In an era where accuracy and efficiency define mineral processing performance, Multotec is advancing the science of separation through its high-efficiency spiral concentrators and cyclones. Leveraging its global expertise, spanning manufacturing, research, and field service operations in more than 100 countries, alongside two decades of experience in Canada, the company continues to strengthen its presence in the local mining sector. Its technologies are already delivering proven results in major coal operations and are equally well suited to achieving the same precision and recovery in iron ore processing applications.

Proven cyclone performance

Multotec’s dense medium and classification cyclones have delivered consistent separation efficiency across Canadian coal operations for the past 20 years. Engineered to perform reliably under the toughest conditions, these cyclones offer long wear lifespan and are simple to maintain, featuring fewer components and flexible configurations. This design aligns perfectly with the sector’s focus on operational efficiency and reduced total cost of ownership.

Niel Lourens, Vice President for Cyclones & Spirals at Multotec, says: “Our product specialists specify the ideal combination of pressure, cone angle, vortex finder, and spigot dimensions to achieve optimal separation efficiency and plant performance. In addition, our North American customers benefit from access to our technical expertise and an extensive selection of spare parts and accessories, ensuring they receive reliable support throughout the lifecycle of their equipment.”

To ensure long-term efficiency and reliability in harsh operating conditions, Multotec optimizes the materials used in its cyclone construction. By incorporating advanced wear-resistant materials, such as silicon carbide in place of traditional liners, the cyclones achieve extended service life, enhanced durability, and reduced maintenance costs and requirements, ultimately minimizing overall downtime.

Innovations in spiral separation

Complementing its cyclone technology, Multotec also offers a range of spiral concentrators that are designed to deliver precise, high-efficiency separation performance and mineral concentration across a range of commodities, including iron ore, coal, gold, copper, nickel, and zinc. The SX7 and MX7 coal spiral concentrator models incorporate two stages of spiraling into a single compact and modular spiral assembly, reducing plant height and floor space requirements.

Lourens says: “These spiral concentrators have proven themselves as highly efficient within the Canadian and USA coal sector, with Multotec having installed several of these units to date, achieving successful recovery results.”

To unlock additional value from existing resources, Multotec’s low cut density SX10 spiral is engineered to achieve a lower density cut point resulting in a lower ash product.

“With a lower cut density, the SX10 spirals are capable of producing a higher grade coal, which is especially important for Canadian coal plants producing higher specification export metallurgical coal,” Lourens adds.

Moreover, Multotec has developed the ultra-fine UX7 spiral, designed to recover heavy minerals with particle sizes of 100 microns and smaller. The UX7 is suitable for a wide range of applications, including iron ore, chrome, manganese, copper, platinum, and mineral sands.

Collaboration for continuous industry improvement

A key differentiator for Multotec in the region is its collaboration with universities and metallurgical research laboratories across North America. These partnerships focus on advancing separation science, optimizing mineral processing flowsheets and enhancing process control to drive greater operational efficiency.

Lourens says: “These research partnerships are essential to how the industry innovates, shares knowledge, and advances mineral processing solutions in line with the sector’s future needs.”

Looking ahead

As Canadian miners continue to seek solutions that balance productivity, efficiency, and environmental performance, Multotec’s spirals and cyclones are helping to drive that transition by combining its global knowledge with local expertise to enable smarter, more sustainable mineral processing.

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It underpins global steel production and is rapidly emerging as a critical component in next generation battery technologies. While close to 90% of manganese output still feeds the steel sector, demand for high purity manganese is rising steadily as electric vehicles and energy storage systems gain momentum.

This dual demand is reshaping how producers view their resources. Increasingly, the focus is shifting to beneficiation strategies that do more than process premium ore. By recovering additional saleable product from fine manganese material that was previously discarded or stockpiled, producers can reduce waste, strengthen value chains and improve resilience through commodity price cycles.

Drawing on extensive global expertise in gravity concentration, Multotec has supplied a modular heavy mineral beneficiation solution to a manganese producer in West Africa. Designed specifically for fine material recovery, the system allows producers to unlock value from fines and maintain profitability even when market conditions soften.

Turning Fine Manganese into Opportunity

Historically, manganese operations have prioritised the lumpy fraction of the ore because it is easier to beneficiate and readily accepted by export markets. Fine material, particularly the minus one-millimetre fraction, has often been overlooked despite the fact that it has already been mined and crushed. This means most of the production cost has already been incurred.

When demand strengthens or prices fluctuate, these fines present a powerful opportunity. With the right gravity separation technology selected according to particle size, shape and density, fine and ultra fine manganese can be transformed into a saleable product that meets offtake requirements.

Spiral concentrators play a central role in this process. They are widely regarded as one of the most efficient and cost-effective methods for beneficiating manganese, particularly fine high-density material. Their low energy demand, minimal maintenance and adaptability make them ideally suited to the complex and variable ore bodies found across Africa.

Menzi Xulu, Senior Process Engineer at Multotec, explains: “Multotec’s SC range of spiral concentrators are suited to fine, high-density mineral separation, which is a key requirement in manganese beneficiation. Our SC20 spirals are typically used in the roughing and scavenging stages, where the focus is on maximizing recovery from the feed. The SC21 spiral is then applied in the cleaning stage to upgrade the manganese and achieve the required product specification.”

To further enhance recovery, Multotec has developed the UX7 spiral, designed specifically to capture ultra fine heavy minerals that were previously lost to tailings. The UX7 is highly effective in the roughing and scavenging of ultra fine manganese, allowing producers to recover value from material that would otherwise be wasted.

This combination of roughing, scavenging and cleaning spirals ensures that value is extracted from the entire orebody, not just the easy to process fractions.

Recovering Fines with a Practical Modular Solution

Recovering fine manganese economically is essential, particularly during periods of lower commodity prices. Multotec addresses this challenge through modular and mobile heavy mineral test plants that integrate several proven technologies into a compact and transportable solution.

Wilna Hoffmann, General Manager for Business Development at Multotec, says: “Fitted with Multotec cyclones, spirals, and pumps, the unit can treat 40 tons per hour of fine material in just three stages to produce a saleable manganese product. It is also operator-friendly and designed as a basic but cost-effective solution that can easily be transported and commissioned quickly.”

One manganese producer in West Africa turned to Multotec to maximise recovery from fine tailings that had long been overlooked. Although the operation had purchased a Multotec heavy minerals unit several years earlier, it had remained idle for nearly three years.

Multotec recommissioned and optimised the unit in just four days. Once operational, the system ran at full capacity and recovered a 47% high grade manganese super concentrate from feed grading 26% manganese.

Across Africa, the opportunity to deploy these modular beneficiation units continues to expand. Their low capital and operating costs, ease of use and ability to recover value from fines offer a practical pathway to unlock mineral resources more fully and strengthen regional mineral value chains.

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The recognition highlights the company’s sustained export growth, strong localisation strategy, and its ability to compete internationally through innovation, quality manufacturing, and skills development.

The award followed a comprehensive evaluation process and reflected Multotec’s long-term contribution to South Africa’s export economy, particularly its success in expanding into international markets while maintaining robust local production, employment, and supplier development.

According to SACEEC, the Exporter of the Year Award identifies companies that demonstrate sustained export growth, strategic market expansion, strong localisation, operational excellence, and long-term international competitiveness, criteria against which Multotec consistently performed.

According to Etienne Smit, Group Supply Chain Manager at Multotec, the award recognises an export strategy deliberately built over many years.

“This acknowledgement shows how Multotec has grown its international footprint while keeping manufacturing, skills and value creation firmly rooted in South Africa. Export success for us is not accidental, it is the result of long-term planning, continuous innovation, and an unwavering focus on quality,” he says.

As highlighted in SACEEC’s evaluation, exports now account for 55% of Multotec’s total turnover, with the company supplying mining and mineral processing solutions to customers in more than 100 countries across six continents. Africa remains the largest export market, contributing over 60% of export revenue, supported by growing demand from Australia, Europe, and the Americas.

Multotec’s ability to compete across diverse regions is underpinned by solutions engineered for specific operating conditions, from copper operations in Zambia to lithium projects in South America.

“Our customers operate in various environments, and our solutions are designed accordingly. That adaptability is a key reason why we are able to compete globally and deliver consistent performance,” Smit explains.

SACEEC’s recognition also reflects Multotec’s continued investment in technology and process innovation, enabling improved plant performance, reliability, and sustainability at mining operations worldwide.

“Innovation is measurable for us,” says Smit. “We use technologies that extend equipment life, reducing downtime, improving yields, and supporting more sustainable operations. These outcomes directly translate into long-term value for our customers.”

Multotec’s global competitiveness is further strengthened by compliance with international standards, including ISO 9001, ISO 14001, and ISO 45001. The company also holds Level 1 Authorised Economic Operator (AEO) status, enabling faster customs clearance, reduced risk, and improved delivery timelines for export shipments.

“These accreditations are critical when operating in international markets. They assure customers that our products meet global quality, safety, and ethical standards,” adds Smit.

Central to Multotec’s export success is its “Global Presence, Local Expertise” philosophy, a differentiator recognised during SACEEC’s assessment. This approach ensures that international growth continues to support South Africa’s industrial base.

The company operates manufacturing facilities and office space exceeding 70 000 m² and employs nearly 1 500 people in South Africa. Export growth directly sustains local manufacturing capacity, supplier development, and skills retention, reinforcing Multotec’s contribution to the domestic economy.

Multotec has also established a local presence in key international markets, including China, Brazil, Australia, Botswana, Zambia, Chile, Canada, Germany, and Ghana. These operations enable in-country assembly, fabrication, technical support, and skills transfer.

“We don’t simply export products,” says Smit. “We share knowledge, by building local capability in our markets, and supporting local teams in maintaining and optimising our solutions. This ensures customers receive fast, world-class service wherever they operate.”

Skills development was a key factor in Multotec’s Exporter of the Year recognition, with investment in people forming a cornerstone of the company’s export strategy. Multotec invests more than R10 million annually in skills development initiatives, including learnerships and technical training programmes.

“Our people are our most valuable asset. They are not just trained to operate equipment, but to analyse, solve problems, and continuously improve solutions. That depth of expertise is what builds trust with international customers and supports long-term relationships,” says Smit.

Multotec continues to expand its global reach through participation in international conferences and exhibitions. These platforms support market entry, brand visibility, and long-term relationship building, enabling the company to share technical expertise and deepen engagement across Africa, South America, Europe, North America, and the Asia-Pacific region.

“Winning the SACEEC Exporter of the Year Award acknowledges our people, innovation and contribution to South Africa’s export economy,” Smit concludes. “The award affirms Multotec’s ability to deliver consistent export growth while strengthening South Africa’s industrial base, aligning directly with SACEEC’s mandate to promote globally competitive, locally rooted exporters.”

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Many conventional methods struggle to meet stricter regulations, sustainable water use targets, and the need to manage both rate of rise and long-term TSF stability.

Multotec’s GV Cyclone was designed specifically for tailings dam applications. Engineered for durability, flexibility, simple maintenance, and process efficiency, the cyclone features a lightweight spin-cast steel shell lined with bonded rubber, allowing it to withstand pressure fluctuations while remaining easy to move on-site.

“By improving material distribution, Multotec’s GV Cyclones help mining operations reduce their environmental impact while maintaining safe and efficient tailings deposition,” says Ernst Bekker, Cyclone Product Specialist at Multotec.

Supporting clients with tailored solutions

A leading South African gold producer, committed to reducing environmental impact, sought a more efficient solution for slurry management. Multotec’s prior experience with the client, including extending equipment wear life, optimising cyclone performance, and supplying fit-for-purpose solutions such as screening media, samplers, and mill liners, made the company the natural partner for the new TSF order.

Overcoming operational challenges

Handling large tailings volumes under tough conditions requires equipment that is reliable, operator-friendly, and durable. Previous deployments of Multotec cyclones demonstrated performance advantages over competing systems, prompting the order for GV Cyclones at the new facility.

Innovative design for optimal performance

Multotec’s team used in-house simulations, test work, and on-site comparative trials to configure the GV Cyclones. Factors such as cone angle, spigot size, and vortex finder selection were optimised to ensure efficient operation.

“The GV Cyclones were designed with operators in mind. Features like the lightweight body, interchangeable cone angles, and quick-release spigots make day-to-day management easier and safer, while still delivering the durability needed for harsh conditions,” explains Blane Pillai, Applications Engineer at Multotec.

The cyclones deliver the optimal volumetric split between overflow and underflow to meet TSF rate-of-rise requirements. Their configuration can be adjusted as deposition conditions evolve, ensuring consistent performance even if ore characteristics change. Built to absorb pressure spikes during start-up, the cyclones also provide stability under demanding conditions.

Key Design Features

• Lightweight construction: 44.6 kg for easy handling, installation, and maintenance

• Durable build: Steel rubber-lined inlet head and cone with 15 mm replaceable liner for long service life

• Quick-change spigot system: Tool-free screw coupling allows rapid replacement without shutdowns

• Flexible operation: Interchangeable spigots, vortex finders, and cone angles (10° or 20°) for full operational control

• Optional movable stands/skids: Simplify relocation and reduce labor requirements

Earlier in 2025, Multotec received an order for over 200 GV250 Cyclones for one of the client’s existing TSFs. Manufacturing is underway, with delivery and on-site installation support scheduled before year-end.

Delivering Results: Efficiency, Safety, Sustainability

Even before commissioning, installations at other sites highlight the benefits.

“Cyclones enable a faster, more controlled rate of rise compared to traditional open spigot deposition, reducing labour intensity, lowering operational costs, and giving operators precise control over dam wall height,” says Erick Herbst, Territory Sales Manager – Capital at Multotec.

GV Cyclones ensure even material distribution, improve water recovery, and support proper deposition characteristics, contributing to safer, more sustainable long-term TSF management.

With durability, lightweight handling, and operator-friendly features, Multotec GV Cyclones are setting a new benchmark for tailings management.

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Bheka Majola, Managing Director for Processing Equipment at Multotec, says the award is not only an indication of the company’s growth over the years but also the culmination of a 15-year strategy to grow its global presence and income from its export business.

The SACEEC Exporter of the Year Awards celebrate the passion and commitment of members who have participated and succeeded, through determination and innovation, in their respective local and export markets.

Majola explains that exports currently contribute 63% of Multotec’s total annual turnover, of which more than 60% is exported into Africa. Multotec has more than 50 years of experience and expertise in supplying a wide range of good quality mineral processing equipment that is backed by field service and maintenance specialists in most of the commodities, including gold, platinum group metals, lithium, and copper.

He explains that to support the growth of its export business, Multotec has had to invest in its manufacturing facilities and now has almost 80 000 m² of manufacturing and storage space in the Spartan, Pretoria, and Secunda areas.

Growing international footprint

“We now employ nearly 2 000 people to service our customers globally and make high-quality products for them. With an increasing international footprint, we are now present on six continents and do business with customers in over 100 countries. We were the first to embrace verification by the South African Bureau of Standards (SABS) to prove that our equipment has more than 60% local content,” says Majola.

“We are proud of our investment in the properties that house our manufacturing, storage, and services space in South Africa, as this is an investment in our economy and provides much-needed local jobs. Our growth enables our people to grow with the company, doing meaningful work and gaining valuable skills and expertise with which they can compete globally. We invest heavily in internal and external training to develop our people.”

He adds that Multotec’s product development is customer-driven to ensure that its products and technologies have value for the customer. The company’s regional branch strategy ensures that it has a local presence close to the customer to service and understand customer needs.

“Because no two processing plants are the same, Multotec is a customer- and a needs-driven company that has an in-depth understanding of our customers’ applications. We engineer solutions that address the specific and unique requirements of each of our customers,” says Majola.

Developing customer trust

“Our range of technologies and expertise extends over the entire flow sheet, meaning that we are not dependent on selling one type of technology. We therefore have the flexibility to ensure that the right application is backed by the right technology within our range of products, so our customers trust us to develop solutions that are specifically suited to their needs, wherever they may be in the world.”

Multotec is enthusiastically engaged in numerous industry conferences and exhibitions. In the past year alone, Multotec actively participated in a total of 24 conferences and events, with a notable presence at 10 international gatherings – presenting at four of those gatherings. The company has a long association with the Electra Mining Africa and South African Coal Processing Society organisations.

“We have invested in solar power to produce some renewable energy for our facilities, and we have invested in generators to enable us to reduce our consumption from the grid during load shedding. This ensures we maintain productivity for our customers, and we contribute to the solution to the country’s power challenges,” says Majola.

Majola adds that Multotec adheres to international standards such as ISO 14001, 45001 and 9001. The company makes products that meet all the major international fabrication standards as specified by its customers and its samplers adhere to the strict and relevant commodity ISO standard for each application.

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Multotec responded to a challenge facing iron ore producers in Australia by developing a rubber screen media solution that negates the risk of fires associated with hot work on screen decks. Shawn Faba, Product Manager: Screening Media at Multotec, explains that while the solution was developed to meet the stringent performance and safety requirements of the Australian mining industry, other mining operations across the world would also benefit from its adoption.

Multotec’s flame-resistant panels have been scientifically developed in collaboration with international academic institutions and raw material suppliers. The product has been tested under controlled laboratory conditions, certified accreditation trials, as well as on a number of sites in real world conditions.

Significant potential benefits

“When we consider an interruption to any production environment, the downtime could easily translate in revenue losses that run into millions of dollars. For example, in Australia, mining houses are tonnage-driven, meaning when you have unplanned downtime of two hours, it could translate to the loss of millions. Fires in the plant can shut down whole modules for weeks at a time. Australia’s miners operate in campaigns – for instance, they’ll operate for three months and then they’ll do maintenance. They don’t stop haphazardly.

“Our product has undergone rigorous testing and has been confirmed to operate continuously to fit existing shutdown campaigns, meeting the mining industry’s stringent requirements. Ensuring high-quality equipment is essential to minimise downtime. This is especially beneficial for plants that operate around the clock, as interruptions can be costly and disruptive,” says Faba.

Developed with safety in mind

“To make the rubber screen panels flame-resistant, we modified the chemical composition of the raw materials used to manufacture the panels. However, the flame-resistant screen panels can be used without compromising on efficiency, compared to conventional rubber screen media,” adds Faba.

He notes that Multotec is proud of the fact that its flame-resistant rubber screen media has received international acceptance and is in use at processing plants of some of the world’s leading iron producers. The flame-resistant screen panels can be used in all screening applications for a variety of duties, both wet and dry.

Fit for any screening-related application

“While we currently supply the flame-resistant rubber screen panels for iron ore screening applications in Western Australia, these panels can also be used in any screening-related application. They can be used extensively in all mineral processing applications, such as coal, iron ore, copper, platinum, diamonds, manganese, and zinc, among others.

In addition to providing the greatest level of fire safety, Multotec’s flame-resistant panels also increase optimal screening performance and plant availability, are available in hard (PD70) and soft (PD45) durometer rubber, and remain robust and extremely reliable under the toughest mining conditions.

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The expansion consists of the installation of three new presses at the factory that will boost manufacturing capacity by 15-20% to meet the demand for larger mill liners, as well the increasingly demand for Multotec’s new integrated mill liners that are replacing steel liners in the market.

Thando Makhoba, Managing Director – Rubber at Multotec, explains that the installation of one new press has already been completed, while the other two will be installed during  August this year. The new presses enable Multotec to manufacture larger mill liners, that are between 10m and 15m in diameter, whereas previously the company focused on 3m to 7m diameter mill liners.

“Most commonly used for platinum and copper applications, the new presses are more modern and offer greater manufacturing capacity, enabling us to produce integrated mill liners – consisting of lifter bars and shell or grate plates – as one piece. Previously, these components were manufactured separately and then installed at a customer’s site, which involved a considerable amount of time,” says Makhoba.

Reduced installation time

“Because we can now produce mill liners as a single unit that is then installed at a mine, it cuts down installation time by at least 24 hours, thus reducing plant downtime and saving clients’ time and money.”

Makhoba says that the growth in demand for mill liners, which prompted the installation of the new presses, was twofold. On the one hand, Multotec benefitted from winning the business of several competitors who have either left South Africa or have scaled down their local manufacturing capacity. On the other, the company has also seen a huge increase in demand for its integrated rubber liners, which are replacing steel mill liners in the market.

Another important feature of the new presses is that they are much safer, as this modern equipment allows operators to have less physical engagement with the machine during production. “The new presses come with a digital Manufacturing Execution System (MES) enabling the operator to log in on an app and monitor what the machine is producing via live data, that shows what is being produced, whether a specific press is running or not and how much capacity a particular machine has available,” says Makhoba.

Paperless shop floor

“Because of the digital MES, there is no need to print job cards anymore, as all the specifications are displayed on the user interface. This plays well into our push towards a paperless shop floor.”

“Furthermore, as part of our commitment to continuous improvement, we have employed a specialist who is an industrial engineer and is very well versed in lean manufacturing principles. Currently, we are also looking for new production and quality engineers, who will be on the factory floor to train our operators on the new technology,” he says.

“With the installation of the new presses, our mill lining factory has become more efficient and we are able to manufacture increasingly bigger mill liners. Ultimately, we don’t provide mill liners, but rather provide solutions,” Makhoba concludes.

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The solution not only showcases the company’s advanced technical expertise, but also its ability to design MultoComposite integrated liners according to customer’s plant needs, specifications and mill operating parameters, through its high-skilled technical and product development teams.

Samuel Hearn, Global Sales Director at Multotec explains that this solution was developed specifically for mines that operate large mills of 8-meter-plus diameter that typically used steel mill liners. “Many mining operations that operate large steel mills are now looking to switch over to composite rubber liners, such as the MultoComposite integrated liners, which have the same application as traditional steel liners and can thus be used across mines in milling circuits,” says Hearn.

Optimum efficiency

The milling circuit is the second comminution stage after crushing. Mills operate at their most optimum efficiency if the mill liners are designed for the operating parameters of the plant. Multotec’s MultoComposite integrated liners are far more cost effective, and lighter to handle. The liner profiles can be uniquely designed to the specification of a specific mill. In addition, the MultoComposite integrated liners reduce installation time, meaning that shutdown periods are shorter.

“The solution was designed in response to the needs of a South African platinum mine that was experiencing challenges with its integrated liner. We modified and improved the previous design, which reduced the wear rate and simplified their installation,” says Hearn.

“One of the biggest benefits is the saving on installation time, which we managed to cut in half. Reduced downtime means that a mine can be up and running quicker and continue to generate profits.”

Software simulation

Hearn adds that Multotec uses state-of-the-art software to run simulations that predict the efficiency and life of mill liners. The company’s Comminution Specialist and Product Development Manager conduct audits on a mill’s historical operating parameters. They then audit the parameters, design the liners, use the software to simulate and improve the customer’s efficiency and life of the MultoComposite integrated liners.

Armando Figueiredo, Product Development Manager at Multotec, says Multotec’s technical team not only develops innovative designs, but also continuously improves processes and efficiencies to meet customer specifications.

“Our facilities are continuously being developed and extended to improve the production rate of the MultoComposite integrated liners. We have recently installed a new high-pressure moulding press and are in the process of installing another new press with yet another on order for the specific manufacture of these products,” he says.

Global applications

Figueiredo notes that the uptake of Multotec’s integrated liners has been significant, with the company supplying clients in South Africa, the DRC, Turkey and North America, among others. We recently designed; manufactured to tolerance and delivered a full set of MultoComposite integrated liners in record time to Turkey.

“We currently have two full-time installation teams that travel to clients around the world and do mill liner installations. We also provide condition monitoring services via our patented Hawkeye software that incorporates a 3D scanner and produce a detailed report highlighting the efficiency of the mill. Hawkeye predicts when the liners start becoming inefficient and foresees the shutdown date. This programme enables us to perform predictive maintenance, meaning that clients’ stock levels can be decreased by as much as 60%,” he says.

Figueiredo notes that Multotec is continuously looking at improving the life and efficiency of mill liners, based on their mill operating history, striving to provide a better solution with every liner replacement.

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Coarse chrome particles in the feed from the nickel laterite deposit were highly abrasive, and were also causing blockages in pipelines, pump boxes, holding tanks and sumps at the operation. According to Faan Bornman, technology manager: research and development at Multotec’s technology division, the aim was to remove the coarse particles via the cyclone underflow, while recovering as much of the valuable cobalt and nickel in the overflow. The coarse material was specified as being between 150 microns and 1 mm in size.

Multotec constructed and shipped a cyclone test rig to the site towards the end of 2021, where it was put to work for two weeks conducting sampling at two strategic points.

“We were able to identify the cyclone configuration that delivered the best efficiency performance at each sampling point,” says Bornman. At both points, the cyclone spigot was optimised at 20 mm for all the tests.

Cyclone configuration

The test work generated a total of 17 tests, resulting in 153 samples which were each dried, weighed, screened for particle size distribution, and analysed by the inductively coupled plasma (ICP) method to measure the elements.

“Our optimal cyclone configuration at the customer’s first sampling point was able to reduce the coarse chrome content of around 10% in the feed to just over 1% in the overflow,” he explains. This result was achieved using a VV250 flat-bottomed cyclone with four barrels, an A inlet head and an A- type vortex finder; the pressure and feed slurry density were also important variables.

Similar success was achieved by the second sampling point, with a similar configuration but with one barrel. Here, the coarse fraction was reduced from almost 15% in the feed to just 1,2% in the overflow – a reduction of over 90%.

“Multotec’s extensive field experience, combined with our metallurgical expertise and wide portfolio of process equipment, gives customers optimal value from our test work capabilities – either on-site or in our extensive facilities in South Africa,” he says.

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According to John Britton, Technical Consultant at Multotec, the two pulping chutes have achieved outstanding results, helping the customer’s facility to cost effectively increase the throughput of its Combined Treatment Plant (CTP).

“At our recent two-year inspection of the plant, we found that the wear rate on the ceramic lining of the wave generator was only 20 mm over that 24 month period,” says Britton. “Each chute was processing 380 tph of recrushed kimberlite product with 380 m 3 of water, rushing down a 28 degree incline.”

Expectations 

Multotec’s patented wave generators use gravity to create a constant turbulent mixing action in the slurry flow that releases the mud, clay and slime sticking to the kimberlite particles. The chutes are positioned to receive material from the High Pressure Grinding Rolls (HPGR) interparticle tertiary crushing circuit. Multotec’s engineered alumina ceramic tiles give the chutes and wave generators high wear resistance.

“The chutes exceeded our expectations in how well they separated the clay from the kimberlite ore and broke up clay balls in the material stream,” he says. “This has really demonstrated the long term capacity of our design to deliver results with hardly any maintenance or operator intervention.”

He highlights that the chutes are stationery structures which rely on the kinetic energy being created by the inrush of slurry flow over the wave generators. This makes the solution much simpler and less energy-intensive than traditional rotary scrubbers with motors, drives and gearboxes. The chute can also achieve its results much quicker, as the material flow passes through in just three to four seconds.

Ekapa CEO Jahn Hohne says he has been impressed by how well the chutes have performed as an alternative to a considerably more costly scrubber circuit and having delivered a 20% increase in throughput through the plant and making a positive economic contribution to overall efficiency. Hohne says he admired Multotec’s innovation capability and looked forward to even further improvements in the design.

Britton notes that, after conducting the wear inspection of the chutes, there were indeed constructive modifications that Multotec was planning. One of these related to the retarder bars, which slow down and divert the slurry flow.

“We believe we can achieve even better results if we remove some of the retarder bars and install another set of wave generators,” he says. “Our results suggest that this will get the ore material even cleaner, before it reports to the screen, the conveyor belt and finally the dense medium circuit.”

The success of the pulping chutes at Ekapa has led to considerable interest from other diamond producers in southern Africa, he notes.

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