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application mining and minerals filter press

MINING AND QUARRYING

MSE filter presses are used in processing plants of the mining industry due to the positive aspect of the great process-technical flexibility among other things. The most frequent applications are the dewatering of fine coal and coal tailings (finest fractions) as well as the solid-liquid separation of the ore concentrate suspension concentrated by flotation and subsequently separated from mineral by-products. At this point, metals such as zinc, iron and copper are extracted, but precious metals such as gold, silver and platinum are also extracted in corresponding mines in the form of a puncture-proof filter cake. Membrane filter presses are preferably used here to achieve quantitatively high yields in cake washing and high dry matter contents by means of squeezing processing.

 

MSE Filterpressen® has proven itself in this context. Our filter presses – with their adapted dewatering technology and the associated special design-typical features for this application – enable a fast cycle time, high filtration speeds during filtration and dewatering of the suspensions as well as a low residual water content of the resulting filter cake solids. These properties and an optimised and efficient design of the processes for the application are of great importance with regard to the requirement for high capacities and above all from an economic point of view.

EXEMPLARY APPLICATIONS IN THE MINING AND QUARRYING INDUSTRY

Desciption follows…

The sometimes strongly fluctuating quality and the specific properties of bentonite place high demands on extraction and processing. Bentonite is found in clayey rocks from natural deposits, which are dispersed in water, for example, and are of particular practical importance for the stabilisation of cavities in the soil, especially in special foundation engineering and deep drilling. Due to the wide range of possible uses, considerable quantities of used bentonite suspensions are produced in this case on various construction sites, which lose the properties relevant to construction when loaded with soil particles and cannot be used in this form. Furthermore, the disposal of bentonite suspensions by agricultural spreading or landfilling entails both ecological and economic disadvantages. Therefore, the processing of bentonite suspensions takes place in several steps.

 

The separation of the solid particles from the bentonite suspension is done in several stages in view of the occurring grain fractions, e.g. by coarse separation (pre-cleaning by screening), medium separation (subsequent cleaning using hydrocyclones) and finally by fines separation. The latter fines separation stage is carried out by filtration with filter presses, in which the suspension slurry is separated from fines. In this context, the consistent implementation of a practical separation process based on MSE filter presses makes a positive contribution to reducing the primary costs and protecting the environment. The filtration carried out here is characterised by the fact that a porous medium – the filter medium – retains the drilling cuttings to be dewatered, while a compressive force presses the water through the pores of the filter cake and filter medium. Depending on the requirements, modern chamber filter presses, membrane filter presses or chamber membrane filter presses are used.

 

Membrane filter presses and chamber membrane filter presses have the special feature of achieving a significant increase in the achievable residual moisture in the filter cake through the squeezing process.  This leads to an increase in the DM content compared to a chamber filter press (membrane technology). The associated reduction in the filtration cycle time also contributes to higher profitability. The dry blowing option leads to a further increase in the DM content by blowing out the existing pore water in the filter cake. This also improves the dissolving behaviour. MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.

The production of bleaching earth requires the preparation of selected bentonite in multi-stage downstream process steps. The raw clay is first pre-crushed, crushed and the clay material plasticised with the addition of water. After subsequent slurrying with water, hydrocyclones separate the admixtures such as sand and coarse components from the clay suspension. In a further process step, the cleaned clay sludge is activated by the addition of mineral acids and the direct introduction of „cooked“ steam. With the help of acid activation, metal ions are replaced by hydrogen ions, creating a large inner surface in the clay. The resulting cooking sludge must then be filtered and dewatered for further processing. In this context, filtration is carried out with the help of MSE filter presses due to their outstanding technical properties. These first clean and dewater the sludge using filter cake washing.

 

The residue from the filter presses is additionally dried using hot gases and then ground to the desired particle size. Our chamber filter presses, membrane filter presses or chamber membrane filter presses offer optimum solid/liquid separation depending on the DM content requirements and batch times. Membrane filter presses and chamber membrane filter presses have the special feature of achieving a significant increase in the achievable residual moisture in the filter cake through the squeezing process.  This leads to an increase in the DM content compared to a chamber filter press (membrane technology). The associated reduction in the filtration cycle time also contributes to higher profitability. The dry blowing option leads to a further increase in the DM content by blowing out the existing pore water in the filter cake. This also improves the dissolving behaviour. MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.

For the production of calcium hypochlorite, the suspension of the calcium hypochlorite dihydrate solids is suspended in an aqueous solution of calcium hypochlorite. The calcium hypochlorite, which is produced as a dihydrate, is filtered in a further step. This is followed by drying and storage of the filter cake produced during filtration. For the filtration and separation of solids from the calcium hypochlorite dihydrate suspension, MSE filter presses have proven themselves due to their excellent dewatering results. Use Depending on the TS content requirements and batch times, modern chamber filter presses, membrane filter presses or chamber membrane filter presses are used for solid/liquid separation.

 

Membrane filter presses and chamber membrane filter presses have the special feature of achieving a significant increase in the achievable residual moisture in the filter cake through the squeezing process.  This leads to an increase in the DM content compared to a chamber filter press (membrane technology). The associated reduction in the filtration cycle time also contributes to higher profitability. The dry blowing option leads to a further increase of the DM content by blowing out the existing pore water in the filter cake. This, in turn, also improves the dissolving behaviour in the filter cake. MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.

During the treatment processing of the mined hard coal, which is separated from the waste rock by several crushing, screening and washing processes, suspensions are produced which have to be filtered, dewatered and finally delivered as plates, pellets or coal dust before further processing, depending on the intended use. This is followed by the separation of the fine coal (finest fraction) contained in the tailings from the added minerals. This is done by the flotation process as an enrichment process. The carbon suspension is fed to a membrane filter press with the aim of solid-liquid separation and the resulting carbon filter cake is dewatered. In this context, MSE filter presses enable high filtration speeds during dewatering of the suspensions as well as a low residual water content of the filter cake solids. This is particularly important from an economic point of view.

CONCRETE GRINDING SLUDGE FILTRATION AND SEPARATION WITH A CHAMBER FILTER PRESS

 

Large quantities of concrete grinding slurry, or concrete washing water, are produced during the manufacture of prefabricated concrete components. Due to stricter environmental regulations, it is no longer possible to discharge the waste water directly into the sewage system. The solids contained in the waste water must be separated from the liquid phase before they can be discharged or reused. For this purpose, MSE has developed treatment plants as compact plants. The plants consisting of a filter press, feed pump, sludge storage with coarse material separator, as well as all other necessary units have already proven effective in practice.

 

BENEFITS WHEN USING AN MSE FILTER PRESS

 

    • Reduction of the sludge volume
    • Improvement of the handling and transport
    • Lowering of the landfill costs
    • Reduction of fresh water and waste water costs
    • Fully automatic process flow – minimisation of the personnel costs = higher economic benefits!!

The process-related waste sludge resulting from the various areas of metal refineries (cleaning, refining, separation, etc.) have to be treated in several steps in the form of landfilling and dewatered using membrane filter presses due to both ecological and economic reasons. During zinc smelting, goethite and gypsum residues with a high iron content are fed to a membrane filter press with the aim of a solids-free filtrate. The solids are then separated from the goethite / gypsum suspension. Modern MSE membrane filter presses are used in this context due to the maximum required filter cake dry matter contents and the associated dewatering degree requirements.

 

These achieve very high dry matter contents (DM containers) at high filtration pressures and downstream filter cake washing as well as through squeezing with membrane filter plates. The achievable low residual moisture leads to excellent economic results. Our filter presses are characterised in particular by high productivity of the filtration process with minimum washing water consumption. Depending on the TS content requirements and batch times, membrane filter presses or chamber membrane filter presses are used for solid/liquid separation. MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.

During ore processing, the finely ground ore (digestion of the contained ore) is concentrated in an aqueous slurry (suspension) by flotation and subsequently separated from mineral by-products. The resulting concentrate suspension is then dewatered. With regard to the ore particle size, filter presses in particular in the form of chamber filter presses or membrane filter presses serve as the solid-liquid separation stage. These dewater the concentrate to the required water content (DMC). Membrane filter presses have the special feature that the resulting filter cake is optionally mechanically pressed out and additionally dewatered in a squeezing operation after filtration and filter cake washing. With the help of the cake dry blowing function, existing pore water in the filter cake is blown out. The resulting higher dry matter content (DM content) generates a better dissolving behaviour of the filter cake. MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.

In general, the extracted raw kaolin is first separated from admixtures such as coarse quartz grains and, if necessary, feldspar or mica in the wet treatment process (slurrying and classifying by means of various washes) during the treatment process. After the thickening of the kaolin suspension, further chemical treatment, flotation and magnetic separation is done. In a further treatment processing step, MSE chamber filter presses are used for appropriate dewatering of the settled pure kaolin (coarse kaolin grain) depending on the grain size (<1ym – approx. 45ym) and the composition. For fine kaolin grains (<2ym), modern membrane filter presses are primarily used due to the considerably reduced filtration cycle which uses squeezing and the associated increased profitability.

 

In addition, the squeezing process primarily achieves higher DM contents (70-80 % depending on the suspension), which reduces the water content in the filter cake to a maximum content (DMC) required for kaolin as a commercial product. Another option for reducing the residual moisture in the filter cake is thermal drying (TCD). The hot filter press used here combines the standard process steps of a conventional membrane filter press (filtration, filter cake washing and squeezing) with the thermal drying function. The advantage of this process is that there is no need for time-consuming external drying. This leads to even higher DM contents. For a detailed description, see Hot Filter Press. MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.

During the treatment process, the raw material is first slurried and separated from admixtures and impurities. A filter press is then used to dewater the slurry chalk/lime sludge to a maximum required residual moisture content (20 – 30%). Depending on the requirements and filtration cycle times, modern chamber filter presses, membrane filter presses or chamber membrane filter presses from MSE are suitable. Membrane filter presses and chamber membrane filter presses have the special feature of achieving a significant increase in the achievable residual moisture in the filter cake through the squeezing process.

 

This leads to an increase in the DM content compared to a chamber filter press (membrane technology). The associated reduction in the filtration cycle time also contributes to higher profitability. Additionally, the dry blowing option offers a further increase of the DM content by blowing out the existing pore water in the filter cake. In this way the dissolving behaviour is also improved. MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.

Due to the increased demand for lithium processing solutions, solid/liquid separation plants are of significant relevance. These must meet the requirements of the rapidly growing lithium salt and lithium carbonate markets and offer high efficiency. The partnership with MSE Filterpressen guarantees the successful implementation of your project and, above all, the safe and efficient operation of your filtration plant – throughout its entire service life.

 

In the technical extraction of lithium salts/lithium carbonates, the contaminated lithium raw materials are processed economically and in an environmentally compatible manner by solvent extraction and precipitation. The filter press separates the suspension of mineral by-products and then dewaters the resulting filter cake. Filter presses are mainly used as chamber or membrane filter presses for solid/liquid separation. These dewater the concentrate to the required water content (DMC).

 

Membrane filter presses have the special feature that the resulting filter cake is mechanically pressed out and additionally dewatered in a squeezing operation after filtration and filter cake washing. The resulting higher dry matter content (DM content) generates a better dissolving behaviour of the filter cake. Our proven filter presses help to release the full value of your raw materials, resulting in high-quality lithium salts/highly pure lithium carbonate. MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.

As a mineral, mullite is a highly refractory aluminosilicate from the silicate mineral class. For the production of mullite, the mined fire-proof bauxite and kaolin are generally ground and homogeneously mixed in a defined ratio in a wet processing process. Once the desired chemical and mineralogical composition has been achieved, the prepared sludge mixture is fed to the chamber filter press with the aim of producing a puncture-proof filter cake solid. This is followed by dewatering of the filter cake formed by the pressure filtration.

 

Here, membrane filter presses make a considerable increase in the achievable DM containers (<30%) and a considerable reduction in the filtration time possible by means of squeezing. This is particularly important from an economic point of view. The filter cake is then squeeze treated using extrusion presses and thermal drying. MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.

The production of porcelain requires various raw materials. The treatment takes place in multi-stage process steps. The raw material kaolin is first dissolved in water. As a rule, the raw minerals quartz and feldspar still have to be ground up. In further downstream processes, the sieving and cleaning of the suspension consisting of kaolin and ground feldspar or quartz, also known as porcelain mass, is done. For the filtration or separation of the solids, the treated suspension is fed to the filter press and dewatered with the aim of a solids-free filtrate. The filter cake resulting from the filtration, the raw mass, is then pressed into so-called slabs for further processing.

 

Chamber filter presses, membrane filter presses or chamber membrane filter presses offer optimum solid/liquid separation depending on the DM content requirements and batch times. Membrane filter presses and chamber membrane filter presses have the special feature of achieving a significant increase in the achievable residual moisture in the filter cake through the squeezing process.  This leads to an increase in the DM content compared to a chamber filter press (membrane technology). The associated reduction in the filtration cycle time also contributes to higher profitability. Additionally, the dry blowing option offers a further increase of the DM content by blowing out the existing pore water in the filter cake. In this way the dissolving behaviour is also improved.

MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.

Filter presses are used in the final phase of the Merrill-Crowe process to extract precious metals, e.g. in gold and silver mines. This is a separation technique used to remove and recover gold, silver and copper from a cyanide solution using zinc dust. The suspension mixed with the zinc dust is fed to the filter press at a filtration pressure of approx. 15 bar. This is followed by filtration of the settled precious metal and dewatering of the filter cake formed to a maximum required level of residual moisture. Depending on the requirements (filtration cycle time and degree of dewatering), chamber filter presses, membrane filter presses or chamber membrane filter presses are used.

The raw material is of particular relevance for the glass and chemical industries. Due to the increasing demands on purity, the mined raw mineral has to be elaborately processed for its industrial application and the associated quality requirements. The treatment processing of the loose aggregates (raw products) extracted from the deposits is carried out in a wet processing process as part of quartz sand washing. The following steps are relevant: Sludge removal, washing, classification and subsequent dewatering. In this context, MSE membrane filter presses are used which achieve very high dry substance contents (DM containers) at high filtration pressures and downstream filter cake washing as well as squeezing with membrane filter plates. This leads to low residual moisture and correspondingly excellent economic results.

 

The dry blowing option further increases the DM content. The compressed air, which passes through the filter cake, presses part of the capillary water out of the cake. In this context, this leads to a reduction of the capillary water adhering between the filter cloth and the filter cake. This also improves the dissolving behaviour and the dry matter content of the filter cake. MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.

During ore processing, the finely ground ore (digestion of the contained ore) is concentrated in an aqueous slurry (suspension) by flotation and subsequently separated from mineral by-products. The resulting concentrate suspension is then dewatered. With regard to the ore particle size, filter presses in particular in the form of chamber filter presses or membrane filter presses serve as the solid-liquid separation stage. These dewater the concentrate to the required water content (DMC). Membrane filter presses have the special feature that the resulting filter cake is optionally mechanically pressed out and additionally dewatered in a squeezing operation after filtration and filter cake washing. With the help of the cake dry blowing function, existing pore water in the filter cake is blown out. The resulting higher dry matter content (DM content) generates a better dissolving behaviour of the filter cake. MSE filter presses are available with a fully automatic design for a fast cycle time and the associated high capacities.