Filtration Solutions

Calcium Carbonate 2011

Challenges selling to White Pigment Producers
Deal mostly with end user/technology owner
Confidentiality/very competitive
Same product/different processes/modifications
Lots of local low cost competitors
Consultative selling
Euro based manufacture

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Advanced Alternative – PF Filters

Providing Value Added Solid/Liquid Separation

• Reduced Lifetime Production Costs
• Improved Product Quality, Value and Consistency
• Improved Safety, Health and Environmental Performance
• Improved Yield

Lowest cost/ton at highest reliability

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Automatic Pressure Filtration
vast experience in:
White Mineral dewatering; including
paper,paint and plastic fillers, paper
coatings and food and pharma additives
Different crystal forms
Different particle size distributions
Coated and uncoated grades
washing of impurities

4 2010 © Outotec 1.6m2 to 168m2

 White Minerals
Precipitated Calcium Carbonate (PCC)
• 40 units sold to 15 different PCC producers
• 39 PF and 1 LSF
• 18 different countries

Talc
• 18 units sold to 3 different talc producers
• 18 PF
• 2 different countries

Ground Calcium Carbonate (GCC)

• 5 units sold to 2 different GCC producers
• 5 PF,
• 4 different countries

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 C 48
The newest highest performance Outotec
Larox C Series PF filter for Industrial Mineral
dewatering

• Filtration area from 48 m2 to 168 m2 (517 – 1808 ft2)

• 33, 45 and 60mm chambers (1.3 – 2.4 in)
• 6m2 plate (65 ft2) – SS and PP materials available
• simple design
• less changeable parts, easy maintenance,
lower operating costs
• Reduced technical time
• Continuous cloth
• Automatic cloth tracking and washing
• Automatic cake discharge
• Short cycle times (more drops/hour)
• Expandable in 12 m2 steps (129 ft2)
• easier to keep clean
• optional maintenance platforms and sheilds
• Meets occupational and safety requirements
3 – 40mT d.s./hr
Depending on application

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 Fully Automatic Operation

•*SCADA based solution available at additional cost*

•supports unmaned operation concept

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 PF Benefits for Carbonates

 Ability to effectively and efficiently dewater fine particles

 Solids content in filter cake from 55% and up to 90% depending on material,
feed solids, particle size and morphology
 Reduced dryer size and therefore capital cost
 Reduced energy/fuel consumption
 Automatic handling of all mineral products
 Flexibility in grade changes
 Consistent results (minimal effect on down-stream equipment)
 Improved product recovery/less solids in filtrate
 Product washing capabilities
 Low operating costs (energy and maintenance)
 Reliable (>90% availability)

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 Larox Experience in PCC Production
Some Typical Results:
”Difficult” PCC, PSD50 < 1 microns (aragonite, rhombohedral, stearate coated)
- capacity: 20 - 90 kg/m2h
- moisture: 35 - 45 %
”Normal” PCC, PSD50 1 - 2 microns (clustered aragonite, scalenohedral)
 - capacity: 75 - 150 kg/m2h
 - moisture: 30 - 40 %
”Easy” PCC, PSD50 > 2 microns (scalenohedral, prismatic)
 - capacity: 90 – 200 kg/m2h
 - moisture: 20 - 35 %
*only estimates, should be confirmed with testing*

total filtration cycle time: 8 – 20min

depending on slurry properties and amount of dispersant
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Larox Solutions for PCC Dewatering

Mass Balance

Slurry 15%w/w 5556 kg

PCC – 1.8um
Solids 833 kg Aragonitic
Liquid 4723 kg

Cake ~70 %w/w 1186kg

Solids ~ 830 kg
Liquid ~ 356 kg

Filtrate ~ 4370 kg
Solids 3 kg
Liquid 4367 kg

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 Larox Solutions for PCC Dewatering
Typical Cycle vs. Energy Consumption in PCC Coating Grade

Solids Relative Dewatering Degree Energy

70% 100%
Cake Air Blowing
94%
67%

14,15 88%
Diaphragm Pressing

20%
30%

Technical
Filtration time 1,35 8%

0% 0,60 4%
Solids 20%
0 2 8 10 13 16.1 kWh/ton D.S.
Cycle Time (min)

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Larox Experience in GCC Production
Some Typical Results:
”Difficult” (<2um ”steep”, heavily dispersed)
- capacity: 50 – 100 kg/m2/hr
- moisture: 28 - 40%
”Normal” (< 3um, with dispersant)
- capacity: 70 - 120 kg/m2/hr
- moisture: 25 – 35%
”Easy” (tailings or waste; > 7um)
- capacity: 200 – 700 kg/m2/hr (concentrated)
50 – 100 kg/m2/hr (low solids; <10%)
- moisture: 10 – 20%

•*only estimates, should be confirmed with testing*

total filtration cycle time: 8 – 20min

depending on slurry properties and amount of dispersant
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 PF Energy Consumption
Est. Typical Cycle vs. Energy Consumption for 2um Undisp. GCC

Solids Relative Dewatering Degree Energy

78% 100%
Cake Air Blowing
94%
75%

11,7 73%
Diaphragm Pressing

48%
51%

Filtration 3,2 20%

0% 1,2 7%
Solids 35%
0 2 4.5 7.5 Technical
11 ~16,1 kWh/ton D.S.
time

Cycle Time (min)

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Why is S/L Separation important to White Pigment producers?

3
ENERGY! (among other operating costs)

2,5

2
price of energy

1,5

0,5

0
Jan 2004 April 2004 July 2004 Oct 2004 Jan 2005 April 2005 July 2005 Oct 2005 March 2006

Time

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 Simplified Larox Pressure Filter Benefits based on Testing
FP vs. PF Results

Reduced drying costs

Drying cost/ton

15 t/hr dry solids production

41
40
39
$/ton dry solids

38 $577200/yr savings
37
36
35
34 -$4.81/t
33
Filter Press @ 38% feed moisture Larox PF @ 35% feed moisture
dewatering equipment
oil = $586/ton

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Automatic Pressure Filter Benefits for Industrial Minerals

Dryer capacity as a result of feed moisture

10 t/hr dry solids production

12
tons/hr dry solids

11,5

11

10,5 +15.9%
10

9,5

9
Conv. Method @ 30% feed Larox PF @ 27% feed moisture
moisture
dewatering equipment

Increased Dryer Capacity

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 Automatic Polishing Filtration

also experience in:

• Polishing centrates and filtrates
• Water recycling
• Effluent water treatment
• Recovery of very fine particle sizes

Up to 720m2

improvement in Larox PF cloth choices has reduced need for polishing of PF filtrate

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 Polishing Filters

Flowsheet
Larox A-series
Polishing
Filter

Product Polished Liquid

or Barren Liquid

Carbonation Slurry Filtrate To effluent

reactor or recycle:
slaking,
carbonator or
diltution

Backwash
Slurry combatable with:
• thickener/clarifier overflow
• centrifuge centrates
• chamber or vacuum filter filtrates
• prior to crystallisation or precipitation

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 Polishing Filter Benefits for IM
savings per year in 95% product recovery
1000ppm (0.1%) solids in feed to polishing filter
800000
700000
600000
500000
400000
€

300000
200000
100000
0
0 10 20 30 40 50 60
m3/hr

€100/t €500/t €1000/t €2000/t

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 Automatic Polishing Filtration
Benefits
Solids content in filtrate 10 to 300ppm depending on particle size and feed
characteristics
Extremely clear filtrate means water may be recycled within the process
Increased product recovery and yield
Waste water effluent treatment savings
Low operational costs (energy and maintanence)
Automatic handling of all products
Flexibility in grade changes

COST SAVINGS!

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 Carbonate References

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Proven Supplier to Carbonate Industry
Conclusion

• Larox PF the chosen equipment for leading global

pigment producers for washing and dewatering – over
260 references total and 40 for Carbonates

• Better process control enables more consistent and

efficient washing and dewatering resulting in a significant
reduction in drying, washing and waste treatment
requirements while producing the highest quality pigment

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 Conclusion

An industry leader and proven solution provider for

industrial mineral dewatering
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 Conclusion
Before
Water

Slurry

Cake
Cake
Energy
Filtrate

W aste
treatm ent

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 Conclusion
After
Water
Larox C-Series
Pressure Filter

Slurry

Cake
Filtrate Cake
Energy

Larox
Polishing
Filter

Waste
treatment

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 Or better still
After
Water
Larox C-Series
Pressure Filter

Slurry

Cake
Filtrate Cake
Energy

Larox
Polishing
Filter

Waste
treatment

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Outotec Larox Filtration Solution address all the
important factors

Lifetime production costs Quality/ value/ consistency

Safety, Health, Environment Yield/ Productivity

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 Thank You!

Sustainable
use of
Earth's natural
resources

28 2010 © Outotec