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senK

rupp

ThyssenKrupp Industrial Solutions

Hydro-cyclonesVacuum belt filters

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ThyssenKrupp Fördertechnik:optimization of solid-liquid-separation

2

Worldwide, ThyssenKruppFördertechnik are one of the leading manufacturers of machinery and plants for themineral processing industry.

On the basis of the experience ofdecades, we are doing researchand development work, theresults of which became an integral part within mineral processing. All over the world,customers are profiting from ourinnovative power. Whether standard- or special designs –ThyssenKrupp Fördertechnikalways offer a complete problemsolution which is frequently optimised in co-operation withthe user.

Reliable, safe, economic, innovative...

ThyssenKrupp Fördertechnik.

1Hydro-cyclone cluster with direct feed to a vacuum belt filter

1

3Fields of applicationand characteristics of hydro-cyclones

2Pre-assembled hydro-cyclone station

Hydro-cyclones are used for continuous separation and deph-legmation of suspended particlesfrom fluids. They are operated at large suspension throughputs withhigh effectiveness.

Hydro-cyclones use the centrifugal force to acceleratesedimentation by tangentiallyentering of the suspension flowto be separated into the hydro-cyclone, where a circularmotion is forced on the fluid. In this range a centrifugal acceleration dependent from theflow rate and the diameter of the hydro-cyclone takes effect on the suspended solid particles. The coarse solid particles concentrate at the circumferenceof the hydro-cyclones, the fineparticles in the centre. The clarified fluid is drawn off byan immersion pipe (vortex finder)in the upper range, the thickenedslurry runs off below (apex finder).

Throughput and separation behaviour of the hydro-cyclonecan be optimised by using of different types, modification ofthe diameter of apex and vortexfinders and the admission pressure.

Fields of applications

•Environmental technology

•Chemical industry

•Food industry

•Mining industry

Characteristics

•reliable operation

•service-friendliness

• high availability

• high throughput

•small space requirements

3

2

4 Advantages of the solid-liquid-separation with hydro-cyclones of ThyssenKrupp Fördertechnik

3Multi-cyclone station with 26 singlecyclones each cluster

3ThyssenKrupp Fördertechnikbuilds complete systems forseparation of slurries by use ofhydro-cyclones. The used material is a polyurethane mixture extremelyresistant to wear and optimallytailored to the frequently abrasive process conditions.

Overflow and underflow nozzlesare sightly exchangeable andare available with various materials and diameters of bore.All components of the hydro-cyclone can be assembled and disassembledquickly.

Reliable operation even in caseof high system pressures isachieved by means of the particularly carefully constructionof the junction points.

5

4Hydro-cyclone connection at feed distribu-tor vessel

5Hydro-cyclone with underflow collectingtank and sample connection

6Hydro-cyclone feeding with hand operatedbutterfly valves

7Extrusion of underflow on nozzle

8Hydro-cyclone head with overflow nozzle inceramic material

7 8

5

4

6

A graduated range of types enables an adjustment to therespective product and therequested separation behaviour.Highest throughput capacitiesand small space requirementare achieved by interconnectingof single hydro-cyclones tolarger units. Complete hydro-cyclon stationsare consisting of:

•Feed distributor

•Hydro-cyclones with butterfly valves

•Overflow pipes

•Overflow collecting tank

•Underflow collecting tank

•Pressure gauging

•Sampling valve

•Supporting structure

An adaption to varying operatingstates is effected by connectionresp. disconnection of hydro-cyclones by means ofbutterfly valves connected inseries. In case of automaticallyworking stations the valves areequipped with pneumatic orelectrical drives.

6 Technical data

Separation curve type 50 F/S/V measured with sand/water slurry

1 10 100Particle size [µm]

100

50

0

Und

erflo

w s

hare

[%

]

type 50 F

type 50 S

type 50 V

Separation curve type 80 F/S/V measured with sand/water slurry

1 10 100Particle size [µm]

100

50

0

Und

erflo

w s

hare

[%

]

type 80 F

type 80 S

type 80 V

Separation curve type 125 F/S/V measured with sand/water slurry

1 10 100Particle size [µm]

100

50

0

Und

erflo

w s

hare

[%

]

type 125 F

type 125 S

type 125 V

Hydro-cyclon

type

50 F50 S50 V80 F80 S80 V

125 F125 S125 V

Hydro-cyclonØ

[mm]

505050808080

125125125

Inputflange

[DN]

323232404040656565

Overflowpipe

connection[mm]

444444626262929292

A[mm]

515515515790790790

1,1551,1551,155

B[mm]

165165165210210210285285285

Throughputmeasured

with sand/water slurry[m3/h] ∆ P [bar]

2.8 3.504.7 3.505.5 3.505.9 2.759.5 2.75

14.5 2.7511.9 2.5019.0 2.5026.6 2.50

NominalØ

underflow[mm]

35869

13101520

NominalØ

overflow[mm]

121518192430303745

A

B

The stated values are only approximate.

The guiding values depend on the crushingduty (characteristics of feed material, product requirements).

In case of need, throughput rates aredetermined for the specified crushing duty.

To keep pace with technical progress, wereserve the right to make improvementswithout prior notice.

7Fields of applicationand characteristic of vacuum belt filters

92x40 m2 vacuum belt filters for dewateringof gypsum from FGD-plant

9

Continuous filtration at highthroughput; maximum levels ofefficiency in filter cake washing;low residual moisture contents –all ensured results withThyssenKrupp Fördertechnikvacuum belt filters.

Our belt filters combine theadvantages of conventional horizontal belt filters with state-of-the-art components, materials and control systems toachieve efficient, reliable andeasily seviced filtering systems.And that with low capital outlayand minimum running costs.

Absolutely reliable vacuumsealing permits continuous operation at differential pressures of up to 900 mbar. Optimum installation flexibility tocorrespond to prevaling requirements ensures economicoperation – whether in wash filtration or in the dewatering ofslurries.

Fields of applications

•Environmental technology

•Chemical industry

•Food industry

•Mining industry

Characteristics

• The natural sedimentationthat boosts the effectivenessof continuous filtrationprocesses. High filtrationspeeds and therefore highspecific throughputs madepossible by minimum frictionbetween rubber belt andvacuum chamber.

• Highly efficient filter cakewashing in single-flow, aswell as multi-stage counter-current washing minimizesthe volume of washing fluidneeded.

• A high vacuum, optimumfilter cake thickness and theadvantages of naturalsedimentation ensure lowresidual moisture in the filtercake that can be reducedeven further by downlineextractors or heaters.

• Continuous washing of bothsides of the filter clothprevents the formation of“blind spots” and ensuresconstant filtering efficiency.

8 ThyssenKrupp vacuum belt filters –optimum solutions for numerous wash filtrationand dewatering processes

10Scheme of a wash filtration installation

11Vacuum filtrate receiver with filtrate pump

12Slurry feed device

13Special spray nozzle system for the clothcleaning with water at approx. 4-5 bar

Whether for multi-stage countercurrent or single-runwash filtration, or for the dewatering of slurries and whet-her flue gas gypsum, coal, che-micals, ores or sand ore to bedewatered or filtered – ThyssenKrupp Fördertechnikdesigns and builds all sizes ofvacuum belt filter installations asthe optimum solution whateverthe requirement.

In multi-stage countercurrentinstallations, the soluble components are washed out ofthe filter cake.Residual moisture is then reduced to the required level ina downline drying zone.

ThyssenKrupp Fördertechnik also supplies low-pressure beltfilters for solids/fluid separation.Here the perforated rubber belt,with its endless cloth, runsthrough a filtering zone above awater trap in which blowerscreate a different pressure of250 mbar. Such installations areused for dewatering of quartzsand, lump coal and ores.

12 13

10

11

9

14Scheme of a rubber belt-vacuum belt filter

15Discharging the drained filter cake

15

Rubber belt-vacuum belt filtersconsist of a conveyor belt thatcarries an endless filter clothand that slides over a vacuumchamber.

Transverse grooves in the belt(which are perforated in themiddle) allow for underpressureto be applied underneath the filter cloth. Wear strips are usedin the friction zones betweencarrier belt and vacuum chamber.

The vacuum chamber is sealedto the atmosphere by a wearbelt floating on a fluid film. Inorder to eliminate as much wearas possible, the carrier belt isrun on air cushions (or glide plates) fitted on both sides ofthe vacuum chamber.

A special material feeder ensures even distribution of theslurry over the full width of thebelt. Side bars prevent the slurryfrom overflowing.

While the filter cake is forming,the filtered fluids flow throughthe cloth and down the groovesto the holes in the middle of thebelt. They flow through theseholes into the vacuum chamberand from there through hosesinto the filtrate manifold andthen into the receiver tank.

Fluid/gas separation takes placein the receiver tank, with thefluid then being drawn off out ofthe underpressure zone.

Once it has passed the dewatering zone, the filter clothleaves the carrier belt and entersits return run vertically so thatthe filter cake is released.

The filter cloth then passesthrough a cleaning area wherehigh-pressure water is sprayedthrough special nozzles to cleanboth sides of it continuously.

A photo-electric mechanismmonitors the filter cloth to ensure straight running.

The belt drive drum is equippedwith an infinitely variable drive.

For wash filtration processes,the vacuum chamber is designed with easily movablecompartments and with severalfiltrate outlets so that the different filtrate concentrationscan be drawn off separately.

14

A

B

CDEFG

H

I

JKL

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

Design

A Cloth guide. The cloth is kept on a straight run by the photo-electrically driven guide roller.B Cloth tensioner. The tensioner at the feed end of the belt keeps the filter cloth

at the right tension. C Vacuum chamber and filtrate manifold are connected by flexible hoses. D Edge section. The special shape of the edge section ensures that the border falls flat

before going over the belt rollers.E Frame, made up of modular steel sections that are rigidly bolted together.F The filtrate manifold collects the filtrate/air and passes it to the reveiver tank.G Air chambers. In its upper run, the carrier belt is supported in the middle by the moving

wear strips.Over its outer areas, the belt is supported on an air cushion formed by air escaping fromthe perforated air ducts on each side of the vacuum chamber.

H Cloth cleaner. The filter cloth runs through a bank of spray nozzles that clean it on both sides.

I Feeder. Is arranged in such a way as to ensure an even distribution of the slurry at all times.

J Transverse grooves and holes. Transverse grooves, with holes in the middle of the beltallow underpressure to be applied over the complete belt width.

K Vacuum chamber, is made up of trough sections bolted together. A pair of HDPE bars onthe top of the chamber form the water seal to the belt.Two endless wear strips are filted between the HDPE strips and the moving carrier belt.

L Lowering device. The vacuum chamber is fixed to the frame during filtration but can easilybe lowered (with all fittings) for inspection and servicing.

10 Technical data

[m2]

0.761.141.521.902.282.683.354.024.695.366.036.427.708.56

10.3010.6010.7012.8014.1017.6017.9021.2021.7022.3024.7026.8027.1031.3032.5035.7036.7038.0040.2043.4044.1048.8051.4054.2058.8066.1073.4078.4891.56

104.64117.72130.80143.88

5B

1VO21VO32VO42VO52VO6

––––––––––––––––––––––––––––––––––––––––––

12B

––––––––––––

3V–

4V––

5V–––––––––––––––––––––––––––––

20B

––––––––––––––––––––

4V––

5V–

6V–

7V–

8V––

9V––––––––––––––

32B

––––––––––––––––––––––––––––––

5V–––

6V–

7V–

8V9V

10V––––––

24B

––––––––––––––––––––––

4V–––

5V–

6V––

7V–

8V–

9V–

10V–––––––––

16B

–––––––––––––––

3V––

4V5V–

6V––

7V––––––––––––––––––––––

45B

–––––––––––––––––––––––––––––––––––––––––

6V37V38V39V3

10V311V3

B[mm]

2,5703,5704,5705,5706,570 4,7005,7006,7007,7008,7009,7008,8009,000

11,20011,400

9,00013,60013,80011,40013,80011,80016,20011,80014,20018,60016,60014,20019,00016,60021,40015,20019,00023,80021,40017,60023,80020,00026,20022,40024,80027,20021,40024,40027,40030,40033,40036,400

C[mm]

3,4504,4505,4506,4507,4505,6806,6807,6808,6809,680

10,68010,70010,55013,10012,95010,65015,50015,35013,05015,45013,70017,85013,80016,10020,25018,50016,20020,90018,60023,30018,70021,00025,70023,40021,10025,80023,50028,20025,90028,30030,70024,77527,77530,77533,77536,77539,775

A[mm]

2,0003,0004,0005,0006,0004,0005,0006,0007,0008,0009,0007,2007,2009,6009,6007,200

12,00012,000

9,60012,000

9,60014,400

9,60012,00016,80014,40012,00016,80014,40019,20012,00016,80021,60019,20014,40021,60016,80024,00019,20021,60024,00018,00021,00024,00027,00030,00033,000

D[mm]

860860860860860

1,1601,1601,1601,1601,1601,1601,4801,6801,4801,6802,1001,4801,6802,1002,1002,6002,1003,0002,6002,1002,6003,0002,6003,0002,6003,8003,0002,6003,0003,8003,0003,8003,0003,8003,8003,8005,1005,1005,1005,1005,1005,100

10B

–––––––––––

3V–

4V––

5V––––––––––––––––––––––––––––––

8B

–––––

2VO42VO52VO63VO73VO83VO9

––––––––––––––––––––––––––––––––––––

H[mm]

1,0001,0001,0001,0001,0001,1001,1001,1001,1001,1001,1001,7001,6001,7001,6001,6001,7001,6001,6001,6001,8501,8501,8501,8501,6001,8501,8501,8501,8501,8502,2001,8501,8501,8502,2001,8502,2001,8502,2002,2002,2002,5502,5502,5502,5502,5502,550

Weight

[kg]

9801,1001,2501,4001,5001,6001,7501,9002,0502,2002,3503,9504,2004,4004,7508,5004,8505,3009,450

10,40012,00011,35013,20013,15012,30014,30014,60015,45016,00016,60028,50017,30017,75018,70030,00020,00031,50021,50033,00034,50036,00052,00054,00056,00058,50060,50063,000

Data for other types and sizes available on request. The values stated are only approximate and are subject to alteration.

The widely varying demands placed on the mechanical separation of fluids and solidsmean that each and every filter installation must be tailored to the on-site conditions.

Type 5-24 B Type 32-45 B

11ThyssenKrupp indexing-filter (CH) A proved filter system

16Scheme of a countercurrent wash filtrationinstallation

17Assembling of 2 indexing filters (CH) fordewatering of ammunition slurry

Where the application for a rubber belt-vacuum belt filter isnot possible, ThyssenKruppFördertechnik builds and deliversindexing filters (CH).

The slurry is continuously fed tothe horizontal filter. Filtrationtakes place on an endless filter cloth which is supported by a trough-shaped,movable vacuum tray mountedon rollers. By vacuum frictionalconnection the tray is synchronously moved with the filter cloth at filtration.

Optimum flexibility of the filtercycle to correspond to the prevai-ling requirements by means of aninfinitely variable drive.The opto-electromechanicalsystem remotely senses the clothposition.

16

17

Wash water 1Wash water 2Wash water 3

Suspension

Driver

Filter Cake

Clothcontrol

Aerationvalve

Butterflyvalve

Filtratepump

Vacuumpump

Clothtensioning

device

Wash waterpump

Clothcleaning

water

Processwater pumpWash filtrate

pump 2Wash filtrate

pump 1

Freshwater

The cloth tension is adapted tothe process requirements by apneumatically operated cloth tensioning system.

When reaching the defined endposition, the vacuum tray isatmospherically ventilated andreturned to initial position bymeans of a pneumatic cylinder.The filtration cycle statrs anew.

12Technical data

Effectivefilter-area[m2]

0.40.60.81.01.52.02.53.03.54.05.06.07.59.0

10.012.515.020.025.030.035.040.0

1,600–––––––––––––––––––––

––––––––––––––––

5,0006,6708,330

10,00011,67013,300

–––––––––––––––

5,0006,0008,000

10,00012,00014,00016,000

–––––––––

3,2004,0004,8006,0007,2008,000

10,000––––––

––––––––––––––

5,0006,2507,500

10,00012,50015,000

––

–––––––

3,0003,5004,0005,0006,000

––––––––––

––––––––––––

5,0006,0006,6608,330

10,00013,30016,670

–––

8001,2001,6002,0003,0004,000

––––––––––––––––

––––

2,0002,6703,3304,0004,670

–––––––––––––

Effective filter width [mm]

250 500 750 1000 1250 1500 2000 2500 3000

Effective filter length [mm]

Data for other types and sizes available on request. The values stated are only approximate and are subject to alteration.

The widely varying demands placed on the mechanical separation of fluids and solidsmean that each and every filter installation must be tailored to the on-site conditions.

13

18Installation of 4 large vacuum belt filters

19Spare parts store

20Lifting of a 74 m2 vacuum belt filter into a gypsum dewatering building

21Whether direct personal collection orworldwide airfreight – we give our customers the fasted possible and mosteconomical method of delivery

The values ascertained by calculation are then practicallychecked using a newly developedcontrol- and diagnosis system.With this system, the mostimportant operating parameterscan be checked again.

Our services comprise projectstudies, damage analyses, planning and execution of conversions for modernisingmachines and plants and forincreasing their capacity as wellas an after-sales service andother services rendered worldwide also for machines andplants of other manufacturers.

The maintenance- and repair service of ThyssenKrupp Fördertechnikoffers local expert consultation.

Repairs are performed by highly-qualified assembly staffusing high-quality tested spareparts.

Increase the productivity of yourmachines and plants.

Contact ThyssenKrupp Fördertechnikworldwide.

• Inspection service

• Stand-by service

• Repair service– on your site– in our Service Center

with workshop

• Diagnosis systems

• Maintenance contracts

• Spare parts service

20

1918

21

Research and development arehighly rating for ThyssenKrupp Fördertechnik.A committed staff, experienceand the ability to also tread newpaths as well as innovativepower, flexibility and know-howare the basis for the successfulpartnership with our customers.

Our experience and our know-how are the results of the permanent critical comparison ofthe design- and dimensioningcriteria with the results frompractical operation.

The starting point are analysesand examinations, of which theresults are the basis for workingout suitable conceptions.

To that end, methods and processes are adopted whichguarantee the best possible solution for the respective task.

Furthermore, thanks to the previous examination of the fundamentals, an optimal adaptation of the systems can bedetermined, for example thedimensioning of componentssubjected to high stress with theaid of FEM-analyses.

Research, developmentand services

Delivery programCrushing technology

•Stationary, semi-mobile andmobile crushing plants

•Gyratory crushers

•KUBRIA® cone crushers

•Double-toggle jaw crushers

•Single-toggle jaw crushers

•Impact jaw crushers

•MAMMUT® single-shaft hammer crushers

•TITAN® double-shaft hammer crushers

•Impact crushers

•Roller crushers

•RollSizers

•SIEBRA® swivel-arm crushers

Screening technology

•Linear vibrating screens

•Circular vibrating screens

•Elliptical vibrating screens

•Eccentric vibrating screens

•Screener Fines screening machine

•Grizzly primary screens

•Vibrating screen feeders

•Unbalance drive units

•Aqua vibrating separators

Grinding technology

•Ball mills

•Rod tube mills

•Hammer mills

•Roll mills

•Separating systems

•Water injection systems

Feeding and conveying systems

•Apron feeders

•Chain conveyors

•Reciprocating plate feeders

•Vibrating screens

•Wobbler feeders

Filtering- and drying technology

•Magnetic separators

•Dryers

•Vacuum belt filters

•CHF vacuum belt filters

•Separating cyclones

•Hydro-cyclones

•Cyclone clusters

•Disc filters

Systems

•Systems for power plants

•Coal preparation systems

Engineering Modernization, RefurbishmentAfter-sales serviceTraining

ThyssenKruppPartners of the mineral processing industry

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0.09ThyssenKrupp Industrial Solutions AG

Business Unit Resource TechnologiesSchleebergstraße 12, 59320 Ennigerloh, Germany, Tel.: +49 2525 99-0 E-mail: info.industrial-solutions@thyssenkrupp.com