SELECTING BATCH-TYPE, FLUIDIZED BED

ENHANCED GRAVITY CONCENTRATING

EQUIPMENT

Many of Falcon’s customers have asked what to look for when selecting their enhanced gravity
concentration equipment. Those that take the time to do an in-depth technical review quickly
conclude that Falcon’s technology delivers superior performance based on a number of criteria:

Concentrating Surface Area (CSA)

This is the surface area inside the bowl of the machine. For machines creating the same
centrifugal field, the unit with the greatest concentrating surface area has the highest inherent
capacity. Falcon’s nomenclature recognizes this important parameter by including it right in the
model number. For example, Falcon's Model SB5200, with nominal bowl diameter of 50”, has a
concentrating surface area that is approximately 5126 square inches (the addition of the lip ring
adds to this). If the depth of the rotor were reduced, however, there would be a corresponding
reduction in surface area. It is incorrect to consider solely rotor diameter when making machine
comparisons. Just as with shaking tables, mineral jigs, cones and spirals, the larger the
concentrating surface area, the more capacity a machine has:

CSA Calculation:

A B
1 Dimensions SB5200
2 Diameter, top of retention zone (inches) 45.50
3 Retention zone slope length (inches) 10.00
4 Diameter, bottom of migration zone (inches) 43.50
5 Migration zone slop length (inches) 33.00
6 Diameter, bottom of migration zone (inches) 28.00
7 CONCENTRATING SURFACE AREA (sq. inches) 5126.31

CSA=1.5708*((B3*(B2+B4))+(B5*(B4+B6)))+(PI()*B6/4)
* Based on Formula for Frustum of a cone

Centrifugal Field (G’s)

Falcon Superbowl machines can be set to create virtually any centrifugal field up to 200 G's and
are designed from the ground up to withstand the loads created by large centrifugal fields. The
first concentrating machines capable of applying over 300 G's were constructed and tested by
Falcon over fifteen years ago. If the gold is very fine, Falcon will recover much more of it than
competitors by virtue of superior centrifugal field. This has been clearly established, not only in
plant conditions but also by many laboratories and researchers around the world. Please refer to
an independent technical paper by Professor Frenay of the University of Liege on Falcon’s Web
Site: www.concentrators.net. It is very persuasive and confirms that increasing centrifugal field
increases the recovery of fines.

9663 - 199A Street, Langley, British Columbia, Canada, V1M 2X7

Phone: (604) 888-5568 Fax: (604) 888-5521 Toll Free: 1-800-990-5568
Email: falcon@concentrators.net Internet: http://www.concentrators.net
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Variable Speed Drives (VFD’s)

Different conditions may require different speeds. All Falcon AutoPAC’s (or electronic controls)
have included variable frequency drives as standard equipment since 1989. Over a decade of
leadership in this area has led to reliable, user-friendly, and cost-effective control of the Falcon
machines all being included in the base pricing.
Purchasers should be wary of machines designed for 60 G’s being sped up with VFD’s.

Acceleration of Pulp
There tends to be a lot of slippage between the pulp being processed and the bowl of the
concentrating machine. This reduces the effective centrifugal field. In Falcon machines, there is
a low-cost impeller that accelerates the pulp. Although there is still some slippage, it is much less
than in devices with no impeller. Reducing the relative velocity between the bowl and the pulp
being processed also lessens wear on the expensive bowl parts.

Unit Capacity
Falcon has recently released its Model SB5200 Superbowl complete with 5200 in.2 concentrating
surface area and 100 HP electric motor. The 5200 shares many components with Falcon’s well-
proven Model C4000 so in reality it is not a “new” machine. With a conservative minimum
capacity of more than 240 t/h solids, it has the industry’s largest unit capacity.

Fluidization Water Demand

Falcon Superbowl Concentrators require fluidizing water to create a soft zone that free
gold can accumulate in. Only the top 1/3 of the bowl is fluidized. The smooth lower
2/3rd of the Falcon rotor allows the heavies to migrate towards the rotor wall before being
recovered in the fluidized riffles:

Canadian Patent No. CA2149978

Issued December 7, 1999

Note:

• Only top of rotor fluidized

• Impeller to accelerate pulp
• Spray bars to rinse concentrate

9663 - 199A Street, Langley, British Columbia, Canada, V1M 2X7

Phone: (604) 888-5568 Fax: (604) 888-5521 Toll Free: 1-800-990-5568
Email: falcon@concentrators.net Internet: http://www.concentrators.net
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ENHANCED GRAVITY CONCENTRATING
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On the other hand, early designs for this type of device fluidize the entire wall of the rotor. For
example, MacNicol obtained a patent in Australia in 1935. Other manufacturers have copied
MacNicol’s pioneering work:

Australian Patent No. 22,055/35

Issued April 2, 1935

Note:

• Entire wall of rotor fluidized

• “Center” discharge

By reducing the fluidized area, Falcon has reduced unit fluidization water demand to
unprecedented low levels.

Off-Line Time
The Falcon Superbowl machine must be taken off line periodically to rinse out the concentrate.
Falcon's AutoPAC control includes not only a variable frequency drive, but also a dynamic brake
that brings the rotor from concentrating speed to rinsing speed very quickly, usually <10 seconds.
Upon reaching rinsing speed, a high-pressure water spray is activated automatically. As the rotor
continues to turn very slowly, the concentrate is quickly and completely washed from the riffles.
High pressure minimizes rinse water demand. Once the concentrate is washed out, the rotor is
accelerated very smoothly back to concentrating speed and then the feed is started again. The
whole rinsing procedure usually takes < 1 minute and is very easy on the drive train.
Automated rinsing systems that involve coasting to rest followed by across-the-line starting may
experience premature failure of drive and electrical components and much longer off-line times.
In addition, rinsing systems based on bowl flooding have been known to cause water balance
problems.
Falcon’s off-line time is the shortest in the industry.

9663 - 199A Street, Langley, British Columbia, Canada, V1M 2X7

Phone: (604) 888-5568 Fax: (604) 888-5521 Toll Free: 1-800-990-5568
Email: falcon@concentrators.net Internet: http://www.concentrators.net
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Internal Pressurization
The Falcon Superbowl actually increases the pressure of the fluidizing water within the machine.
Water is introduced to the fluidized zone of the rotor through a hollow rotating shaft, and then
through spokes and hoses. The centrifugal field actually pumps the fluidizing water into the
fluidized zone at a higher pressure than where it is introduced to the non-rotating frame. This
pressurization effect is a function of bowl diameter and thus is most pronounced in the Falcon
Superbowl Model SB5200, a 240-t/h machine weighing 10 tonnes:

Rotor Bowl

Rotor Shaft

Pressure
Fluidization Water

Internal pressurization reduces the pressure at which fluidizing water must be delivered to
the Falcon machines.

Fluidization Water Injection Hole Plugging

With fluidized bed type concentrators, water is injected into the fluidized zone through relatively
small diameter holes. In the Falcon design, these holes are perpendicular to the bowl wall and are
as short as practical. It is well known that the tendency for holes of this type to plug with solids is
a direct function of their length. In addition to the Falcon holes being as short as possible, the
centrifugal acceleration is parallel with the holes as opposed to being more or less perpendicular.
Falcon machines are known for their lack of plugging problems.

Fluidization water Fluidization water

Centrifugal force

Rotation Centrifugal force Rotation

9663 - 199A Street, Langley, British Columbia, Canada, V1M 2X7

Phone: (604) 888-5568 Fax: (604) 888-5521 Toll Free: 1-800-990-5568
Email: falcon@concentrators.net Internet: http://www.concentrators.net
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Control Philosophy
Fluidization water injection holes become plugged even in the Falcon Superbowl over time.
Falcon controls fluidization water injection rate to its Superbowl machines with pressure. With
this strategy, the fluidization conditions around each open hole remain in a constant optimized
state. Falcon considered and rejected the strategy of injecting a constant total volume of water
over time since the conditions around each open hole change from being optimum when all of the
holes are open to very much less than optimum as holes become plugged. Further, open holes are
subjected to higher and higher velocities as more of the holes become plugged. In addition to
poor metallurgical performance, controlling flow rate and monitoring pressure creates a risk of
damage to the rotor from excessive velocity. Falcon’s strategy of controlling fluidization water
pressure and monitoring flow rate is clearly superior.

Conclusions
Falcon’s recent gains in market share have been achieved by delivering superior equipment at
realistic prices. Those that take the time to make even a cursory technical comparison can see
how Falcon has distinguished itself from competition.

9663 - 199A Street, Langley, British Columbia, Canada, V1M 2X7

Phone: (604) 888-5568 Fax: (604) 888-5521 Toll Free: 1-800-990-5568
Email: falcon@concentrators.net Internet: http://www.concentrators.net
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