Virto-Cuccolini’s X-Line innovative screening technology in support of mine tailings recovery

Tailings management is today at the centre of a global discussion within the mining industry.

Since the tragedy taking place at the Corrego do Feijão mine in Brasil in 2019, an international panel of experts has been analyzing and discussing new standards for the management of tailings facilities.

The result is a set of guidelines released in August 2020 – the Global Industry Standard on Tailings Management – which is opening a new vision for tailing facilities and their management, including a stronger safety concept for the surrounding areas.

Besides safety, also environment and finances can benefit from innovative management of tailings. The truth is, that what has always been considered as waste, still contains a good amount of valuable product that can be recovered and reused – provided of course that the right technology is available to support this process.

In facts, most coal fines (<1mm) were previously discarded due to unavailability of processing technologies to produce a premium product for export. Further research has shown that most of the fine coal is normally contaminated by <45 µm particles which cannot properly and efficiently be removed by cyclones.

Following is what Virto-Cuccolini could experience back in 2014-15 when first testing the use of X-Line multi-frequency screening technology within the recovery of a tailing facility in Vreiheid, South Africa.

In that case, our objective was to test the ability of our X-Line rectangular screens to reduce the content of ash within anthracite coal waste fines from 35 to 16% at a yield of 40-50%. Virto-Cuccolini’s X-Line screens were installed at the recovery plant to screen about one mln tons of fines being drained from three different dumps.

In particular, a scalping screen had the task to separate the main product pumped from the pond between the oversize > 3mm and the undersize < 3 mm.

The undersize was screened by two Virto-Cuccolini’s screens at 100 µm with a flow rate of about 40 t/h, of which about 30% was a solid product. At this stage, the first macro-dewatering process took place.

After this, the product was further separated by density through four spirals and finally treated by four Virto-Cuccolini’s X-Line dewatering screens which refined the job at 250 µm, leaving the product at a final humidity of about 15%. The final product showed an ash content below 16%, which could make into metallurgical quality coal. At full production, the plant was delivering about 160-200 tons of screened product per day.

Here is the video of this incredible first experience for us:

What is so special about X-Line innovative multi-frequency screening technology, which brought us to achieve such results?

X-Line’s power is focusing on keeping the screening mesh free from clogging.

With this special feature, obtained by applying an incredible force on the screen’s mesh only, it is easy to achieve fine screening in combination with significant flowrates, and therefore, create new perspectives for industrial applications.

Virto-Cuccolini’s X-Line screens were able to:

– create a new fine and less toxic product

– free the pond from the tailings and bring it back to its natural conditions

– optimize the use of energy within the process

– minimize downtime and maintenance

It is, therefore, with enthusiasm that we welcome the new tailings management guidelines!

We are sure that Virto-Cuccolini’s range of X-Line multi-frequency screens, together with the experience we could accumulate so far, will be a useful solution in support of a new way to manage tailings facilities and bring more respect for people and environment.

Would you like to learn more about tailings management by Virto-Cuccolini’s X-Line multi-frequency technology? Send us a message with your case by using the form here below, and we’ll come back to you at soonest with our proposed solution!




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    Here is our article on African Mining Brief Magazine, Nov/Dec 2019 Edition

    Full digital copy of this African Mining Brief Magazine edition can be downloaded here.

    VIRTO changes the screening game.

    YOU CAN RECEIVE OUR FREE ADVICE TO SELECT THE TYPE OF SIEVE MORE SUITABLE TO YOUR PROCESSING NEEDS, BY CONTACTING US




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      Here is our interactive ad page on mine.h5mag.com:

       

      September 2019: http://mine.h5mag.com/mine_sep19/virto_cuccolini

      VIRTO changes the screening game.

      YOU CAN RECEIVE OUR FREE ADVICE TO SELECT THE TYPE OF SIEVE MORE SUITABLE TO YOUR PROCESSING NEEDS, BY CONTACTING US




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        Night is falling in a coal beneficiation plant, somewhere in South Africa.

         

        After a busy day, our commissioning activity for 2 units of X-Line screens is successfully accomplished.

        Our objective was to deslime coal at 75 micron: a typical task for our rectangular X-Line screens within mining industry, which come into play when sieving gets tough!

        Some more process insight:

        • Task: beneficiating of the coal waste stream
          • screening at 75 µm
          • 25-35% solids concentration
          • over 90% efficiency
          • expected yield of +40%
        • Technology: X-Line Multi-frequency screening, up to 500 G force directly on the mesh
        • Results: Dramatic ash content reduction and the increase of the Calorific Value to marketable specifications

        Here are some pictures from our commissioning activity:

        Have you ever experienced our innovative X-Line screening technology?

        Watch here our X-Line in action:

        VIRTO changes the screening game.

        YOU CAN RECEIVE OUR FREE ADVICE TO SELECT THE TYPE OF SIEVE MORE SUITABLE TO YOUR PROCESSING NEEDS, BY CONTACTING US




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          A note by our Founder, Alexandre Gaydamak (originally appeared: April 10, 2019 on LinkedIn):

          For centuries the Mechanical Screening Industry has followed the same fundamental logic:

          Agitate the body and the screening media as a singular entity of the machine.

          The hope is to maximise the amount of energy retained on the mesh from the motion of the screener.

          Thereby, agitating the material and maximising the opportunity for undersize particles to pass.

          Whether by hand, from antiquity, or with modern day powerful electric vibratory motors, the logic has remained the same.

          Find the best combination of machine size, energy input and strength to build vibratory screens to process material.

          However one of the biggest challenges remains the prevention of the mesh from clogging and blinding.

          In the quest to deliver more energy to the mesh, manufacturers have continued to design and build machines that can operate with higher G-force inputs.

          Today’s modern designs can apparently operate with as much as 10 G-force of energy.

          Anything higher results in structural failures of the equipment.

          Will there be a technological disruption

          that massively increases this energy input

          without putting the structural integrity under question or at risk? 

          Centuries of development have maxed out at 10 G-force.

          After all of this progress, users are still faced with the same age-old challenges, high energy input, results in high usage of consumables and requires substantial energy inputs.

          In addition, the footprint of screens has continued to increase as more structural weight was engineered into the design thus increasing the power consumption further.

          Is there a disruptive technology out there that has fundamentally changed the method of delivering energy efficiently to the screen media?

          Is there a technology

          that can deliver 100s of G-force

          directly to the point where it is needed the most?

           

          Is that technology able to physically withstand the rigors of such high forces, and do so with relatively small machine foot prints and substantially low energy inputs?

          This would truly be a game changer and a fundamental technological disruption.

           

          “Oscillation will accomplish wonders” – Nikola Tesla

           

          Disruptive innovations tend to be produced by outsiders and entrepreneurs in startups, rather than existing market-leading companies.

          The business environment of market leaders does not allow them to pursue disruptive innovations when they first arise, because they are not profitable enough at first and because their development can take scarce resources away from sustaining innovations.

          A disruptive process can take longer to develop than a conventional approach and the risks associated with it are incrementally greater than evolutionary forms of innovations.

          However, once they are deployed to the market, they achieve a much faster penetration and higher degree of impact.

          When a technology that has the potential for revolutionising an industry emerges, established companies typically see it as unattractive: it’s not something their mainstream customers want, and its projected profit margins are not sufficient to cover big-company cost structures.

          As a result, the new technology tends to get ignored in favor of what is currently popular with the preferred customers.

          But then another company steps in to bring the innovation to a new market.

          Once the disruptive technology becomes established, smaller-scale innovations and upgrades rapidly raise the technology’s performance on attributes that mainstream customers value.

           

          This is what Virto Group has achieved.

           

          After 15 years of research and development and over 450 screening units sold worldwide in industries ranging from mineral mining beneficiation to aggregates and fine metal powders.

          Virto Group has proven that the Virto X Line screening technology is a disruptive innovation.

           

          The Virto X Line is the only disruptive innovation

          in mechanical screening technology for the past 150 years.

           

          Different sets of values:

          • Up to 500Gs acceleration to the screening surface,
          • Highest efficiency and throughput per square meter of screening surface in the market,
          • Overtaking the market for hard to screen materials (from 20mm with 25% moisture content and below 1mm with up to 7 % moisture content).

           

          Will you join the evolutionary process of mechanical vibratory screening?

           

          Followers risk losing their competitive edge to other players in their industry.

          Find out for yourself and contact Virto Group.

          We welcome the opportunity to prepare a feasibility study and test your products in our dedicated test center for all your screening applications – ensuring the project is technically feasible and economically justifiable.

          Contact us on support@virtogroup.com

          VIRTO changes the screening game.

          YOU CAN RECEIVE OUR FREE ADVICE TO SELECT THE TYPE OF SIEVE MORE SUITABLE TO YOUR PROCESSING NEEDS, BY CONTACTING US




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