UF6500R2.

0 Operations and Maintenance Manual

Contents

5. Start-up and Operation ..................................................................... 5-1

Overview of Operation .............................................................................................. 5-1
5.1 Pre-Start Checks .................................................................................. 5-2
5.2 Slurry Feed ........................................................................................... 5-2
Table 5.2-1 Tons Per Hour .................................................................................... 5-3
Oversize Particles Excess Density ........................................................................... 5-4
Density ...................................................................................................................... 5-4
High S.G. Gangues ................................................................................................... 5-4
Feed Relative To Speed And Vibration..................................................................... 5-5
Rotational Speed....................................................................................................... 5-6
5.3 Starting the Concentrator.................................................................... 5-6
5.4 Optimization ......................................................................................... 5-7
Variable Lip ............................................................................................................... 5-7
General Procedure to Determine Optimum Run Time.............................................. 5-8
5.5 Rinsing .................................................................................................. 5-9
5.6 Shut Down ...........................................................................................5-10
Vibration Shut Down ............................................................................................... 5-11
5.7 Vibration...............................................................................................5-11
Table 5.7-1 RPM vs. G’s...................................................................................... 5-12

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UF6500R2.0 Operations and Maintenance Manual

5. Start-up and Operation

IMPORTANT: Although this manual provides general operating guidelines, it is

important that qualified factory personnel commission the equipment. Incorrect
installation and/or operation causing failure will not be covered under warranty.

With the Falcon AUTOPAC operating functions will be performed automatically after
start-up. Refer to the AUTOPAC portion of the manual for additional programming and
operational instructions.

The following operating instructions assume that equipment has been correctly installed
and commissioned.

WARNING!
USE SAFETY PRECAUTIONS WHEN WORKING WITH, ON OR
AROUND ROTATING MACHINERY AND ELECTRICAL EQUIPMENT.

Each installation is unique, therefore it is not possible to specify exact procedures for
start up, operating, rinsing, and shut downs. The procedures mentioned in the following
sections are only meant to give the operating personnel general guidelines to help
optimize the performance of the machine, and minimize downtime.

Falcon has a highly qualified staff to help with installation and optimization. Please do not
hesitate to ask for assistance.

Overview of Operation

See section 1.0 Introduction.

In an Ultra-Fine concentrator the rotor lip is systematically moved inward to gradually

increase the concentrate mass retained in the rotor bowl. The principle is to maximize
recovery by collecting a layer of target mineral along the inside of the bed of concentrate,
then move the lip ring to again maximize recovery during the next segment.

This can either be done manually such as in a laboratory machine or automatically with a
Falcon AUTOPAC.

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Shown below is an simple example of a laboratory machine:

LIP RING LIP RING LIP RING

TARGET TARGET TARGET

MINERAL MINERAL MINERAL

GAUNGE GAUNGE GAUNGE

In an automated machine the above steps are called “segments”, and there are normally
10 separate segments in a run cycle.

See 4.11 Control Philosophy.

5.1 Pre-Start Checks

Check the following before starting the machine:

1. Voltage to the AUTOPAC is correct and constant.

2. All electrical connections comply with local standards.
3. Feed stream is within recommended limits.
4. Feed valve is functioning correctly.
5. Machine rotor is free of debris, and the rotor turns freely.
6. Water and air systems meet requirements and do not leak.
7. Water supply is flushed and free of suspended solids (sand, etc.).
8. A “cold commissioning” has been performed (see 4.0 AUTOPAC section).

5.2 Slurry Feed

IMPORTANT: It is extremely important to make sure the available air pressure is reliable
and constant before introducing any feed into the machine.

Feed material must only be introduced when the rotor has reached operating or run
speed, otherwise the unit may flood. Before starting the concentrator it is recommended
that the feed be tested using a bypass system to see if it is within design limitations.

Optimum feed volumetric rates and pulp densities will vary greatly with different materials
There is no minimum density for the feed stream but the recommended maximum is
20%. For low-density feed the throughput may be governed by the maximum slurry
capacity of about 2400 USgpm or 9085 l/m.

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For estimating and set up purposes begin with the nominal values given in section 2.
Specifications and the following table:

IMPORTANT: The Shaded area in the following table represents solids throughputs
exceeding the recommended limits. Operating at or above these limits may adversely
affect performance and may significantly increase wear.

If the feed characteristics are within the recommended limits the film of slurry moving up
the migration zone should be relatively even, and the impeller and the bottom portion of
the rotor should be visible during operation. If there is a large amount of slurry “swirling”
around near the base of the rotor walls this indicates exceeding the feed limits, a worn
impeller, or unsuitable rotational speed.

The following table is provided to aid in determining feed rates. It shows the relationship
between a volumetric pulp flow rate and % solids content of the feed, and how they
determine the solids throughput.

Table 5.2-1 Tons Per Hour

S.G. Solids 2.7

PULP
PULP FLOW IN GALLONS PER MINUTE
DENSITY
(% SOLIDS) 500 650 700 850 1000 1150 1300 1450 1600 1750 1900 2050 2300 2450
3 3.8 5.0 5.4 6.5 7.6 8.8 9.9 11.1 12.2 13.4 14.5 15.7 17.6 18.7
4 5.1 6.7 7.2 8.7 10.3 11.8 13.3 14.9 16.4 18.0 19.5 21.0 23.6 25.1
5 6.5 8.4 9.0 11.0 12.9 14.8 16.8 18.7 20.7 22.6 24.5 26.5 29.7 31.6
6 7.8 10.1 10.9 13.3 15.6 17.9 20.3 22.6 24.9 27.3 29.6 32.0 35.9 38.2
7 9.2 11.9 12.8 15.6 18.3 21.1 23.8 26.5 29.3 32.0 34.8 37.5 42.1 44.9
8 10.5 13.7 14.7 17.9 21.1 24.2 27.4 30.5 33.7 36.9 40.0 43.2 48.4 51.6
9 11.9 15.5 16.7 20.3 23.9 27.4 31.0 34.6 38.2 41.7 45.3 48.9 54.9 58.4
10 13.3 17.3 18.7 22.7 26.7 30.7 34.7 38.7 42.7 46.7 50.7 54.7 61.4 65.4
11 14.8 19.2 20.7 25.1 29.5 34.0 38.4 42.8 47.3 51.7 56.1 60.6 68.0 72.4
12 16.2 21.1 22.7 27.6 32.5 37.3 42.2 47.1 51.9 56.8 61.7 66.5 74.6 79.5
13 17.7 23.0 24.8 30.1 35.4 40.7 46.0 51.3 56.6 61.9 67.3 72.6 81.4 86.7
14 19.2 24.9 26.9 32.6 38.4 44.1 49.9 55.7 61.4 67.2 72.9 78.7 88.3 94.0
15 20.7 26.9 29.0 35.2 41.4 47.6 53.8 60.0 66.3 72.5 78.7 84.9 95.2 101.5

The specific gravity of the feed pulp material may also vary. If it is higher than 2.7 kg/l,
the tons per hour solids in the feed will be slightly higher for the given pulp density and
volumetric flows shown.

When no solids are fed into the unit clear water may be left running in most cases without
substantial loss of target minerals, provided the concentrator is operating at speed and
target mineral capacity has not been exceeded.

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Oversize Particles

Oversize particles will adversely affect the performance of the machine. To prevent
problems and maximize performance it will usually be necessary to install a screen
ahead of the machine. This can be of either static or vibrating type, and should not be
installed directly on top of the machine impeding easy removal of the lid.

If oversize is allowed to enter the machine it is likely to be captured in the retention zone
during the run cycle. During the rinse cycle this oversize will be rinsed from the rotor
basket down into the base of the rotor bowl, and may obstruct or even plug the gap
between the rotor baffle and the rotor bowl wall. If this happens it will restrict the flow of
concentrate out of the machine, subsequently decreasing metallurgical recovery.

Other problems created by oversize are imbalance, reduced actual concentrate volume
(less recovery volume for target mineral), and increased maintenance requirements.

In addition to eliminating problems, classifying the feed will improve metallurgical

performance as sharper separations can be accomplished between gangue and target
minerals.

Density

Optimum flow rate and density will vary slightly with different materials. For estimating
and set up purposes, begin with the nominal values given in Specifications. A good
indication that the machine is functioning correctly is if you can see the impeller (not
covered with material) during operation.

Generally, high density feed streams will adversely affect separation efficiency. It is
recommended that the density be kept below the maximum of 20% solids.

High S.G. Gangues

Solids throughput is partially dependent on particle size and specific gravity. Generally,
coarser and denser particle streams reduce the maximum throughput, and require even
lower feed densities. Where a high specific gravity gangue is present, decreasing the
speed and/or the feed density may help prevent ‘packing’ of solids in the retention zone.
Reducing the maximum particle size will also help.

Conversely, finer and lighter particle streams generally allow an increase the maximum
throughput and require less water in the feed.

Optimum operating conditions for a given material are usually determined and
established during a commissioning visit. Continuing laboratory analysis of the feed,
concentrate and tailings will be necessary to maintain the optimum conditions.

The figure on the following page describes the relationship between the volumetric feed
volume, feed density, maximum particle size and rotational speed and how these relate
to vibration.

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Feed Relative To Speed And Vibration

The Falcon UF Concentrator was designed to recover much finer target minerals than
other gravity concentrating technology. It achieves this using the patented smooth rotor
wall that allows the migration of fine target particles to the outer wall through the flowing
film without being disrupted by process water or riffles. This is finally captured in the
retention zone at the top of the rotor bowl.

The higher the centrifugal field, the thinner this flowing film thickness is due to the
increased velocity (feed being constant). If the volumetric feed rate is insufficient to
maintain a consistent film thickness throughout the circumference of at least 2 times the
maximum particle size, then there is a tendency for “beaching” of solids below the
variable lip. This will usually cause an imbalance due to the magnitude of mass
differentials at high G’s.

In summary, the machines are capable of processing a high volumetric feed volume but if
the volume is less than 50% of maximum then the feed density and maximum particle
size may be limited. Vibration levels of 10 – 15% are normal but if these rise to being
consistently > 25% then one of the following should be done; the feed density lowered,
particle size reduced, speed reduced, and/or volumetric throughput increased.

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Rotational Speed

The rotational speed of the rotor bowl determines the ‘G’ forces impacted on the material
moving through the machine. This is calculated by the formula:

G-FORCE = Rotor ø (inches) x r.p.m.2

70471

Generally, the fine streams (< 50 microns) require higher G’s for optimal recovery and
coarser streams lower G’s. The rotational speed can be set in the VFD or the HMI. See
also Table 5.7-2 RPM vs. G’s.

5.3 Starting the Concentrator

IMPORTANT: Test the feed system before starting to make sure the feed valve
operation conforms to the control philosophy in 4.11.

WARNING!
DO NOT OPERATE OR ENERGIZE THE MACHINE WITHOUT ALL
GUARDS IN PLACE.
DOING SO COULD RESULT IN INJURY.

Before starting the machine study the AUTOPAC functions and control philosophy and be
familiar with the operating parameters such as run speed, rinse speed, acceleration time,
deceleration time, run cycle, rinse cycle, etc. It is recommended that a qualified factory
representative be present during start up.

It is recommended that a water test be done first. Once the user is familiar with the
machine and the operating conditions and parameters are established, press Start to
bring the machine to operating speed.

If the machine does not reach operating speed within the time set for the acceleration
ramp, shut the machine down and determine the cause of the problem. If no mechanical
problem is apparent and the rotor spins freely, an electrical or programming problem is
likely.

Check the machine before the introduction of any water or feed material for any abnormal
vibration. If vibration is excessive or a problem is observed immediately shut off the
concentrator and investigate cause. See previous sections and also 5.7 Vibration.

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WARNING!
VIBRATION MEANS THAT THERE IS SOMETHING OUT OF
BALANCE. RECTIFY BEFORE RECOMMENCING OPERATION.

The following is a procedure for a typical machine start-up to be integrated with other
plant procedures.

1. Parameters correctly set.

2. Press Start, machine accelerates to run speed and feed is introduced.
3. Run operation will continue until a rinse function is activated and/or a shut down
occurs either automatically or manually.

The Emergency Stop button should only be pressed in emergencies, for normal shut
down always use the normal stop key.

IMPORTANT: Observe the following cautions during operation:

• Operate the machine only with correct parameter set-points.

• Do not allow the machine to be decelerated and stopped unless the feed is stopped
first (this should be automatic).
• Do not set acceleration or deceleration time below the recommended safe limits or the
VFD may fault.
• Set the rinse time to make sure the rotor is thoroughly clean after each rinse.
• Do not start the machine until first checking to see that the rotor is clean.

5.4 Optimization
To determine the optimum operating parameters for the desired concentrate
grade/recovery, some experimentation and sampling may be required. Falcon
recommends that a thorough study of the metallurgical requirements be done before
devising a sample program.

Variable Lip

During operation, air pressure is piped through the shaft and into the compressed air
chamber which automatically and systematically move the variable lip inward, this
gradually increases the concentrate mass retained in the rotor bowl.

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In addition to determining optimum operating conditions the commissioning

representative can recommend an optimum concentrate mass and corresponding
Segment air pressure levels and times.

To fully determine if the operating parameters are set correctly for maximum possible
recovery it will be necessary to do laboratory analyses of the feed, concentrate and
tailings. It may also be necessary to investigate different operating conditions, such as
speed, feed density and run cycle time.

General Procedure to Determine Optimum Run Time

During commissioning a run cycle time will be recommended based on the application,
objective, and visible analysis of the concentrate and tailings. A typical run cycle would
be less than 20 minutes in duration, producing a mass yield to concentrate of 2 – 20%
depending on the feed rate.

Falcon recommends that a thorough sampling program be followed for the first two
weeks of operation and periodically thereafter.

The following procedure can be used as a guide to determine the optimum run time for
any particular material:

1. Operate the concentrator for 20 minutes at approximately constant operating

conditions such as feed rate and pulp density, air pressures, etc.

2. Collect tailings samples for each of ten 2-minute operating periods during the 20-
minute period (i.e.: Sample #1 = 0-2 minutes, Sample #2 = 2-4 minutes, etc.). The
samples can be collected by taking cuts every 30 seconds using a sampling
system.

3. Analyze these samples to determine when there was a significant change in tailings
grade over the course of the run period. If no change was evident then repeat the
test using a 30-minute run. If the tailings grade increased during the 20-minute run
then decrease the run time according.

In some near capacity situations and when processing some types of feed, depending on
its characteristics, it may be advantageous and convenient to reduce the run time
dramatically and re-process the small volume of rougher concentrate in a clean-up cycle.

An additional UF concentrator or the original concentrator, when off line, can be used for
this clean-up operation to produce a primary high-grade concentrate when lower volumes
can allow optimum feed parameters. The tails from the cleaner operation should be
reprocessed through the rougher cycle feed. This is usually the best way to achieve
higher-grade final concentrates without sacrificing high recovery.

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5.5 Rinsing
The AUTOPAC automatically controls feed valve operation, variable lip pressure,
deceleration, rinse speed, rinse and flush water introduction, and drain time. See 4.
AUTOPAC for programming details.

Typical rinsing / run cycle procedure with an AUTOPAC:

1. Run cycle times out.

2. Variable lip pressure remains constant at Segment-10 level.
3. Rinse Delay begins, feed piping empties.
4. The machine decelerates to rinse speed.
5. Rinse water / spray nozzles turn on as the speed goes through the VFD threshold
level.
6. At rinse speed, variable lip pressure is exhausted to zero and the rinse cycle timer
begins.
7. The Rinse cycle times out.
8. Rinse manifold water turns off.
9. Drain time begins and machine coasts to allow for the rotor to completely empty.
10. Drain time expires and the flush solenoid energizes to flush material from the
concentrate launder.
11. The machine accelerates to run speed with the feed turned on as the machine goes
through the VFD threshold level.
12. At run speed the run timer is started and the variable lip pressure is increased to
Segment-1 level.

See 4.11 Control Philosophy.

The rinse cycle is the term describing the time of operation when the machine
decelerates and rinses the target mineral from the machine. The run cycle begins again
once acceleration has begun.

The rinse delay is important to set correctly, as this function stops the feed a pre-set time
before initiating the deceleration. This feature is necessary when the feed valve is located
some distance from the machine, as feed material downstream may still slump into the
rotor during deceleration and rinsing even after the feed stops. This could cause the
grade of the concentrate to be compromised and possible plugging in the bottom of the
rotor. The rinse delay is usually less than 5 seconds..

A normal rinse cycle normally takes less than one minute from start to finish, or off-line to
on-line again. During the first few days of operation observe the concentrate rinsing from
the rotor during the rinse speed, and determine the time it takes to effectively clean the
rotor. Normally this is between 20 and 30 seconds.

The drain time is typically short also, between 3 and 20 seconds.

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If more than one minute is required for the concentrate to be completely removed from
the rotor during the complete rinse cycle, check for the following:

1. Spray nozzles are not blocked or plugged.

2. Variable lip pressure is not completely exhausting.
3. The exit area around the baffle is not blocked, preventing the contents of the rotor to
freely drain.
4. The discharge ports beneath the baffle are clear (it will be necessary to remove the
baffle to investigate this).

The complete rinse cycle should be witnessed periodically to insure the rotor is
completely clear of concentrate at the end of the cycle.

5.6 Shut Down

The AUTOPAC automatically controls shut downs. See 4. AUTOPAC for programming
details.

Using normal STOP initiates a controlled shut down which includes a rinse delay,
deceleration, and timed rinse cycle before stopping the machine. This allows the machine
to always stop clean.

The following describes what happens when normal Stop is used:

1. Normal stop button is pressed.

2. Variable lip pressure adjusts to and remains constant at Segment-10 level.
3. Rinse Delay begins, feed piping empties
4. The machine decelerates to rinse speed.
5. Rinse water / spray nozzles turn on as the speed goes through the VFD threshold
level.
6. At rinse speed, variable lip pressure is exhausted to zero and the rinse cycle timer
begins.
7. The Rinse cycle times out.
8. Rinse manifold water turns off.
9. Drain time begins and machine coasts to allow for the rotor to completely empty.
10. Drain time expires and the flush solenoid energizes to flush material from the
concentrate launder.

See 4.11 Control Philosophy.

After each shut down inspect the machine for wear. It is important to implement a
preventative maintenance procedure to optimize performance and extend the life of the
machine. For shut downs of more than one day, drain the water from the machine by
opening the flushing valve attached to the rotating union at the bottom of the machine.
This will help prevent scale or rust build-up within the machine.

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Vibration Shut Down

If the machine reaches a vibration level above the set Vibration Level a controlled shut
down will be initiated and a message will appear on the HMI. If a vibration shut down
occurs it will be necessary for operating or maintenance personnel to investigate the
cause and remedy. For more information regarding the vibration switch operation see
sections 4. AutoPAC, 5.7 Vibration and vibration monitor manual in Section 9.

IMPORTANT: If vibration shut down occurs, never re-start without checking the cause.

5.7 Vibration
Prior to leaving the factory all machines are run at full speed, balanced, and run
repeatedly to check for any abnormal vibrations. Upon installation, some vibration of the
unit during operation is normal and safe as the feed material causes varying degrees of
imbalance in the rotor. If excessive vibration is observed, investigate the cause.

The AUTOPAC employs a machine mounted vibration monitor to effect a controlled shut
down if vibration becomes excessive.

IMPORTANT: Do not override or bypass the vibration switch, operating with excessive
vibration may cause premature bearing failure and will void warranty.

Excessive vibration indicates a severe imbalance, possibly caused by

1. Improper feed conditions causing excessive or uneven concentrate distribution

within the rotor. Adjusting the feed characteristics (density, particle size, etc.) to
specifications will eliminate the problem.
2. Improper operating conditions, rotational speed too high for given application.
3. Foreign matter in the rotor, such as grinding balls, oversize, dropped tools, etc.
4. Structural damage to the rotor basket, rotor, shaft, lining, etc.
5. Damage to or improper operation of the variable lip.
6. Worn, damaged or miss-aligned bearings.
7. Improper maintenance practices. During maintenance, make every effort to
maintain the balance of the machine. For example: when relining apply new lining
evenly, and repair worn or damaged surfaces to be consistent with surrounding
material.

WARNING!
VIBRATION MEANS THAT THERE IS SOMETHING OUT OF
BALANCE. RECTIFY BEFORE RECOMMENCING OPERATION.

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In many cases vibration can be minimized by changing feed and/or operating conditions
such as increasing feed throughput, decreasing feed pulp density, and reducing speed.
See previous sections. Improper maintenance of the rotor bowl or improper feed
conditions are usually the most common cause of vibration.

Excess vibration due to structural damage such as a misaligned or bent rotor may be the
result of improper handling during shipping and may require repair, re-balancing and/or
replacement not covered under warranty.

Table 5.7-1 RPM vs. G’s

This chart relates Hz. to rotational speed and G’s imparted on the feed material.

FALCON DATA SHEET: SEPARATION "G" FORCE

Concentrator Model: UF6500 BLACKHAWK PD
Rotor Diameter: 44.25 INCHES
Motor Frequency: 60 Hz
Motor Speed: 1780 RPM

Max. Rotor Speed: 740 RPM

AUTOPAC MOTOR ROTOR ACCELERATION

Hz RPM RPM "G"
40 1187 494 156
45 1335 556 197
50 1483 618 243
55 1632 680 295
60 1780 742 351

39.25 1164 485 150

42.39 1258 524 175
45.32 1345 560 200
48.07 1426 594 225
50.67 1503 626 250
53.14 1577 657 275
55.51 1647 686 300
59.95 1779 741 350

Note: Speeds given are theoretical calculated values and do not take into account possible
slippage of motor or belts.
For a more accurate determination measure the actual rotor speed.
Running motor at excessively low speeds for long periods may cause overheating and
premature failure.

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