Novel Filter Aid for Improved Efficiency of

Pressure Filters
Gyan Ranjan Das, Subhashree Singh, G.V. Kiran, Anand Purohit, Alok Tripathy, Dr. S.K. Biswal

Gyan Ranjan Das,

Co-founder, Innocule
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Brief Company Profile of INNOCULE

INNOCULE is a start-up founded two IIT Bombay Alumni in 2014 and is based out

of Bhubaneswar
It deals with innovative specialty chemicals to enable mineral processing industries

overcome operational difficulties and maximize cost-effectiveness while

processing low-grade ores.
Research collaboration with CSIR IMMT (Institute of Minerals and Materials

Technology), Bhubaneswar
Our team believes in:
The People Who Are Crazy Enough to Think They Can Change the World, Are the Ones Who Do
- Steve Jobs

Current Challenges for Beneficiation Plants

High Clay
Content

Constantly
degrading
ore quality

Soft Ore

Challenges
to Address

Retrofitting
in previously
designed
technologies

Chemical Route to Address Those Challenges

Crushing
Flow aid
(Stickiness
Inhibitor)
Grinding Aid

Washing
Dispersant

Classification/
Grinding
Dispersant

Dewatering Methods
/ Filtration
Dewatering Aid
Filter Aid
Flocculant

Dewatering Steps for Pelletization Plants

Thickening

Filtration

Pellet Making
If cake moisture is around
10%, it can be sent to
pelletizing Disc
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Current Problems in Pellet Plants

Filter cake is wet

and sticky

Sticky filter cakes

cause blockage of
chutes

Possible Solution:
FILTER AID
Higher moisture
makes induration
process expensive

Excess moisture
can dampen the
formation of pellets
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What is Filter Aid?

Polymers/Speciality chemicals/inert materials/combination of all

that can improve filtration efficiency in terms of throughput and
moisture reduction in the cake

Generally, added to the slurry before filtration

Sometimes, can also be applied as a precoat or to the cake

after filtration

Types of Filter Aids

Chemically Inert
Improve cake permeability
Forms a porous layer on the
septum and becomes the
filtering medium
Light in weight
High dosage is required

Chemically Active
Polymers/speciality
chemicals adsorb onto the
surfaces of particles
Promote coagulation,
capillary pressure reduction,
hydrophobicity and surface
tension reduction
Added in very minute
quantity

Problem at hand?

<45 Mic particles:

Iron concentrate grade:
Goethite:
Alumina:
Cake Moisture:

61%
60-61%
upto 10-15%
5-8%
10.5-11.5% (sticky at times)

Target Moisture:

Around 9-9.5% without hampering production rate

Methodology Followed to Develop Filter Aid

Literature Survey

Vacuum Filtration

Lab Scale Filtration

Pilot Scale Filtration

(Make: Diemme)

Plant Scale Trial

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How does our Filter Aid (FAM product range) work?

Enlarge
capillary
radius of
pores in cake

Lower
Surface
Tension

Increase
Contact
Angle
Decrease
Viscosity

Filter Aid

Reduce
Swelling
property of
clay

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Test results of Pilot Pressure Filter

After getting encouraging results in vacuum filtration, trial was conducted in pilot
pressure filter

Cycle Time
(Min)

FAM 110
Dosage
(gm / MT)

Cake
Thickness
(Cm)

2.8

12

11.6

50

2.8

12

10.8

-0.8%

100

2.8

12

9.8

-1.8%

Moisture
(%)

Change
(%)

(Feeding + Pressing)

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Case Study: Plant Scale Results with FAM 110

Feeding:
Flushing
with
Air:
Slurry Density
(Gram/ml)
Squeezing with Air:

Operating
4 min Parameters
5 min
1.97
7 min
90

Filling time (in Sec.)

Flushing pressure:
Filtration time (in Sec.)
Squeezing pressure:
Slurry
Pressingdensity:
time (in Sec.)

1.5

Filing Pressure (Bar)

5.5 bar
Filtration Pressure (Bar)
12 bar
2.1 gm/cc
290
Pressing Pressure (Bar)

10.3

420

8.5

250

Air drying time (in Sec.)

7.2

Air Drying Pressure (Bar)

Summary of the results

Filter Aid Dosage

Throughput

Cake Moisture

Reduction in
Moisture content

Gram / MT

MT

Blank

28.5

10.25

Reference

Test-1

25

28.5

9.59

0.66

Test-2

35

29

9.37

0.88

Test-3

45

28.5

8.72

1.53

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Conclusions

Moisture reduced by 1-2% by addition of FAM 110

(from 10.25% to 8.72% @ 45 gram/MT)

Cycle time and production rate kept constant

Filter cake was friable and non-sticky

Cost: Approximately Rs. 5-10/MT of dry matter

Flexibility to increase throughput - reduce cycle time or reduce moisture

Environmental Friendliness:

Dosage is as low as 25-100 grams / MT

Environmentally safe chemicals

Energy saving in induration stage and pelletizing disc

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Advantages of using Filter Aid (FAM product range)

Reduced moisture content in the cake

Easier and efficient handling of filter cake due to reduced stickiness

Enhanced throughput of the filtration process

Higher percentage of green ball formation of the concentrate because of

optimum water content in the cake

Increased recovery of water in filtration

Less energy in induration stage

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INNOCULEs Product Offerings

Typical Beneficiation Process

Crushing

Flow aid
(Stickiness
Inhibitor)

Grinding/Washing

Dispersant
Grinding Aid

Classification

Dispersant

Dewatering Methods
/ Filteration
Dewatering Aid
Filter Aid
Flocculant

Customized Products products are developed as per plant raw material and design,

thereby more cost effective with enhanced value addition

Research MoU with Institute of Minerals and Materials Technology (formerly RRL,

Bhubaneswar) one of the renowned research and consulting organisations engaged

in mineral processing
One stop solution for all process related issues through process optimization and/or

additives
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Thank you for your attention!

Please feel free to contact us incase you need any clarification. Contact details:
Gyan Ranjan Das
Cell: +91 9238306546
Email: gyanranjan.das@innocule.co.in
www.innocule.co.in
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