Australian Patented Technology ~ PCT pending months in process operation. Two Phase Solids Flow Distribution with a difference

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1 FloCEP ~ Australian Patented Technology ~ PCT pending 39 + months in process operation Two Phase Solids Flow Distribution with a difference A Step Change producing low cost process profit using a balanced Flow Distribution System for Hydro cyclones, Classifiers, Thickeners, Filters and more Jul 2015 Copyright 2015

2 Recognising a problem To identify whether your system is performing at the optimum point there are some indicators from your process which can be used. Examples: Hydro cyclones do not wear evenly and require high man hours to maintain Spiral classifiers are not evenly loaded and show uneven wear Thickeners the solids loading of the thickeners are difficult to balance Filters unbalanced loading High man hours trying to adjust valves to manage flows Can t balance the overflow particulate sizing Cause Mal distribution This is where the solids phase of flow to the components is not even. This cannot be successfully corrected by adjusting the lean phase flow with valves; once the dense phase is at the outlet it s too late to balance the solids flow. This is due to differential in densities of the lean and dense phases, particulate sizing and velocities. Low distributor pot velocities results in uncontrolled solids phase distribution

3 Typical 4 port cluster standard distributor flow profile Est. inlet pipe velocity 2.85m/s to cluster the cluster velocity 0.36m/s with an est. deposition velocity of 2.25m/s

4 Typical 8 port cluster standard distributor velocity profile Feed pot distributor ID 1042mm mean average velocity of 0.93 m/s Est. deposition velocity of 2.23 m/s based on inlet velocity Riser pipe velocity mean ID average 2.89 m/s

5 Typical 10 Port Cluster standard distributor velocity profile Feed pot distributor ID 1275mm mean average velocity of 0.22 m/s Too low and promotes mal distribution Estimated deposition velocity of 1.93 m/s Cranked cyclones performance can be effected depending on the feed density Flow rate 1022 m3/h Est. inlet velocity 3.43 m/s

6 19 Port Cluster standard distributor velocity profile Feed pot distributor ID 1070mm mean average velocity of 0.27 m/s Too low and promotes mal distribution Estimated deposition velocity of 2.13 m/s Cranked cyclones performance can be effected depending on the feed density Inlet pipe 350NB Est. inlet velocity 2.89 m/s Flow rate 860 m3/h Est. inlet velocity 2.89 m/s

7 FloCEP MAXbend Cyclone cluster upgrade Original 16 outlet cluster 15 cyclones installed, ceramic pup spools, cyclones Cavex 400 installed vertical, distributor diameter 1250mm lined with 6mm S45 rubber Cyclones service frequency 3 4 days, Distributor service interval = 6 weeks New FloCEP MAXbend cluster retrofit 12 outlet cluster 12 cyclones installed, rubber pup spools, cyclones Cavex 400 installed vertical, Variable area distributor maximum diameter 1100mm lined with 6mm S45 rubber Cyclone service life days, Distributor service life = 170 weeks + no service required to date Results are significant for a device that does so much extra work FLOprep pre conditions flow stream FLOdistributor, is tuned to site conditions then set Installation time for the retrofit 12 hrs

8 FloCEP MAXbend 12 port cluster Feed pot FLOdistributor with the lid lifted showing part of the diverter Eliminates mal distribution Pup spool velocity of 2.06 m/s Vertical cyclones for enhanced performance Flow conditioning for enhanced performance

9 FloCEP MAXbend 12 port cluster general arrangement FLOdistributor max ID 1070mm top, the distributor has an internal diverter. This distributor promotes flow profiling to keep the dense phase entrained. Pup spools Inlet 400NB Flow rate 800m3/h The MAXbend flow conditioning technology used to prepare the feed flow into the distributor static device

10 FloCEP MAXbend Process & Maintenance Benefits delivered Zero maintenance to date on the distributor Zero maintenance to date on the pup spools Zero maintenance to date on the pre conditioner and pipe Flow Conditioning Device Hydro cyclone maintenance out to 90 day cycles+ Balanced flow mass flow regardless of units on line Improved overflow cut > 4% and stability Improved underflow P80 and reduced fines recycle Reduced kwh per tonne of feed to the mill

11 Applications The FloCEP distributor system works by splitting flows evenly to whichever multiple devices are attached to it and on line. Examples : Hydro cyclones Spiral classifiers Thickeners Filters Process stream splitting Banjo boxes (conventional term) Any stream which needs to be evenly diverted Processes that FloCEP Applications can be applied to: Gold, Iron Ore, Alumina, Oil & Gas (LNG Risers) to name a few Any wet process plant This technology challenges all traditional text book methods and installations. Until now there has been no other alternative that works. Component manufacturers are highly unlikely to be supportive of this technology as their products remain in operation for a significantly longer amount of time.

12 We address the cause of mal distribution Significantly extends the life of attached components any make Highly efficient over current methods No additional pressure drop over standard systems Higher process returns and fast ROI Rental & lease options available Any materials of construction & line specification Proven on solids loadings to ~65% by weight and with an abrasion index of > ~47 Instrumental in an increased recovery of ~>4% A step change in the battle against process costs Successful plant trials prove that Flow Conditioning technology works. Summary customer comment we have seen a step change in our recovery Scott Doig Managing Director scott@maxbend.com.au