Minerals and cement industry equipment and services supplier FLSmidth has officially launched its modular Reflux Classifier (RC) plant, which is suitable for fines gravity separation applications.

This integrated engineered modular solution is based on a fundamental component – FLSmidth’s well-proven RC technology, which improves the performance of gravity separation circuits, thereby outperforming existing technologies, such as spirals and hydrosizers.

The RC comprises the lamella settler, autogenous dense-medium separation, and the fluidised bed separator.

“The RC technology is based on dense-media separation, [which] is combined with a lamella plate design that is unique to the RC and, therefore, allows for the recovery of the valuable material in the processing plant,” FLSmidth country head and minerals sub-Saharan Africa VP Deon de Kock told Mining Weekly at the launch of the 100 t/h modular plant at the FLSmidth Supercentre, in Delmas, Gauteng, last month.

Plant components include tanks, FLSmidth Krebs pumps, cyclones, Krebs Tech-Taylor valves, Technegate valves, the FLSmidth Ludowici vibrating screen, the Reflux Classifier and dewatering equipment, as well as the Meshcape Screen Media that comprises the polyurethane screen panels. The plant is also fitted with a lightning protection system for optimum safety.

Further, the RC plant is automated, using advanced instrumentation and control, and includes the FLSmidth automation control system control centre.

FLSmidth sub-Saharan Africa engineering manager Byron Sadler noted during the launch that all process parameters were monitored to allow for consistent operation and, therefore, better recoveries.

The FLSmidth equipment technologies also interface optimally with the RC, which ensures that the feed material is correctly prepared prior to its reporting to the RC so that it operates to specification.

In addition to the operational advantages stemming from using technologies from one supplier, customers could leverage this single point of contact from an on-site support perspective, Sadler explained.

This modular solution is targeted at various applications, including chromite, chromite from upper group two (UG2) platinum-group metal circuit applications, iron-ore, metallurgical and thermal coal, mineral sands, spodumene, cassiterite and other heavy mineral applications.

In terms of recovery efficiency, this plant will allow for some UG2 chrome recovery operations to more than double their current output, as it can, for example, produce between 10 000 t and 13 000 t of chrome concentrate, according to De Kock.

“We can achieve anything from 15% to 22% additional yield on this spiral tail that currently goes to waste,” he enthused.

The plant can also be installed in interstage applications to treat spiral tailings, bypass some spiral plants completely and produce similar recoveries to those of the spiral plants, which can amount to an additional yield of 10%, according to De Kock.

Additionally, the modular RC plant can be integrated into a brownfield plant and retrofitted to replace less efficient technology.

Users can leverage the flexibility of the plant’s modularity, as each section is contained within the dimensions of a 20-foot shipping container. The combination of these sections or containers allows for the plant to be configured according to various and specific process requirements.

The configuration is easily adjustable to accommodate the changing process or ore conditions within given parameters, and this offers enhanced flexibility.

The dimensions of the unit and the modularity of the plant allow for easy relocations where needed, while rapid on-site installation is possible, as the frames of each modular section are easily assembled and locked together.

The speed of installation depends on the amount of existing infrastructure provided by a customer. Although minimal capital outlay is required from customers, they are required to provide power access, process water feed and feed material.

To provide customers with easy access to the solution and enhance productivity partnerships with the mining industry, FLSmidth will offer the plant on a build, own, operate and maintain, model or a build, own, operate and transfer model.

This will be the first time that FLSmidth will launch the plants worldwide on such models for the RC technology, according to Sadler.

De Kock further explained that, during these periods, the company would work on a full outcomes- based model, where FLSmidth would be paid for each tonne of chrome concentrate, coking coal or iron-ore produced.