A Discussion on Falcon Semi-Batch Concentrator and the Effects of Gravitational Force and Fluidization Water Pressure to Efficient Recovery

Using Sample Laboratory Ore

V.O.L.Tabell Department of Mining, Metallurgical and Materials Engineering University of the Philippines, Diliman vo_tabell@yahoo.com
Abstract
This paper discusses basic principles that govern the Falcon Semi-batch concentrator. The falcon concentrator is one type of centrifugal gravity concentrators that effectively recovers heavy but fine particles from a feed. The flalcon experiment was done, but the acid digestion and spectrometry parts were not; hence, the analysis for the effects of particle size and varying force of gravity on the recovery of gold and pyrite particles were not made. However, sufficient discussions with regards to the effects of back pressure water and high force of gravity to the proper distribution of the heavy and light particles to the riffles of the spinning rotor were made. Setting the correct fludization water pressure value has a larger effect on the efficient recovery of concentrates.

1. Introduction
The Falcon Concentrator is specifically designed for concentration of fine heavy particles [1]. One of the two types, the Falcon SB (semi-batch) concentrator is a spinning fluidized bed batch concentrator. It is designed principally for the recovery of free gold in grinding circuit classifier underflows where a very small, usually less that a percent, mass is required. The feed first flows up the sides of a cone-shaped bowl, where it stratifies according to particle density before passing over a concentrate bed fluidized from behind by back pressure water. The bed retains dense particles such as gold, and lighter gangue particles are washed over the top [2]. Periodically, the feed is stopped and the concentrate is rinsed out. Rinsing frequency, which is under automatic control, is determined from grade and recovery requirements. Accelerations of up to 300 times the force of gravity are used in the SB machine [3]. The Semi-batch Concentrator was engineered with simplicity in design, efficiency of use and maximization of results. Even when other gravity recovery processes prove unsuitable, Falcon Concentrators are able to recover ultra fine liberated particles and make high quality separations by utilizing a high gravitation field. In

some instances, a Falcon circuit can achieve as high as 80% of the overall plant production depending on the percentage of native metal present [4].

Figure 1. The actual Falcon SB concentrator [1] This concentrator produces high-grade concentrates while requiring little or no operator intervention. The two-stage bowl design yields superior separations and easy wear-part replacement [5]. Other than free gold, the Falcon SB units work best for recovery of silver and platinum as well.

V.O.Tabell. Falcon Concentrator. Page 1 of 3

2. Methodology
Four sets of two kilogram samples were prepared before the concentration process. Each of the two kilogram samples were ground to a specific mesh size and applied with a specific amount of gravitational force. The settings are shown in Table 1 below. Table 1. Samples E F G H Feed Size 140 140 230 230 G 150 G 200 G 150 G 200 G The power selector switch was set on the VFD panel to the on position. The motor was started by pressing the RUN/STOP button. The fluidization water valve was opened so that the pressure gauge read about 2 psi [5]. The next step was the establishment of the fluidization water pressure value. This was done by introducing a small amount of feed into the system to establish a bed in the rotor, and then quickly pressing STOP and slowly shutting off the fluidization water while the rotor stops. The funnel lid was removed in order to inspect the concentrates collected in the riffles. The concentrates should not be packed hard but should just start to gently slump out of the lower riffles. If the concentrates seem packed in the riffles then the impeller bolt should be rechecked once more if it was left loose [5]. After establishing the fluidization pressure value, the materials were recombined and the separation of the pulp was done at consistent feed rates. This was done by pouring the pulp from a bucket to the feeder at the top of the system using a dipper [5]. The color of the tails exiting the L40 was checked. If the color goes clear during the pouring of the sample, it could mean that too many solids are being retained in the rotor bowl. If this occurs, the test needs to be restarted all over again [5]. The tails and concentrates of the concentration process were collected and dried using a pressure filter. The obtained moist sample was left to dry in a filter paper for acid digestion and atomic adsorption spectrometry.

The two kilogram samples were mixed into a pulp using water in a bucket. This was done for all the four samples, all maintaining constant pulp densities. The parts of the concentration system are illustrated in figure 2 below.

3. Results and Discussion

Figure 2. Laboratory-scale falcon SB concentrator [5] The water supply was connected to the concentrator. The yellow power cord from the variable frequency drive (VFD) was connected to the motor to check the voltage. Before pouring the sample pulp into the feeder, the unit was checked for cleanliness from old samples and that that rotating union drain valve was closed [5]. The impeller bolt was tightly secured before the funnel lid and scalping screen was placed, the supply water was turn on afterwards [5].

3.1. Analysis of the Data

After drying the samples after filtration, the concentrates were weighed. Table 2 shows the measured weights of the concentrates and tails. These samples underwent the acid digestion process, and proper procedures were made. The sample was heated in an aquaregia solution at high temperature and diluted in water. The samples were also placed in separatory funnels with determined amounts of methyl isobutyl ketones and finally placed in storage bottles, ready for the atomic V.O.Tabell. Falcon Concentrator. Page 2 of 3

adsorption spectrometry stage. However, the lack of reagents in the laboratory led to the dismissal of this step; hence the gold content of all the concentrates remained undetermined. Table 2. Weights of concentrates and tails Samples EC FC GC HC Weights, g 47.1325 47.429 41.6042 27.6813 Samples ET FT GT HT Weights, g 780 1350 1045 680

fluidization water pressure value to ensure the most efficient recovery of concentrates. An additional benefit of the process is that the heavy fraction or underflow is partially dewatered and effectively deslimed. Ultra-fine particles contained in the feed report more or less in proportion to the water and since the underflow has very high pulp density, only a small fraction of the slimes report to this stream [1].

4. Conclusion
The paper discussed the basic principles that governed the semi-batch falcon concentrator. Since the falcon experiment was done, but the acid digestion and spectrometry parts were not, data that could be calculated and analyzed were not presented. However, sufficient discussions with regards to the effects of back-pressure water, high force of gravity to the proper distribution of the heavy and light particles to the riffles of the spinning rotor were made.

Therefore, the analysis for the effects of particle size and force of gravity applied were not made. .

3.2 Discussion
The Semi-batch concentrators employ an elutriated zone at the top of the rotor, requiring the addition of a small volume of process water. These units can process particles as large as 6mm, but are also very efficient at the recovery of very fine particles [5]. The addition of fluidization or back-pressure water from behind the riffle beds enables heavy particles to migrate to the bottom or outside of the bed and to be retained in preference to the lighter particles. The heaviest layers pass over the concentrate bed retained in the riffles at the top of the rotor bowl [5]. Higher Gs permit effective recovery of even very fine particles, even those below 10microns, and the depth of the concentrate bed allows coarser particles in the feed stream to be safely recovered. When the bed has built up to a sufficient grade, the feed is stopped, for as little as 30 seconds, the rotor slowed and the built in spray manifold rinses the concentrate under the rotor baffle and out the rotor discharge ports into a concentrate launder [5]. From the methodology, the fluidization water was slowly shut off as the rotor gradually stopped rotating. This was because shutting all of the fluidization water supply too soon will cause the concentrates to pack in the riffles. Conversely, if the fluidization water was shut off too slowly, the concentrate may be flushed out of the riffles and report to tails. It was important to establish a

References
[1] "FALCON CONCENTRATORS." N.p., n.d. Web. 27 Mar. 2013. <http://www.concentrators.net/pdf/Ver%203.0%20 Complete.pdf >. [2] Wills, B.A., and T.J. Napier-Munn. Will's Mineral Processing Technology: An Introduction to the Practical Aspects of Ore Treatment and Mineral Recovery. 7th Ed. Woburn, MA: Butterworth Heinemann, 2006. [3] McAlister, S. and Armstrong, K.C. (1998). Development of the Falcon concentrators, SME Preprint, 98-172. [4] "Falcon Gravity Concentrators." Linked In. N.p., n.d. Web. 28 Mar. 2013. <http://www.linkedin.com/company/soloresources-pty-ltd/falcon-gravity-concentrators987603/product> [5] "Falcon Semi-batch Concentrator Laboratory Model L40." Operations and Maintenance. Sepro Mineral Systems, n.d. Web. 27 Mar. 2013.

V.O.Tabell. Falcon Concentrator. Page 3 of 3

V.O.Tabell. Falcon Concentrator. Page 4 of 3