A8 0 MineralsProcessing GB

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E K A T O
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MINERALS PROCESSING
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Advanced Process Solutions
Services offered by EKATO:

Analysis of mixing processes Simulation and testing in 3 l, 50 l and 1 m horizontal and vertical models Optimized agitator designs Design optimization, e.g. designs and best locations for acid feed pipes, slurry draw-off points and gas feed pipes CFD simulations Stress calculations of vessels and internals using FEA EKATO mechanical seals and integrated seal support systems Materials of construction include titanium, duplex steels, Inconel, Hastelloy Protective coatings for impellers Consulting / training at customers plant site Worldwide service facilities
EKATO Lab Testing
EKATO offers laboratory testing facilities at different scales and vessel geometries. For autoclave feed tanks and similar applications, tests are carried out with original samples. Using test results and EKATOs well proven design procedures, scale-up to commercial scale designs can be calculated with confidence. 100% mixing efficiency can be achieved at minimum power input and agitator size. Flow behavior of samples can be measured with a rotational viscometer. Measurements / services : Mixing time characteristics Solids suspension Residence time distributions (solid / liquid) Mass transfer Flow velocities Power numbers ungassed / gassed Radial forces on the shaft Surface phenomena Rheological properties Particle characterization (microscopy) Validation of CFD models
Shear Stress
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Ore slurries exhibit shear thinning or Bingham plastic flow properties. Non-Newtonian rheology with high apparent viscosity requires that the agitator design prevents cavity formation-which would lead to reduced mixing efficiency of the vessel volume.
Alumina Processing
EKATO develops customized agitation equipment to optimize mixing performance for all applications in alumina plants. For precipitation vessels the multistage VISCOPROP design achieves a uniform solids concentration from bottom to top at an optimal energy input. Particle concentrations of 1000 g/l or even higher can be handled.
Down Flow velocity distribution in an aluminium hydroxide precipitation vessel
Flow direction
Shear Rate
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3 3 2 2 1 1 1 2 3 Directed strong axial flow towards the problem zones. Reversed flow lifts the particles and evenly distributes them throughout the tank. Two large vortices divide the vessel into two sections; this has to be considered carefully when choosing feed pipe locations.
High Pressure Acid Leach (HPAL)

The innovative EKATO solution for horizontal autoclaves The process performance of the first compartment of an industrial leach autoclave effectively controls the overall process efficiency of the entire autoclave. Rapid blending of the slurry and sulfuric acid as well as homogeneous solids suspension are strongly influenced by the mixing efficiency.
A specially developed hydrofoil impeller improves blending and solids suspension in the compartment. The problem zones at the lowest point of the hemispherical head and at the lowest point at the overflow weir require strong directed flows provided by the new EKATO hydrofoil impeller. This fullfills the solids suspension criteria most economically. Power reductions of the order of 30% are achieved compared to standard impeller systems. Mixing times are much lower compared to conventional systems, resulting in faster and more efficient mixing of the slurry and sulfuric acid. Optimization of the feed point designs and locations leads to even better process results. Depending on the rheological behavior of the slurry one- or two-stage impeller designs are recommended.
Atmospheric Leach
EKATO specializes in design of agitator systems for specific gaseous mass transfer requirements, regardless of the feed gas dilution. EKATO systems combine agitator and sparger designs that enable extremely high gassing rates without affecting solids suspension, and at the same time minimizing the required installed power for the agitator.
Other Applications
EKATO supplies agitators for a wide range of applications, such as: CIL, CIP, CN-Detox, Autoclave Feed Tanks, Neutralization Tanks, Hydrogen Reduction Autoclaves, Sulphide Pressure Leach Autoclaves, Sulphide Precipitation Autoclaves, Storage Tanks, etc.
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Pressure Oxidation (POX)
To achieve a sufficiently high oxygen transfer rate during acidic pressure oxidation (POX) of sulphide concentrates different impeller designs are selected. An optimized Rushton impeller design is often chosen if abrasion is an issue due to the ore type. The impeller tip speed and therefore abrasion of the impeller blades is minimized. In combination with coated impeller blades impeller lifetimes are maximized. In other cases specialized impeller designs for gassing applications like the EKATO PHASEJET or the EKATO COMBIJET are recommended to provide high oxygen transfer rates and oxygen utilization with reduced motor sizes.
EKATO Titanium Agitators

EKATO manufactures all titanium welded parts in a clean room which has been specially developed for this purpose. Continuous monitoring of the process parameters makes it possible to guarantee that the titanium-specific advantages remain unchanged even after machining. By means of high quality systems EKATO has been able to acquire its leading position worldwide and can guarantee the highest benefit for its customers.
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1. 2. 3. 4. Automatic rell and cooling system for 6 agitators ESD64H - Heavy duty high pressure seal ESD64H - Cross sectional drawing Pressure compensator
EKATO Mechanical Seals

ESD Seals are robustly designed. Negligible loads on the product side of the seal rings due to the ESD specific pressure compensator concept and perfectly controlled seal temperatures by direct cooling of the seal and flanges increase the lifetime of the seals significantly. In conjunction with fully automated refill systems together with cooling and emergency operations, false operation can be prevented. Thus overall system availability can be increased, resulting in reduced maintenance and life cycle costs.
Advanced Process Solutions
EKATO SERVICE
With EKATO your service is in good hands. The EKATO worldwide service network guarantees the shortest reaction times to all questions concerning mixing technology and for all EKATO products. Furthermore EKATO Service is your partner for a complete range of service requirements: from full service contracts to spare parts all from one source. EKATO Service has taken the lead worldwide for mixing technology and agitator servicing.
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On-site supervision Training of operating and maintenance personnel Start-up support Overhaul, inspection, maintenance Repairs Spare parts service Preventive maintenance 24-hour service worldwide
EKATO Rhr- und Mischtechnik GmbH Kppelemattweg 2 79650 Schopfheim Germany Tel. +49 (0) 7622 29-0 Fax +49 (0) 7622 29-213 e-mail: info@ekato.com
EKATO Corporation
48 Spruce Street Oakland, NJ 07436 USA Tel. +1 201 825 4684 Fax +1 201 825 9776 e-mail: info.vus@ekato.com
www.ekato.com
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Services offered by EKATO:

EKATO Lab Testing

Down Flow velocity distribution in an aluminium hydroxide precipitation vessel

High Pressure Acid Leach (HPAL)

EKATO Titanium Agitators

EKATO Mechanical Seals

Advanced Process Solutions

Africa / Asia / Australia

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