• Description

    MINERAL RECOVERY DOWN TO 3 MICRONS AND FORCES UP TO 600 G’s

    Falcon UF Gravity Concentrators Key Advantages

    • High gravitational fields (up to 600 G) allows recovery of ultra fine particles
    • The variable frequency drive (VFD) and a dynamic braking system are used to greatly reduce offline time for concentrate flushing
    • Recovery of previously unrecoverable values from flotation concentrate
    • Advanced wear materials and a modular design decreases downtime and reduces maintenance costs
    • No process water consumption during concentration
    • Greater than 95% mechanical availability, extremely low operating costs
    • Small footprint
    • Fully automated, “one touch” operation that provides the least amount of offline time and
      highest possible concentrate security

    Ultra fine mineral recovery has been a mining industry goal for many years. With Falcon’s UF line of  gravity concentrators there is now a way to economically recover and upgrade particles as fine as three microns. The primary objective of the Falcon UF Gravity Concentrator is to scavenge ultra fine mineral particles that are typically rejected from mining plant processes as slimes.

    Using a variable lip controlled by air pressure the Falcon UF Gravity Concentrator is extremely flexible, allowing for a wide range in metallurgical operation from high mineral recovery to high mineral upgrade. Rinse times are generally less than a minute as Falcon Gravity Concentration equipment uses a variable frequency drive (VFD) with a dynamic braking system to quickly slow the bowl down, rinse out the concentrate, and then return to full operational speed. Falcon UF Gravity Concentrators can operate anywhere from 50 to 600 G’s. Operating in rougher-cleaner or rougher-scavenger configurations, this gravity concentrator can provide an almost unlimited range of possibilities.

  • Applications

    The Falcon UF Gravity Concentrator is used in a variety of mining applications, including:

    • Recovery of ultrafine slimes (tin, tantalum, tungsten, etc.)
    • Scavenging from deslime cyclone overflow
    • High recovery upgrade of fine flotation mineral concentrates

    Sepro’s line of enhanced gravity concentrators provides the best value and performance for your application. Installed in a variety of recovery mineral processes throughout the world, Falcon Gravity Concentrators are well proven as the optimal choice for fine metal and mineral recovery by gravity.

    Our team of dedicated metallurgists and engineers continue to research and develop Falcon Gravity Concentrator technology, resulting in much higher efficiencies on the latest machine models. Sepro Mineral Systems recognizes that each gravity concentration circuit is unique, offering a line of mineral recovery equipment that is unequalled in parametric flexibility.

    Common Application Circuits for Falcon UF Gravity Concentrators

    Ugrading Fine Flotation Concentrate

     

     

     

     

     

     

    As Falcon UF technology is limited in throughput capacity, suitable applications are often found in downstream processes such as cleaner applications, upgrading of ultra-fine flotation concentrates to saleable grade or the removal of heavy minerals or metals from a pre-concentrate.

    Closed-Circuit Upgrade of Deslime Cyclone O/F

     

     

     

     

     

     

    Ultra-fine and dilute streams, that contain previously unrecoverable values, can be processed by the high G-Force Falcon UF centrifuges. As no fluidization water is added into the circuit during the concentration cycle, Falcon UF technology is suited to multi-stage rougher – cleaner – scavenger circuits to upgrade high value, low tonnage streams.

     

  • Specifications

    Falcon Ultra-Fine Gravity Concentrators

    2.211-Falcon-UF-Specifications-Chart

  • Automation

    Each of Sepro’s high quality Falcon Gravity Concentrators are supplied with a Programmable Automation Controller (AutoPAC). Sepro incorporates industry leading automation technology to enable long-term, maximum mineral recovery on site with each unit.

    The standard Falcon Gravity Concentrator AutoPAC includes a programmable variable frequency drive and dynamic brake to control various operating parameters including acceleration ramp, centrifugal field, deceleration ramp, and power draw. The dynamic brake is an integral part of the AutoPAC, as it allows the rotor bowl to come to a stop rapidly to reduce lost production time or in the event of a malfunction. In order to withstand the demands of short concentrating cycles, UF AutoPAC’s are equipped with oversize dynamic brakes and drives to prevent overloading even when required to rinse concentrate every two minutes.

    Some of the key automated features include: vibration sensor/monitor, safety limits, alarms, timers, solenoid control, data trending and automatic shut-down. The splash proof AutoPAC cabinet also houses a touch-screen Human Machine Interface (HMI). This HMI is used to control and monitor the operating parameters which assists with the optimization of concentrate production.  Optionally, the AutoPAC can also be connected to an on stream analysis system which allows the Falcon Concentrator to maintain optimum metallurgical performance while operating conditions change.

    The comprehensive Falcon AutoPAC is simple to operate as all controls and programmable features are factory preset before commissioning. The standard version offers the flexibility of being a complete control package that can operate as a stand-alone unit or can also be integrated into onsite MCC, DCS, PCS, SCADA, etc.

    Process Water Manifold

    • Proportional Valve
    • Pressure Transmitter
    • Solenoids for Rinse, Flush, Exhaust and Lip Wash

    Autopac

    • Single NEMA 3R / IP54 panel
    • Siemens 7″ Colour Touch Screen HMI with Ethernet
    • Siemens PLC with Ethernet
    • Siemens VFD with Ethernet
    • Complete with Pushbuttons, Relays, Mains Disconnect and Protection Devices
    • 24VDC Control Voltage for Solenoids/Instrument
    • Dynamic Braking package

    Air Compressor

    A source of clean, dry, high-pressure air is required for the operation of the Falcon UF Gravity Concentrator throttling valves that regulates the heavies underflow rate. Sepro supplies several compressor options for purchase with this model, contact us for more information.

  • FAQ

    What are the major industries that use Falcon UF Gravity Concentrator technology?

    Falcon UF Gravity Concentrators are used for Ta, Sn, Coal, Iron ore, Titanium sands and Cr applications.

    What is Falcon UF Gravity Concentration technology?

    Falcon UF Gravity Concentration technology allows for the recovery of ultra fine minerals – All previous enhanced gravity concentration technologies have failed to achieve meaningful recovery of particles finer than 10 Microns. Sepro Mineral Systems’ UF technology is a true recovery breakthrough in this size fraction, with gravitational fields reaching up to 600 Gs.

    It’s very new technology. What about its mechanical robustness?

    Sepro Mineral Systems’ Falcon UF Gravity Concentrator machines run on mechanical platforms that have been proven over almost two decades in plant environments.

    Why should I choose a Model UF Falcon Gravity Concentrator?

    • High gravitational fields (up to 600 G) allows recovery of ultra fine particles
    • The variable frequency drive (VFD) and a dynamic breaking system are used to greatly reduce offline time for concentrate flushing
    • Recovery of previously unrecoverable values from flotation concentrate
    • Advanced wear materials and a modular design decreases downtime and reduces maintenance costs
    • No process water consumption during concentration
    • Greater than 95% mechanical availability, extremely low operating costs
    • Small footprint
    • Fully automated, “one touch” operation that provides the least amount of offline time and highest possible concentrate security

    Does this gravity concentrator consume process water?

    None is required except for periodic rinsing of mineral concentrate. There is never a need for high quality process water to be injected through small holes that tend to plug up. Low quality water can be used for rinsing.

    What are the differences between the Falcon SB, C and UF Gravity Concentrators?

    Falcon SB Gravity Concentrators are batch-type concentrators that use fluidization water to obtain a high-grade concentrate and a mass pull to concentrate << 1%. SB Gravity Concentrators are used primarily for the recovery of precious metals in the free, metallic state.

    The Falcon C Gravity Concentrators, on the other hand, do not require any fluidization water and are mainly used for pre-concentration and scavenging where high mass recoveries are required. C Gravity Concentrators can pull up to 40% of the feed mass as concentrate.

    Falcon UF Gravity Concentrators are the latest addition to the Falcon family with a very specialized function: the recovery of ultra-fine concentrate down to 3 microns. The UF Gravity Concentrator uses a variable lip controlled by air pressure to achieve maximum particle recovery.

    How do I compare machines from different manufacturers?

    Concentrating surface area (CSA), centrifugal field, machine power and weight are most important.

    What operating costs can be expected?

    Overall operating costs will be lower than for Sepro’s Falcon SB Gravity Concentrators, parts costs are expected to be less than 0.01 USD per ton treated.
    What operating availabilities does Sepro Mineral Systems equipment attain?
    Sepro Mineral Systems maintains mechanical availability >95% as long as equipment is installed and maintained according to our recommendations.

    What do your model numbers mean?

    The model prefix designates the machine type. The suffix is the approximate concentrating surface area of the machine in square inches. A UF1500 Gravity Concentrator is batch unit with approximately 1500 in² of concentrating surface area.

    How sharp a separation does the Falcon UF Gravity Concentrator make?

    UF Gravity Concentrators are capable of producing extremely high grades of concentrate through multiple concentrating stages. Concentrating ratio at each stage is variable according to mineral, but is usually about 4-10.

    What top size should be fed to Falcon UF Gravity Concentrators?

    Top size is 38 μm. Falcon UF’s are specifically designed for recovery of extremely fine minerals, down to 5 microns and less. If your separation involves target minerals coarser than 1 mm, it would be best to look at other technologies for the coarse fraction.

    How do lab results compare with those in the plant?

    Lab results appear to be slightly better and Pilot Plant results are indistinguishable from production. Both types of test are available through Sepro Mineral Systems.

    Can concentrate be cleaned to saleable grades?

    Yes.

    How do you calculate the “G” forces produced by a centrifugal field?

    Centrifugal Field in G’s = Rotor Diameter (inches) x RPM2 ÷ 70471.

    Are there ‘gravity-only’ flowsheets available?

    Yes, Sepro Mineral Systems has developed unique flowsheets to help clients achieve previously unobtainable recoveries without using any reagents such as cyanide. Visit Falcon UF Applications for several example ‘gravity-only’ flowsheets.

  • Technical Papers

    Sepro Mineral Systems devotes a substantial amount of time and revenue to the design and metallurgical performance of its mineral processing technology. A large portion of this is conducted by Research Institutes, Universities and onsite trials.

    Our company appreciates the commitment and research conducted by the various parties throughout the mining industry. The technical papers contained herein are our proof of the time spent on designing the best range of mineral processing equipment for the mining industry, and a tribute to those involved with Falcon Gravity Concentration technology.

    No.TITLEOVERVIEW
    1.Pushing The Limits of Gravity ConcentrationView PDF
    2.Improving Fine Particle Recovery through Equipment Behavior ModificationView PDF