Optimized thickeners in coal preparation plants

Using optimized thickeners for level measurement applications in a coal mind can yield safer and
more efficient plant control.
Level measurement equipment is part of almost every process in a coal mine. You hardly see the
instruments but they are there and make a huge difference when it comes to efficiency, safety and
automated control of the plant. Optimizirano thickeners u ugljenu pripreme postrojenja

Koritenje thickeners optimiziran za mjerenje nivoa aplikacije u ugljena um moe prinosa i sigurnije
uinkovitiju kontrolu postrojenja.
Razina mjerne opreme je dio gotovo svakog procesa u rudarstvu. Vi jedva vidi
instrumenti, ali oni su tamo i ine veliku razliku kad je rije o efikasnosti, sigurnosti i
automatska kontrola postrojenja.

All mining concentrators and coal preparation plants have tailings thickeners. These instruments treat the
process water by removing suspended solids and then returning the water back to the concentrator or
coal prep plant. They then pump the solids to a tailings dam.

Sve rudarstvo Koncentratori i pripreme uglja biljke imaju pljeva thickeners. Ovi instrumenti gozba
potrone vode putem uklanjanja suspendirane tvari, a zatim se vraaju vodu natrag u koncentrator ili
ugljen prep biljka. Oni su zatim pumpa solids da pljeva brana.

Reliable bed levels

Most tailings thickeners do not run efficiently because of a number of factors including:
1. The thickener does not have a reliable bed level interface transmitter that will work under all
environmental settling conditions and is not affected by density change; and
2. The thickener does not have turbidity or a suspended solids transmitter that will provide feedback to
the control room operator on how the flocculent dosing system is working.
By not utilizing a bed level transmitter that is affected by density, tailings thickener bed level are generally
run too low in the cone of the thickener reducing the underflow density that is pumped to the tailings dam
and also pumping too much water in the tailings.
The net effect is that the tailings dams will fill in volume faster, and there ill be an additional cost of
pumping the water back from the tailings dam to the concentrate or prep plant.
Most tailings thickeners utilize an automatic flocculent dosing system that takes samples of feed well
water and carries out an automatic jar settling test. This is so important where multiple coal/ore types are
processed through the plant because of different settling rates and characteristics. However, the
observers or clarometers floc batch systems fail from time to time and the tailings thickener can change
very quickly to not settling out the suspended solids.
The clarity output from higher end transmitters can alarm this condition to the operator in the control
room. Some even have a hindered layer output that can also be used in the control loop for the floc
dosing system as a back up. The use of a bed level transmitter will allow the tailings thickener to be run
automatically in conjunction with the underflow density transmitter and torque amps from the scraper.
This can:
1. Reduce costs in chemicals, broad spectrum floc dosing/coagulant dosing;
2. Return water pumping costs from the tailings dam;
3. Reduce tailings volume to the tailings dam; and
4. Increase the quality and volume of water returned to the concentrator from the thickener.
High powered sonar transducer
Hawk has developed a high powered range of multiple crystal array sonar transducers that have the
capability of operating and penetrating suspended solids to give reliable performance measuring the
heavy density BED level.

Pouzdan krevet razine

Veina pljeva thickeners se ne odvijaju uinkovito zbog niza faktora, ukljuujui:
1. Thickener nema pouzdanu razinu krevet suelje odailja koji e raditi pod svim
okolia naseljuju uvjetima i ne utjee promjena gustoe i
2. Thickener nema zamuenja ili suspendirane krutine odailja koji e pruiti povratnu informaciju
operatorom kontrolnoj sobi kako flocculent doziranje sustav radi.
Po ne koristi predajnik krevet razini koja je izvjetaen mimo gustoa, pljeva thickener krevet razini su openito
tranje preniske u stoac thickener smanjenja gustoe ispod granice koja se pumpa za pljeva brana
i crpne previe vode u pljeva.
Neto efekt je da pljeva brana e popuniti volumen bre, a tu bolestan biti dodatni troak
ispumpavanje vode iz lea pljeva brane da se koncentriraju ili prep postrojenja.
Veina pljeva thickeners koristiti automatsko doziranje flocculent sistem koji uzima uzorke hrane i
voda i obavlja automatski jar rjeavanje testa. To je toliko vano gdje se vie ugljena / rude vrste su
obraen kroz biljka zbog razliitih naseljavanja cijene i karakteristike. Meutim,
promatraa ili clarometers floc hrpa sustavi ne s vremena na vrijeme i pljeva thickener moe promijeniti
vrlo brzo da ne naseljavanju iz suspendirane tvari.
Jasnoa izlaz iz vii kraj pretvornici mogu alarm ovaj uvjet da operator u kontroli
soba. Neki ak imaju 'sprijeen sloj' izlaz koji se moe koristiti u kontrolnoj petlji za floc
doziranje sustav kao back up. Koritenje odailjaa krevet razini omoguit e pljeva thickener biti tranje
automatski u suradnji sa odailjaa ispod granice gustoe i okretni moment od pojaala strugalicom.
To se moe:
1. Smanjite trokove u kemikalija, irokog spektra floc doziranje / koagulant doziranje;
2. Povratak trokovi ispumpavanje vode iz brane pljeva;
3. Smanjiti pljeva na volumenu pljeva brana i
4. Poveajte kvalitetu i koliinu vode se vratio na koncentrator s thickener.
Visoki powered sonara sonde
Hawk je razvio visoku powered niz viestrukih polja kristalne sonara sonde koje su
mogunosti operativnog i prodoran suspendirane tvari dati pouzdane performanse mjerenja
teka gustoa KREVET razin

Each sonar transducer can perform two independent functions simultaneously. The second channel can
be used to provide clarity or simple turbidity output, or a second density interface as it measures, either a
second density in the interface column or the suspended solids levels between the BED level and the
face of the sonar transducer near the launder level.
The clarity output gives excellent process feedback information to the control room operators on how well
the flocculent dosing system is working. The hindered layer or interface layer gives feedback of how
well the settling characteristics are in the thickener and whether the broad spectrum flocculent is working
well, or whether coagulant maybe required.
If there are sufficient hours lost in production in the coal preparation plant, caused by tailing thickener
settling problems, then process plant managers may want to think about using a process control system
such as the ORCA Sonar.
These sorts of control systems can:
Identify settling efficiencies caused by coal-type changes;
Control the underflow pump to optimize the underflow density;
Identify that the clarometer or observer instruments are working;

Svaki sonara sonde mogu obavljati dva nezavisna funkcija istovremeno. Drugi program moe
biti koritena za pruanje jasnoa ili jednostavno zamuenost izlaz, ili drugi gustoe suelja kao to je mjera,
ili
drugi gustoe u stupcu suelja ili suspendirane krutine razinama izmeu LEAJ razine i
lice sonara sonde u blizini prati razinu.
Jasnoa izlaz daje odline informacije procesa povratne operatori kontrolnoj sobi koliko dobro
flocculent doziranje sustav radi. 'Sprijeen layer' ili 'suelje layer' daje povratnu informaciju o tome kako
dobro naseljavanje karakteristike su u thickener i da li irok spektar flocculent radi
dobro, ili da li moda koagulant potrebna.
Ako ima dovoljno sati izgubljeni u proizvodnju u tvornici ugljena pripremu, uzrokovane kraj signala thickener
rjeavanje problema, a zatim proces upravitelji postrojenja svibanj itanje to misliti o koritenju sustava
kontrola procesa
kao to ORCA sonar.
Ove vrste sustava upravljanja mogu:
Utvrditi rjeavanje uinkovitost uzrokovane ugljen-type promjena;
Kontrola nedovoljni tok pumpa za optimizirati nedovoljni tok density;
Prepoznati da su "clarometer 'ili' promatra 'instrumenata rad
Osigurati kontrolu petlje za podrku clarometer promatra ili kad oni ne uspijevaju;
Osigurati ulaznoj kontroli petlju za automatsko doziranje koagulant, smanjenje trokova kemijske i
Osigurati pouzdan proces indikacije za control room operators, koji je u velikoj mjeri tranje pljeva
thickeners
neefikasno, s niskim zbijen kreveta, zbog straha od bogging strugalicom.
Contribute a better translation
Provide a control loop to support the clarometer or observer when they fail;
Provide a control loop input for automatically dosing the coagulant, to reduce chemical costs; and
Provide a reliable process indication for control room operators, who largely run tailings thickeners
inefficiently, with low compacted beds, because of fear of bogging the scraper.

Successful application
The customer had multiple coal types that they processed through the coal preparation plant. Some of the
coal types had different settling characteristics. This affected the tailings thickener efficiency and the
clarometer instrument, that tested settling rates in the incoming feed well, failed from time to time,
meaning that the floccing rate changed and the suspended solids increased, decreasing the quality of the
return water back to the prep plant.
Hawk provided a high-powered, 3 crystal sonar transducer with automatic scum cleaning impact plate.
The two outputs of the sonar system provided: bed level (heavy density compacted interface); and
hindered interface (lighter density interface).
This heavier bed level output was used as one of the input loops, to control the underflow pump so that
there was a maintained bed depth under all settling conditions, guaranteeing an optimized density being
pumped to the tailings dam.
The hindered interface level output was used in conjunction with the heavy compacted bed level to
determine changes in settling conditions. If the two densities parted and the clarometer was dosing at

approximately 80 per cent of the broad spectrum flocculent, then coagulant was dosed to guarantee the
settling in the thickener. As the two densities again came together, with the hindered layer settling down
in the thickener again, the coagulant was stopped automatically. If the hindered layer rose away from the
compacted bed level and the clarometer did not change its dosing rate, the Sonar took over the flocculent
dosing control as a backup.
The high powered 3 crystal array transducer penetrated the suspended solids, even under poor settling
conditions. The clarity output could also be used, in the floc dosing control loop to automate this function
if the clarometer failed.

Uspjena primjena
Kupac je imao vie vrsta ugljena koje su obraene kroz biljni ugljen pripremi. Neki od
ugljen vrsta je rjeavanje razliitih karakteristika. To je utjecalo na efikasnost i pljeva thickener
'clarometer' instrument, koji testira naseljavanje stope u dolaznih feed dobro, nije s vremena na vrijeme,
to znai da floccing stopa promijenila i suspendirane krute tvari poveava, smanjuje kvalitetu
povratak natrag u vodu prep biljka.
Hawk pod uvjetom high-powered, 3 kristalno sonar sondom s automatskim pjena za ienje utjecaja na tanjur.
Dva izlaza iz sustava sonara pod uvjetom: krevet razina (teki gustoa zbijen suelje), te
ometano suelje (upalja gustoa suelje).
Ova tea krevet izlazni nivo je bio koriten kao jedan od ulaznih petlje, za kontrolu pumpe ispod granice, tako da
dolo je zadrala leaj dubina u svim uvjetima taloenje, garantirajui optimizirana gustoa bie
pumpa za pljeva brana.
Ometano suelje razina je izlaz se koristi zajedno s tekim zbijen krevet na razini
utvrditi promjene u naseljavanju uvjetima. Ako dvije gustoe rastali i clarometer je doziranje u
oko 80 posto od irokog spektra flocculent, onda koagulant bio doziran jamiti
naseljuju thickener. Kao dvije gustoe ponovno doao zajedno sa slojem ometano taloenje down
u thickener opet, koagulant je automatski zaustavljen. Ako je sprijeen sloj rua daleko od
zbijen krevet razina i clarometer nije promijeniti svoje doziranje stopa, Sonar preuzela flocculent
doziranje kontrolu kao sigurnosna kopija.
Powered visok 3 sonde kristalno polje ule suspendirane krutine, ak i pod slaba taloenje
uvjetima. Jasnoa izlaz takoer bi se mogla koristiti, u floc doziranje kontrolu petlje za automatiziranje ove funkcije
ako clarometer nije uspjelo

Hawk - an Australian Manufacturer

Hawk is an Australian manufacturer with a long experience from tough mining
environments. The products need to be durable and reliable and stand rain,
wind, dust, snow, sleet, foam or scum. Used in the mining industry for key
efficiencies with tailings dams and downstream processes, the Orca
equipment received two Breakthrough Product of the Year awards in USA
2008. Hawk manufacturers the largest range of sonar transducers to provide
optimized performance, for all bed level thickener applications e.g
concentrate thickeners etc.

Hawk je australski proizvoa sa dugogodinjim iskustvom iz tvrd rudarstvo

okruenja. Proizvodi moraju biti trajan i pouzdan te stajati kiu,
vjetra, praine, snijeg, susnjeica, pjena ili ljam. Koristi se u rudarskoj industriji za
klju
uinkovitosti s pljeva i nizvodno brane procese, Orca
oprema dobio dva "Proboj Product of the Year" nagrada u SAD-u
2008. Hawk proizvoai najvei raspon sonara sonde kako bi osigurao
optimiziran izvoenje, za sve razine krevet thickener aplikacija, npr.
koncentrat thickeners itd.

For further information, please contact:

US
Jack Evans
Hawk Measurement
Phone: +1 888 429 5538
Phone: +1 978 304 3000
Email: info[at]hawkmeasure.com
Australia
Marie Osterskog
Hawk Measurement Systems
Phone: +61 3 9873 4750
Email: marie.osterskog[at]hawk.com.au
About Hawk
Hawk, a world leader in level, positioning and flow measurement technology,
provides cutting- edge equipment to the global industrial market. With over 30

years of experience, Hawk offers a record of success in a wide range of areas

including mining/mineral processing, water supply/waste water, bulk material
handling and chemical. Hawks ongoing commitment aims to provide industry
leading technology and cost- effective solutions. For more information about
Hawk, please visit www.hawkmeasure.com