Vertical Dewatering Roller Assembly for High-Throughput Slurry
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Solution Overview
Problem
Current methods for dewatering mine tailings, such as tailings dams and traditional filtration, face challenges in efficiently handling high production rates of mine tailings, particularly in achieving efficient filtration of 50,000 to 100,000 tons per day or more, due to limitations in equipment size and dewatering efficiency.
Innovation Solution
A dewatering assembly comprising a frame with rotatably supported dewatering rollers and an endless filter belt that travels vertically through a dewatering gap, assisted by a feed hopper with sealing wings for pressurized slurry feed, allowing for enhanced gravity-assisted material transport and filtration, and optionally featuring multiple pairs of rollers and filter belts for progressive dewatering and increased efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional filtration methods are used, then water removal is achieved, but production rate is limited to 30,000 tons per day or less
Solution Approach 1:
The filtration system is divided into multiple plate and frame assemblies that can be stacked vertically. Each assembly contains individual plates and frames that work together to create filtration chambers, allowing the system to handle high production rates through parallel processing while maintaining manageable individual component sizes
Solution Approach 2:
The system transitions from horizontal to vertical stacking of plate and frame assemblies. Multiple filtration units are arranged in a vertical column,充分利用 vertical space to increase production capacity without expanding the horizontal footprint, enabling handling of 50,000 to 100,000 tons per day
2Productivity
If filter pressing is used for high production rates, then throughput increases, but dewatering time increases
Solution Approach 1:
Slurry is pre-conditioned and fed under pressure into the filtration chambers before the actual filtration process begins. This preliminary pressurized feeding ensures proper distribution and initial consolidation of material, reducing the time required for effective dewatering at high throughput rates
Solution Approach 2:
The system enables continuous operation with multiple plate and frame assemblies working in sequence. While one assembly is being pressed, another is being discharged and reloaded, eliminating idle time and maintaining continuous productive action throughout the system
3Productivity
If plate and frame filter presses are increased in size, then production rate increases, but equipment complexity and space requirements increase
Solution Approach 1:
Instead of using one large filter press, the system employs multiple smaller plate and frame assemblies stacked vertically. Each assembly is a complete functional unit that can be independently operated, maintained, and replaced, achieving high production rates through parallel processing of multiple smaller units
Solution Approach 2:
The system utilizes vertical stacking to arrange multiple filtration assemblies in the height dimension rather than expanding horizontally. This vertical configuration achieves the required production capacity of 50,000 to 100,000 tons per day without proportionally increasing the equipment's horizontal footprint
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The assembly achieves efficient dewatering of mine tailings and other slurries at high production rates by maximizing gravity benefits and reducing dewatering time, with the ability to handle up to 100,000 tons per day or more, while minimizing water leakage and ensuring effective filtration and solid transport.
Implementation Method 1
an endless filter belt arranged to travel through the dewatering gap in a substantially vertical direction upon rotation of the dewatering rollers
Implementation Method 2
The slurry enters the gap from above, so that vertical material transport is achieved and assisted by gravity
Implementation Method 3
The sealing of the engagement zone provided by the sealing wing of the feed hopper allows for a pressurized slurry feed which reduces dewatering time
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A dewatering assembly (1) comprises a frame (2); a pair of dewatering rollers rotatably supported by the frame (2) with their curved outer peripheral surfaces facing each other so as to form a dewatering gap there between; an endless filter belt (11, 12) arranged to travel through the dewatering gap in a substantially vertical direction upon rotation of the dewatering rollers, wherein the endless filter belt (11, 12) forms an engagement zone (30) with one of the dewatering rollers in which successive portions of the endless filter belt (11, 12) engage with and disengage from successive portions of the curved outer peripheral surface of the dewatering roller; and a feed hopper (16) arranged above the dewatering gap for feeding a slurry into the dewatering gap. The feed hopper (16) comprises a sealing wing (38) covering the one of the dewatering rollers (5, 6), and the filter belt (11, 12) engaged therewith, in at least a part of the engagement zone (30).