Thickening technologies

Leading edge technologies for thickening and

clarifying

Outotec is the global leader in the design, fabrication

and supply of thickening and clarifying solutions for
the minerals industry. The revolutionary SUPAFLO ®
high rate thickener has pioneered and redefi ned
thickening and clarifying methods around the world.
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SUPAFLO® thickeners and clarifiers

Innovation is standard

SUPAFLO ® thickeners and clarifi ers operate in minerals processing, chemical,

water treatment, industrial and effl uent applications throughout the world.
The fi rst SUPAFLO ® thickener was installed in 1985, and the many innovative
features of these units, including an ongoing commitment to testwork,
research and development, and after sales service, have ensured their rapid
acceptance in a wide range of industries.
Outotec’s worldwide network manufactures and supports SUPAFLO ®
thickeners, with design offi ces in Australia, China, Europe, North America,
South America and South Africa. This means that no matter where you are,
SUPAFLO® advanced technology is easily accessible to you.
SUPAFLO ® thickeners include a number of innovative features in
their design. Special attention is given to engineering design of feedwells,
rake profi les, drive systems and control strategies to meet the challenge
of dewatering materials that are often problematic for normal thickeners.
Our experience in testwork, design, operation, installation and service of
thickeners and clarifi ers throughout the world is your guarantee of quality.

Gold tailings, Australia.
Lime saturator, Australia.
Sludge clarifier, Australia.
Mineral sands tailings, Australia.
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Advantages of SUPAFLO®
Low capital cost
n Optimized design
n High rate units reduce area
by up to 90%
n Precise test work procedures
allow accurate sizing
Low operating cost
n Patented ”Autodilution” systems Paste thickeners, Australia.
minimize flocculant consumption
n Floc-Miser feedwell ensures
effi cient fl occulation
n Simple control system provides
stable operation
Guaranteed performance
n Bench-scale and pilot tests
provide data for direct scale-
up and written guarantees
High reliability
n Patented ”low drag” rake arm
reduces torque loading on drive
n Proven hydraulic drive and rake
Copper tailings, Chile.
lift offers three levels of system
protection
n Robust control system
Short delivery time
n Full range of CAD designs are
quickly tailored to customers'
needs
n Global sourcing network
Worldwide service
n Laboratory and on-site testing
n Design offi ces in North America,
Australia, China, South America,
Europe and South Africa
n Ongoing process and technical Paste plant, Sweden.
support provided through local
offi ces
Copper tailings, Chile.
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Complete service
Testwork
The bench or pilot scale testwork can be conducted
either on site or in one of our laboratories around the
world. Process guarantees are given based on test
results.

Selection
The testwork results and our previous experience
are used to select the appropriate size and type
Design of thickener or clarifi er to satisfy the process
The selected unit is tailored requirements for each application.
to the needs of the user in
one of our regional CAD
design offi ces.

Fabrication
Our project engineers monitor fabrication to
ensure that the equipment quality meets all
aspects of our ISO 9001 accreditation.

Installation
We provide complete installation
or supervision as required.

Commissioning
Mechanical and process
commissioning is also
performed by Outotec
trained engineers.

Process and technical support

Process advice, technical support and service
are provided through the Outotec worldwide
network.
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Bench-scale and pilot plant testwork

Testwork is required for the selection of correct thickener or clarifier size and configuration for your

application. Outotec is renowned for its professional testwork service using cylinder settling tests,

continuous dynamic bench-scale tests and pilot plant tests.

High rate thickeners and clarifiers

Our product range includes:
The method generally used to accurately determine the size and expected
n SUPAFLO ® high rate
performance of SUPAFLO® high rate thickeners and clarifiers is dynamic
thickeners
bench or pilot scale testwork, as static settling tests do not adequately
n SUPAFLO ® high compression
simulate the high rate principle. Continuous bench-scale tests are
thickeners
performed in our 100 mm (4”) diameter dynamic thickener or clarifier at
n SUPAFLO ® paste thickeners
site or in our laboratories. A sample of slurry containing 10–25 kg (22–
n SUPAFLO ® conventional
55 lb) of solids is all that is required for a series of tests to determine
thickeners
underflow density and overflow clarity for a range of feed rates and
n SUPAFLO ® clarifi ers
flocculant dosages.
n SUPAFLO ® solids contact
clarifi ers
Pilot plant testing
n SUPAFLO ® lime saturators

We can supply pilot scale thickening and clarifying equipment to meet your
process requirements. The size and configuration is based on material
characteristics and performance goals. We have units for conventional
settling, high rate thickening and/or clarifying, high compression and paste
thickening. Typically a one meter (3.28 ft) diameter skid-mounted pilot unit
complete with a flocculant make-up system, automatic flocculant addition
and underflow withdrawal, is available for on-site testwork. A feed rate of
1-8m3/h (4.4-35.2 US gpm) of pulp is required for the pilot plant thickener/
clarifier. A database of all SUPAFLO® thickener test results from around the
world is constantly updated for preliminary thickener sizing and to assist in
selection of full-scale units.
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SUPAFLO® high rate thickeners and
clarifiers
n Floc-Miser feedwell
n De-aeration chamber
n Defl ector plate
n Controlled bed level
n High throughput per unit area
n Free standing or in-ground tanks
n Short retention time
n Optional underfl ow recycle
n Clear overfl ow
Our high rate thickeners and
clarifi ers are suitable for all
applications where fl occulants can
be used in the process. Also ideally
suited to clarifying, with overfl ow
being fi ltered through a fl occulated
solids bed. External underfl ow
recycling is sometimes used to
improve fl oc formation and particle
capture.
Nickel tailings, Australia.
SUPAFLO ® high compression
thickeners
n Floc-Miser feedwell
n De-aeration chamber
n Controlled bed level
n High throughput per unit area
n Free standing or in-ground
tanks
n High rake torque capacity
n Extended high compression zone
n Supapickets (static and
rotating) for improved water
release
n Increased underfl ow density
SUPAFLO ® high compression
thickeners provide consistently
higher underfl ow density while
maximizing solution recovery.
They are used for increasing
tailings dam capacity, counter-
current decantation, increasing
fi lter capacity and increasing
recovery of process water or
chemicals.
5 x 20 m paste thickeners shipped to New Caledonia.
SUPAFLO ® paste thickeners
n Floc-Miser feedwell
n De-aeration chamber
n Controlled bed level
n High throughput per unit area
n Free standing tanks
n High rake torque capacity
n Extended high compression zone
n Supapickets (static and rotating)
for improved water release
n Maximum underfl ow density
n Underfl ow slurry yield stress
>200Pa
THE SUPAFLO ® paste thickener is
designed to produce a consistent
paste underfl ow with process control
and mechanical reliability second
to none. Primarily used for tailings
disposal and pre-leach applications.
Paste thickeners can be used for any
application where underfl ow yield
stress in excess of 200Pa is required.

SUPAFLO ® conventional thickeners
and clarifiers
n Small or shallow feedwell
n Flocculants not essential
n Insensitive to short-term
process changes
n Drive and rake torque to
suit application
Conventional thickeners and
clarifi ers are available as
”traditional” conventional units or
fi tted with fl occulating feedwell.
Hybrid versions are also available
in which various design features
of our high rate thickeners are
used, for particular applications.
These modifi cations can result in
improved overfl ow clarity, lower
fl occulant usage, higher feed rates
and improved control.
Copper concentrate, Argentina.
SUPAFLO ® solids contact and
reactor clarifiers
n Combines flash mixing, floccu-
lation, clarifying, sludge collection
and thickening in one operation
n Minimizes chemical requirements
by using the solids contact or
seeding principle
n Variable speed impeller and
separate rake drive mechanism
n Deep clear water zone
n Internal or external recirculation
option
n Dual chemical dosing option
A variable speed impeller can be used
to internally recirculate and mix
fl occulated underflow, raw feed and
chemicals to optimize fl occulant
usage and overflow clarity. Typically
used for water or waste-water
applications, where chemicals are
added to enhance fl occulation and
sedimentation.
Lime saturator, Australia.
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Lime saturators
n Saturated lime solutions
n Over 85% usage of available
Ca(OH) 2
n Variable speed impeller and
separate rake drive mechanism
n Controlled sludge level
n High rate feedwell for improved
solids dispersion
n Internal or external recirculation
option
Lime saturators are used to make
clarified saturated lime solution for
drinking water plants. Milk of lime
solution is fed continuously into the
reaction zone, where it is mixed
with recycled sludge. The sludge is
controlled at the required level by
varying the sludge withdrawal rate.
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The high rate Floc-Miser feedwell

Feedwell features Turbodil™ system

The heart of the thickening or clarifying process begins
with effective flocculation. The SUPAFLO® Floc-Miser
feedwell addresses the key elements of this process by
controlling the mixing and contact conditions in a unit
reactor.
In-house CFD modelling in addition to independent
®
analysis has shown the SUPAFLO feed system is
superior to others available in the market.
Key elements
n De-aeration of feed slurry
n Controlled mixing
n Controlled pulp injection velocity
n Variable depth fl occulant spargers
n Restricted bottom exit to eliminate short-circuiting
n Density optimisation
Autodilution system
To decrease the feed solids level prior to flocculation,
SUPAFLO® has developed the patented ”Autodilution”
system which harnesses the natural head difference
across the feedwell wall to drive supernatant liquor
into the feedwell where slurry dilution, mixing and
flocculation take place.
”Autodilution” maintains the density in the
feedwell within the optimum range for flocculation,
irrespective of feed flow rate or density.
Dilution Water
In some circumstances, the process dictates that an
alternative feed dilution scheme be adopted. Such
circumstances include:
n A very high degree of feed dilution required
by the process
n The requirement for dilution systems to operate
over a wide feed volume variation
n Thickener operation with coarse particle sizes
and simultaneous requirement for dilution to
low feed solids
n Very large feedwell diameters where mixing
energy over and above that generated by the
incoming feed needs to be provided
Outotec has developed a patented system of forced
dilution – Turbodil™ – using low head axial pump to
drive dilution water into the feedwell.
Retrofit and benefit
The benefi ts of the SUPAFLO® Floc-Miser feedwell
in both conventional and high rate thickeners are
dramaticly:
n Reduced fl occulant cost – an investment in a
Floc-Miser feedwell is usually recovered in
3–12 months
n Increased settling rates i.e. higher solids
throughputs
n Increased underfl ow density for a given
fl occulant dosage
n Elimination of dilution water pumping costs
n Improved CCD wash effi ciency

Floc-Miser
Feedwell Many thickeners have now been retrofi tted with the
S.G = 1.1
Feed Slurry
S.G = 1.0 Floc-Miser feedwells, including large conventional
Overflow
thickeners of up to 90 m diameter.

S.G = 1.05
Fluidized Bed

S.G = 1.6
Thickener Underflow
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SUPAFLO® high rate thickener control

Outotec specialists provide expertise for the control
and operation of the thickening process. Smaller Oscillation
Higher Average Density Supaflo
p Control Strategy
t

Underflow % Solids
Control philosophy

Control systems are built around two fundamental

Larger Oscillation
Normal
r Control Strategy
t
and simple control loops: Lower Average Density

n Flocculation is controlled by varying the flocculant

Average
r Density
pump speed to achieve a consistent flocculant
0 4 8 12 16 20 24
dosage rate per tonne dry solids feed. Bed level is Time (hrs)
used as feedback to control the g/tonne set point.
n Solids inventory is controlled by varying the
underflow pump speed to achieve a constant bed mass. Froth management

By controlling flocculation and solids inventory, the For concentrate thickeners directly downstream
thickening process is stabilized and a consistent of fl otation processes, froth contamination of the
underflow density is achieved. thickener surface and overfl ow can be problematic.

Surface froth can result in:

n Loss of product
n Increased maintenance costs
n Reduction in thickener performance
Floc M
MF LT
Froth Collection
Feed

Froth collection is achieved by means of a froth baffl e,

Overflow rotating booms and a collection box. Froth is swept in
to the box and removed from the thickener surface.
Sprays are used in conjunction with the system to
reduce surface froth.

PT
Underflow Frothbuster™ Deaeration

Frothbuster™ removes air from the thickener feed

slurry prior to the thickener feedwell. This improves
fl occulation and dramatically reduces the amount of
fl oating froth.

Typical froth problem. Frothbuster™ Froth removal after Frothbuster™

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High capacity
drive systems

Outotec pioneered the now universally accepted use of planetary gearboxes on full span bridge

thickeners. Our drive range encompasses single planetary and multi-pinion gearboxes with

hydraulic or electro-mechanical designs for full span and centre column thickeners.

Hydraulic rake drive Drive protection and rake lift

A slow-speed hydraulic motor, acting through a high-
effi ciency planetary gearbox, is used to drive the rakes.
The optional rake lifting mechanism comprises a number
of hydraulic cylinders operating in parallel, which
raise and lower the drive base.
®
SUPAFLO rake drives are designed to meet
each specific application, using off-the-shelf components
wherever possible. This system has distinct advantages
over traditional multi-stage electromechanical drives:
n Planetary gearbox gives excellent torque and
thrust load capabilities
n Accurate torque measurement through hydraulic
pressure
n Three levels of drive protection
n Intrinsically safe rake lift
n Reversible
The SUPAFLO ® hydraulic rake drive offers three levels
of drive protection:
n The pressure on the main hydraulic drive is
monitored by a pressure transducer which
activates the automatic rake raise/lower function
n An independent pressure switch also monitors the
hydraulic pressure and activates an alarm and
motor trip at a higher pressure set point
n The fi nal level of protection utilizes a pressure
relief valve in the hydraulic circuit to guarantee
the drive never exceeds the design torque rating
n No possibility of over-torque on start-up

Rake lift – lowered position. Rake lift – raised position.

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SUPAFLO®
multi-pinion
drives

SUPAFLO ® column drives (SCD) and

bridge drives (SBD) The maintenance features:
n Single pinion assembly units can be removed
Our engineers have developed high capacity multi- without draining oil
pinion drives, using the latest gear manufacturing n Spherical roller lower pinion bearings
technology, specifi cally with maintenance in mind. The n No upper pinion bearing required
ring gear and pinion components are readily available
from major manufacturing centers around the world. The rake lift on all center column drives is easily
accessible, above the drive head. Drives can remain in
Standard drives are available, from 750 kNm to operation with a single pinion removed for maintenance.
8750 kNm, and feature:
n Commercial one-piece ring gear and bearing
n Induction hardened metric module gear teeth
n Oil bath lubrication of gear and bearing assembly
n Splined drive from reducer to pinion
n Self-aligning lower pinion bearing
n Hydraulic drive for load balancing between pinions
n Fabricated base housing designed by FEA
n Stress relieving all fabrications prior to
commencement of machining
n Optional hydraulic rake lift
 3008EN. Pinta/Libris, Helsinki, Finland. July 2007
Outotec, formerly Outokumpu Technology, is a worldwide technology
leader in minerals and metals processing, providing innovative and
environmentally sound solutions for a wide variety of customers in
minerals processing, iron and steel, aluminum and non-ferrous metals
industries. Outotec Oyj is listed on the Helsinki Stock Exchange.

thickening@outotec.com
www.outotec.com

Copyright © 2007 Outotec Oyj. All rights reserved.

Outotec and More out of ore! are registered trademarks of Outotec Oyj.