DESIGN AND OPERATION OF A PINNED BED CLARIFIER

IN SOLVENT EXTRACTION
by Baxter1 K.G., Richmond2 G.D., and White3 M.
1 Technical Manager - Copper - Bateman Brown and Root.
2 Group Metallurgist - Western Metals.
3 Manager, Mineral Processing ConSep Pty Ltd.

1.0 INTRODUCTION
In October 1998 a new autoclave leaching and solvent extraction circuit was commissioned on
the Gunpowder Copper mine site (subsequently Mt Gordon Operations, Western Metals) in
Northern Queensland to treat secondary copper sulfides. A key component of the new process
plant was the Pregnant Liquor Solution (PLS) clarification circuit which was developed around
the concept of a Pinned Bed Clarifier (PBC).
The concept of the PBC is not new. Small scale
units operating on similar principles have been
used on river water clarification in Africa and a
device described as buoyant media filtration has
been used in the electroplating industry. The
incentive to progress application of the
technology came from the failure of conventional
clarification options to meet the tight
requirements for suspended solids levels in the
PLS liquor feed to solvent extraction.
Research of published literature on the topic (see
references) established that a PBC should be
capable of meeting the project process
requirements. Bateman Process Equipment
(BPE) were approached to assist in the
development of a test work program and to
provide a pilot rig to evaluate the performance of
a unit on real liquors produced in a pilot plant on
site.
Picture 1: Pinned Bed Clarifier
The pilot unit design was based around the Ultrasep thickener configuration with the required
modifications. Data from the pilot test program met process expectations and a decision was
made to proceed to engineering.

2.0

PROCESS ISSUES

A key issue in the design of an agitated leach followed by solvent extraction is to ensure that
the PLS feed to solvent extraction is properly clarified and protected from process upsets. The
process requirement was to produce a PLS stream containing less than 40 ppm suspended
solids.
The process slurry entering the solids liquid separation stage can be categorized as follows:
Solution Flowrate
Solids Flowrate
Temperature
Size Distribution
Liquor S.G.
pH

223 - 283 m/h

55 - 84 t/h
40 - 45 C
P80 = 75 - 106 m
1.15 - 1.23
<1

Test work had shown that under normal operation the overflow from a thickener treating
leached slurry contained too high a level suspended solids for subsequent sand filtration prior
to solvent extraction. Attempts to further coagulate/flocculate those fines were unsuccessful.
Evaluation of a range of pressure filters with and without precoat failed to provide satisfactory
unit filtration rates and the requirement for precoat was excessively high.
However if the thickener was allowed to run dirty by the reduction/elimination of flocculant
addition then the subsequent dirty overflow could be readily coagulated and flocculated. That
is, a certain minimum solids loading was required before sufficient size flocs could be formed.
A range of coagulants and flocculants were tested. Responses varied with different ore types
but a combination of up to 20 ppm PEG coagulant and 20 ppm of nonionic flocculant give the
best results.
The process issue then became one of clarifying a PLS stream of up to 283 m/h containing
5,000 - 50,000 ppm suspended solids of less than 10 m to <40 ppm suspended solids. The
suspended solids were a mixture of fine pyrite, silica, gangue and sulphur that exhibited a
bimodal size distribution with peaks at 0.8 microns and 8 microns. The ultra-fines present in
this stream proved to be difficult to filter by conventional means.
Sand filters cannot be used at the high suspended solids loading hence the initial test work
focussed on pressure filtration with and without a precoat on the filter cloth. Subsequent
evaluation of a range of pressure filter equipment and precoat types failed to provide
satisfactory unit filtration rates and the requirements of precoat were excessively high.
Filtration of the PLS through a flocculated blanket of solids was proposed and after some
investigation and a literature survey of the concept, it was decided to produce a pilot unit. The
unit was taken to site and installed as part of the pilot plant that was operated on site to provide
test work data for the process.
The results achieved were within the target suspended solids range and there was sufficient
confidence in the robustness of the concept to proceed to engineer a full scale unit to the
required duty.

3.0 CONCEPT
The concept of a PBC differs from the wide range of flocculated bed clarifiers that have been
used in the mining industry to date. Most have relied on the rise velocity of the solution to
suspend the bed and as such the operation of a unit was sensitive to fluctuations in the feed
rate.
In this case, as illustrated by Figure 1, the PBC comprises a cone and outer cylinder outer
body similar to a pachuca with a central feed pipe down to the level of the top of the cone. The
greater proportion of the flocculated solids are withdrawn through the base of the cone and a
smaller proportion rise with the liquor flow and are pinned against a layer of fine beads that are
in turn pinned against a fine screen deck. The screen is located horizontally in the top of the
cylindrical section of the unit.

Feed

Feed pipe
Liquor
Level
Overflow Launder
Screen

Overflow

Beads
Pinned Bed

Backwash Pipe

Underflow
Figure 1: Pinned Bed Clarifier

Configuration

The feed pipe is extended above the platform level on the top of the unit and the differential
head between the overflow of the clarifier and the level in the feed pipe provides a measure of
the differential head through the flocculated bed.
The benefits of this approach are:

the unit is not sensitive to fluctuations in feed flow rate

the backwash cycle could be initiated from the differential head
the flocculated bed is packed tightly against the beads and provided a tight fluid path to
trap any fine flocculated solids.
lower operating cost than pressure filtration options
low operator supervision
lower capital cost than pressure filtration options

Periodically, the clarifier can be back-washed and the flocculated bed back flushed out the side
of the unit. Once the bed is re-established, the unit returns to service.
Conceptually, the PBC satisfied the requirements of the process.

4.0 PILOT TEST WORK

In parallel with this work Bateman Process Equipment (BPE) were also conducting thickener
test work on site for other applications as part of the pilot program plant designed to test the
new process route at Mt Gordon. Test work was carried out on site using the Ultrasep ultra
high rate thickener pilot unit (Picture 2). The Ultrasep is a rakeless thickener which uses height
and sloping surfaces to assist in consolidation of the underflow. The layout of the machine was
similar to that envisioned for the PBC and so it was decided to test the concept by modification
of the Ultrasep.
Several parts were manufactured to allow the Ultrasep
to function as a PBC demonstration unit. These parts
included an extended feed well, a fine mesh screen
and the means to retain it within the tank shell and a
supply of suitable fine beads. The underflow
arrangements of the Ultrasep were adapted to provide
the back wash capacity for cleaning of the bed.
Due to the relatively large size of the Ultrasep pilot
unit the Mt Gordon pilot plant was unable to provide
enough feed to test the process to its limits. A
synthetic feed was therefore arranged using a mixed
tank with solution from the process and solids added
from a dry filtrate stockpile. A simple system of a
pump, control valves and bypass hose was arranged
to allow the flow rate to be varied. Due to the low feed
density there were some concerns about floc
contacting so a static mixer was placed in the feed line
just down stream from the floc injection point to
improve floc mixing.
Picture 2: Ultrasep Pilot Plant

The components were installed in the Ultrasep and test work commenced. Partly due to the
short time scale and partly due to the nature of test work a number of minor problems were
experienced with the feed arrangements. These problems included variation in the feed flow
rate, variations in the feed density due to the manual mixing of the synthetic feed and coarse
particles scooped up with the dry filtrate blocked control valves and the static mixer. The
modifications to the Ultrasep also proved to be less than ideal in some areas.
Despite these problems the first round of test work showed excellent promise. Output clarity,
although variable, was significantly better than that achieved with conventional clarifiers, with
some readings better than 40 ppm. Viewing windows in the Ultrasep allowed observation of the
bed formation, conditions leading to channeling through the bed and the impact of backwash
on bed cleaning. The test work showed that significantly better clarity was achieved by dosing
floc well ahead of the test unit to allow for floc contacting.
Information gained from the first round of testing was used
in the design of a dedicated PBC demonstration unit
(Picture 3). The PBC demonstration unit is a simplified
section through a PBC. The diameter is only 200 mm so
flows are well within the capacity of small scale pilot plants.
It is constructed entirely in plastic both for corrosion
resistance and to allow easy observation of floc build up
and cleaning. The unit was provided with a small header
tank which does the dual duty of providing residence time
for floc contacting and gives variable head to drive the
system. A manual backflush valve was provided.
A test program was commenced using the PBC
demonstration unit. Work was carried out to optimize the
type of beads used in the pinned bed, establish driving
head required, throughputs, backflush rates and estimated
period between backflushing. Regular samples were taken
for overflow clarity. Information collected in the first round of
testing proved invaluable as a springboard to the second
test series which was very successful. The 200 mm PBC
demonstrator produced consistent overflow clarity of better
than 20 ppm with some figures as low as 12 ppm. Build up
rate of the pinned bed, throughput, backflush rates and
driving head were very consistent throughout the testing
giving us good confidence in the data.
Picture 3: Clarifier Pilot Plant
Commissioning of the Gunpowder PBC and subsequent test work at other sites has shown
that scale up from the 200 mm unit to full size is reliable and has allowed us to establish the
operating parameters for the PBC on a range of different feed types.

5.0 PROCESS IMPLEMENTATION

The PBC is the key component of the Mt Gordon PLS clarification circuit. The overall circuit
configuration including the PBC, illustrated in Figure 2., is discussed below.
The autoclave leach circuit discharges to a conventional hydroclassifier designed to produce
an underflow density suitable for the residue belt filter and overflow liquor containing a majority
of the -10 micron fines. The overflow is collected in a surge tank that has approximately 0.8
hrs of live capacity at the maximum overflow rate. A pump on the surge tank feeds overflow
back to the hydroclassifier feed to allow the rise rate in the hydroclassifier to be adjusted and
regulated to control the fines off-take to the PBC.
A second pump on the hydroclassifier overflow surge tank pumps up to a flocculant
conditioning tank which overflows under gravity into the feed pipe of the PBC. Coagulant is
added to the pump discharge and is mixed by a static inline mixer ahead of the conditioning
tank. Either nonionic or cationic flocculant can be added to the conditioning tank.
The PBC overflows to a transfer tank. Clarified PLS is pumped from the transfer tank at a rate
controlled by the level in the surge tank but generally at a flow-rate less than the circulating
flow through the PBC. The differential between the clarifier feed rate and the PLS feed rate
overflows the transfer tank under gravity back to the hydroclassifier surge tank. The clarifier
feed rate is set to keep this differential positive. In this manner the flow rate to the PBC can be
maintained at a constant rate regardless of fluctuations in the overall plant feed rate, and the
transfer tank is always run full.
The pinned bed is established by a horizontal screen panel located some 1.5m below the
overflow point of the clarifier. A layer of fine, low density beads is trapped against the screen
by the up-flow within the clarifier and fine flocculated solids aggregates as a layer below and to
an extent within the beads. This bed of flocculated fines is extremely effective in trapping all of
the fine solids within the rising flow in the clarifier.
Back flushing if the bed is achieved by opening a large dump valve at the base of tank for
about one minute. This occurs without interruption to the feed. As the overflow is larger than
the inflow the tank level drops. Back flow through the beads expands the bed and the
flocculated solids.

Nonionic Flocculant
Cationic Flocculant

Flowmeter

In Line Mixer

CCD Wash
Circuit

Backwash
Valve

Coagulant

Leach Circuit
Discharge

PID

Sand
Filters

Control
Valve

VSD

Control
Valve

Residue
Filter

VSD

Transfer
Tank

Figure 2: PLS Clarifier Circuit

Pinned Bed
Clarifier

VSD
Flocculant
Conditioning
Tank

Surge Tank

Hydroclassifier

Clarifier overflow is pumped from the transfer tank to a series of three sand filters operating in
parallel which perform a final clarification on the PLS. The sand filters also act as a final safety
check against any process upset of the pinned bed which could discharge high levels of
suspended solids to solvent extraction. In practice, the concept of providing the sand filter
backup has proved to be correct and on irregular occasions has performed the duty required
with very high but short term solids feed loading.

6.0 OPERATIONAL DATA

Given stable operating conditions the PBC has produced good clarities since the day it was
commissioned.
The initial operation of the PBC was made difficult by the transition ores at the top of the
orebody containing more siltstone which produced variable fines in the feed to the leach circuit.
Also the grinding circuit was operated at a lower feed rate to minimise the amount of coarse
particles entering the leach circuit. This also increased the amount of fines being generated.
The variable nature of the feed to the PBC resulted in flocculant being added to the
hydroclassifier. Further coagulation and flocculation ahead of the PBC was then not as
effective leading to variable results in the PBC overflow and to overflocculation of the solids in
the PBC. The overflocculation and variable load to the PBC led to pump discharge problems
and periodic overloading of the PBC.
In May 1999 the ore feed increased in sulphide content to average orebody levels. A trash
screen on the grinding circuit cyclone overflow also allowed the grind to be coarsened. These
moves allowed flocculant additions to be discontinued to the hydroclassifier. Circuit operation
then reverted to the original design parameters with a corresponding decrease in process
disturbances in either the overflow clarities or loading within the PBC.
Overflow clarities of <30 ppm solids are now regularly achieved. Even during periods when the
operation of the PBC was less then ideal the clarities produced were satisfactory and far better
than could have been expected from a conventional clarifier judging from pilot plant
experience. Together with the protection of the downstream sand filters very few solids ever
reach the solvent extraction circuit. The amount of crud formed in the solvent extraction circuit
has been extremely low in direct contrast to the pilot plant operation.
Generally the backwash of the PBC has been undertaken on a manual basis with a backwash
occurring one to three times a shift. The backwash cycle requires only about five minutes and
overflow clarities are re-established quickly.

1400
1200

PPM

1000
800

Sand Filter Output

PBC Output

600
400
200

Date
Graph 1: Pinned Bed Clarifier Performance

1/05/99

1/04/99

1/03/99

1/02/99

1/01/99

1/12/98

1/11/98

1/10/98

1/09/98

1/08/98

7.0 ENGINEERING ISSUES

The design of the PBC was based on the standard 6 m Ultrasep with some modifications. The
feed well and internal dilution circuits were reduced in diameter to the limits set during test work for
feed well residence time etc. This allowed an increase in area of the bead bed which gives the
benefits of increased capacity. The height of the feed well was modified to allow for the depth of
the bead bed and to provide for the static head. Fine mesh screens were designed to retain the
beads, the whole supported by a system of radial beams between the tank shell and the feed well.
The forces applied to the feed well are normally downwards due to mass of settled material. In this
case the dominating force is uplift due to the buoyancy of the beads and the head loss across
them from the up flow, transmitted to the feed well via the radial beams. Due to the corrosive
nature of the process liquor all wetted components were designed in 316 stainless steel.
A number of minor problems became apparent in the weeks following commissioning. The first
was due to material selection. The overflow launder is fitted with screw adjusters for leveling.
Despite all components being in 316 ss, someone decided to 'improve' it and installed brass nuts
to prevent them binding on the adjusters. These of course dissolved rapidly, dropping the launder
out of alignment.
The next problem to surface was of a more serious nature. Our engineering department had
designed the radial beams supporting the bead retaining screen on a stress basis. However,
excessive deflection allowed the screen sections to buckle, leading to leakage of beads into the
overflow. The beams were redesigned with the deflection limits in mind and the problem was
rectified. This was the biggest problem experienced. It was timed to fit in with a plant outage and
so did not result in any loss of production.
Other problems are inherent in the nature of the machine, such as handling of the beads
themselves. Liquid level in the PBC needs to be watched closely even with the machine off line. If
liquid levels drop too far the beads sink down below the feed well and de-watering cone. When
levels rise again the beads float up and block the feed well, as well as being unavailable for the
pinned bed function.
When this situation occurred by accident due to a leaking valve a remedy needed to be found
quickly. The solution taken was to completely drain the PBC. The beads were then washed out of
the underflow and strained into 20 bulka-bags. The underflow valves were closed, the unit refilled
above the feed cone and the beads poured back into the top of the unit through and opened
screen panel. Thanks to the ingenuity of the people on site the entire operation was accomplished
in two hours.

8.0 CONCLUSIONS
As a first time installation a number of process, mechanical and operational problems were
experienced. As our knowledge and experience with the unit has increased these have been
overcome so that the PBC is now an operationally robust and stable piece of operational plant. It is
able to handle a wide range of flows and solids loading without constant attention from the
operators. Clarity is not affected by solids in feed or by throughput within the design range.
Operation attention is decreasing as experience is gained with the unit.

The test work and scale up procedure has been shown to be reliable and consistent. Mechanical
design has been improved to overcome initial structural problems and the loads applied by
operation of the machine are now well understood, providing a sound basis for future designs.
Further design refinements present themselves as a means of improving operation in aspects
such as bead loading.
The combination of the PBC and sand filters provides good output clarity at far lower capital and
operating costs than pressure filters alone. In many cases the PBC alone may suffice.
Solution clarity is becoming an issue on more and more processing plants with the increasing
prevalence of hydrometallurgical process routes. The PBC represents a unique new process
option for plants where solution clarity is an issue. PBC test work has now been carried out at a
number of other sites. This work has confirmed the operating parameters and clarities achievable
and provided a reliable model for design and performance prediction. The Pinned Bed Clarifier can
now be offered as a standard piece of equipment with confidence in its performance.
REFERENCES
Scalise J. Filtration concepts for water soluble non ferrous wire drawing.
International

Wire Journal

Van Aswegen. The clarification of uranium pregnant solution at Buffelsfontein by a circulator

Clarifier. S.A.I.M.M. April 1963.
Kun L. E., Oelofsen R. O., and Van Vuuren E. J. J. Hopper clarification of gold pregnant solution
at Vaal Reefs South. S.A.I.M.M. March 1979.
Miamis #2 Tailing operation PLS Clarifiers. A.I.M.E Spring Hydrometallurgy Meeting 1992
Hunter J.S. Performance of buoyant media filter in metal plating shop wastewater treatment. #M
Company.