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High Efficiency Concentrator

High efficiency concentrator is suitable to dewater concentrate and tailings in concentrator plant.

  • Applied Material:Slime, waste water, waste slag, etc
  • Capacity:5.6-6250t/d
  • High efficiency concentrator is suitable to dewater concentrate and tailings in concentrator plant. The high efficiency concentrator produced by our company is a machine for removing the water in the ore concentrate and the tailings in the ore beneficiation plant.

What is a Thickener?

High Efficiency Concentrator

Concentrate Thickener definition:

Thickener (also known as thickener or agitator) is suitable for concentrate and tailings dehydration treatment during the beneficiation process to increase the slurry concentration from 20-30% to 40-70%.

It is of great significance to improve the utilization rate of backwater, the concentration of bottom flow and protect the environment.

In fact, the high efficiency concentrator is not a kind of simple sedimentation equipment, but a new type of dehydration equipment combined with the characteristics of mud layer filtration.

It is divided into central transmission type, peripheral transmission type, sludge, intermittent type, vertical flow and continuous thickener.

A thickener is a device used to separate solids from liquids in a slurry, increasing the solids concentration.

It is a crucial step in mineral processing, wastewater treatment, and other industries. A concentrate thickener specifically increases the solids concentration of mineral concentrates before further processing, like filtration or tailings disposal.

The goal is efficient sludge thickening.

Table of Contents

What are Types of Gravity Thickeners in Mineral Processing?

There are several types of gravity thickeners used in mineral processing:

  • Rake Thickener: A conventional thickener with a rake mechanism to move settled solids to the discharge point.
  • Efficient Thickener: An advanced design with improved settling rates and underflow density.
  • Tilted Plate Thickener: Uses inclined plates to increase the settling area and improve efficiency.
  • Deep Cone Thickener: A cone-shaped thickener designed for high underflow density and efficient solids removal.

Each type offers unique advantages depending on the application and material characteristics.

What are Applications of Thickeners/Clarifier?

Thickeners and clarifiers are used in a wide range of applications:

  • Mineral Processing: Thickening mineral concentrates like copper, gold, iron ore, and lithium.
  • Wastewater Treatment: Removing solids from municipal and industrial wastewater.
  • Chemical Processing: Separating solids from liquids in chemical production processes.
  • Pulp and Paper Industry: Recovering fibers from pulp slurries.
High Efficiency Concentrator Application.jpg

High-efficiency thickeners are particularly suitable for mineral concentrates that require high underflow density and clear overflow, maximizing water recovery. This is applicable in different mining lvl.

High efficiency concentrator is suitable for dehydration, concentration and treatment of tailings in concentrator factory, and widely used in metallurgy, chemical industry, coal, non-metallic mineral processing, environmental protection and other industries.

Which Mineral Concentrates can Use this High-Efficiency Concentrator?

A High-Efficiency Concentrator is very versatile and can be used for almost all types of mineral concentrates.
Common Applications Include:

  • Base Metals: Copper, Lead, Zinc, Nickel
  • Precious Metals: Gold, Silver (especially for tailings)
  • Iron Ore
  • Industrial Minerals: Phosphate, Potash
  • Coal

They are used primarily to:

  • Maximize water recovery
  • Reduce the plant’s footprint (save space)
  • Improve tailings management

In short, if you need to dewater a slurry efficiently, a high-efficiency concentrator is a suitable choice.

What are Advantages of Concentrate Thickener?

Concentrate thickeners offer several advantages:

  • High Underflow Density: Produces a concentrated slurry for efficient downstream processing.
  • Clear Overflow: Recovers water for reuse in the plant, reducing water consumption.
  • Reduced Tailings Volume: Minimizes the volume of tailings for disposal, reducing environmental impact.
  • Improved Filtration: Provides a consistent feed to filtration equipment, improving performance.
  • Lower Flocculant Consumption: Optimized design reduces the need for flocculant.

ZONEDING thickeners are designed to minimize water and flocculant consumption, saving you money and resources.

What is the Structure of Efficient Thickener?

An efficient thickener typically consists of:

  • Feedwell: Introduces the slurry into the thickener, promoting gentle flocculation.
  • Tank: A circular tank where solids settle to the bottom.
  • Rake Mechanism: Moves settled solids to the center discharge point.
  • Underflow Pumping System: Removes the concentrated slurry from the bottom of the tank.
  • Overflow Weir: Collects the clarified water from the top of the tank.
  • Drive Mechanism: Powers the rake system and ensures efficient solids transport.
  • Control System: Monitors and adjusts process parameters.
High Efficiency Concentrator structure

The structure of our slurry thickener contributes to efficient sludge thickening. The high efficiency concentrator generally consists of the thickener pool, transmission device, lifting device, feeding device, unloading device and signal safety device. The main feature of this machine is to add a certain amount of flocculant to the pulp to be concentrated, so that the ore particles in the pulp will form flocculation groups and accelerate its settlement rate, so as to improve the concentration efficiency.

How Does the Gravity Thickening Equipment Work? Thickener work principle

Gravity thickening equipment works based on the principle of gravity settling. The slurry enters the thickener through the feedwell, where flocculants are added to promote the aggregation of fine particles. The aggregated particles settle to the bottom of the tank, forming a concentrated slurry. The clarified water rises to the top and is discharged over the overflow weir. The rake mechanism moves the settled solids to the center discharge point, from where it is pumped out as underflow. This is the core of thickening.

High Efficiency Concentrator work principle

The working principle of a high-efficiency concentrator involves two main aspects: increasing the size of solid particles and expanding the settlement area.

Increasing the size of solid particles in slurry and the settlement area of high-efficiency concentrator can improve the processing capacity of high-efficiency concentrator. The particle size of settling particles can be increased by adding flocculant to high-efficiency concentrator to make fine particles agglomerate. The inclined plate in the high-efficiency concentrator can increase the settlement area, shorten the settlement distance of particles and improve the concentration efficiency. The test and industrial production shows that under the same processing capacity, the diameter of the high-efficiency thickener is only two-thirds to half of the diameter of the ordinary thickener, and the area is about one-ninth to one-fourth of the ordinary thickener, while the processing capacity per unit area can be increased several times to dozens of times.

Why is the Concentrate Thickener Efficient?

Concentrate thickeners are efficient due to several design features:

  • Optimized Feedwell Design: Promotes gentle flocculation and minimizes turbulence.
  • Large Settling Area: Provides ample space for solids to settle, increasing throughput.
  • Efficient Rake Mechanism: Moves solids to the discharge point without disturbing the settled bed.
  • Automated Control System: Maintains optimal process parameters, ensuring consistent performance.

ZONEDING thickeners incorporate these features, making them highly efficient in solids recovery and water conservation.

Parameters Of High Efficiency Tailings Thickner / Concentrator 

High Efficiency Concentrator

Model GW-3 GW-5 GW-8 GW-10 GW-12 GW-20 GW-30 GW-40 GW-50
Filter area(m2) 3 5 8 10 12 20 30 40    -
Cylinder size(mm) φ1068×1060 φ1600×1060 φ2000×1500 φ2000×1750 φ2000×2000 φ2500×2650 φ3350×3000 φ3350×4000 φ3350×5000
 cylinder speed(r/min) 0.156-1.56 0.156-1.56 0.1-0.6 0.1-0.6 0.1-0.6 0.14-0.54 0.12-0.56 0.12-0.56 0.12-0.56
Vacuum pressure(KPa) 60-80 60-80 60-80 60-80 60-80 60-80 60-80 60-80 60-80
Swept volume(m3/min.m2) 0.5-2 0.5-2 0.5-2 0.5-2 0.5-2 0.5-2 0.5-2 0.5-2 0.5-2
Blast pressure(Kpa) 10-30 10-30 10-30 10-30 10-30 10-30 10-30 10-30 10-30
Blast volume(m3/min.m2) 0.2-0.4 0.2-0.4 0.2-0.4 0.2-0.4 0.2-0.4 0.2-0.4 0.2-0.4 0.2-0.4 0.2-0.4
Capacity(t/h) 0.8-1.5 1.6-2.4 2.8-3.6 3-4 3-5 3-8 4.5-12 6-16 7.5-20
Cylinder motor(kw) 1.5 1.5 2.2 2.2 2.2 3 4 4 5.5
Stirring motor(kw) 0.75 0.75 1.5 1.5 2.2 2.2 3 3 4
Weight(kg) 2635 2850 5455 6317 6365 10600 17200 19500 21500

What are Features of Thickening Machine from ZONEDING?

  • The flocculant is added to increase the particle size of settling solids, thus speeding up the settlement.
  • The inclined plate is installed to shorten the settlement distance of ore and increase the settlement area.
  • It can play a role in flocculating, filtering, compressing, and improve the treatment capacity of thick facies layer deposited by mud.
  • It is equipped with complete automatic control facilities.
High Efficiency Concentrator

ZONEDING thickening machines are known for:

  • High Efficiency: Achieves high underflow density and clear overflow.
  • Durable Construction: Built with high-quality materials for long-lasting performance.
  • Advanced Control System: Provides automated control of process parameters.
  • Low Maintenance: Designed for easy maintenance and minimal downtime.
  • Customization: Can be customized to meet specific plant requirements.

ZONEDING machines help in efficient slurry thickening and provide clear thickener meaning.

How to Measure Density in Thickening Process?

Density in the thickening process can be measured using various methods:

  • Density Meters: Installed in the underflow line to continuously monitor the slurry density.
  • Nuclear Density Gauges: Non-invasive gauges that measure density based on radiation absorption.
  • Manual Sampling: Collecting samples and measuring their density using a hydrometer or density bottle.

Accurate density measurement is crucial for controlling the thickening process and optimizing underflow density.

How does this Sludge Thickener Minimize Water and Flocculant Costs?

This sludge thickener minimizes water and flocculant costs through:

  • Efficient Settling: Maximizes solids settling, recovering more water for reuse.
  • Optimized Flocculation: Reduces flocculant consumption by promoting efficient floc formation.
  • Automated Control: Fine-tunes process parameters, minimizing water and flocculant usage.

ZONEDING thickeners use advanced control systems to minimize flocculant use, reducing your operating costs.

How to Choose a Suitable High-efficiency Thickener for Your Plant?

Choosing a suitable high-efficiency thickener involves considering:

  • Slurry Characteristics: Particle size, density, and settling characteristics.
  • Throughput Requirements: The volume of slurry to be processed per day.
  • Underflow Density: The desired solids concentration in the underflow.
  • Overflow Clarity: The required water quality for reuse.
  • Plant Layout: The available space and configuration of the plant.
  • Budget: The capital and operating costs of the thickener.
  • Consider thickener sizing calculation for your plant.

Consulting with a thickener manufacturer like ZONEDING can help you select the best thickener for your needs.

What is Price of Thickeners? And affecting factors?

The price of thickeners varies based on:

  • Type: High-efficiency thickeners are generally more expensive than conventional designs.
  • Size: Larger thickeners cost more due to increased material and manufacturing costs.
  • Materials of Construction: Using corrosion-resistant materials increases the price.
  • Automation Level: Automated control systems add to the cost.
  • Manufacturer: Established manufacturers with a reputation for quality may charge more.

Obtaining quotes from multiple manufacturers is essential for comparing prices and features.

How to Install Mining Thickener and What is Commissioning Process?

Installing a mining thickener involves:

  • Site Preparation: Preparing the foundation and ensuring proper drainage.
  • Equipment Assembly: Assembling the tank, rake mechanism, and other components.
  • Piping and Electrical Connections: Connecting the slurry feed, underflow, and overflow lines.
  • Control System Setup: Configuring the control system and calibrating instruments.

The commissioning process includes:

  • Testing: Testing the equipment and control system to ensure proper operation.
  • Startup: Gradually introducing the slurry and adjusting process parameters.
  • Optimization: Fine-tuning the process to achieve optimal performance.

Professional installation and commissioning are crucial for ensuring the thickener operates efficiently and reliably. The commissioning process should consider flocculant consumption

How to Maintain your thickener?

Maintaining your thickener involves:

  • Regular Inspection: Checking for wear and tear, corrosion, and leaks.
  • Lubrication: Lubricating moving parts to prevent wear and ensure smooth operation.
  • Cleaning: Removing scale and debris from the tank and rake mechanism.
  • Filter Replacement: Replacing filters in the hydraulic and lubrication systems.
  • Calibration: Calibrating instruments to ensure accurate measurements.
  • Prompt Repairs: Addressing any issues promptly to prevent further damage.

Proper maintenance ensures the thickener operates efficiently and reliably for many years. Part of maintenance is to clean clarifiers and thickeners.

Successful Case for ZONEDING Thickeners

High Efficiency Concentrator
High Efficiency Concentrator
High Efficiency Concentrator

ZONEDING thickeners have been successfully used in numerous mining operations worldwide. For example, our high-efficiency thickeners have significantly improved water recovery and reduced tailings volume in a copper mine in Chile. Another successful case involves the use of our thickeners in a lithium mine in Australia, where they have helped to produce a high-density concentrate for efficient downstream processing. These cases demonstrate the effectiveness and reliability of ZONEDING thickeners in various applications.

FAQ

Question 1: What is the difference between a thickener and a clarifier?
A thickener primarily increases the solids concentration of a slurry, while a clarifier removes suspended solids from a liquid to produce a clear effluent. They both are clarifiers and thickeners.
Question 2: What is the role of flocculant in the thickening process?
Flocculant is added to the slurry to promote the aggregation of fine particles, which enhances settling and increases the settling rate.
Question 3: How do I control the underflow density in a thickener?
Underflow density can be controlled by adjusting the underflow pump speed, rake lifting mechanism, and flocculant dosage. You can find the right underflow density control.
Question 4: What is the typical residence time in a thickener?
The typical residence time in a thickener ranges from 2 to 8 hours, depending on the slurry characteristics and throughput requirements.
Question 5: How often should I replace the rake blades in a thickener?
The frequency of rake blade replacement depends on the abrasiveness of the slurry and the operating conditions. Regular inspection helps to determine when replacement is necessary.
Question 6: Can I use a thickener for multiple types of mineral concentrates?
Yes, but the thickener may need to be adjusted to optimize performance for different slurry characteristics.
Question 7: What is the energy consumption of a high-efficiency thickener?
The energy consumption depends on the size and design of the thickener. High-efficiency thickeners typically consume less energy per ton of solids processed compared to conventional designs.
Question 8: What are the advantages of using an automated control system in a thickener?
An automated control system provides precise control of process parameters, improves efficiency, reduces operator workload, and minimizes process variability.
Contact ZONEDING today to learn more about our high efficiency thickeners and how they can optimize your mineral processing operations.

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