courier_engl 16.4.

2003 09:56 Sivu 13

ADASTRA Helsinki

Courier® 6 SL
The high-performance
on-stream XRF
slurry analyzer

The high-power

analyzer system offers

the best sensitivity and

short cycle time for

process management,

monitoring and control.

0303E
courier_engl 16.4.2003 09:55 Sivu 2

Courier® 6 SL

Courier® 6 SL is the high-performance model in the Courier® on-
stream XRF analyzer family for the real-time elemental assaying of
slurry process streams. The high-power analyzer system offers the
best sensitivity and short cycle time for process management,
monitoring and control in all sizes of minerals processing plants.
It is complemented by the Courier® 3 SL analyzers for distributed
applications and remote sampling points. Outokumpu provides
Customer Support Agreements to guarantee the maximum
performance and availability of the system.

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Ass ay

What can a Courier® analyzer do for you?

■ Sampling and analysis are automatically done in the same
consistent way around the clock. This creates savings in assaying
costs and metallurgical sampling.
■ Recoveries are better, as process upsets are detected and solved
rapidly. Frequent assays are necessary for real-time process
monitoring and control.
■ Assay accuracy is comparable with a high-quality manual sample-
laboratory procedure. Courier® on-stream analyzers use the same
Wavelength Dispersive X-ray fluorescence (WDXRF) analysis
technology as used in high-performance laboratory analyzers.
■ Results from process tests and changes are readily available, which
motivates and speeds up process development.

■ Concentrate quality is controllable and undesired variations are ■ Modular Courier® analyzer systems can be upgraded and expanded
minimized. Plant operation is optimized with less circulating loads as plant requirements change.
resulting in higher throughput.
courier_engl 16.4.2003 09:55 Sivu 3
Dependable assays from
representative samples
Sampling
Proven Outokumpu primary samplers are used to sample process
flows. A representative 70–300 l/min primary sample is circulated
through a fast loop to the secondary sampler and back to
a convenient return point in the process. The height loss of the sample
is only 1 meter. Primary samples are not mixed with each other.
A smaller secondary sample is divided out for accurate analysis. The
secondary sample stream is sampled by a calibration sampler for
laboratory assaying during calibration.
When the basic design rules are followed, the primary sample
streams can be used to collect representative composite samples for
metallurgical accounting. Composite sample collection is built into
the Courier® 6 SL sample multiplexers.
Representativity of samples
When considering the representativity of samples used for assaying,
every step from the process stream to X-ray fluorescence analysis has
to be taken into account. X-ray fluorescence radiation penetrates the
sample slurry only a short distance, typically less than 1 mm. The
sample right at the surface of the analyzer window has to represent
the whole process flow for accurate on-stream process assays.
Outokumpu-developed Jet Cell™ technology ensures that fresh
representative sample reaches the critical area for analysis.
Timeliness of assays
The major benefit of using the Courier® on-stream analyzer is the
frequency and speed of accurate assaying. This allows for fast
reaction to changes in the metallurgical behavior of the flotation
circuit. The cost of frequent laboratory assays required by proper
process control is prohibitive.
If the assays are based on strongly filtered or averaged
measurements over a long period of time, the assays cannot be used
for process control. Long time delay from actual process changes
to control action makes feedback control unstable and the reported
process trends become misleading.
courier_engl 16.4.2003 09:55 Sivu 4

Main Rougher
Feed Feed

Flash flotation control Primary Rougher Rough

Monitoring the grinding circuit flash flotation concentrate grade Concentrate Concent

helps to produce high-grade concentrate, which is easy to clean.

Significant overall recovery improvement can be obtained in this way.

Cleaner
Primary rougher flotation control Tails
Monitoring the primary rougher concentrate grade is critical for the
production of high-grade concentrate, which can often be added to
the final concentrate.

Rougher control Cleaner control

If the rougher section is working properly, the rest of the flotation
circuit is much easier to run. The roughers should produce optimal
grade rougher concentrate with acceptable recovery. Rougher tails
have to be monitored for recovery control. If the rougher tails grade
is too high, there is often not enough scavenger circuit capacity to
prevent recovery loss.
Getting final product quality, while keeping an eye on circulating
loads in cleaner section, is critical.
The Courier® system is able to measure low assays of penalty
elements in the presence of high main element grade to ensure
the best quality of concentrate produced.

Concentrate grade is controlled by flotation cell air, level and
reagents. Optimal concentrate grade depends on feed grade,
mineralogy, circulating loads and other circuit parameters. On-
stream analysis is vital for optimizing rougher concentrate
production.
Scavenger control
The rougher tails are already under control, so the scavengers just
lower the final tails assay. Accurate tails assay is important for
recovery monitoring and requires high sensitivity and accuracy
from the analyzer.

FrothMaster™ froth measurements can be used to complement the The scavenger concentrate assay is watched to keep the circulation
Courier® on-stream analyzer information for optimal rougher control. under control.
 courier_engl 16.4.2003 09:55 Sivu 5

If you can float it, we can control it

Scavenger Flotation
Rougher Tails Tails
Tails Zn Grade Control
Grade High and Recovery Low
Zn_Rougher_Air: +50.00
Zn_Rougher_Level: -10.00
Grade High and Recovery Normal
Scavenger
Grade Normal and Recovery low
Concentrate
Grade Normal and Recovery Normal
ougher Middling Execute fuzzy:
centrate Tails Mass Pull Control
Zn Recovery

Basic flotation circuit control loops

Typical basic control loops used for flotation control
are illustrated below. Successful assay control
requires that the key operating parameters of
a flotation machine are under control.

The setpoints of the basic control loops are

determined by the process operator or an expert
system. The Outokumpu Proscon Advanced Control
Final
Concentrate Tools package (ACT) can be used to optimize plant
operation. Example of a typical grade-recovery
optimization scheme is shown in the above picture.

Reagent setpoint Air setpoint Cell level setpoint

Reagent Air

Particle size FT FT
density
FC FT LC Cell level
AT Analysis sample points
pH LT
LT Level sensor
FT Flow sensor
LC Level controller
FC Flow controller
pH pH sensor
courier_engl 16.4.2003 09:55 Sivu 6

Courier® 6 SL analyzer system

Primary sampling
The primary sampler directs a part of the process stream to the
multiplexer for secondary sampling. A range of proven
Outokumpu primary samplers is available for various situations.

NLA launder primary

The low head required by the Courier® 6 SL analyzer usually allows sampler with mechanical
the sample flows to be handled by gravity without the need for cutter cleaner

pumping. Whole small process flows can be taken through

the analyzer secondary sampling system without sampling.

Depending on process requirements, the primary sample flow can

be continuous with or without automatic periodic flushing.
Alternatively, the sample flow can be stopped and the delivery line
flushed automatically between the samples. Controlled sampling
features now offer great flexibility.

Analyzer control
The Courier® 6 SL analyzer probe control panel has a graphic
terminal complemented by control switches and indicator lamps.
Most recent assays and analyzer status are shown on the display.
The same cabinet houses interface and control modules for primary
and secondary sampling system monitoring and control.

Demultiplexing
Optional demultiplexing can be used to divert the small slurry
flow through the analyzer flow cell to appropriate point.

Assaying
The Courier® 6 SL analyzer probe combines the high-performance
wavelength and the economic energy dispersive X-ray fluorescence
PSA pressure pipe
methods in a unique and cost-effective way. The analyzer has an primary sampler
for pump outlet
automatic reference measurement for instrument stability and self-
diagnostics. The analyzer probe contains the core analytical
components of the analyzer in a protective IP56 (designed to meet
NEMA 4X) stainless steel enclosure.

Calibration sampling
The built-in calibration sampler helps the operator to take a truly
representative and repeatable sample from the measured slurry for
comparative laboratory assays. The calibration data can be read from
the analyzer into the management station Outocal™ calibration
program.
courier_engl 16.4.2003 09:55 Sivu 7

Secondary sampling
Full primary sample flow is cut by an air-cylinder-actuated Primary
sample in
sample hose. The same cylinder moves the hose to the other
direction across a cutter at programable intervals to collect
a representative composite sample.

Trash is removed from the samples by self-cleaning screens and

entrained air is minimized in a level controlled constant head tank.
The tank provides a stable sample flow to the analyzer flow cell.
Primary sample availability and flow rate are monitored for
diagnostic purposes.

1m
The multiplexer operation is designed to minimize the sample Composite
sample
changeover times in large systems. While a sample in one
multiplexer is still being measured, the next sample is already
Primary
being conditioned in the second multiplexer unit, allowing a fast sample return
measurement cycle for all streams.

Secondary
The measurement sequence is fully programable. sample
to analyzer
For example, critical streams can be measured more
frequently and more measurement time can be used for Secondary sampler principle
tailings streams. The switching time between samples is
used for internal reference measurements, which are used for
monitoring and automatic drift compensation. Analyzer management
Courier® 6 SL analyzers can be networked together to share
Composite sample collection of all streams is a standard a common analyzer management station PC. Calibration and
feature of the multiplexer. An optional filter diagnostic data for on-site service requirements and remote
unit dries the composite samples. support.

The management station displays the assays, trends and analyzer

status information. It is also used for setting up the functions and
parameters of the Courier® 6 SL analyzers. The analyzer
management station collects analyzer system calibration and
diagnostic data for local and remote support.

Outocal™ calibration program can be run in the same PC to access

calibration data and calculate the best models for assay calculations.

Only one connection to the plant process control (DCS) system is

Analyzer management station required. The Outokumpu automation product range has
compatible PROSCON® 2100 process control and management
systems for metallurgical applications.
courier_engl 16.4.2003 09:56 Sivu 8

The secrets of high performance

25 l/min sample

ANALYZER PROBE PROB

50µ thick Jet flow

window cell spectrometer signal
preamplifier

detector

atic digital
om
aut rence multichannel SAMPLING
e
ref ter x-ray tube
t analyzer and
shu
microprocessor
for

filter signal
preamplifier
1mm X-ray SAMPLING
sensitive layer detector

EDXRF channel

Controlled turbulent flow

provides a representative
sample and prevents scaling.
sample out

Sample presentation Analysis

Patented Jet Cell technology ensures that a representative fresh
TM
sample is always presented for assaying at the window surface.
The flow cell window is cleaned and slowly abraded by active
slurry contact. It can be changed manually or automatically by
the AWC 4030 Automatic Window Changer option.
Courier® 6 SL excites the sample in the flow cell sensitive layer
using a high-intensity X-ray tube. Atoms in the sample react by
emitting fluorescence radiation, which is characteristic of each
individual element in the sample.
Courier® 6 SL uses high-resolution wavelength dispersive
analyzer technology for critical assays. Complementary energy
dispersive technology is used to increase the range of elements
analyzed and to extend the capability of the system to measure
up to 12 assays per stream.

Analyzer system control

The primary and secondary sampling system and analyzer
measurements are controlled by the Probe Control Set.
The scalable modular system has several ICM 4300 Interface and
Control Modules connected by a fast serial bus.

Each multiplexer unit is controlled by its own module. Primary

sampling is controlled by available I/O in the multiplexer control
modules or a dedicated unit in case of a large analyzer system.

AWC 4030 Automatic Window Changer

 courier_engl 16.4.2003 09:56 Sivu 9

PROBE CONTROL SET Wavelength dispersive channel WDXRF, 0.12% Zn

counts per second

CONTROL

PLANT
DCS

SAMPLING

ANALYZER
MANAGEMENT The wavelength dispersive technology. The wavelength dispersive
STATION PC
detection channel measures only the narrow element peak (blue). A high-resolution
spectrometer separates the peak before the detector. Nearby element peaks do not
overlap and background signal is minimal. Because the full capacity of the detector
Main controller
is used for the relevant peak, a high-power X-ray tube can be used and analyzer
speed and sensitivity are high.

Wavelength dispersive detection is used in high-performance laboratory analyzers.

Several element-specific wavelength dispersive channels are used in Courier® 6
analyzers for the simultaneous measurement of the critical elements to be assayed.

Scatter
Energy dispersive
channel EDXRF,
0.12% Zn
counts per second

Energy dispersive technology. The energy dispersive detection channel (Si(Li),

Si-PIN or proportional counter) measures the whole spectrum (blue). Measuring a small
Zn peak (green arrow) is a challenge, since most of the detected counts cannot be used
for the specific assay. Limited resolution and its deterioration above 10 kcounts per
second count rate limit seriously the useful X-ray intensity. Analyzer speed and sensitivity
are low.

Energy dispersive detectors can be used for measurement of high-grade assays as a

cost-effective complement to wavelength dispersive detectors in less critical
measurements. One energy dispersive detector can measure many element peaks at
the same time.
courier_engl 16.4.2003 09:56 Sivu 10
Specifications
Analysis method
Wavelength dispersive X-ray fluorescence
method using X-ray tube excitation. Energy
dispersive channels are available. No
radioactive isotope sources are used,
minimizing fire and disposal risks.
Number of sample streams
One Courier 6 SL analyzer system can
®
measure up to 24 sample streams. Each
multiplexer module handles up to 6 sample
streams.
Number of simultaneous assays
Courier 6 SL analyzer can provide up to 12
®
simultaneous assays for elements from
calcium to uranium (atomic numbers 20 to
92) and solids content from each process
sample. Multiple models can be used for
assay calculation.
Sample measurement time
Sample measurement time is selectable for
each sample. Typical time is 15–30 seconds.
Analysis cycle
Normal analysis cycle for 12 samples is
from 9–10 minutes and for 18 streams
12–15 minutes, providing on the
measuring time for each sample.
Assays are calculated and updated from
fresh measured data for each cycle.
Measurable concentration range
Typical measurable concentration range is
0.002 % – 100 % by weight for slurries.
Stability
Short-term stability of the analyzer under
the specified conditions is better than 0.1 %
relative.
Automatic internal reference measurements
compensate for long-term drift.
Minimum detection limit
For most elements in slurry samples,
detection limit is 3–30 ppm with the
WDXRF-measurement channel. With the
EDXRF-measurement channel minimum
detection limit is typically 30–500 ppm.
Accuracy
Outokumpu accuracy specification is based
on measurement of flowing slurry samples
using measurement times of real
applications. Briquette measurements and
long measurement times give unrealistic
results. Accuracy of measurement is a
function of the sample parameters such as
matrix composition, mineralization and
particle size.
Under normal operating conditions, 3–6 %
relative standard deviation for minor
concentrations and 1–4 % relative standard
deviation for major concentrations is
achieved for individual slurry sample
measurements of concentration levels, well
above the minimum detection limit.
Analyzer calibration
Optional integrated calibration sampler
takes a repeatable and representative sample
for the analyzer calibration. Outocal ™
software is available for interactive
calibration model design.
Maintenance
The Courier® 6 SL analyzer is designed to
require minimal maintenance. The analyzer
probe window change is automatic, with an
Automatic Window Changer option.
The analyzer has built-in self- and remote-
diagnostics capabilities.
Installation requirements
The Courier® 6 SL analyzer can be installed
on one (low–head) or two levels or in
a prefabricated shelter.
Flushing water
Sand-filtered raw water, 2–6 bar (30–85 psi)
average 30 l/min (8 gal/min)
peak 100 l/min (26 gal/min)
Instrument air
Pressure 5–10 bar (75–145 psi)
16 Nl/min (4.2 norm. gal/min)
average consumption
Power supply
Single phase AC, 230V +10%, -15% at 10A
50/60 Hz or 115V ±10% at 20A 50/60 Hz.
Double conversion 3 kW UPS, 10 minutes
minimum.
Operating ambient temperature
at sea level
+5 – +45°C (41–113°F). Temperature control
is based on air-cooled heat exchanger. Water
cooling is available for special conditions.
Storage temperature
-25 – +60°C (-13 – 140°F)
Environmental classification
Analyzer multiplexers, probe and probe control
set, IP56 (designed to meet NEMA 4X).
Shipping and installed weight
Typical total shipping weight is 1000 kg (2200
lbs) for a 12-stream system, 1250 kg (2750 lbs)
for a 18-stream system. One 6-stream multi-
plexer unit weight is 225 kg (500 lbs).
courier_engl 16.4.2003 09:56 Sivu 11

ISO 9001 quality assurance

Outokumpu Minerals Processing Technology Two-level installation layout

is ISO 9001 accredited and has a rigorous LSA sampler
Process flow
the quality expectations of customers are met. by gravity

The analyzer has certification

according to EMC, LVD and MD directives.
Multiplexer

Composite
sampling

Analyzer
Probe Control Probe

2300–3300
Set

PSA
sampler

Process flow
by pressure Demultiplexer

Note: These specifications are for

a typical configuration and project scope Low-head installation layout
only. Actual scope and performance data
does vary according to individual plant Process flow
LSA sampler

and project specifications and product by gravity

variations. Please see the product data

sheets and installation manual for details.

Probe Analyzer
Control Probe
Multiplexer
Several Courier® 6 SL sampling and Composite
sampling
analyzer system features are covered
by patents.

Courier® and Proscon® are registered

Demultiplexer
trademarks of Outokumpu Oyj.

PSA
sampler

Process flow
by pressure
courier_engl 16.4.2003 09:56 Sivu 12

ADASTRA Helsinki
Outokumpu has long and broad experience in the
recovery and refining of base metals. The company has
developed a comprehensive line of metallurgical
processes and related advanced equipment, from grinding
to metal production. Outokumpu TankCell® technology is
used by major mining companies around the world. State-
of-the-art on-stream analyzers and automation systems
have been used in Outokumpu’s concentrators and
refineries since the late 1960’s. The company is the market
and technology leader with more than 700 on-stream
analyzer systems delivered to minerals processing and
metallurgical applications.

Worldwide sales and service:

AUSTRALIA GERMANY POLAND
Outokumpu Technology Pty. Ltd. Outokumpu Technology GmbH Outokumpu Poland Sp.zo.o.
Sydney Alsdorf Warsaw
Tel. (61) 2 9984 2500 Tel. (49) 2404 670 80 Tel. (48) 22 825 8252
Fax (61) 2 9984 2501 Fax (49) 2404 670 8200 Fax (48) 22 825 1961

Outokumpu Technology Pty. Ltd. Pannevis Filtrationsanslagen RUSSIA

Perth Wiesbaden ZAO Mineral Processing Engineers
Tel. (61) 8 9211 2200 Tel. (49) 611 80 1034 St. Petersburg
Fax (61) 8 9211 2201 Fax (49) 611 80 1038 Tel. (7) 812 324 1330
Fax (7) 812 324 1339
BRAZIL JAPAN
Outokumpu Technologia Brazil Ltda. Outokumpu Japan K.K. Outokumpu Norilsk
Belo Horizonte Tokyo Norilsk
Tel. (81) 3 3863 6581 Tel. (7) 3919 220 579
Tel. (55) 31 3282 1112
Fax (81) 3 3863 6571 Fax (7) 3919 220 765
Fax (55) 31 3282 9875
KAZAKSTAN SOUTH AFRICA
CANADA Outokumpu Technology Outokumpu Technology (Pty.) Ltd.
Outokumpu Technology Inc. Representative Office Johannesburg
Burlington Almaty Tel. (27) 11 799 2410
Tel. (1) 905 335 0952 Tel. (7) 3272 672715 Fax (27) 11 799 2449
Fax (1) 905 335 4775 Fax (7) 3272 509942
SWEDEN
CHILE MEXICO Outokumpu Technology
Outokumpu Técnica Chile Ltda. IPC Chihuahua, S.A. de C.V. Smedjebacken
Santiago México Tel. (46) 240 66 8900
Tel. (56) 2 379 4700 Tel. (52) 614 81 3636 Fax (46) 240 66 8901
Fax (56) 2 223 4989 Fax (52) 614 81 3637
U.S.A.
CHINA THE NETHERLANDS Outokumpu Technology Inc.
Outokumpu Beijing Royal Pannevis Denver
Representative Office Utrecht Tel. (1) 303 792 3110
Beijing Tel. (31) 30 2482 411 Fax (1) 303 799 6892
Tel. (86) 10 6506 5951 Fax (31) 30 2482 402
Fax (86) 10 6500 6512 Outokumpu Technology Inc.
PERU Jacksonville
FINLAND Outokumpu Técnica Perú Tel. (1) 904 353 3681
Outokumpu Technology S.A.C. Fax (1) 904 353 8705
Automation Lima
Espoo Tel. (51) 1 221 0833 Pannevis Inc.
Tel. (358) 9 4211 Fax (51) 1 221 2633 Rockaway
Fax (358) 9 421 3156 Tel. (1) 973 627 6469
Fax (1) 973 627 7029
0303E

Outokumpu Technology is near you

e-mail: automation@outokumpu.com, www.outokumpu.com