MANUAL FOR INLINE PRESSURE JIG IPJ2400

www.gekkos.com

Table of Contents
1. 2.
2.01 2.02 2.03 2.04 2.05 2.06

INTRODUCTION INSTALLATION
Pressure Differentials_________________________________________________________ 5 Feed Preparation ____________________________________________________________ 6 Maintenance Requirements ____________________________________________________ 6 Power Requirements _________________________________________________________ 6 Water Addition ______________________________________________________________ 6 Hose Sizes and Expected Flows ________________________________________________ 7

3 5

FEED AND TAIL CONNECTIONS CONCENTRATE OUTLET

2.07

7 7

Screens and Ragging ________________________________________________________ 8

3.
3.01

OPERATION
Influence of Key Variables on Output ___________________________________________ 11

11
14 14 15 15 15 15 16 16 16 16 17 18 19

GD6 CONTROLLER (VSD/PID) CONTROL COMPONENTS COMMISSIONING PRESSURE DIFFERENTIAL WATER SUPPLY FLUSHING POINTS CONCENTRATE TRANSPORT DILUTION WATER TO TAILINGS RAGGING FEEDING MECHANICAL ISSUES START UP PROCEDURE SHUT DOWN PROCEDURE

4.
4.01 4.02 4.03 4.04

TROUBLE SHOOTING
Summary - Trouble Shooting Step by Step _______________________________________ 20 Pulse Stopped _____________________________________________________________ 22 Coarser Particles in Concentrate than Screen Aperture _____________________________ 22 Blockages ________________________________________________________________ 23

20

CONCENTRATE LINE TAILINGS LINE FEED LINE LOCATION OF CONTROL SYSTEM DIAGRAM OF COMPLETE CONTROL SYSTEM

23 23 23 25 26

5.
5.01 5.02

MAINTENANCE
List of Components _________________________________________________________ 28 Maintenance Inspections and Frequencies _______________________________________ 29

28

6.
6.01 6.02 6.03

IPJ ABBREVIATIONS & TECHNICAL DIAGRAMS

Abbreviations List___________________________________________________________ 37 Technical Support __________________________________________________________ 37 Technical Diagrams _________________________________________________________ 37

37

InLine Pressure Jig - the new art in Gravity Separation

1.

INTRODUCTION

The Inline Pressure Jig (IPJ) was developed by Sandy Gray, Technical Director of Gekko Systems and a former mine manager with 17 years experience in gravity separation. Gekko Systems has proven the IPJ's performance through intensive on site research and development to ensure high efficiency and ease of operation. The IPJ utilizes the benefits of traditional circular jig design, but increases the recovery rates of heavy minerals as a result of introducing a low velocity, submerged, thick bed separator. The IPJ is a true single hutch, circular jig with a moveable screen. Feed is pumped or gravity fed into the centrally located distributor. The feed velocity slows as the slurry radiates across the circular bed. The bed comprises a wedge wire screen and ragging. The screen itself then pulsates vertically with a saw tooth action. This process is encapsulated and operates under pressure. Hutch water is added; this combined with slurry creates a semi-static column through which the bed is pulsed, eliminating surface tension. During the down-stroke of the bed, separation occurs based on relative density, size and shape of the material particles. The upstroke produces a suction phase that causes the heavier concentrate to be drawn down through the ragging and into the hutch. This is continuously discharged via the concentrate outlet. The lighter fraction, known as gangue or tailings, is discharged to the tails and exits the unit under pressure. The main areas to become familiar with when operating the IPJ are those that control and maximize operation. The display on the control box, which is located on the IPJ, indicates the cycles per minute of the ram. The cycles per minute of the ram are controlled through a PID controller. A variable speed drive and hydraulic flow valve controllers positioned on the IPJ leg are used to obtain the desired stroke length. Other areas to note are location of the feed inlet, tails discharge, screen, diaphragm and ragging. The IPJ has been used to recover gold, diamonds, tantalum, tin, native copper, sulphides, garnet, manganese and metal from slag.

1.01 Safety Before Installing and/or Operating this equipment the Owner/Operator is encouraged to perform a Hazard Identification and Risk Assessment on the unit and its immediate area. This safety Audit should cover at least the following areas: 1.The foundations for the Unit are suitable. 2.The power supply to the Unit is safe and installed in compliance to local regulations. 3.All operators have been suitably trained and inducted on the use of the Unit. 4.A detailed start up and shut down procedure should be available to the Operator. 5.The area adjacent to the Control Panel is free from tripping hazards. 6.A clearly identified lockout procedure is in place for both the Operator and Maintenance Personnel. 7.The Operator has ready access to the Emergency Stop. 8.A procedure for Visitor Access near the Unit should be developed. 9.All pipework and Valves are clearly identified and readily accessible.

InLine Pressure Jig - the new art in Gravity Separation

10.A Bursting Disc rated at 220 kPa is fitted to protect the unit from over pressure. This disc is not to be tampered with and should only be replaced with a genuine spare part from Gekko. 11.A Maintenance Schedule for the Unit should be developed. 12.All Maintenance should be performed by suitable qualified personnel and a logbook maintained to record all work performed on the Unit. 13.Control of Access to the Control Panel and to other Machine settings is by authorised Personnel only. 14.All signs and decals required are present and remain legible. 15.Lifting Facilities for Maintenance Personnel are available and are safe to use. 16.Handrails, steps etc should be provided if required. Any concerns relating to the safe operation of the Unit that can not be resolved by site Personnel should be directed to Gekko Systems.

InLine Pressure Jig - the new art in Gravity Separation

2. 2.01

INSTALLATION
Pressure Differentials

The InLine Pressure Jig is a fully encapsulated device and therefore is capable of operating at greater than atmospheric pressure (up to 220 kPa). It is not necessary for the unit to work at its maximum pressure. It is, however, necessary for the unit to be completely full of slurry. In order to achieve this, the tailing discharge pipe must rise above the top of the jig or the friction and discharge head in the tails pipe must be great enough to fill the top of the jig with slurry. The unit is completely full when water/slurry is coming out of the air release valve on top of the jig. The internal operating pressure of the jig is determined by the Total Tail Head (TTH). The TTH is described as the: STATIC HEAD + FRICTION LOSS + DISCHARGE LOSS The STATIC HEAD is the fixed physical height to which the tails pipe runs. The FRICTION LOSS is the frictional resistance to flow through the pipe. The DISCHARGE LOSS is the pressure drop across any device connected to the tailings pipe i.e. cyclone. In order to achieve the TTH, the feed head must be greater than the TTH. If the slurry is pumped through the unit, it is preferable to have a variable speed drive on the pump to allow for inconsistent feed density and volume flows. In order to ensure reliable concentrate flows, the concentrate head must be lower than the TTH. The IPJ is best suited to direct pumped feed at medium to high densities, e.g. 30% -80% Solids by Weight (Cw). However for low head differential (gravity) feed it is necessary to allow large margins in the available feed head for variations in feed density and volume flows.

InLine Pressure Jig - the new art in Gravity Separation

2.02

Feed Preparation

The IPJ will accept a maximum feed particle up to 25 mm. The minimum internal opening is a 75mm. The unit will not be blocked by the passage of occasional oversized spheres to 50mm. For application as a rougher, separating particles of high s.g differential, a coarse feed may be appropriate. Depending on the application and required recovery it may be necessary to screen the feed to the IPJ. If the unit is to be used for the separation of particles of low s.g differential then a higher recovery and concentrate grade can be achieved with a well prepared and sized feed. High loadings of coarse scat material from the grinding circuit may cause some loss of efficiency. The feed may be pumped or gravity fed to the unit. The density of the feed can be between 3080% solids (Cw). For high density feed or low feed rates a water injection point should be introduced at the feed point for dilution.

2.03Maintenance Requirements
The IPJ requires maintenance from time to time. Lifting facilities are essential to remove the outer cover for internal maintenance and servicing. It is necessary to allow room overhead to remove the outer cover. The outer cover must be lifted at least 2000 mm to allow the internal screen frame to be fully removed. The top cover weighs approx. 1400 kg on the IPJ 2400 model. If possible the IPJ should be located under an overhead crane or gantry.

2.04Power Requirements
The IPJ 2400 Power requirement is 4.0 kW, 3ph, 415 volt. (The power configuration may alter for specific applications) The standard configuration is an electric motor driven hydraulic power pack. The standard configuration is 3 ph, 415 volts and earth, however it is possible to supply in virtually any configuration 1 ph, petrol or diesel. This must be specified on order. The control box contains, 415V, 240V and 24V supply voltages. Please consult with a qualified Electrician before opening the control box.

2.05Water Addition
The IPJ requires hutch water addition to enable proper dilation of the bed. The requirement varies between 6 - 20 litres per second, normal range is 10 litres per second. (35m3/hr). Coarse jigging applications (+14mm) may require up to 20 litres per second (50m3/hr). Supply pressure must be at least 100 kPa above the maximum internal operating pressure of the unit. The required water supply pressure is >320 kPa The water inlet fitting is an 80 mm NB table D flange.

Water supply can be of poor quality with no effect on the operation of the unit. The use of water with high calcium content may cause a buildup of scale on the screen.

InLine Pressure Jig - the new art in Gravity Separation

2.06

Hose Sizes and Expected Flows

FEED AND TAIL CONNECTIONS The IPJ is supplied with 150mm and 200mm fittings. The feed pipe is a 200mm Table "D" Flange sitting in a horizontal position. The tailings fitting is a 150mm Table "D" Flange with studs fitted. It is possible to reduce the dimension of the inlet and outlet pipes to the IPJ however consult the manufacturer prior to final design. CONCENTRATE OUTLET The concentrate outlet is an 80 mm Nominal bore Table "D" flange. The size of this outlet can be reduced with a fixed rubber orifice or by installing a smaller hose diameter on the outlet. By reducing the diameter of the outlet the total water consumption of the IPJ can be reduced. Concentrate density will rise with a decrease in outlet diameter. (See Operation section) The most common arrangement is the use of 25-80mm grit blast hose and fittings in conjunction with a rubber spigot. (20-50mm). Flow can be controlled by either the use of a spigot or by increasing the head height to which the concentrate flows. If a larger diameter hose is required the total flow can be controlled by raising the hose outlet to a level at which the flow is reduced. (Concentrate velocity must be kept high enough to reliably transport solids). Any combinations of hose are possible. If long scats penetrate the bed they can cause blocking in the concentrate line and a larger hose and orifice must be used. The higher the internal operating pressure of the IPJ, the smaller the spigot or the higher the discharge head required to maintain a given concentrate flow rate. An isolation valve (e.g. saunders valve) should be installed to enable operators to quickly clear any blockages or change concentrate lines. The concentrate should be maintained below 25% solids (w/w%) to ensure reliable flow and operation.

InLine Pressure Jig - the new art in Gravity Separation

2.07

Screens and Ragging

wedge wire 0.5-25mm screen aperture

(as ordered)

support frame

Screen choice is made on the basis of desired recovered particle size and shape. Where possible, it should be large enough to be capable of passing the maximum size of particle required to report to the concentrate. Where a large range of feed and heavy mineral particle size exists this may not be possible. However it may be possible with the use of various screen configurations to maximize the recoverable particle size. For example, alluvial gold is commonly flat whilst the gangue is normally spherical or cubic. This allows the efficient use of wedge wire screens where most gold particles are flat and will pass on edge through a relatively fine screen. Diamond recovery applications usually require a concentric screen configuration to prevent any hang up in the bed. NOTE: USE THE LARGEST SCREEN POSSIBLE TO MINIMISE BLOCKAGE To achieve self-ragging beds (i.e. coarse or heavy particles from feed) it may be necessary to lose some efficiency. It is, however, possible to achieve very high-grade concentrates with selfragged beds. The screen size must be chosen to ensure that some of the coarser particles in the feed cannot pass through the screen but are in fact held above the screen to form natural ragging. This means the loss to tail of the greater proportion of these particles (unless they are few in which case they will settle in the bed e.g. coarse gold particles) Screen plugging is alleviated on the fine screen configurations by the use of a layer of high s.g spherical particles of a given size (e.g. lead shot) this forms a layer directly on top of the screen. This layer acts as a rolling screen, which has an effective aperture equal to the interstitial space between the particles. These particles stop sub-angular, on size (same size as screen aperture) particles from accessing the screen and jamming.

InLine Pressure Jig - the new art in Gravity Separation

2.08

Monitoring & Control Systems

The IPJ is supplied with a cycle display, magnetic flow meter on the hutch water inlet and basic hydraulic flow controls. In addition other parameters that can be measured are: Feed flow rate* & density m3/hr< 200 Tail flow rate* & density m3/hr< 260 Concentrate flow rate* & density m3/hr< 30 > 2 Hutch Water Flow m3/hr< 55 > 20 Jig internal operating pressure* kPa< 200 > 10 Pulse rate* cyc/min< 250 > 50 Pulse wave form Sawtooth/Variable Hydraulic pressure* kPa> 2,500 < 10,000 Hydraulic temperature OC<60 Hydraulic oil level, 75% (As per sight glass)

The parameters, which can be externally controlled, are: Hutch water flow* Pulse rate Length of stroke Feed rate

* Main parameters An optional package to remotely monitor or control any of these parameters can be supplied. The control package can be either mounted at the jig or in the control room. All sensors and controls can be supplied by Gekko Systems and can be linked to a current plant automation and control system. (DSC, SCADA, etc)

2.09

Summary of Design Capacity/Criteria

Power Requirement approx. 5.5 kW, 3ph, 415volt. Jig Internal Pressure10- 200 kPa Feed capacity 0-100t/hr Concentrate 0.5-35 t/hr Tails 0-250m3/hr Feed Flow 0-200m3/hr Hutch Water 6-20 litres/second (supply +350 kPa) Pulse Rate 50-200 cyc/min Pulse wave form Sawtooth/Variable StrokeLength 0-20 mm Hydraulic pressure 2,500-10,000 kPa Hydraulic Temp Less than 60 0C Hydraulic Oil Level As per sight glass

InLine Pressure Jig - the new art in Gravity Separation

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2.10

Technical Specification

Model IPJ 2400 Design Pressure 200 kPa Design Temperature 60 0C Vessel Designation NumberClass 3 Hydrostatic Test Pressure 300 kPa

2.11

Operating Clearance

For a comfortable operating zone it is suggested that some minimum clearances and supplied lid weights for lifting facilities of the IPJ lid in the specification sheet. These clearances allow for ease of removal of the IPJ lid for inspections and maintenance. For clearance of the screen frame with incorporated room for lifting facilities we suggest that additional heights are added to the operating zone, mainly for the implementation of a gantry and operator comfort when removing the lid. These heights are especially critical if the IPJ is in an enclosed arrangement. If the IPJ is located in an open arrangement then a crane can be used for maintenance or a gantry installed. Make sure that the feed pipe can be disconnected from the unit to allow removal of the middle inspection hatch.

InLine Pressure Jig - the new art in Gravity Separation

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3.
3.01

OPERATION
Influence of Key Variables on Output Variables
Hutch Water Addition (m3/hr) Feed Rate (tonnes/hour) Ragging Density Up Down Up Down High Low Large Small Ragging Density High Low

Impact
concentrate/density
Lower con mass/density Higher con mass/density Higher upgrade Lower upgrade Higher upgrade Lower upgrade Increased mass/lower density Reduced mass/higher density Increase S.G of concentrate Lower S.G of concentrate

on
Recovery
Reduced fines recovery Greater fines recovery Lower recovery Higher recovery Lower recovery Higher recovery Reduced upgrade ratio Higher upgrade ratio Higher grades/low recovery Lower grades/high recovery Higher recovery Lower recovery High rec/bed fully dilated Low rec

Ragging Size/Shape

Pulse Cycle Frequency

Faster Slower

Increased con mass/density Reduced con mass/density If cyc/min constant > mass If cyc/min constant < mass

Stroke Length (Variable to feed size) Feed Size Range

Long Short

Large Small Large Small

Reduced con mass/density Increased con mass/density Increased con mass/density Reduced con mass/density Increase con mass/density Reduce con mass/density Increased recovery Decreased recovery Increase recovery/Dec grade Reduce recovery/Inc grade

Screen Size Aperture

Screen Open Area

Large Small

NOTE: Generally a reduced mass flow to concentrate will increase the concentrate grade.

InLine Pressure Jig - the new art in Gravity Separation

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3.02

Operator Checklist
Item Pulse Check Check for: Action: To alter into correct range, use the delay trim dial inside elec.box when, on internal or PID on outside & ensure that cyc/min are in operating range.

Cont. box 50-200 cyc/min, depends on parameters set by operator.

(cycles/minute)

Flow Meter.

Meter Display

Ensure water flow is in a positive direction.

No action need be taken, only alter if the flow rate is low. Turn the hutch water up to optimum range.

Water flow inadequate, action must be taken.

Turn up hutch water until suggested minimum flow rate is obtained. If there is no flow, commence shutdown procedure and flush out the hutch water line and clear the IPJ unit.

Feed

Pump/IPJ

Flow rate

Observe feed via a sampling point on feed line or check tailings flow rate.

Concentrate

IPJ outlet

% Solids

Sample for %solids, ensure in it is within the suggested operating range. If too low, insert a smaller spigot Optimise hutch water addition to lowest point in the operating range. Monitor for 10 minutes and adjust if required. If too high, increase hutch water or increase spigot diamter.

Flow rate

Too much flow, optimize parameters or decrease hutch water addition. low flow, increase hutch water flow check for blockages.

Tailings

Tails line

Flow rate

Visual check for flow, if the flow rate appears to be low or irregular, shut off the feed and flush unit with clear water dump the tails line, restart and monitor

InLine Pressure Jig - the new art in Gravity Separation

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3.03

Ragging and Screens

The standard configuration of the screen in the IPJ is stainless steel wedge wire screen with a nominal aperture of between 2 and 25mm. The wedge wire screen is designed in such a way as to minimise the ability of "on-size" particles to become lodged in the screen aperture. This is called "plugging", if plugging occurs the efficiency of the screen area will be reduced. The screen is made up of individual wedge shaped wire strands welded to a lower support frame. In order to ensure high efficiency of operation of the IPJ it is necessary to maintain the integrity of the screen. When using coarser screens (5-25mm), the ragging should be as spherical as possible to prevent plugging of the screen. The ragging should also be of a close size distribution to ensure an even flow of hutch water through the screen. The ragging must be coarser than the screen aperture. The ragging layer of the IPJ can be varied to give differing results. The main variables are S.G of the ragging, depth; depth of intermediate, high s.g ragging; and size of the ragging. The introduction of a specific S.G. ragging allows for the separation of minerals with low S.G differentials. If two minerals, with one of S.G. 2.4 and the other 3.5, are to be separated, the S.G of the ragging would ideally be 3.0. This allows an ideal cut-point to occur and optimise the yield to concentrate. The IPJ parameters can be altered to shift the cut-point, by increasing or decreasing the concentrate yield. The overall depth of the ragging layer can control the concentrate grade and mass flow. Normally a deep ragging bed (100mm) produces a lower yield, higher-grade concentrate. This depth can be increased with the installation of specialised upper screen clamp rings The ragging size distribution dictates the interstitial spacing of the bed and can have an effect on concentrate yield.

3.03.1 Gold Application The finer screens (0.5-4mm) can be overlain with a layer of lead shot. This lead shot creates a high S.G. layer, which serves to reduce the flow of gangue material to the concentrate hutch. Due to the density of the lead and the high interstitial spacing, the lead shot helps to provide an even flow of water through the screen and ragging. This in turn ensures no "dead spots" occur on the screen. As a result of the high S.G. of the lead shot and its spherical shape the ragging is not easily dilated during the dilation stroke. It tends to roll rather than become suspended. The interstitial spaces of the lead shot forms the actual effective aperture through which the concentrate must flow. By increasing the length and velocity of stroke greater dilation of the shot occurs and hence greater mass flow to concentrate. A thick layer of an intermediate heavy ragging layer (e.g. lead shot) can restrict concentrate yields.

3.03.2 Diamond other Applications A synthetic ragging is recommended for the ragging layer when separating diamonds. The synthetic ragging is a lead/polyethylene composite, which can be supplied by Gekko Systems to a certain size and density depending on the specific application and screen aperture. As the size and density of the synthetic ragging can designed especially for a particular application, the optermision of the IPJ slip point can easily be achieved.

InLine Pressure Jig - the new art in Gravity Separation

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3.04

Electrical and Hydraulic Pulse Controllers GD6 CONTROLLER (VSD/PID)

The GD6 controller is located within the control box of the IPJ and is the heart of the control system. It was developed to simplify the control of the IPJ stroke shape (length, upstroke rate, downstroke rate and overall cycles per minute). It is possible to adjust the cycle rate and stroke length from the control panel, with the downstroke speed being adjusted from a control valve on the leg of the unit. All of the control parameters can be recorded and historical settings can be reinstalled at any time. This allows for far greater flexibility with regards to remote commissioning or advice on initial settings from the manufacturer.

CONTROL COMPONENTS
1. Pulse Rate (cycles per minute) PID controller The PID is set to control the number of cycles per minute at which the ram operates. The PV display indicates the rate the ram is actually running (Process variable) and the SP display indicates the Set Point, the rate that you wish the unit to run at. To change the pulse rate use the up and down arrow keys to change the SP value and then press the SET/ENTER button to confirm the value. The PV value should alter and match the new set point. 2. Length of Stroke (hydraulic drive speed) This stroke length pot on the front of the control panel, controls the speed of the hydraulic pump and the oil flow rate to the hydraulic ram. The faster the pump, the more oil that is pushed into the ram in the given time and thus, the further it travels in the upward direction. The control is turned anticlockwise to increase stroke length. (1 = short, 10 = long). If the cycles per minute are changed then the stroke length will change (a stroke rate increase = a shorter stroke length). 3. Down Stroke Velocity The down stroke velocity is controlled by the rate at which the oil is allowed to return from the pressure side of the ram to the tank. When the ram is in the downstroke mode the oil flows back through a control valve, located on the leg of the jig within the hydraulic control block. This valve meters the return flow and restricts the velocity of the falling ram. (1 = slow down, 10 = fast >200mm/sec).

InLine Pressure Jig - the new art in Gravity Separation

15

3.05

Operation

The IPJ operates with the pulse set as a saw tooth pattern (Figure 1). This differs from other jigs that often have a harmonic pulse or sinusoidal pattern (i.e. pulses at the same up and down speed). Previous research and test work with the IPJ has indicated that a saw tooth pulse (slow upward pulse with a fast downward pulse) achieves the maximum recovery rates and upgrade ratios. This pattern is achieved by ensuring that the down stroke valve is set correctly. The down stroke should be set sufficiently fast enough to ensure that a stroke ratio of between 3:1 and 4:1 is obtained, i.e. upstroke 3-4 times longer than the down stroke. Once set, the PID or delay trim pot can be used to alter cycles per minute.

Figure 1. Saw Tooth Pattern of Inline Pressure Jig

UPSTROKE

DOWN STROKE

TIME

COMMISSIONING
Gekko Systems will make a technician available for commissioning. Commissioning is not included in the price of the equipment and arrangements should be made with your local supplier. All Gekko Systems technicians are qualified professionals with extensive experience in the mining industry.

PRESSURE DIFFERENTIAL
The most important issue when commissioning the unit is to make sure that the flow rates are correct. If the unit is operational sound, then metallurgical optimisation is easy to perform. As already mentioned the tails line should be raised above the unit to ensure that the IPJ is full of slurry. The differential between the tails line and the feed line should be large enough to ensure that the feed can travel through the IPJ and still have enough pressure for the tails to exit.

WATER SUPPLY
The hutch water supply needs to be constant and at the pressures (+350Kpa) and flow rates (50m3/hr) specified. Problems can occur when at the end of shift when operators clean down the mill using large volumes of water. This can limit the available supply to the IPJ and cause the unit to bog.

FLUSHING POINTS
It is also important to ensure that the feed line and the jig can be flushed clean. An isolation valve on the feed line is necessary with a ~2 water injection point located beneath the valve. A 3-4 dump valve located on the lowest section of the tails outlet is also recommended. This enables the unit to be easily flushed if bogging occurs. An isolation valve e.g.

InLine Pressure Jig - the new art in Gravity Separation

16 Saunders valve should also be installed on the concentrate line to allow for the concentrate line to be quickly removed and cleared without shutting down the jig. Ball valves or butterfly valves are not recommended, as the concentrate is very abrasive and these valves will wear very quickly.

CONCENTRATE TRANSPORT
The concentrate line should not be too long or too high above the unit. The IPJ concentrate is normally very dense and can be troublesome to transport. The internal pressure of the jig will govern where the concentrate can be transported to. i.e. the higher the internal pressure of the unit, the further the concentrate can be transported. If the internal pressure is too low, the tails line can be raised to increase the pressure. However, it is important to ensure that there is still adequate head pressure for the feed line. If the concentrate needs to be transported a very long distance, a short concentrate line, discharging directly into a sump/pump system is desirable.

DILUTION WATER TO TAILINGS

It is important to ensure that a percentage of your hutch water reports to the tailings stream. This performs two functions. One, it helps the bed to dilate and increase recovery and two; it removes very fine slimes from the concentrate stream by providing an up flow through the bed. To test if this is the case, the jig should be filled using the hutch water supply. The concentrate valve and feed isolation valve should be closed. The breather valve should be open to let any entrapped air escape from the unit. Once the unit is filled with water, shut the breather valve and allow the unit to pressurise. Water should be now evident in the tails line. This will be the total flow of hutch water (ensure feed valve is isolated). Open the concentrate valve and allow water to flow to the concentrate line. Approximately 20m3/hr of the hutch water should be reporting to the tails stream and the rest to the concentrate stream. If there is no water reporting to the tails stream then the hutch water needs to be increased or a smaller concentrate line is required (spigot).

RAGGING
If the unit is filled with ragging on site, some particles may be oddly shaped or too small and report to the concentrate hutch. The unit should be turned on and allowed to jig for 2030 minutes to remove this fraction. The concentrate hutch should then be cleared before adding feed.

FEEDING
If possible, slowly introduce feed to the system. This will allow the flow rates in all streams to be observed as the feed tonnage increases.

InLine Pressure Jig - the new art in Gravity Separation

17

MECHANICAL ISSUES
The IPJ wont reach the desired pulse rate If a high cycle rate is set and the ram does not respond then the oil flow may not be sufficient to accommodate this high rate. In this case, increase the stroke length output and the unit may respond. In order to ascertain if oil flow rate is the reason high cycle rates cannot be achieved it is possible to push the SET/ENTER button on the PID controller. If the output value shown is "0" then the oil flow is low or the unit has reached its maximum capability. Press the SET/ENTER button again to resume. The ram is making a banging noise If the ram is hitting the top of the stroke (mechanical banging sound) the length of stroke should be reduced. Check that the proximity switch is correctly positioned, to ensure the ram does not hit "bottom" during operation. This will result in damage to the ram. PID controller not responding The pulse is normally controlled via the hydraulic flow control valves and the PID controller on the outside of the control box. However if the controller has no effect on the pulse cycle rate, the pulse can be changed using the GD6 controller within the electrical box. The GD6 controller can be switched from external to internal control by pressing the black button on the front panel of the unit. It also has three indicating lights and a potentiometer. The top green light indicates whether there is power to the GD6 unit, the red light indicates when the proximity switch is off and the time delay is on, and the last light indicates that the solenoid is powered. The delay trim dial controls the combined cycles per minute of the pulse and the length of the stroke. If turned up the pulse speed is increased and the stroke length shortened, vice versa if turned down. Ram slowing down over time The ram may slow down and eventually stop over a period of time. This may be a result of a small leak or crack within the hydraulic tank. The internal gear pump is connected to a flexible hydraulic line that, may, over a period of time perish and crack. This results in the gear pump, pumping oil back into the tank and not to the ram. The motor should be removed from the tank and the hose reattached. If the gear pump is cracked or the seals have failed, a replacement pump or seals will be required. Ram operating intermittently The ram may occasionally not respond exactly to the PID set point. i.e. it may slow down and speed up intermittently. This may be due to the auto tune function within the PID controller. If this occurs contact Gekko Systems to obtain internal parameters or alternatively replace the controller with a spare unit and return the other unit to Gekko Systems.

3.06

Hutch Water Addition

Through control of the hutch water addition, concentrate grade and mass can be readily manipulated. Hutch water addition also controls the dilution of the tailings stream. All water added at the hutch is distributed to the tailings and concentrate streams. The water balance for the hutch water is: HUTCH (DILUTION) WATER FLOW TO TAIL = HUTCH WATER ADDITION - CON WATER FLOW Most of the hutch water added to the system will report to the concentrate flow.

InLine Pressure Jig - the new art in Gravity Separation

18 In order to ensure a clean concentrate the hutch water addition must be sufficient enough to provide a positive flow up through the screen and ragging layer. The volume of water that does not flow to the concentrate will report to the tails stream. This water is the tail dilution water, which has a minimum setting of 20 m3/hr. A minimum of 20m3/hr of hutch water should report to the tailings stream. The flow rate of the concentrate is usually optimized during commissioning and is set using different diameter pipes, spigots and orifices. This flow rate will normally remain relatively constant during operation. Operators must allow for a change of concentrate rate during commissioning, as it may take a couple of days for a natural bed to build up and allow the unit to reach a steady state. When adjusting the hutch water, the concentrate flow rate should be checked to ensure that an additional 20-25 m3/hr is reporting to the tails line.

3.07

Air Release Systems

The feed to the IPJ enters the chamber and moves across a circular bed. As the feed moves across the bed, the velocity drops and as a result the finer heavy particles have a chance to sink and report to concentrate. If air is allowed to gather in the top of the jig the level of slurry is lower and therefore the same volume of feed has to move faster across the bed. This can prevent the recovery of fine mineral. The IPJ has an auto air release system to prevent this from occurring. An air-actuated valve is located on top of the jig and is controlled by an electronic timer within the control panel. The timer has an ON time and an OFF time. The ON time will be the time that the valve is open allowing air to escape from the jig and the OFF time will be when the valve is closed. These times need to be optimized during commissioning. It is better to have the valve open more frequently at shorter time intervals rather than for long periods, as this can cause a pressure drop within the IPJ and may cause the unit to experience problems. Alternatively a 1 constant air bleed line can be installed.

3.08

Instructions for Start-up/Shut-down Procedures

This set of procedure is generic only. It is recommended that a site-specific set of procedures be developed during commissioning.

START UP PROCEDURE
The IPJ must be full of water/slurry in order to run efficiently. The volume of water above the screen dictates the velocity at which the slurry flows across the screen. 1. 2. 3. 4. 5. 6. 7. Ensure all hatches (lid) are securely closed. Open air release valve at top of unit. Turn on hutch water to maximum and fill the unit. When water flows from the air release valve, turn air release valve off. When water begins to flow from tail discharge at a constant flow, set the flow rate of hutch water to around 35m3/hr. Ensure concentrate flow is running. Start pulse and set to around 100 cyc/min. Adjust the pulse so that down stroke is three to four times as fast as the upstroke. This can be done via the stroke length and down stroke controls in conjunction with the PID controller on the panel box.

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19 8. 9. 10. 11. 12. 13. 14. Readjust down stroke to soften, by turning back the down stroke control knob. Turn on the feed. Watch tails for signs of feed flowing through the unit. Observe concentrate flow, if too much mass reduce number of pulses per minute i.e. speed of the upstroke. Allow for the unit to fill with slurry, thus giving time for the bed to fill with heavy minerals. Re-adjust pulse to give the desired concentrate flow. Alter hutch water to desired operating level.

NOTE: Watch concentrate flow closely on initial start up.

SHUT DOWN PROCEDURE

1. 2. 3. 4. 5. 6. Turn hutch water to maximum. Shut off feed to IPJ, if possible turn flush water onto feed inlet. Increase pulse to shake up jig bed and free remaining mineral. Allow 10-15 minutes for the unit to flush itself clean. Stop the pulse and allow the concentrate line to run clean. Turn off hutch water leaving the unit full of water. This will prevent the bed from rusting if steel is present in the system.

If an internal inspection is required, allow the unit to empty via the concentrate hose. Once inspection is complete remember to clean the o-ring underneath the lid to ensure that a proper seal is maintained. If there is steel in the IPJ bed then remember to fill the unit with water.

3.09

Alarms, Indicators and Protective Devices

Optional alarms provided with the IPJ controller include a Hi/Low pulse rate and low hutch water. Audible/indicator alarms are available and can be linked to DCS if required. The high and low pulse rate values are set within the PID controller, with the appropriate parameters determined by Gekko Systems, in conjunction with the purchaser. The low hutch water is retransmitted from the flow meter (optional). When the pulse rate (cycles per minute) or hutch water flow falls/rises out of the given parameters, a general alarm will sound and a warning light will be displayed on the relevant gauge. The appropriate action can then be taken by the operator to rectify the problem, and reset the alarm (optional). A number of automation systems are available. Please contact Gekko Systems for further information. A bursting disc is used on each of the models, designed to burst at approximately 220 kPa, if the internal operating pressure rises above this value. (A pressure switch can be installed to monitor the pressure and shut down the feed if the pressure gets to high.) If the unit happens to burst a disc, a replacement should be sourced from Gekko. Low level and high temperature switches are fitted to the IPJ hydraulic tank. The low level switch is activated when the level in the hydraulic tank drops below 40% and the temperature switch at 70 degrees. If either of these conditions are met then the VSD will fault. These switches must be connected for the IPJ to operate. InLine Pressure Jig - the new art in Gravity Separation

20

4. TROUBLE SHOOTING 4.01 Summary - Trouble Shooting Step by Step

Possible Cause
Bogged Jig

Fault
No pulse

Counter Measures
1. Visually observe tailings, little or no tails flow indicates that the density is too high, or there is insufficient hutch water flow 2. Immediately commence shut down procedure, then release pressure in the jig via relief valve on IPJ lid. 3. Open dump valves and flush out jig, refill with water & test pulse action, if no pulse commence following steps. 4. Make sure that there is adequate hutch water flow. 1. Check that the motor is turning, if not check for tripped electrical switches. If tripped, reset & restart motor. 2. If motor is still going, look for pressure in the hydraulic pack. No pressure in pack, then assume a faulty ram or hydraulic flow valve controllers. Remove ram/flow valves and assess damage. Replace or refit ram/flow valves as necessary. 1. Check that power light is on to control box, if not look for tripped electrical switches, reset and restart. (electrician only) 2. If power light on, look at solenoid power, check solenoid with multimeter and do a magnetism test. If there is no power or magnetism replace the solenoid. 1. Look on the back of the proximity switch down on the ram. If red light is off then the switch may be faulty, take switch off clamp. If metal at face and red light off then check power to prox, if power then prox faulty. If no power check pulse control box. 2. Pass a metallic object in front of the switch, at the same time observe that the time delay switch comes on in the GD6 controller box once the object has passed. If not then the switch is inoperable and should be replaced.

Hydraulics

Time delay controller in electric's box

Proximity switch

Should be approx 3mm from base block in the down position and the light should be on . If not remove and clean proximity. Place metal on the face of the prox. If light is still off then check power to prox. If ther is power to prox then prox light or prox are faulty. If no power check pulse control box.

Water meter 'Very low' Flow

Drop in Hutch water press.

1. Hutch water pressure may drop as other areas in an existing plant are using too much water. Check main supply pressure. 2. Check flow meter, if the reading has dropped on the display, turn hutch water up until setting is correct. 3. If the gauge still reads low, turn off feed and flush the unit. 4. Flush feed, tail, hutch and concentrate lines, then restart the IPJ. 5. Check water supply pressure. 1. Turn hutch water to maximum, if low flow refer to above procedure. 2. If pressure exists, remove concentrate hose and unblock. 3. If there is flow simply flush concentrate line and refit. 4. If concentrate line clean and there is no flow from the concentrate outlet on the jig, check for blockage. 1. If particles coarser than screen aperture are in the conc. then a torn diaphragm is the most likely cause. As particles that would normally reside in the tails are passing through the hole in the diaphragm and into the hutch.

Concentrate line blocked

Hutch water pressure

Particles larger than screen size in the

Diaphragm 'ripped/torn'

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21
concentrate. 2. Commence shut down procedure, unbolt jig lid and remove. 3. Assess diaphragm and replace, remember when sealing off to have the screen in the raised position and 25mm overlap on inner cone and screen ring. This will result in a fit that will give an outward protrusion of the diaphragm when lowered, see 4.03. Centre dist'r pot loose. 1. Check center distributor pot to ensure fixing bolt has not come loose.

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4.02

Pulse Stopped

The pulse may stop for a number of reasons. It may be the result of the IPJ becoming bogged with too much feed, a faulty proximity switch/solenoid, low hutch water addition or the failure of the hydraulic pack. If pulse has stopped and IPJ is being fed and cannot be re-started, immediately commence shut down procedure. If this occurs on start-up, the first thing is to check the feed pipe at the top of the jig. Sometimes on start-up this may block and restrict the pulse action. Remove the top lid of the jig and remove any built up solids from the distributor pot. Check the feed inlet for any blockage. If this occurs during operation or repeatedly then the feed pipe length should be shortened. Remove the lid and use an oxy-acetylene torch or an angle grinder to remove 100mm from the feed pipe. If the pulse stopped during normal operation it could be a number of different things. Once IPJ has been shut down, try to restart pulse. If unsuccessful, check the hydraulic pack and check the top of the motor to see if the fan is turning, if pressure is not rising up on the pack then the solenoid may be faulty (the solenoid is located on the hydraulic control group on the IPJ side leg). Check lights on yellow GD6 controller box inside the electrical unit. If power light off then there is no power to the controller, check for tripped out switches. No power to the solenoid indicates that the solenoid may be faulty, check power to solenoid with a multi-meter at electrical termination box on the IPJ leg and also check magnetism of the solenoid. If the solenoid is not faulty then check that the red light is displayed on the back of the proximity switch, if not then the switch may need to be replaced. If there is power and the above items have been checked and cleared, the next suspect item is the ram. Start the pulse and observe the pressure gauge on the hydraulic pack. With the ram becoming stuck after the up stroke and pressure rising inside the pack, then this may be the result of the solenoid not registering the down pulse and releasing the pressure. Another scenario is no pressure inside the pack at all, a faulty ram and flow valve controllers will produce no pressure. This is the result of the seals inside the ram failing or simply the result of wear. Hence steps to follow are to remove and assess the ram, check flow valve controllers and test pressure in the hydraulic pack. To check ram internal wear, remove lower ram hose at ram (block hose end) and observe oil flow from ram port with unit running. If ram is in good condition virtually no flow will come from this port. If the flow is approximately 0.1litres/min then the ram will need to be replaced soon, if the flow is higher than this, immediate ram replacement is required.

4.03

Coarser Particles in Concentrate than Screen Aperture

If there are particles coarser than the screen aperture in the concentrate, this is the result of wear on the diaphragm inside the jig; this seals the pulsating screen frame and the inner cone. If damaged it will allow material, which would normally reside to tailings, pass through the diaphragm and into the hutch contaminating the concentrate. Commence the shutdown procedure and unbolt the jig top and remove. Inspect diaphragm, if faulty replace with a new diaphragm. If the diaphragm is not damaged inspect the screen for holes. We recommended that before joining the new diaphragm; if any irregular thickness is apparent, the ridges should be ground down to create an evenly sloped surface. This will results in a tighter seal between the cone/frame. To join the urethane diaphragm, firstly remove old diaphragm and clean the screen frame and inner cone. Wrap the new diaphragm around the cone/frame and mark the appropriate length. Before trimming to length, deduct an additional 25mm if fitting for the 2400, or 15mm if fitting for the 1500 from the length. This will result in a tighter fit that will stretch around the cone/frame, making it easier to secure the diaphragm with the stainless steel strapping. When cutting ensure that cut is square and any rough edges are filed away. Butt the two ends and check that the fit will be square and tight before gluing. We recommend the use of Loctite 406. After gluing, clamp the join and allow glue to cure for the recommended time. Once cured grind down joined surface so that it is flat, then replace diaphragm. Secure with the supplied stainless steel strap and clamps. NOTE: The screen must be lifted to a raised position before the diaphragm is secured, resulting in a fit that will give an outward protrusion when the screen is lowered. To raise the screen frame, turn InLine Pressure Jig - the new art in Gravity Separation

23 the hydraulic down stroke control to the off position, turn on the pulse and hold a metal strip in front of the proximity switch until the ram reaches its maximum upward stroke.
poly-urethane diaphragm s/steel strap jjig bed

25 mm

distributor pot

screen frame

25 mm

screen frame in raised position

fixed inner cone

diaphragm, will protrude outwards when screen frame is lowered outer cone

gap between outer cone and inner cone

Figure 2. Diaphragm replacement

4.04

Blockages CONCENTRATE LINE

In the case of reduced concentrate flow, shut off the isolating valve and quickly remove the hose. Turn the valve back on and see if there is flow from the hutch, if so, flush concentrate the concentrate line and reconnect. If there is no flow from valve, immediately turn up hutch water to maximum. If there is no flow from the hutch then check for blockages. In some cases, the jig pulse can be stopped to prevent further concentrate from reporting to the hutch. This will allow time to clear the line without shutting down the jig.

TAILINGS LINE
If there is no tailings flow and the IPJ is still operational, this indicates that the density of the feed may be too high or that the hutch water pressure is insufficient and the unit has become bogged. Immediately turn off the feed, turn off the hutch water and release the pressure in the unit via the relief valve, situated on top of the IPJ. Open the dump valve on the tails line and flush the unit. Check pressure in the hutch line and ensure greater than 350 kPa, restart unit. It is extremely important to shut down the jig immediately when the tails line is blocked. If the feed and hutch water are left on then the pressure within the unit will exceed 220Kpa and the bursting disc will fail. The disc will allow the slurry to exit the jig and prevent mechanical failure.

FEED LINE
If there are no solids reporting to the tails and concentrate lines it is possibly due to a feed pipe blockage. Most blockages occur when the line has not been flushed with water after shutdown or there has been a slow leak of solids from the feed isolation valve. If an isolation valve is located above the jig, it is possible for very fine material to settle in the centre pot and slowly fill up the line. The material is very difficult to move as it plugs the line. The lid should be removed and the line cleared. Care must be taken to ensure that the feed is isolated as the line can clear quickly at high velocities.

InLine Pressure Jig - the new art in Gravity Separation

24 If the problem persists, then the feed pipe (within the jig) should be reduced by ~100mm. This will allow the hutch water to wash any residual solids away from the center pot area. Checking that the hutch water flow is in the correct operating range and that there is a steady/normal feed rate to the jig can prevent most blockages. The pressure within the jig should remain at a constant when operating at a steady state. Operators should always keep a constant log of the internal jig pressure to ensure that the unit is at a steady state.

4.05

Location of Mentioned Trouble Shooting Items

Figure 3. Important locations on Jig

Bursting Disc Bursting Disc Bursting Disc

Proximity Switch

The jig may also have a pressure gauge located on top of the unit on above the control panel indicating system pressure. (The gauge will range from 0300Kpa.) Another pressure gauge is located above the hydraulic tank and is used to test hydraulic pressure. (The relief valve will release at 2700Kpa) A proximity switch is located at the base of the hydraulic ram. This detects the number cycles that the jig is pulsing and is instrumental in the operation of the unit. A termination box is located on the leg of the jig and contains wiring for both the proximity switch and the flow meter.

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LOCATION OF CONTROL SYSTEM

HYDRAULICS The hydraulics system is located on the front of the jig. It consists of: 4.0KW flange mounted motor 20 liter hydraulics tank, Oil filter, Sight glass and temperature probe Control block located on the leg of the unit.

The control block contains the down stroke valve, pressure relief valve and non-return valves. A hydraulic schematic is included in the appendix section.

FLOWMETER The flow meter is located on the front of the jig inline with the hutch water connection. The hutch water flow rate is indicated in m3/hr A manual Ball Valve is also located on the hutch line to adjust hutch water addition.

CONTROL PANEL

The control panel is located on the front of the jig. Some models may differ in appearance, however they will all contain the same components. The panel contains: Variable Speed Drive PID controller and control potentiometer Air release timer Isolating switch and on/off switches. Emergency stop

The control box also contains the GD6 controller inside. This can be switch from external to internal control if the PID controller fails.

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DIAGRAM OF COMPLETE CONTROL SYSTEM

The complete control system (excluding the hydraulic control block, located on the leg) can be relocated away from the jig. A junction box and extra hydraulic lines will be required.

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IPJ2400 - GA

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5. MAINTENANCE 5.01
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

List of Components
Hydraulic Ram Hydraulic Oil (40 litres),Tellus 68 Oil Filter element Screen Assembly (3mm app) Screen Frame Blocks Diaphragm upper Diaphragm lower O ring upper and lower and hatch Screen calmp plug insert Screen support Retaining Frame Rupture disc Plug in relay Transformer Pushbutton station Pushbutton contact block Circuit Breaker 3 A Pushbutton actuator Pushbutton actuator Contact block Contact block Contact Switch complete GD6 Controller Feed Pipe Distributor Pot Motor (4.0 kW) Hydraulic Pump KVIP 2.6 Hydraulic Block with Solenoid Flow control Control valve and Relief valve (total kit) Motor / pump coupling and spider Hydraulic tank hose PID Controller Upper diaphragm clamp Detector Proximity Switch Hydraulic & Jig pressure gauge 4 KW Variable Speed Drive 4 kW VSD Keypad Stroke Control Potentiometer Parker B5E6BB 24 V Solenoid Valve 5/2 Timer for Auto Air release system Dynacool cooler 50mm Pinch valve Pump Bell Housing Bowl retaining bolt and plug Screen retaining frame clamp (inner & outer) Poly shaft protector Flowmeter Poly tails sleeve 3M502 8M271 3M807 2M103 8M104 8M101 8M109 8M105 & 105C & 105B 8M016 1M057 8M410 1E109 1E405G 1E513A 1E510C 1E610G 1E505G 1E506B 1E513B 1E507H 1E510C 1E521A 1E201 1M050 1M005 2E001C 3M609A Ref Gekko 3M512A 3M607 608 & 610 3M102 1E206 8M403B 1E501 3M903 & 3M910 1E205B 1E205A 1E514 7M004B 1E104 3M906 6M532 3M611 5M623 & 8M015 1M054 & 1M056 8M103A 1E002B 6M700

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5.02

Maintenance Inspections and Frequencies

The InLine Pressure Jig requires little maintenance, with maintenance mainly focused on the regular servicing of hydraulics. Additional areas that need to be monitored are ragging, diaphragms and the screen. All maintenance staff / operators should obey the site specific tag out and isolation procedures. If the site does not have any specific isolation procedures please contact Gekko Systems for recommended procedures. To ensure correct operation of the InLine Pressure Jig it is recommended that a maintenance procedure be developed in line with the specific site and operational conditions that the IPJ operates under. All adjustable parameters should be recorded so that the unit can be readily set up following maintenance or after replacement of components.

RECOMMENDED SERVICE SCHEDULES/INSPECTIONS As a minimum, the Maintenance Procedure should include the following: Frequency Daily Description Visually check that the unit is working Listen for any abnormal noises. (bearings, air leaks) Check that flow rates are within required range Visual check of air fittings and hoses Listen for abnormal knocking sounds Comment Check IPJ operating parameters if abnormal knocking sound is noticed. Refer to IPJ maintenance manual for further detail. Replace ragging if signs of wear or dissipation is noticed.

Monthly

Visually check for Oil leaks Check valves Check hydraulic Oil Level Inspect fine ragging (if used) Change hydraulic oil filter Inspect course ragging (if used) Change hydraulic oil Check the Oil and replace if necessary Inspect upper diaphragm

1000 Hours 2 Monthly 2000 Hours 3 Monthly

The Oil should be drained and replaced every 2000 hours.

6 Months Yearly

Inspection of Lower diaphragm Check the pipe work for wear replace if necessary Inspect and service the hydraulic ram Check shaft wear and shaft protector condition. A major overhaul of the unit is recommended to ensure that peak operating efficiency is maintained.

2 Yearly

Recommended service schedules/inspections:

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HYDRAULICS
The hydraulic components can be easily serviced by shutting down the IPJ, removing the oil via the drain plug and the oil filter by screwing off in a counter clockwise motion.

RAM
The ram requires visual monitoring only, if there is oil leaking from the seals or there is erratic pulsing the ram may need to be replaced. The ram can be removed by jacking up the screen frame (with a porta-power unit or lifting it from the top), undoing the hydraulic hoses and removing it from the collar. Assess the ram, if inoperable, replace with a new unit. To reinstall, jack up the screen frame, place ram in the collar provided at the base and refit the hydraulic hoses. Lower the screen frame down slowly and evenly on the ram, ensure hydraulic connections are facing the flow valve controllers. When servicing the hydraulics and the IPJ unit is inoperable it is advisable to consider other parts that may require maintenance. A 2-3 monthly appraisal for internal maintenance is advised. This can be done by removing the IPJ lid and visually checking certain internal aspects, such as the depth of the ragging, the shape and size of the ragging, worn areas on the screen, and especially condition of the diaphragms. These areas are outlined in figure 3.

Control Head Gear Pump Hoses Motor Please contact Gekko Systems for exact specifications on the above equipment.

RAGGING
Lead Shot for the Gold application (fine screens 0.5-4mm) If there is noticeable lead shot in the concentrate and the ragging depth is less than 20mm, more lead shot is required to bring the depth back up to between 20-25mm. When lead shot is present in the IPJ concentrate is increasing it is recommended that all the lead shot be removed from the jig bed and replaced with new lead shot. Efficiency within the unit will be reduced as the lead ragging is consumed, with some screen areas becoming blocked. The greater the pulse frequency the greater the wear on the lead shot and screen. To maximise screen/shot life run IPJ at the softest settings possible to achieve required results. Coarse Ragging (coarse screens 5-25mm). Magnetite, quarts and synthetic When using coarse ragging of a specific density care must be taken to ensure that other heavy minerals do not completely displace the ragging. On inspection the bed depth should be noted and if it is too low, the ragging should be replaced. New ragging should be near sized and high aspect ratio. (e.g. spherical). It is desirable to run the jig with water only for ~20 minutes to shake down and remove any undersized ragging. This will report to the concentrate hutch and should be cleared by removing the concentrate line before start up.

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Screen
Screen life is estimated at 12 months, depending on the material being treated and the pulse rate. When checking the ragging it is advisable to look for wear areas on the screen and make a note of the screen condition, as this will allow sufficient time for ordering a new screen. (Screen availability is 4-6 weeks) When replacing the screen it is necessary to remove all the bed material and ragging. Unbolt and remove the screen ring and then the screen itself. Replace with a new screen and bolt down ring. Remember to fill the rings with the desired ragging. Lead shot should be to a depth of 20-25mm and coarser ragging, 75-100mm. The clamping device for the screen is shown in figure 4 below. It is particularly important to frequently inspect finer screens (0-4mm) as the open area can increase dramatically with small amounts of wear. (e.g. a 2mm screen wearing out to 3mm will increase the open area by 100%.) This may result in very high concentrate yields and lower grades. Coarse screens should be checked for any damage, which may allow coarser than desired particles into the concentrate hutch. These can block lines and damage downstream pumps.

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SCREEN CONFIGURATION

Screen Support block

Screen Frame

Screen frame block mount

clamping device for screen M10x130 bolt

lead shot ragging 20-25mm

screen ring

specific S.G ragging 100mm s/steel wedge wire screen

screen frame support Figure 4

screen support block location & securing device for

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5.03

Recommended Spare Parts List

Order from: Gekko Systems Pty Ltd Ph: (61 3) 5339 5859 321 Learmonth Rd. Ballarat, Vic 3350 Fax: (61 3) 5339 5803 email: gekkos@gekkos.com.au A list of critical spares has been provided. Please contact Gekko Systems for a complete customized list for your application and location.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Hydraulic Ram Hydraulic Oil (40 litres),Tellus 68 Oil Filter element Screen Assembly (3mm-diam) Diaphragm upper Diaphragm lower O ring upper and lower O ring hatch Rupture disc GD6 Controller Motor (4.0 kW) Hydraulic Pump KVIP 2.6 Hydraulic Block with Solenoid Flow control Control valve and Relief valve Motor / pump coupling and spider Hydraulic tank hose PID Controller Upper diaphragm clamp Detector Proximity Switch 2.2 KW Variable Speed Drive 2.2 kW VSD Keypad Parker B5E6BB 24 V Solenoid Valve 5/2 Shaft protector Lead shot Ragging

3M502 8M271 3M807 2M103 8M102 8M109 8M105 and 8M105C 8M105B 8M410 1E201 2E011C 3M609A 3M512A 3M607 608 & 610 3M102 1E206 8M403A 1E501 1E205B 1E205A 7M004B 8M103A

Please provide a purchase order number and a clear description of the parts required. Stating the machine number will also ensure that the correct parts are supplied. (This information is on the nameplate, located on the leg of the jig). Postage and handling costs are additional, with all unit prices subject to change.

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5.04

Technical Schedule INLINE PRESSURE JIG - 2400

ITEM NO.IPJ - 2400 TECHNICAL DATA ITEM OFFERED Seller Gekko Systems Pty Ltd Equipment Name Primary Gravity Concentrator Make INLINE PRESSURE JIG Model IPJ2400 SizeLxWxH 2500,2500,3200 PRESSURE Maximum Operating Pressure 200 kPa Minimum operating pressure 20kPa Pressure drop across jig at design flow, 10 kPa WATER SUPPLY Hutch Water Requirements, 75 m3/hr max Hutch Water Requirements, 30 m3/hr min Minimum pressure, 350 kPa Water quality poor, < 500 um @ < 2% Cw CONCENTRATE Concentrate recovery 0.5 - 30.0 t/hr Expected concentrate recovery 6.0 - 20.0 t/hr RAGGING Type of ragging Hematite, Magnetite, Lead and synthetic Quantity of ragging, 400 litres Size of Ragging, 2 30 mm SCREEN Screen Aperture, 1-25 mm Materials of Construction Stainless Steel Type Wedgewire PULSE VARIABLES Stroke Frequency range 80 220 cycles/min Stroke length, 3 20mm Upstroke velocity variable Down stroke velocity variable

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ELECTRIC MOTOR / HYDRAULIC DRIVE

MOTOR Make Teco Voltage, 415 V Frame Size 132M / 100L Rating, 4.0 kW Speed, 1440 rpm HYDRAULIC DRIVE Make Rexroth Model 11 / 8 Rating, 4.0 kW Total installed power Quantity and type of hydraulic oil 24 litres / ISO-068 Pump capacity 4.4 LPM Description The unit consists of a motor driven gear pump, which provides a continuous flow of fluid to the control head. The control head actuates the ram. The control head consists of an overload, solenoid valve and various valves for flow control to the ram in both the up and down direction. The control head is in turn controlled by the electronic control system. Oil flow rate is controlled by variable frequency drive on the hydraulic pump motor. This reduces heat build up.

CONTROL SYSTEM
The electrical control cabinet is a single unit located locally on the IPJ. It can be removed and mounted either in the MCC (option) or in the vicinity of IPJ units. Description of control system The electrical control system is centered on Gekko Systems GD6 controller. A proximity switch monitors the hydraulic ram position. The GD6 controls the bed cycles per minute through a TIMER / SSR system. It also converts the pulse rate to an analogue voltage signal. The GD6 can be locally or externally controlled. The cycle rate is overseen and controlled by a Yokogawa PID controller using the GD6 external analogue output and analogue input.

INSTRUMENTATION
Type Magnetic flow meter Make Yokagawa Model AXF080G Electrical Signal 4 - 20 ma Type Proportional controller Make Yokogawa Model UT520 Electrical Signal 4 - 20 ma (in) 4-20 ma (out) Retransmission 4 - 20 ma (PV, SV, OP) Alarm contacts 3 (relay) Type Cycle rate controller Make Gekko Systems Pty Ltd Model GD6 Electrical Signals Pulse rate out. 0 - 10 vdc Pulse rate control (input) 0 - 10 vdc / 4-20 ma Voltage output (aux) 24 vdc Type Variable frequency controller Make Allen Bradley InLine Pressure Jig - the new art in Gravity Separation

36 Model AB160 Electrical Signals: Frequency rate out. 4 - 20 ma Frequency rate control (input) 0 - 10 vdc / 4-20 ma

FOUNDATION LOADINGS
Static (vertical, operating) 10500 kg Dynamic (vertical) 1400 kg @ 220 cycles per min Total sanded mass ( S.G.2.6) 15750 kg

LININGS
Cone linings Linatex rubber (3 mm), high build at wear points (6 mm). Shaft lining Polyurethane wear sleeve

PACKAGING, TRANSPORT, STORAGE, AND HANDLING INFORMATION

Total transport mass 3500 kg Mass of heaviest item for erection 3500 kg Mass of heaviest item for maintenance 2000 kg Dimensions of all items for transport LxWxH IPJ 2500 x 2500 x 3500

OTHER
Required maintenance clearances 1000 mm vertical, 1000 mm horizontal Manufacturers standard painting and protective coating system Blast to. Class 2.5, Amerloc 400,Luxathane final exterior. Holding down bolts - size and quantity 16 only M16 x 40 Lubrication requirements Hydraulic oil 2000 hrs

BATTERY LIMITS
Inlet nozzle type, size 200 Table D FL Outlet nozzle, size 150 Table D FL Water inlet nozzle, size 80 Table D FL Concentrate outlet nozzle, size 80 Table D FL Instrument air 8mm, 100PSI Power 415V, 3 ph, 50Hz

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6. IPJ ABBREVIATIONS & TECHNICAL DIAGRAMS 6.01 Abbreviations List

IPJ = InLine Pressure Jig S.G. = specific gravity TTH = total tail head Cw = % solids by weight

6.02

Technical Support

Gekko Systems Pty Ltd will provide full technical support and after sales service for every unit sold. Please contact Gekko Systems to discuss any specific service arrangements. For updated spare parts listings, quotes and technical information please contact, Gekko Systems Pty Ltd. Australia (Head Office) 321 Learmonth Rd. Ballarat 3350 Victoria Australia Phone +61 3 5339 5859 Fax +61 3 5339 5859. email: services@gekkos.com.au Gekko Systems - South Africa. PostNet 429, Private Bag X29 Gallo Manor, 2052 South Africa. Phone +27 11 448 1222/3/4 Fax +27 11 448 1230 email: gekkos@gekkos.co.za Gekko Systems - Canada email: jennifera@gekko.ca This document is a dynamic document and all input from operator experience would be greatly appreciated. Please forward any comments to any of the addresses above.

6.03

Technical Diagrams
See attached GAs 1. 2. 3. General Electrical Hydraulic

InLine Pressure Jig - the new art in Gravity Separation