XD48 Presentation

EXTENDED DUTY (XD48)
MAINTENANCE TRAINING
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
CONTACT INFORMATION
DON JANTZ
EMAIL: DON.JANTZ@FLSMIDTH.COM
DIRECT: +1 604 455 1498
MOBILE: +1 604 614 4660
2
HISTORY
▪ Established in 1980 Knelson specializes in
“gravity concentration” and has become
the world leader in this technology
▪ Our corporate Head Office in Langley,

British Columbia houses our
manufacturing, sales, engineering, and
research and development
▪ We have Agents world-wide to offer

customer and machine support
3
WORLDWIDE
DISTRIBUTION
4
OUTLINE
▪ How it Works
▪ Preventative Maintenance
▪ Major Maintenance
▪ Rotor removal
▪ Bearing replacement
5
HOW IT WORKS
6
What do Batch Knelsons
Recover?
▪ Free gold, the “yellow” stuff
▪ Free silver
▪ Silver/gold alloys
▪ These are called “Gravity

Recoverable Gold” or GRG
7
WHY GRAVITY?
▪ Free gold recovered in grinding and
poured into a bar of dore gives
downstream benefits
▪ Increase in overall recovery
▪ Increase in gold payment
▪ Smaller downstream plant size
▪ Less strips
▪ Less loading on carbon
▪ Improved security
8
APPLICATIONS
▪ Recovery of heavy minerals and

metals from a lighter background
material using ‘centrifugal’ forces
▪ Primary application is free gold

recovery from gold mill grinding
circuits
9
APPLICATIONS
▪ Also used in heavy mineral recovery from
base metal grinding circuits for platinum,
silver, copper, etc
▪ Ideal for tailings re-treatment
▪ Other applications: tin recovery, coal

cleaning, iron ore recovery, industrial
minerals, floatation concentrates
10
WHEN SHOULD A KNELSON
BE USED?
▪ Samples from alluvial deposit contain
traces gold
▪ When visible gold has been detected
▪ When free gold losses have been

detected in mill tailings streams
11
WHEN SHOULD A KNELSON
BE USED?
▪ High gold “inventory” has been detected
in any closed grinding circuit
▪ When gold has been detected when

relining mills, cleaning sumps and at
other collection points
12
KNELSON
CONCENTRATORS
HOW IT WORKS
13
MACHINE OVERVIEW
FEED SLURRY
FLOW
CONCENTRATE
CONE
CONCENTRATE WATER JACKET

LAUNDER
TAILINGS
LAUNDER
DRIVE SYSTEM
ROTARY UNION
14
HOW IT WORKS
▪ A Knelson Concentrator can best be

described as a high speed centrifuge
that uses an advanced fluidization
process to recover fine gold
▪ During operation entire rotor

assembly spins clockwise at a pre-
determined speed to create a
centrifugal force of 60-200x gravity
15
HOW IT WORKS
▪ It is important to realize that the

concentrator works on a repeating
batch “cycle”
16
HOW IT WORKS
▪ Fluidization water flows
into the water cavity
through the rotor shaft
▪ Pressure forces water

through the fluidization
holes into the
concentrating rings
▪ The concentrator starts

up and the rotor reaches
operating g force
17
HOW IT WORKS
▪ The injection of
ROTOR ROTATION
fluidization
water is
CONCENTRATING RING
tangential and
counter
clockwise to the
WATER CHAMBER
rotation of the
ROTOR HOUSI NG cone
18
CLOCKWISE ROTATION
VIEWED FROM THE TOP
19
HOW IT WORKS
▪ Feed slurry enters

unit and is
distributed from
deflector pad
▪ Centrifugal force
drives it outward to
the cone wall
20
HOW IT WORKS
▪ Starting from the

bottom the solids
fill each ring
▪ Once rings reach

capacity a
concentrating bed is
formed
21
HOW IT WORKS
▪ The fluidisation water
expands the bed,
enabling fine gold
particles to “sink” into
the porous
concentrate bed
▪ Concentration of
heavy particles will
continue, while light
particles will be
rejected
22
HOW IT WORKS
▪ Duration of
concentrating cycle
varies depending on
application
▪ At the conclusion of
the concentrating
cycle the bed
material is flushed
out the concentrate
launder
23
HOW IT WORKS
▪ Maximum screen opening size for slurry
feed is ~6mm or ¼ inch (2mm is
recommended)
▪ Concentrator can recover particles as fine

as 25 microns
▪ The Knelson accepts feed slurry as dense

as 75% solids; 50% to 70% is most
common
24
Fluidization Water Flow
▪ Controlled by piping train,

instruments, and PLC
XD48 AUTO PIPING
A
B C
D
A ACTUATOR & POSITIONER

B PRESSURE TRANSMITTER
F C
D
DIFFERENTIAL PRESSURE TRANSMITTER
MAGNETIC FLOW TRANSMITTER
E SEGMENTED BALL VALVE
F FILTER SCREEN
AUTOMATED CYCLE
▪ When the concentrator is started the

computer turns on the fluidization water
▪ After water flow is achieved the motor will

start. Once the motor and water pressure
reaches their set points the feed slurry
will be turned on
▪ Once the predetermined concentrate cycle

time has elapsed the feed slurry is shut off
27
AUTOMATED CYCLE
▪ Then the motor is shut down, as the

spinning rotor assembly slows down the
fluidizing water flow is ramped down
▪ Once machine stops, fluidization water is

turned back on to flush the concentrate
into the concentrate launder
28
KNELSON
CONCENTRATORS
SAFETY
CONSIDERATIONS
29
CONCENTRATOR
ISOLATION
▪ There are up to 5 energy sources
▪ Three phase power (motor and rotation)

▪ Single phase power (instruments and PLC)
▪ Water
▪ Air
▪ Feed
▪ Each of these requires isolation

30
SAFETY
CONSIDERATIONS
▪ NEVER operate concentrator with
inspection door open or unsecured
▪ NEVER operate unit with

emergency stop disabled or not
functioning
31
SAFETY
CONSIDERATIONS
▪ ALWAYS wear your Personal
Protective Equipment (PPE) when
working on or near concentrator
▪ When checking for lining wear be

cautious of possible sharp metal
edges
32
SAFETY
CONSIDERATIONS
▪ ALWAYS use an anti-seize
compound on fasteners, and be
sure fasteners are proper thread
type
▪ NEVER use impact tools on

stainless steel fasteners
33
SAFETY
CONSIDERATIONS
▪ NEVER weld or torch cut on

machine
▪ NEVER run concentrator without

water flow
34
KNELSON
CONCENTRATORS
PREVENTATIVE
MAINTENANCE
PREVENTATIVE
MAINTENANCE
▪ Lubrication
▪ Water Filter/Strainer
▪ Wear areas inspection
▪ Drive components
▪ Cone cleaning
KNELSON
CONCENTRATORS
LUBRICATION
AREAS REQUIRING
LUBRICATION
BEARING CAPS (4)
BEARINGS (2)
MOTOR
ROTARY UNION (1)

EXAMPLE OF GREASE NIPPLE
CONFIGURATIONS
Bearing Caps Bearing Inserts Rotary Union

LUBRICATION SCHEDULE
▪ Bearing-End Cap: 6 grams every Day
▪ Rotary Union: 2 grams every Day
▪ Bearing-Insert: 4 grams every Day
▪ Re-greasing to be performed while unit is

running, and at operating temperature
Values for XD48 Concentrator

PILLOW BLOCK GREASING
REQUIREMENTS
Model Bearing end caps Bearing inserts
Interval Quantity Interval Quantity

hour gram hour gram
XD20 40 3 40 1
XD30 40 4.5 40 2
XD40 Lower 40 6 40 3
XD40 Upper 40 8 40 5
XD48 40 10 40 7.5
41
GREASE EQUIVALENCY LIST
Grease Brand Grease Name
*Shell GadusRail S2
Mobil Unirex N3
Mobil Mobilgrease XHP 223
FAG/Schaeffler Arcanol VIB3
* Knelson recommended grease
42
MOTOR SPECIFICATIONS
▪ Standard Service:
Maximum ambient temperature is 40º C.
Atmosphere clean, little corrosion.
▪ Severe Service:
Maximum ambient temperature is 50º C.
Atmosphere moderate dirt, corrosive.
43
MOTOR SPECIFICATIONS
▪ Extreme Service:
Ambient temperature >50º C or class H insulation.*
Atmosphere severe dirt, abrasive dust, corrosive.
* Special high temperature grease recommended
44
MOTOR LUBRICATION
SCHEDULE
Horse Power Interval Weight of
grease
40 hp 3700 hrs. (5 months) .76 (oz) / 20.1 (grams)
75 hp 1750 hrs. (2.5 months) .81 (oz.) / 23 (grams)
100 hp 1750 hrs. (2.5 months) 1.25 (oz) / 33 (grams)
Standard service shown
CAUTION: Many bearing failures occur by forcing bearings to push surplus grease
around, generating excess heat and resulting in the softening of the grease and
eventual breakdown of the lubricating film. DO NOT OVER GREASE the bearings.
45
MOTOR GREASE
EQUIVALENCY LIST
Grease
*Polyrex EM (Mobile)
Texaco Polystar
Rykon Premium #2
Pennzoil Pen 2 Lube
Cheveron SRI
* Recommended grease
46
AUTOMATED
LUBRICATION SYSTEMS
▪ Consists of an
automatic grease
pump and reservoir
supplying a
manifold (injectors)
which distributes
the grease to the
bearings
47
AUTOMATED
LUBRICATION SYSTEMS
▪ Injector location
on upper frame
under tailings
launder
▪ Grease nipples can

still be utilized if
auto lube fails
AUTOMATED
LUBRICATION SYSTEMS
• Grease
nipples can
still be utilized
if auto lube
system fails
49
AUTOMATED
LUBRICATION SYSTEMS
▪ The grease
reservoir is filled
manually from the
bottom using a
plunger and
grease cartridges
▪ The grease
reservoir must
never be filled by
removing the lid
and filling from
the top
50
KNELSON
CONCENTRATORS
FLUIDIZATION
WATER
51
FLUIDIZATION WATER
FILTER
▪ 30, 50 (standard) or
100 mesh self-
cleaning filter is
designed to remove
loose particles of rust
and other suspended
contaminates
▪ Rotational flow forces

suspended particles to
settle into debris basin
1. FILTER HOUSING
2. DEBRIS BASIN
3. BALL VALVE
4. CLAMP
5. TOP GLAND RUBBER
6. PLUG
7. SPIN PLATE
8. SCREEN COLLAR
9. SCREEN
10. LOWER GLAND RUBBER
FLUIDIZATION WATER
FILTER
▪ Designed to cope with
SMALL quantities of solids
▪ NOT designed as a catch all
for poor water quality
▪ Remove weekly for

cleaning
▪ Ensure assembled correctly
FLUIDIZATION WATER
▪ Normal concentrating flow rates
▪ 230 to 295 US gpm or 52 to 67 m3/hr (G6 Cone)
▪ 180 to 230 US gpm or 41 to 52 m3/hr (G5 Cone)
▪ 125 to 190 US gpm or 28.4 to 43 m3/hr (G7 Cone)
▪ Normal flushing flow rate is 10% to 20% higher
55
FLUIDIZATION WATER
▪ Normal concentrating operating pressure

range is 5 to 12 pounds per square inch or
34.5 to 69 kilopascal
▪ Normal filter differential pressure range is 4

to 8 pounds per square inch or 28 to 56
kilopascal
56
FLUIDIZATION WATER
Pressure Gauges & Readings
▪ Depending on concentrator age and model

Knelson uses two different pressure gauges
▪ Gauge Pressure (PSIG)
▪ Absolute Pressure (PSIA)
57
ROTARY UNION
MECHANICAL SEAL
C ▪ A: Rotating seal
B
A face
▪ B: Stationary seal
face
▪ C: Stationary spring
assembly
58
VIEW OF ROTARY UNION
▪ Proper water
flow
▪ Keep Union
clean
▪ Lubricate
59
KNELSON
CONCENTRATORS
WEAR AREAS
INSPECTION
60
CRITICAL WEAR ZONES
1 6
Zone Description Inspection Interval
2 (hrs)
7 1 Feed Tube 1000 (1 month)
2 Concentrating cone top 500 (2 weeks)

3 flange
3 Tailings launder: bottom 2000 (3 months)
4 8 surface
4 Wear cone 500 (2 weeks)
5 5 Deflector pad: outer edge 500 (2 weeks)

9 and supports
6 Tailings launder cover 500 (2 weeks)
impact zone
7 Concentrating cone lower 500 (2 weeks)
rings
8 Deflector pad: centre 500 (2 weeks)
9 Tailings launder: outlet 2000 (3 months)
61
CRITICAL WEAR ZONES
D Item Description
B A Cone Flange
C B Concentrating Rings
C Wear Cone
D Feed Deflector Pad
E Feed Deflector Pad
E
62
CRITICAL WEAR ZONES
▪ Use a wear
indicator tool to
measure the
extent of wear in
the concentrate
cone
63
CRITICAL WEAR ZONES
▪ The indicator is
positioned so the
lead edge is
resting against
the back of the
concentrate cone
64
CRITICAL WEAR ZONES
1. Ensure correct orientation of 2. Insert the wear indicator tool into

the wear indicator tool (as the ring and use the markings to
shown) determine the level of wear on cone
65
WEAR PARTS
▪ Replace worn parts before structural
damage can occur
▪ Most critical
▪ Deflector pad
▪ Wear cone
▪ These parts protect the urethane

concentrating cone
66
AREAS OF WEAR
▪ Deflector pad
wear
67
AREAS OF WEAR
▪ Deflector pad
wear
68
AREAS OF WEAR
▪ Example of
extreme wear
69
AREAS OF WEAR
▪ Example of
extreme wear
70
AREAS OF WEAR
▪ Example of
extreme wear
71
AREAS OF WEAR
OTHER WEAR AREAS
▪ Check between the
rotor housing lip and
the inner wall of the
tailings launder for an
accumulation of solids
▪ Clean the entire
circumference to
extend life of both the
rotor lip and launder
wall
73
KNELSON
CONCENTRATORS
CONE CLEANING
74
CONE CLEANING
INTERVAL
▪ Typical cone cleaning interval can
be as infrequent as every 6 months,
to as often as every 1 week
▪ Two major drivers for cone cleaning
▪ Solids
▪ Scale
75
SOLIDS
DE-SILTING
▪ Solids tend to build NOZZLES
up in the top of the

water jacket
▪ De-silting holes can
manage small
amounts of solid
only
▪ Solids buildup in the
water jacket can
lead to rotor
imbalance and poor
recovery
76
SOLIDS
DE-SILTING
NOZZLES
▪ Large thickener upsets can

cause very large amounts of
solids to build up in the water
jacket, normally at the top
▪ This can cause the fluidization

process to stop and causes a
large loss in recovery
▪ The only real way to manage

this degree of solids is to not
have them enter the machine
77
SOLIDS
▪ Solids also
directly affect
the life of the
rotary union
ROTARY UNION
78
SCALE
▪ Scale builds up in
all areas of the
water jacket, on
the cone surface,
and in the
fluidization holes
▪ Anti-scaling
reduces the
amount of scale
79
OPERATING PRESSURE
▪ As either solids or
scale blind the
fluidization holes, the
concentrator will start
to increase in
operating pressure
▪ First the warning
pressure will be
reached, then the
concentrator will shut
down on high
operating pressure
▪ At this point the cone
must be removed for
cleaning
80
CONE CLEANING
MECHANICAL
▪ Use the special
tool and bits
supplied with your
machine to clear
the fluidization
holes
▪ NEVER use a
power drill to
clean the
fluidization holes
81
CONE CLEANING
Matrix Cone Model Shown

82
KNELSON
CONCENTRATORS
PREVENTIVE
MAINTENANCE
83
DAILY PM SCHEDULE
▪ GREASE bearing end caps, bearing inserts
and rotary union. (Refer to the manual for
the amounts)
▪ VISUALLY INSPECT for:

▪ unusual or excessive vibration
▪ water leaks
▪ slurry spillage
84
DAILY PM SCHEDULE
▪ Open Filter Drain for 3 seconds and
check for solids or discoloration
▪ Check that fluidizing water

pressure and filter differential
pressures are indicating normally
▪ Normal differential pressures are 4

to 8 pounds per square inch or 28
to 56 kilo pascal
85
WEEKLY PM SCHEDULE
▪ Check feed screen to be sure screen

is not blinded off and all water
sprays are unplugged and
positioned properly
▪ Remove lids and observe operation.

Check shutdown, flush and start-up
sequence
86
WEEKLY PM SCHEDULE
▪ Isolate (Lock Out) unit and check by
probing with wire/rod that the 12 x 1/8”
(3mm) silt bleed nozzles (outboard of the
concentrate cone fastening bolts) are
clear
▪ At the same time look at and feel the

inside of the rings of the concentrate
cone for scale build up and polyurethane
wear. Also check deflector pad and wear
cone
87
WEEKLY PM SCHEDULE
▪ Remove filter screen and clean,

ensure proper reassembly
88
MONTHLY PM SCHEDULE
▪ Wear areas in the concentrator

must be closely inspected once a
month
▪ These areas include the deflector

pad, wear cone, wear skirt and
concentrate cone
89
MONTHLY PM SCHEDULE
▪ The bottom rings of the cone will

wear slightly, but excessive wear
will require attention, as will any
areas where the polyurethane or
Linatex® lining is thin. If any metal
is exposed it must be replaced
immediately
90
MONTHLY PM SCHEDULE
▪ Check the belt tension

every month and
inspect drive system
▪ Check for wear on the

sheaves, in particular if
there has been slurry
spillage on the drive
system
91
PREVENTIVE
MAINTENANCE
▪ After a concentrate cone change apply
fluidization water and test run unit.
▪ NOTE: Never run machine without fluidizing

water being applied.
▪ If the rotating union is leaking water, it

should be replaced.
92
PREVENTIVE
MAINTENANCE
▪ Recommend dedicated storage for

special tools, small parts, grease
guns, etcetera in a location close to
the concentrators
93
KNELSON
CONCENTRATORS
TROUBLESHOOTING
94
IMPROPER SHUTDOWN
▪ Will cause recovery loss and/or equipment
damage/inefficiencies
▪ Shutting off or reducing the fluidization water

below recommended flow rates while cone is
rotating can cause the fluidization holes to plug
▪ Shutting off the machine while fluidization water

is at full flow will cause small amounts of
concentrate to be lost to tailings
95
TYPICAL MAINTENANCE
ISSUES
▪ Concentrate cone scale cleaning
▪ Bearing lubrication
▪ Drive belt inspections and

adjustments
96
TYPICAL MAINTENANCE
ISSUES
▪ Piping runs and angles
▪ Inspection for lining wear
▪ Rotor balance (excess vibration)
97
INSTALLATION RELATED
PROBLEMS
▪ Design of structural support
▪ Must be allowed to oscillate on

vibration isolators
▪ Vibration harmonics
98
ROTOR BALANCE
▪ If encountering problems with new

cone rotate one bolt hole at a time
till optimal balance is achieved
▪ Water overpressure can damage

concentrate cone causing an
imbalance
99
ROTOR BALANCE
▪ A Concentrate cone installed improperly
will cause imbalance over time as
concentrate packs in uneven pockets
▪ Water leakage from the hub water seal or

from around rotor housing flange. In
extreme cases because of worn silt holes
100
TROUBLESHOOTING
EXCESSIVE VIBRATION
▪ Check for concentrate build up in the cone rings
▪ Check for oversize material in the concentrate

rings as it may indicate problems with screening
▪ Excessively worn parts will cause the rotor

assembly to be unbalanced. Such as lining wear
so extreme that metal is visible
101
TROUBLESHOOTING
EXCESSIVE VIBRATION
▪ Worn bearings
▪ Carcass of drive belt damaged or

separating
▪ Vibration isolator damaged or

separating
102
TROUBLESHOOTING
EXCESSIVE VIBRATION
▪ Hard piping not allowing machine

to move properly
▪ Screen hopper on unit using non-

screen hopper vibration isolators
103
TROUBLESHOOTING
EXCESSIVE WATER PRESSURE
▪ Concentrating cone fluidization

holes plugging off
▪ Ball valve improperly set
▪ Check ICS set points
104
TROUBLESHOOTING
PREMATURE WEAR
▪ Over feeding designed tonnage can

result in the material being pushed
under the deflector pad and
creating a grinding action instead
of being forced out to the cone wall
105
TROUBLESHOOTING
PREMATURE WEAR
▪ Feed particles oversized
▪ Tramp steel >6 mm not being

eliminated from the feed
106
MAINTENANCE
CHECKPOINTS
▪ Check condition of RPM
sensors for spacing and
damage from slurry
accumulating on drive
sheave
▪ Instrumentation should
be re-calibrated every
2 years
107
KNELSON
CONCENTRATORS
XD48
CONCENTRATE CONE
REMOVAL
108
CONCENTRATOR
ISOLATION
▪ There are up to 5 energy sources
▪ Three phase power (motor and rotation)
▪ Single phase power (instruments and PLC)
▪ Water
▪ Air
▪ Feed
▪ Each of these requires isolation
109
CONCENTRATING CONE
REMOVAL
▪ Remove lid
assembly from
the tailings
launder
110
CONCENTRATING CONE
REMOVAL
▪ Remove all bolts

on top flange of
concentrate cone
CAUTION: Isolate and lock out all power sources, water lines,
and feed lines, before performing maintenance on the machine.
111
CONCENTRATING CONE
REMOVAL
▪ Insert bolts into
threaded lifting holes
on top flange of
concentrate cone and
tighten down equally
to pry cone out from
rotor housing
112
CONCENTRATING CONE
REMOVAL
▪ Remove bolts and install
lifting eyes into threaded
holes to remove
concentrating cone
Model Lifting Eye Bolts
Qty Size (mm) Size (in)
XD20 2 n/a 1/2"
XD30 2 n/a 1/2"
XD40 3 M12 n/a
XD48 3 n/a 5/8”
48 MATRIX 3 M16 n/a
113
CONCENTRATING CONE
REMOVAL
▪ Lift concentrate
cone out of
rotor housing
114
KNELSON
CONCENTRATORS
XD48
CONCENTRATE CONE
INSTALLATION
CONCENTRATE CONE
INSTALLATION
▪ Inspect silt
nozzles and
clean or
replace if
necessary
CONCENTRATE CONE
INSTALLATION
▪ Ensure hub seal groove
and O-ring located at
bottom of concentrate
cone are in good
condition
▪ Clean hub and flange
▪ Grease O-ring
117
CONCENTRATE CONE
INSTALLATION
▪ Ensure concentrate
cone gasket is in good
condition
▪ Replace if necessary
CONCENTRATE CONE
INSTALLATION
▪ NOTE: Be sure
lifting eye bolts are
completely
threaded into metal
flange below
urethane on
concentrate cone
119
CONCENTRATE CONE
INSTALLATION
▪ Ensure locating dowel pin
on underside of
concentrate cone flange
lines up with receiving
hole in top of rotor
housing
Note: Hard shell concentrate cones only

120
CONCENTRATE CONE
INSTALLATION
▪ Install
concentrate cone
121
CONCENTRATE CONE
INSTALLATION
▪ Apply anti-seize
compound to
concentrate cone
bolts and torque in a
criss-cross pattern to
50 foot pounds or 68
Newton-meters
122
CONCENTRATE CONE
INSTALLATION
Model Top Flange Bolts
Qty Size Torque
mm In N*m Ft-lb
XD20 8 n/a 1/2" 54 40
XD30 12 n/a 1/2" 54 40
XD40 24 M12 n/a 61 45
XD48 36 n/a 5/8” 68 50
123
CONCENTRATE CONE
INSTALLATION
▪ Example of Anti-
Seize Lubricant
124
MATRIX CONE ASSEMBLY
125
▪ Install O-ring
on lower cone
Deflector Pad
126
▪ Install wear
cone and
deflector pad
into lower cone
127
▪ Install M16
bolts to secure
wear cone and
deflector pad
to lower cone
but do not
tighten
Note: XD48 values shown
CAUTION: Do not use impact wrenches on fasteners. Impact wrenches can cause galling and
destroy threads. Always lubricate threads with Never-Seez® or equivalent anti-seize compound.
128
▪ Remove M16 bolts

one at a time and
apply a bead of
silicone to threads
and then reinstall
129
▪ Torque M16
bolts to 50 foot
pounds or 68
Newton meters
CAUTION: Do not use impact wrenches on fasteners. Impact wrenches can cause galling and destroy
threads. Always lubricate threads with Never-Seez® or equivalent anti-seize compound.
130
▪ Lift upper cone

onto lower cone
and install M10
bolts
CAUTION: Do not use impact wrenches on fasteners. Impact wrenches can cause galling and
destroy threads. Always lubricate threads with Never-Seez® or equivalent anti-seize compound.
131
▪ Torque M10
bolts to 20 foot
pounds or 27
Newton meters
132
GENERATION CONE
ASSEMBLY
133
BELT TENSIONING
▪ Drive belt tension
can be measured
using an
electronic
tensioner or with
a manual spring
tensioner*
*Supplied by Knelson
134
KNELSON
CONCENTRATORS
XD48
AREAS OF
FLUIDIZATION
PRESSURE LOSS
AREAS OF FLUIDIZATION
PRESSURE LOSS
▪ Fluidization water
surging from open
bolt hole
▪ To repair install
missing bolt
136
PRESSURE LOSS
▪ Fluidization water
squirting from
unseated or bent
concentrate cone
flange
▪ To repair replace
flange gasket and
torque bolts
137
PRESSURE LOSS
▪ If concentrate cone
flange is damaged a
bead of silicone can
be applied to rotor
housing to seal cone
138
PRESSURE LOSS
▪ A damaged hub
seal O-ring or
missing O-ring can
cause pressure
loss
139
KNELSON
CONCENTRATORS
NEW DESIGNS
140
APPLICATION
SPECIFIC CONES
▪ Key considerations used in the

customization process are:
141
MATRIX CONE
▪ Modular design – easy replacement

of consumable wear parts
▪ No return of used cone shell
required
▪ Large bore fluidization holes
▪ Process water use
▪ Reduced fluidization hole
cleaning frequency (5x
improvement)
▪ Available in:
▪ QS Series: 30”, 40”, 48”
▪ XD Series: 30”, 40”, 48”
142
MATRIX CONE
▪ Has larger holes angled at a shallower
angle
▪ Should result in less hold blinding and

longer intervals between cleaning
▪ Application specific fluidization hole

patterns
▪ Metallurgical recovery is equivalent or

superior to Standard Generation Cone
143
CONE ADVANCEMENTS
▪ Old drilling procedure ▪ New drilling procedure
144
CONE ADVANCEMENTS
145
CONE ADVANCEMENTS
146
KNELSON
CONCENTRATORS
EQUIPMENT &
ACCESSORIES
OPTIONS
147
KNELSON ACCESSORIES
▪ Cone cleaning
stands
148
KNELSON ACCESSORIES
▪ Mineral Tables
149
THE END
AS YOU CAN
CLEARLY SEE IN
SLIDE 397… “POWERPOINT”
POISONING.
150

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EXTENDED DUTY (XD48)

▪ Our corporate Head Office in Langley,

▪ We have Agents world-wide to offer

▪ These are called “Gravity

▪ Recovery of heavy minerals and

▪ Primary application is free gold

▪ Ideal for tailings re-treatment

▪ Other applications: tin recovery, coal

▪ When visible gold has been detected

▪ When free gold losses have been

▪ When gold has been detected when

CONCENTRATE WATER JACKET

▪ A Knelson Concentrator can best be

▪ During operation entire rotor

▪ It is important to realize that the

▪ Pressure forces water

▪ The concentrator starts

▪ Feed slurry enters

▪ Starting from the

▪ Once rings reach

▪ Concentrator can recover particles as fine

▪ The Knelson accepts feed slurry as dense

▪ Controlled by piping train,

A ACTUATOR & POSITIONER

▪ When the concentrator is started the

▪ After water flow is achieved the motor will

▪ Once the predetermined concentrate cycle

▪ Then the motor is shut down, as the

▪ Once machine stops, fluidization water is

▪ Three phase power (motor and rotation)

▪ Each of these requires isolation

▪ NEVER operate unit with

▪ When checking for lining wear be

▪ NEVER use impact tools on

▪ NEVER weld or torch cut on

▪ NEVER run concentrator without

BEARING CAPS (4)

ROTARY UNION (1)

Bearing Caps Bearing Inserts Rotary Union

▪ Rotary Union: 2 grams every Day

▪ Bearing-Insert: 4 grams every Day

▪ Re-greasing to be performed while unit is

Values for XD48 Concentrator

Interval Quantity Interval Quantity

* Knelson recommended grease

* Special high temperature grease recommended

75 hp 1750 hrs. (2.5 months) .81 (oz.) / 23 (grams)

100 hp 1750 hrs. (2.5 months) 1.25 (oz) / 33 (grams)

Standard service shown

▪ Grease nipples can

▪ Rotational flow forces

▪ Remove weekly for

▪ 230 to 295 US gpm or 52 to 67 m3/hr (G6 Cone)

▪ 180 to 230 US gpm or 41 to 52 m3/hr (G5 Cone)

▪ 125 to 190 US gpm or 28.4 to 43 m3/hr (G7 Cone)

▪ Normal flushing flow rate is 10% to 20% higher

▪ Normal concentrating operating pressure

▪ Normal filter differential pressure range is 4