High Efficiency Hydrofoil Agitators

Presentation by Chemical Plant & Engineering Pty Ltd Australia

Company Introduction
Chemical Plant and Engineering Pty Ltd (CPE) was formed in 1953 and has over 30 years of equipment supply history with many leading Mining companies.

Is an operating subsidiary of CEM International Pty Ltd and is a wholly owned Australian company. Designs and manufactures process equipment for the wine, food, mineral processing, chemical, water and wastewater treatment industries. Offers a complete engineering service starting from laboratory and pilot plant testing through to detail engineering design, manufacturing, and supervision of installation and commissioning.
CPE HAS MANUFACTURING FACILITIES IN BOTH AUSTRALIA AND CHINA

Company Introduction

CPE design / engineering philosophy is to provide the client with BEST SOLUTION to their problem at a cost effective price.
We CUSTOM design and engineer every product to the requirements of the client. We do not supply standard off-the-shelf equipment for any application.

Laboratory testing is available to understand the rheology of nonNewtonian fluid required for agitator design
CPE provide ENGINEERED solutions for every project.

Local Sales & Support

Chemical Plant and Engineering Pty Ltd (CPE) is represented in the Americas by Crimar Industrial, based in Tucson, Arizona, with offices in Chile, Mexico, and China and sales agencies in Brazil and Canada Crimars primary focus is on the mining and water treatment industries in the global market

Agitation Technology

The flow generated and the energy consumed by an agitator (just like a pump) are determined by published formulae that recognise the degree of work required to create process change. The degree of work reflects the magnitude of the forces to be overcome and the environment in which this has to occur.

For a given process situation (tank size, physical and chemical nature of fluid etc) and a given set of physical conditions (diameter, speed etc) the effectiveness with which process change is accomplished is determined by the geometry of the device (impeller in this case).
Each Impeller is uniquely defined by two dimensionless groups
Nq which is the pumping number Np which is the power number.

Agitation Technology
In order to make a comparison of flow between agitators the only item that changes in the formula below is Nq

Primary Pumping Capacity:

Q = Nq N D3 n
Q = Nq = N = D = n = Primary Pumping Capacity (m3/min) Pumping Number Shaft Speed (rpm) Impeller Diameter (m) Number of impellers

Agitation Technology
In order to make a comparison of power required between agitators, the only item that changes in the formula below is Np.
Absorbed Power:

Power = Np (N/60)3 D5 f n
Power Np N D n f = kW = = = = = = Power Number Shaft Speed (rpm) Impeller Diameter (m) Number of impellers Density (kg/m3) Viscosity Factor

Agitation Technology

An agitator impeller is defined by its Power Number, Np, and its primary Pumping Number, Nq. The relationship between power number and pumping number defines the efficiency of an impeller. These numbers are constant.

Agitation Technology

The flow generated is a measure of the extent to which the shape impacts the fluid ; for example blades that impact at 90o(S4) will exert more force on the fluid (and thus create more flow) than a flat disc which impacts the fluid at 0o and creates little or no flow.
Conversely the work required to overcome the resistance to flow created by the S4 is significant whereas the flat disc is able to move through the fluid relatively easily. Older technology was focussed on ensuring sufficient flow was created to achieve process change without a lot of consideration for the energy being consumed. Modern technology strives to achieve a combination of effective flow whilst consuming a lower amount of energy. The RTF4 impeller has the best ratio of flow created per unit of energy input.

Agitation Technology

The flow generated is a measure of the extent to which the shape impacts the fluid ; for example blades that impact at 90o(S4) will exert more force on the fluid (and thus create more flow) than a flat disc which impacts the fluid at 0o and creates little or no flow.
Conversely the work required to overcome the resistance to flow created by the S4 is significant whereas the flat disc is able to move through the fluid relatively easily. Older technology was focussed on ensuring sufficient flow was created to achieve process change without a lot of consideration for the energy being consumed. Modern technology strives to achieve a combination of effective flow whilst consuming a lower amount of energy. The RTF4 impeller has the best ratio of flow created per unit of energy input.

Agitation Technology

Flat Blade Turbine (S4)

Pitch Blade Turbine(P4)

Propeller

Hydrofoil

Agitation Technology Shift

Technology Progression
Impeller Efficiency Curve
3.5

2nd Generation Hydrofoil

3

RTF4

2.5

Pumping No./Power No.

1st Generation Hydrofoils

1.5

Turbine Impellers

0.5

0
Rushton 6 Blade 90 Pitch Blade Turbine 45 Pitch Blade Turbine Prochem Maxflo Philadelphia Denver Equipment MIL Chemineer HE3 Warman AF Lightnin A310 CPE RTF4

Impeller Data
Manufacturer/Type CPE RTF4 Hydrofoil Lightnin A310 Hydrofoil Ekato Hydrofoil Power Number 0.15 0.30 0.32 Pumping Number 0.50 0.56 0.50

Chemineer HE-3 Hydrofoil

Warman AF Hydrofoil Philadelphia Hydrofoil 45o Pitch Blade Turbine 90o Pitch Blade Turbine

0.36
0.37 0.40 1.37 3.50

0.50
0.58 0.50 0.68 0.74

Rushton 6 Blade Disc

5.00

0.82

High Efficiency RTF4 Hydrofoil

WHY IS IT BETTER?
The RTF4 Hydrofoil was developed to reduce power consumption by maximizing flow and minimizing turbulence (or shear). It does this by transferring the available energy into pure axial flow without turbulence at the impeller

HOW DOES IT WORK?

Increasing width Profiled Edge Blade twist The Arch

High Efficiency RTF4 Hydrofoil

WHY IS IT BETTER?
The RTF4 Hydrofoil is manufactured in dedicated tooling to ensure the shape profile is maintained Unlike the first generation Hydrofoils the shape is not taken from commercially available components (i.e. line pipe) and made to suitthe shape is optimum and has been developed first in theory and then manufacturing tooling made. Independent verification by CSIRO has validated the dimensionless groups (Np & Nq) that define this shape.

Benefits to Mineral Plant Processing Operators

Power Savings generated by implementation of a programme to retrofit second generation hydrofoil impeller technology.
Ability to increase tank flow if required to increase yield or to reduce scale accumulation (if applicable) without the need to change the drive train Capacity expansion if required without the need for expensive modifications to tank and agitator mounts etc Increase of drive train service factors resulting in lower loadings, longer operating life and reductions in downtime and maintenance.

Power Savings

An example of the potential benefit by replacing impellers with latest generation technology.

Design Agitator Flow = 150,000 gpm (568 m3/min)

P4 Pitch Blade Impeller Diameter Impeller Speed (rpm) P4 Pitch Blade Lightnin A310

CPE RTF4 150" 20.5

150" 15.1

175" 9.5

150" 18.3

Power Consumption (Hp)

23.5

12.7

9.17

6.44

* Calculations based on SG = 1.0 and single impeller system.

Power Savings

In this example the annual benefits to plant operators would be as follows:

Annual savings based upon 98% utilisation @ A$ 0.10/kWh Annual savings based upon 98% utilisation @ A$ 0.12/kWh Annual savings based upon 98% utilisation @ A$ 0.14/kWh

P4 Blade ( original configuration) P4( modified configuration) Lightnin A310

Nil (base case) A$6868 A$9220 A$12967

Nil (base case) A$8242 A$11064 A$15236

Nil (base case) A$9615 A$12908 A$17776

CPE RTF4

Process Improvement

Agitator intensity is measured on a scale from 1 10 with scale 1 being very gentle agitation and scale 10 being rigorous turbulent flow agitation. Application of technology that has been developed for certain applications over many years will generally suffice however in certain markets additional flow is required to address other process issues (like scale accumulation) For example in a typical off bottom suspension application the design would call for a scale 3 degree of agitation whereas in an alumina application one might apply scale 4 or 5 to keep the internal tank velocities higher and thus limit potential for scale to adhere to the tank wall. CPE analyses the entire application including related tank connections to ensure these are adequate and not sites for scale to commence to deposit.

Scale of Agitation Intensity

1 3

h Solids homogeneously distributed for full tank height (agitation Intensity = 9)

Unstable fillets on vessel bottom (agitation Intensity = 1)

Particles swept off vessel bottom and uniformly suspended for 13 of tank height (agitation Intensity = 3)

Mechanical Service Factors

Drive train selection involves the application of routine mechanical engineering data however the degree of safety applied between a theoretical requirement and actual installed capacity can sometimes vary.
In OEM applications we apply a service factor of between 1.5 and 2.5 ( the higher the service factor the longer the component life) In applications where an RTF4 is retrofitted we can generally increase the process performance significantly without need to change motor or gearbox capacity and in some cases we increase the gearbox service factor thus increasing service life.

Current Market Activity

BARRICK GOLD LIHIR GOLD RESOLUTE MINING NEWMONT MINING NEWMONT MINING
Granny Smith Mine (Australia)

(Lightnin Agitators)

Completed 2008

Lihir Gold Mine (Papua New Guinea) Completed

(Lightnin Agitators)
(Mixtec Agitators)

Carpentaria Gold (Australia)

Completed 2007 Ordered 2009 Waiting for approval to proceed

- Mill 5 Quarry (USA)

(Lightnin Agitator)
Phoenix Gold Mine

(Hayward Gordon Agitators)

ALL CPE RTF4 RETROFITS

Retrofits
Chemical Plant & Engineering, through use of its world leading RTF4 Hydrofoil, can offer retrofitting solutions for installations not meeting the process requirements. These limiting factors might be

Power Supply Degree of Agitation

Detailed below are some case studies of industrial applications highlighting the actual situation and benefits delivered in a significant process plant situation.

Case Study Poseidon Gold

Plant Operator: Date: Application: Process Data: Tank dimensions Operating volume (m3) Specific gravity solids Specific gravity liquid Specific gravity slurry % solids by weight Solids size (micron) Poseidon Gold Big Bell Mine 1994 Gold Leaching 13.6m diam x 14.1m 2000 2.7 1.0 1.47 50 120

Process Limitation/Problem: Insufficient agitation due to agitator power consumption exceeding available motor power.

Case Study Poseidon Gold

Application Installed Power Shaft RPM Impeller Type Impeller Diameter Power Draw Excl. Drive Losses Agitation Scale Pumping Capacity Gold leach 55 kW 13.8 2 x Lightnin A310 4.88 metres 29.6 kW (i) 2 (ii) 1.8 x 106 litres/minute

Notes: (i) Original recommended speed was 16.7 RPM but insufficient drive power was available to support this operating condition in the application (Power draw @ 16.7 RPM = 52.5 kW excluding drive losses). (ii) Agitation Scale 2 will only provide off bottom suspension of solids.

Case Study Poseidon Gold

Original
Application Installed Power Shaft RPM Impeller Type Impeller Diameter Power Draw Agitation Scale Pumping Capacity (m3/min) Gold leach 55 kW 13.8 2 x Lightnin A310 4.88 metres 29.8 kW 2

Retrofit
Gold leach 55 kW 16.7 2 x CPE RTF4 5.334 metres 41.1 kW 5

1800

2500

Therefore the RTF4 impeller created 40% more pumping capacity for no increase in installed power. Tank yield improved proportionately. Scale 5 agitation intensity provides complete uniformity suitable for overflow discharge.

Big Bell purchased one retrofit in 1994 as a trial and after successful commissioning purchased a further four units.

Case Study Lihir Gold

Plant Operator: Date: Application:
Process Data: Tank dimensions Operating volume (m3) Specific gravity solids Specific gravity liquid Specific gravity slurry % solids by weight Solids size (micron) 13.7 m diam x 15.0 m 2182 2.9 1.0 1.33 40 150

Lihir Gold 2005 Gold Leaching

Process Limitation/Problem: Agitator performance was satisfactory however excessive power consumption was noted.

Case Study Lihir Gold

Original
Application Installed Power Shaft RPM Impeller Type Impeller Diameter Agitation Scale Pumping Capacity (m3/min) Power Draw (Actual) Gold leach 75 kW 20 2 x Lightnin A310 1 x 4125 mm 1 x 4775 mm 5 2006 75 kW

Retrofit
Gold leach 75 kW 20 2 x CPE RTF4 2 x 4700 mm 5 2082 46.2 kW

The RTF4 impeller retrofit created savings of 38% on power usage whilst creating slightly more pumping capacity. Improved solids suspension also noted.

Case Study Lihir Gold

PROCESS OUTCOMES:

Good agitation was achieved in the tanks with minimal solids buildup in the bottom. Power consumption was reduced considerably after the agitator retrofit.

Agitator life was increased due to minimal erosion due to solids buildup.

Gold Leach Agitators Installed at Lihir Gold

Case Study Lihir Gold

Case Study Barrick Gold (Granny Smith)

Plant Operator:
Date: Application:

Barrick Gold Granny Smith Mine - Australia 2008 CIP

11.1 m diam x 12.3m 1190 2.8 1.0 1.47 50 140

Process Data: Tank dimensions Operating volume (m3) Specific gravity solids Specific gravity liquid Specific gravity slurry % solids by weight Solids size (micron)
Process Limitation/Problem:

Some settling of solids and poor overall distribution of solids in suspension.

Case Study Barrick Gold (Granny Smith)

Original
Application Installed Power Shaft RPM Impeller Type Impeller Diameter Power Draw Agitation Scale Pumping Capacity (m3/min) CIP 45 kW 25.6 1 X Lightnin A310 1 x Lightnin A510 2 x 3750 mm 44.6 kW 5 1346

Retrofit
CIP 45 kW 19.7 2 x CPE RTF4 1 x 4300 mm 1 x 3810 mm 18.3 kW 5 1337

Therefore the RTF4 impeller maintained the existing pumping capacity with a corresponding 59% reduction in power draw.

Case Study Barrick Gold (Granny Smith)

Case Study Newmont Gold (Phoenix)

Plant Operator: Date: Application: Process Requirement: Process Data: Tank dimensions Operating volume m3 Specific gravity solids Specific gravity liquid Specific gravity slurry % solids by weight Solids size (micron) Newmont Gold 2009 CIP Improved solids suspension 11,125 mm x 13,198 mm 1223.6 3.1 1.0 1.6 55 max 208m

Process Limitations: Existing installation indicates flow available from the agitator is grossly undersized for this solids loading and the flow being generated based upon the existing impeller characteristics represents about 60% of that necessary for the effective solids suspension for the solids data provided for the application. The required flow to provide a scale of 5 intensity is 2247 m3/min

Case Study Newmont Gold (Phoenix)

Application Installed Power Shaft RPM Impeller Type Impeller Diameter Power Draw Agitation Scale Pumping Capacity CIP 55kW 20 2 x Hayward Gordon 4115mm 46.2 kW (inc 10% belt drive loss) 1 2 (i) 1393 m3/min

Notes: (i) The scale of 1 2 intensity available from the existing agitator will result in ineffective suspension of the larger and / or heavier particles and they will accumulate on the tank bottom and eventually form a solid mass which when contacted by a rotating impeller blade generate significant stresses that may result in catastrophic failures that are being experienced,

Case Study Newmont Gold (Phoenix)

Original
Application Installed Power Shaft RPM Impeller Type Impeller Diameter Power Draw Agitation Scale Pumping Capacity CIP 55kW 20rpm 2 x Hayward Gordon 4115mm 46.2kW 1-2

Retrofit
CIP 55kW 20rpm 2 x CPE RTF4 4826mm 52.7kW 5

1393m3/min

2247m3/min

Retrofit - Material of construction: Mild Steel External Lining: Natural Rubber

Case Study Newmont Gold (Phoenix)

Comments on Retrofit
Guidelines for the retrofit set by the client required the utilization of the existing mechanical drive train. Consequently the design was based upon the existing gearbox output shaft speed to ensure the unit operated within the available torque capacity of the gearbox. Analysis shows that the RTF4 impeller was able to achieve the required flow for solids suspension (Scale 5) based upon the design data provided. The consumed power of 52.7kW included a 10% allowance for losses in belt drive. The selection was also made on the basis that the maximum recommended tip speed for rubber lined impellers in abrasive environments, as quoted by rubber manufacturers, was 5m/sec The tip speed for the 4826mm impeller was 5m/sec at 20rpm.

Agitator Retrofit Analysis Mineral Processing Applications

Conclusions

Utilisation of the RTF4 impeller in mineral processing plants, either OE supply or as a retrofit, will reduce agitator operating costs. Additional benefits will also result in the form of reduced scale build, better service life and reduced maintenance cost. Chemical Plant is able to undertake an evaluation of refinery problem agitator applications and provide recommended courses of action if mineral processing plant operators have an interest in adoption of this technology.

CPE Local Representative

Crimar Industrial
6720 E. Camino Principal, Tucson, AZ 85715 (520) 574-8350 usa@crimar.com www.crimar.com
Santiago, Chile office: (56)2 431 5424 Regus CCU, Av. Vitacura 2939 Piso 10, Las Condes, Santiago, Chile chile@crimar.com Sonora, Mexico office: (662) 2-60-03-03 Blvd. Garcia Morales No.326, Col. El Llano, Hermosillo, Sonora mexico@crimar.com Hebei, China office: (1590)321-6384 c/o Hauhua Zhongyi GFRP Co. Ltd., South Rd., West Belt Highway, Shijiazhuang, Hebei 050091 china@crimar.com Brazil agent: InTec Inovao Aplicao Industrial Ltda. (55) 71-3289 3611 Av. Lui Tarquinio Pontes, 2,580, Lauro de Freitas, Bahia, Brasil brazil@crimar.com Canada agent: SinFin Ltd., (416) 474-1588 31 Daffodil Avenue, Thornhill, Ontario,Canada canada@crimar.com

Contact Us
CHEMICAL PLANT & ENGINEERING Pty Ltd

Phone + 61 393094822 Fax + 61 393090069 Mobile + 61418368881

Website www.cem-int.com.au/ourbusinesses/cpe/

Address P.O. Box 160 Broadmeadows Victoria Australia