Evolute

feedwell upgrade:
Carpentaria Gold
tails thickener

Case Study
FLSmidth designed and constructed a new Evolute feedwell
to replace an older design at Carpentaria Gold. The
improvements in settling rate and overflow clarity resulted in
lower operational expenditure on chemical, electricity, water
and maintenance, and improving the efficiency and availability
of the gravity concentrator.

Evolute feedwell
upgrade: Carpentaria
Gold tails thickener

FLSmidth was
approached by
Carpentaria gold to
conduct a
performance review
of the 22m tails
thickener with a
focus on optimisation
and modernisation
options to improve
gold, water and
cyanide recovery.

(Top) Carpentaria Gold tails thickener before feedwell upgrade

(Bottom) Carpentaria Gold tails thickener after feedwell upgrade

The customer
Carpentaria Gold Pty Ltd Ravenswood Operation is located
approximately 95km south-west of Townsville in north-east
Queensland. The processing plant processes 1.5 million tons
per annum of high grade underground ore using single
stage crushing, SAG (semi-autogenous grinding) and ball
milling, and carbon-in-leach processing with a gravity circuit
for recovery of free gold. In 2013 the Ravenswood
Operation produced 141,846 ounces of gold.
The problem
Carpentaria Gold Pty Ltd Ravenswood Operation, in
Queensland Australia, continually strives to increase overall
gold production by improving mining and processing
efficiencies. Ongoing improvement initiatives have been
successful in increasing overall plant recovery in 2013 gold
recovery was 94.9%. This highly optimised plant continues
to emphasise continuous improvement. Despite the already
excellent recovery rates, the plant still sought to further
increase gold recovery, and target operational improvement
projects aimed at reducing cyanide consumption and
minimising raw water requirements.

Knelson concentrator

The performance of the tails thickener is central to cyanide

and water recovery and raw water usage. FLSmidth was
approached by Carpentaria Gold to conduct a review
performance of the 22m tails thickener with a focus on
optimisation and modernisation options to improve gold,
water and cyanide recovery.
Gravity Gold Recovery
Gravity gold is recovered with a Knelson concentrator early
in the process which accounts for approximately 60% of the
overall gold recovery at Carpentaria Gold. Slurry is pumped
into the Knelson concentrate cone. The concentrate cone
which contains a series of concentric rings that collect the
gold as it spins at a high speed to create centrifugal force.
Water is pumped into the rings through capillaries (narrow
hollow tubes) to fluidise the bed, optimising the separation
of particulate gold from the slurry. Clean process water is
essential to maximise gravity gold recovery from the Knelson
concentrator. If there are solids present in the process water
the capillaries become blocked which increases the water
pressure and reduces gold recovery. The concentrator then
needs to be shutdown frequently and taken offline for time
consuming and costly maintenance to unblock the
capillaries, which impacts gold recovery and raises
maintenance costs.
Raw Water Usage and Cyanide Recovery
Operation of slurry thickeners is generally a compromise
between clean overflow water and underflow density. Either
the 22m tails thickener will achieve a high underflow density
which enables maximum water and cyanide recovery. Or it
operates to improve overflow water clarity enabling a
positive impact on gravity gold recovery. The second option

Water jacket

Capillary
(water inlet)

Gold bearing slurry

Concentrate collection ring

is achieved primarily through reducing mud bed levels and

increasing flocculant dose. However, the consequence of this
approach is inevitably lower underflow density, reduced
water recovery and therefore increased raw water usage,
lower cyanide recovery, and excessive flocculant usage.

The solution

FLSmidth designed a
new feed system
incorporating E-duc
feed dilution
technology and our
latest revolutionary
thickener innovation
- Evolute feedwell.

Alternate solutions considered

1. New thickener
A new thickener with higher side wall height and a
longer mud residence time would enable cleaner
overflow water with higher underflow density. This
would enable improved gravity gold recovery and
maximum water and cyanide recovery. This option
would involve a significant capital expense.
2. Process water filtration plant
This option would enable the thickener to operate
achieving maximum underflow density, water and
cyanide recovery, and the solids removed from the dirty
overflow in a filtration plant. Again, this option would
involve a significant capital expense.
3. Upgrade the existing thickener
The lowest cost option would be to upgrade the feed
system of the tails thickener to enable high underflow
density (aiding water and cyanide recovery) and the
production of clean overflow water for optimum gravity
gold recovery.

Feedwell design prior to upgrade

Final solution
The original feed system on the tailings thickener installed in
2000 was based on a higher feed rate using the technology
of the day. The feed system was corroded and in need of
replacement. After years of being fed leach tailings it had
reached the end of its serviceable life. This presented an
excellent opportunity for Carpentaria Gold to investigate
modern technology alternatives.
FLSmidth designed a new feed system incorporating E-duc
feed dilution technology and our latest revolutionary
thickener innovation - Evolute feedwell.

As installed Evolute feedwell upgrade design

Evolute feedwell
technology

The Technology
The Evolute feedwell is the result of years of laboratory,
CFD (computational fluid dynamics) and pilot scale
development work. It is designed to maximise the critical
parameters of best practice feedwell performance, and
incorporates all the benefits of both closed and open bottom
feedwells, maintaining all the positive attributes of both
designs without the drawbacks. Those being;
Larger aggregate growth with less flocculant
E-Duc feed dilution and flocculation prior to the feedwell
allows for excellent mixing conditions for contact of
flocculant. This, followed by the low turbulence and further
flocculation in the Evolute feedwell, provides the optimal
environment for flocculation and aggregate growth,

minimising flocculant and increasing settling rates.

Maximising aggregate size with minimal flocculant allows for
improved compaction in the mud bed, improving rheology
and increasing underflow density.
Full width entry Evolute shelf increases residence
time and reduces short circuiting
The unique full shelf width entry of the Evolute feedwell
allows for maximum residence time within the feedwell,
increasing mixing and aggregate growth as well as reducing
un-agglomerated fines and un-absorbed flocculant.
The involute shape of the Evolute feedwell promotes even
distribution of agglomerated solids into the thickener,
minimising the risk of point loading of the raking
mechanism, and maximising settling capacity of the

thickener, whilst reducing internal dilution within the

feedwell, negating any benefits of closed bottom feedwells.
Low shear exit improving settling rate and clarity
The open exit of the Evolute feedwell provides a large
surface area for aggregate throughput. This large surface
area reduces velocities and turbulence as the slurry exits the
feedwell, reducing shear and minimising aggregate breakage
which can occur in closed bottom feedwells. The reduced
shear induced breakage increases settling rates, improves
clarity and maximises density.
Installation
FLSmidth and Carpentaria Gold collaborated at the start of
the project to establish measurable performance criteria to
determine qualitative and quantitative benefits of the
upgrade. The criteria included;
Overflow water clarity
Knelson concentrator feed water pressure
Knelson concentrator scheduled maintenance intervals
Flocculant consumption
Underflow density
Cyanide recovery
Raw water usage
Scale inhibitor usage

CFD image showing fluid vectors exiting the Evolute feedwell

Baseline qualitative and quantitative performance was

measured for a period of time prior to the feedwell upgrade.
Naturally, the performance was re-measured after the
installation period.
The Evolute feedwell upgrade was designed specifically for
retrofitting onto the existing structure. FLSmidth engineers
designed the new feedwell for easy installation, utilising a
segmented shell and clamps for attachment leaving minimal
work to be done on site. This allowed for the installation to
occur without having to lift the bridge and mechanism. The
removal of the old feedwell and installation of the Evolute
took only two shifts to complete on site.

Results
250

200

Pressure (kPa)

BEFORE UPGRADE

SHUTDOWN

The upgrade to the Evolute feedwell on the 22m tailings

thickener at Carpentaria Gold completed in October 2013
brought about immediate improvements in thickener
operation. Process data from the site PI and laboratory data
from grab samples have shown:
The Knelson concentrator process water feed pressure
stabilised, indicative of negligible capillary fouling. The
result being the security of full plant availability ensuring
gravity recovery of gold as well as a reduction in
maintenance costs.
Visibly significantly improved thickener overflow clarity
Significantly improved solids settling rate, leading to a
40% reduction in flocculant
Improved settling coupled with the reduction in
overflow solids allowed for increased mud bed growth
and underflow density
Reduced pumping costs for tails dam water reclamation
Reduced raw water intake
Increased recovery of cyanide that would have been lost
to tails
Lower solids in the process water allowed for a ~35%
reduction in scale inhibitor chemical

Rapid pressure rise,

short maintenance
intervals

150

100

No change
in pressure
maintenance:
capillaries
cleaned

Maintenance
interval
extended

50

0
8/13

8/13

9/13

10/13

11/13

Knelson process water pressure before and after upgrade

Minerals
Headquarters
FLSmidth USA Inc.
7158 S. FLSmidth Drive
Midvale, UT 84047-5559
USA
Tel: +1 801 871 7000
Email: info.slc@flsmidth.com

Regional Office
FLSmidth Pty Ltd
67 Randle Road
Pinkenba, QLD 4008
Australia
Tel: +61 (7) 3121 2900
Fax: +61 (7) 3121 2988
info.australia@flsmidth.com

Copyright 2016 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied),
and information and data contained in this brochure are for general reference only and may change at any time. Please contact us for specific information or data that may relate to your interest.

www.flsmidth.com

Rev: 5/17/2016 acu-us

PI data of flocculant dose before after retrofit