Advanced Sludge Dewatering Project with Plate Filter Press in South Africa

Slurry Conditioning:

• Feed slurry from the thickener underflow is pumped to a conditioning tank.
• Flocculants are automatically dosed and mixed to promote agglomeration of fine particles, forming larger flocs that are easier to filter.

Filtrate Handling & Water Recycling:

• The clean filtrate water is collected in a central manifold and directed to the process water recycling system.
• This clear water is immediately available for reuse in the mill, significantly reducing freshwater consumption.

Automation & Control:

• The entire process is managed by a Programmable Logic Controller (PLC).
• The system automates the entire cycle – filling, squeezing, air blowing, and cake discharge – ensuring optimal operation, consistent results, and minimal manual intervention.

High-Pressure Filtration (Core Process):

• The conditioned slurry is fed into an Automatic Plate Filter Press by a high-pressure slurry feed pump.
• Filling & Filtration: The press is filled, and high pressure (typically 16-25 bar) is applied. Water (filtrate) passes through the filter cloth, while solids are retained in the chambers, forming a cake.
• Cake Squeezing: A membrane squeeze system (if equipped) inflates to further compress the cakes, mechanically expelling more water and achieving exceptionally low moisture content.
• Cake Washing (Optional): For concentrate, a water wash cycle can be introduced to remove impurities or residual process chemicals.
• Cake Drying & Discharge: Compressed air is blown through the cakes to displace additional water. The plates are then automatically pulled apart, and the solid, dry cakes fall by gravity onto a conveyor belt for disposal or transport.

Key Features & Outcomes of the Expansion:

• Superior Dewatering Performance: Consistently produces a solid, handleable filter cake with very low moisture content, transforming slurry into a semi-solid material.
• Enables Dry Stack Tailings: The dry tailings cake is ideal for conveyor transport and dry stack disposal, eliminating the need for traditional tailings ponds and associated environmental risks.
• Reduces Transportation Costs: For concentrate, the lower moisture content directly translates to reduced mass and freight costs to the smelter.
• Maximizes Water Recovery: Achieves a high rate of process water recovery and reuse, a critical factor for sustainable operation in water-scarce regions.
• Robust & Automated Design: The automatic plate filter press is designed for reliability and continuous operation in demanding mineral processing environments, reducing labor costs and improving safety.