large molecules with molecular weights in the millions.

The chains uncoil due to charged site repulsion and hydration effects around the charge
sites. The charge groups on the flocculant polymer chain interact with the surface
charge on the solids particles.

The large molecules can reach out a long way and can interact with multiple particles
simultaneously holding them, drawing them together.

+ + + +

A. Two particles B. Flocculant


in suspension adsorption

+ + + +

Polymeric
Flocculant
Molecule C. Flocculant D. Particles
bridging flocculated

Figure 3. The flocculation process

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

With no flocculant, the solids settle slowly. Adding, for example, 10 g/t flocculant
increases the settling rate and increases the settled bed density. A 20 g/t flocculant
settles faster and gives a higher settled density. More flocculant generally increases the
underflow density and improves the clarity of the overflow. Too much flocculant,
however, can lead to overflocculation and inclusion of excess water within the floccs,
reducing the underflow density.

1. Underflow density 3. Flocculant dosage


2. Optimum flocculant dosage

Figure 4. Optimum flocculant dosage

Preparing the flocculant correctly is also important to thickener performance. Typically


the flocculant should be diluted into the range 0.025% to 0.05% w/v before addition to
the feedwell. This is often achieved with a secondary stage of dilution after the
flocculant preparation plant. Consult with the flocculant supplier for details on optimal
flocculant performance.

2.5.1 Coagulants
Coagulants are used when the majority of solids flocculate and settle well but the
background liquor is murky due to the presence of colloidal particles - very fine and well
dispersed.

Coagulants that are used vary among applications. One low cost option is to use
inorganic salts, the most common being Fe3+, Al3+ and Ca2+.

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

2.6 The high rate thickener


The high rate thickener (HRT) has been designed for efficient feedwell flocculation and
feed distribution to give it a higher area throughput (or solids loading) of 0.35-1.5 t/m2h.
This means that a high rate thickener can have a smaller footprint than a conventional
thickener and reduce costs. It is relatively fast to react to changes and is suitable for
automation with control based on constant solids inventory. The HRT can process a
high density underflow and is best suited for a relatively consistent process.

Typical applications include:

 Replacement for conventional thickeners


 Tailings
 Concentrates
 CCD
 Pre leach and post leaching duties
 Precipitation duties
 Water/waste treatment

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Ø16m High Rate Thickener Description of Equipment

3 Main components

3.1 Tank and support structure

3.1.1 Support structure


The support structure holds up the tank and contents (at full underflow SG). This design
utilizes radial beams supporting a scalloped floor to increase strength at reduced
weight.

Figure 5. Construction of radial beam thickeners

3.1.2 Tank
The tank is constructed from Carbon Steel. The conical tank floor and walls are
delivered in sections of plate and are welded together on site.

Figure 6. A typical radial beam thickener tank

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Ø16m High Rate Thickener Description of Equipment

3.1.3 Bridge
Spanning the tank is a bridge. The bridge is supported by a beam construction and
allows access to the equipment and instruments over the thickener. The bridge also
supports the weight of the rake mechanism and other equipment.

3.1.4 Vane feedwell


Incoming feed enters the circular feedwell tangentially, promoting a gentle mixing of the
pulp. Diluted flocculant can be injected into optimal locations in the feedwell, the feed
pipe or autodils. Efficient dispersion of the flocculant is ensured by the mixing action of
the pulp, aided by the vane plates.

The feedwell is sized to allow for de-aeration of the incoming feed pulp. Feed is injected
into the pulp bed at an angle controlled by the deflector cone. The design allows for
even distribution of feed across entire floor.

1. Deflector cone 4. Shelf


2. Plate gap space 5. Feed transition
3. Vanes 6. Mixing baffle

Figure 7. Components of the vane feedwell

3.1.5 Flocculant Delivery Box (Floc Box)


The Floc Box performs secondary dilution of the flocculant mix and controls its rate of
addition into the feed.

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Ø16m High Rate Thickener Description of Equipment

Flocculant is normally prepared in two stages. Firstly as a relatively high concentration


(0.25% - 0.50% w/v), also known as stock solution. In this form it is too viscous to mix
effectively into the slurry, so a secondary dilution to approximately 0.025% w/v follows.
The stock solution is more resistant to damage through shearing than the final dilution
flocculant. In Floc Box, stock solution is delivered to the first chamber of the box,
together with the secondary dilution water. This secondary dilution occurs on the bridge
of the thickener, minimising unwanted flocculant shearing prior to deliver to the feedwell.

The box is placed so the thickener operator can easily see into the box and adjust the
flow split. Concentrated flocculant solution and dilution water are injected together from
spray bars giving the initial dispersion. A series of baffles then mix the solution down to
the required level of dilution.

3.1.6 Deflector cone


The deflector plate is used to inject the feed into the thickener bed and minimize short
circuits. The deflector gap has adjustable supports to allow for changes in feed velocity
and a shaft-mounted scraper to prevent blockage. The ideal injection velocity will
normally depend on the underflow density. Injecting the feed into the bed ensures that
fine or unflocculated particles do not float across the thickener surface into the overflow.

Figure 8. Deflector cone

3.1.7 Overflow launder


The overflow launder discharges the clear liquor. Notched weir plates are used to
ensure an even flow from the thickener. Final discharge is into an overflow box.

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

Figure 9. Clear liquor spilling into an overflow launder

3.2 Rake and rake drive equipment

3.2.1 Hydraulic powerpack


Powers the rake lift mechanism and the hydraulic motor which drives the rakes.

The variable speed drive has an electric motor directly coupled via bellhousing and
flexible drive coupling to a variable displacement axial piston pump. The final rake
output speed or tip speed is fully adjustable from zero up to the maximum pump output
flow, via the onboard pump flow control screw.

A fixed volume gear pump for the rake lift is through driven from the rake drive piston
pump.

The reservoir is mounted to the base frame with integral drip tray and sun shade cover.
System filtration is via a 10 micron return filter, the reservoir has a 3 micron air breather.
An air blast cooler cools the return oil from the circuit.

Solenoid control valves are mounted on a manifold. The manifold also incorporates the
system pressure relief valves, flow and check valves.

3.2.2 Rake drive


The drive system comprises of a hydraulic motor on a multistage planetary gearbox.
The gearbox output shaft couples to the drive shaft.

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

Thickener gearboxes take a low torque or high rpm input and convert it to a high torque
or low rpm output.

Thickener gearboxes are epicyclic planetary in design. They consist of a number of


stages, each with its own fixed ratio. The overall gearbox ratio is the product of the
stage ratios. Larger, higher torque, gearboxes require higher ratios, and more stages, to
generate the higher torque.

Figure 10. Internal parts of a multi-stage planetary gearbox

3.3 Rake arms


The thickener is equipped with four rake arms fitted with blades arranged to sweep the
entire floor of the thickener twice every revolution. Rake blades scrape the solids along
the floor towards the centre where it is removed as underflow. The rakes are supported
by the drive shaft that is attached to the main drive head output shaft. Normal rotational
direction is clockwise.

3.3.1 Auto lifting/lowering mechanism


The lifting and lowering of the rakes is controlled by the torque. Raising the rakes
reduces the risk of bogging the drive and gives the operator extra time to overcome the
process anomalies causing the high torque.

The rakes can be manually raised and lowered using buttons. The lifting action occurs
through the use of hydraulic rams powered by a pump on the powerpack. Raising speed
is fixed based on the setting of the flow control valve in the rakelift hydraulic circuit. The
lowering speed, whilst fixed at the same speed as the raise rate, is interrupted with
adjustable pauses to control the rate of lowering.

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

Figure 11. Hydraulic rake lift mechanism

Control of automatic lifting and lowering occurs as follows:

When torque increases to 50% of maximum, the rake lift is activated. The lift continues
to raise the drive head until either:

1. Torque drops below 45% or,


2. Drive reaches the high limit switch.

When torque decreases below 40%, the rake lift is lowered. This operates for two
seconds every two minutes, so gradual lowering occurs, and cycling is prevented.

3.4 Thickener control

3.4.1 Control panel


The control panel is used for local control of the thickener. It can be tied into site
supplied PLC/DCS to supply monitoring signals. It provides stand-alone alarms and
logic used for troubleshooting and commissioning.

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

Figure 12. An example relay panel

The set points and deadbands associated with high torque alarm, high torque trip and
100% drive capacity are set at the factory and should only be adjusted by an Outotec
representative, or after consulting the Outotec Service and After Sales Division.

The relay panel for the Thickener includes the following items:

 Power isolator
 Emergency stop button
 Rake torque display 0-100% (digital)
 Lamp test push button
 General power outlet
 Rake drive controls
 Rake lift controls
 Hydraulic powerpack controls
 Bed mass display 0-100% (digital)
 Rake height display 0-100% (digital)
 Bed level display 0-100% (digital)

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

3.5 Instruments

3.5.1 Torque measurement


The hydraulic pressure is indicated on a digital display, scaled 0-100%. The signal is
generated by a pressure transmitter mounted on the hydraulic power pack.

3.5.2 Gearbox oil level switch


The planetary gearbox is fitted with an oil level switch that activates an alarm on the
control panel and the DCS when the oil level drops below the safe level.

This alarm does not stop the rake drive in instances of low oil level, it is an alarm only.

3.5.3 Powerpack oil level switch


Detects the level of oil in the powerpack tank and activates when the low limit is
reached.

3.5.4 Temperature switch


Monitors the temperature of the oil in the powerpack tank and activates when the high
limit is reached.

3.5.5 Torque trip switch


This is a pressure switch that trips the powerpack when the torque exceeds a pressure
equivalent to 95% torque. If this happens, the control panel will indicate that the rake
torque has tripped.

3.5.6 Rakelift limit switches


Limit switches that indicate that the highest or lowest rake height has been reached.

3.5.7 Bed level detector


Bed level is detected using a floatation device, carefully weighted so that it floats at the
top of the bed level. Magnetic sensors determine the height of the float.

The bed level sensor generates a 4-20 mA signal, which represents 0 to 100% bed
level. This signal can be used for flocculant dosing control.

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

Figure 13. A float sensor for bed level detection

3.5.8 Bed mass transmitter


The bed mass transmitter monitors the fluid pressure at the bottom of the thickener and
reports the bed mass as a percentage of two initial set values. The transmitter returns a
4-20 mA signal to the control panel. This signal can be used to control underflow
withdrawal.

3.5.9 Rake height indicator


The rake height indicator utilizes an ultrasonic detector to measure how high the rakes
have raised.

This instrument generates a 4-20 mA signal, which represents 0 to 100% rake height.

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

4 Technical data

4.1 General data

Table 1. General data

General data Description

Manufacturer Outotec Pty Ltd

Client company Minera Panamá S.A.

Site / Project name Cobre Panama

Thickener type High Rate Thickener

Application Concentrate Filter Area Settler

Client Equipment Number 712-TH-9001

4.2 Process details

Table 2. Process details

Process Description

Solids Feed 133.0 t/hr

Dry Solids SG 3.870

Liquor SG 1.000

Feed 354 m3/hr

Feed % solids (w/w) 29.40

Feed Pulp SG 1.279

Diluted Feed % Solids: 29.40

Underflow % Solids 65.0

Underflow SG 1.931

Flocculant Dosage 20 g/t

Deflector Plate Gap 72 mm

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

4.3 Tank

Table 3. Tank details

Tank Description

Tank Construction Type Welded Radial Beam Tank

Material Carbon Steel

Lining Paint

Tank Diameter 16 m

Sidewall Height 2400 mm

Floor Slope 1:6

Bridge Type Full Span – Beam Bridge

4.4 Mechanism

Table 4. Mechanism details

Mechanism Description

Drive Type Hydraulic

Motor Type OMS 125

Gearbox Type Bonfiglioli 315 L4 HZ

Gearbox Ratio 1:566

Rake Speed 0.199 rpm

Maximum Operating Torque 140,000 Nm

Rake Arm Qty. 2 Long + 2 Short

Rakelift Type Hydraulic

Rakelift distance 300 mm

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Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Outotec Document ID:
P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

4.5 Hydraulic Powerpack

Table 5. Hydraulic Powerpack

Hydraulic Powerpack Description

Motor Data WEG 7.5kW 4P 60Hz 460V Frame: 132S

4.6 Feedpipe and Feedwell

Table 6. Feedpipe and Feedwell details

Feedpipe and Feedwell Description

Feedpipe Diameter DN 350

Feedwell Diameter 2000 mm

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P2383T30 IOMS Manual B P2383-T30-C004
Ø16m High Rate Thickener Description of Equipment

5 Product modifications

Modifications, repairs, and/or changes to the equipment are not allowed without
Outotec’s prior written permission and may only be carried out by appropriately qualified
personnel subject to prior authorization by Outotec.

In case of any modifications, repairs or changes made to the equipment without the
prior written authorization by Outotec, Outotec shall not be liable under any theory of
law for any direct or indirect cost, loss, or damage, including but not limited to damage
to any property or person, loss of use, loss of production, or loss of profits or anticipated
profits, loss by reason of shut-down or non-operation, increased expenses of operation,
increased use of raw materials, energy or labor, liability arising out of or in connection
with pollution or contamination, or the cost of repair to or replacement of any equipment,
facilities or goods and/or third party services related thereto. Any warranty, guarantee or
indemnity provided to or in relation to the equipment by Outotec shall no longer apply to
the equipment in the event of such unauthorized modification, repair or change.

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P2383T30 IOMS Manual B P2383-T30-C004
Outotec (Head Office) Outotec (Sydney) Outotec (Perth)
P.O. Box 1000 28 Rodborough Road 40 Kings Park Road
FI-02231 Espoo, Finland Frenchs Forest NSW 2086 Australia West Perth WA 6005
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