KNELSON CONCENTRATORS

INTRODUCTION

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 26 agents world-wide to offer customer
and machine support.

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.

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.

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.

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.

TYPICAL GRAVITY CIRCUIT

Take 10% to 50% cut
of cyclone U/F.
+2 mm

SAG
Mill
Ball
Mill

KC
Conc. to
gold room

KNELSON CONCENTRATORS
MACHINE OVERVIEW

MACHINE OVERVIEW
The Concentrate Cone.
The Rotor Housing/Shaft & Bearings.
The Tails Launder/Upper Frame.
The Concentrate Launder.

INTERIOR CUT-AWAY VIEW

CONCENTRATE
CONE

FEED
SLURRY
FLOW

DE-SILTING
HOLES

FLUIDIZATION
HOLES

CONE RING

CONCENTRATING
BED

WATER
CAVITY
FLUIDIZATION
WATER FLOW

MACHINE OVERVIEW
The Lower Frame.
Drive Sheaves & Belt.
The Water Filter and Rotary Union.
The Drive Motor & Instrumentation.

KNELSON CONCENTRATORS
HOW IT WORKS

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 60x gravity.

HOW IT WORKS

Conventional
concentrating device
examples are jigs,
shaking tables and
sluice boxes. They
operate at only 1x
gravity.

HOW IT WORKS

Rotational forces
amplify differences in
the specific gravity of
the fine gold particles
and waste minerals.

HOW IT WORKS

The concentrate cone is urethane lined and

incorporates a series of rings increasing in
diameter from the bottom to the top.
Around the circumference of each ring are
precisely sized, and numbered fluidization
holes.

HOW IT WORKS

ROTOR ROTATION

CONCENTRATING RING

WATER CHAMBER
ROTOR HOUSI NG

This injection is
tangential and
counter clockwise to
the rotation of the
cone.

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.

HOW IT WORKS

Feed slurry enters unit

and is distributed from
deflector pad.
Centrifugal force
drives it outward to
the cone wall.

HOW IT WORKS

Starting from the

bottom the solids fill
each ring.
Once rings reach
capacity a
concentrating bed is
formed.

HOW IT WORKS
Water injected from water cavity fluidizes the
bed.
Optimum fluidization occurs when inward flow
of water through the bed balances with the
outward force of the solids.

HOW IT WORKS
This enables fine gold
particles to sink into
the porous concentrate
bed.
Concentration of heavy
particles will continue,
while light particles will
be rejected.

CLOCKWISE ROTATION
VIEWED FROM THE TOP

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.

HOW IT WORKS
Maximum screen opening size for slurry feed is
~6mm or inch .
Excellent recovery is maintained for particles
as small as 25 microns.
The Knelson accepts feed slurry as dense as
80% solids; 50% to 70% is most common.

OPERATIONAL OPTIMIZATION

OPERATIONAL OPTIMIZATION

AUTOMATED CYCLE
When the concentrator is started the computer
turns on the fluidization water.
After after water pressure and flow are achieved
the motor will start. Once the motor reaches a
set speed the feed slurry will be turned on.
Once the predetermined concentrate cycle time
has elapsed the feed slurry is shut off.

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 gold concentrate
into the concentrate launder.

AUTOMATED CYCLE
13
3

14

16

9
10

11
12

15

17

IMPROPER SHUTDOWN
Will cause recovery loss and/or equipment
damage/inefficiencies.
Shut off or reducing by the wrong amount of
fluidization water while cone is rotating will
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.

IMPROPER SHUTDOWN
Depending on installation a timer maybe
required to allow feed to clear pipe before
concentrator starts flush cycle.
Fluidization water should be shut off when
rotor stops.

KNELSON CONCENTRATORS
PARTS OF A KCXD48
KNELSON
CONCENTRATOR

XD48 MACHINE

XD48 ROTOR SECTION VIEW

LIDS REMOVED

WEAR SKIRT REMOVED

FLEX*FLO INNER CONE

FLEX*FLO INNER CONE

FLEX*FLO INNER CONE

FLEX*FLO INNER CONE

FLEX*FLO INNER CONE

FLEX*FLO INNER CONE

FLEX*FLO INNER CONE

INNER CONE

INNER CONE

INNER CONE

INNER CONE

DEFLECTOR PAD & WEAR

CONE
Wear Cone

Deflector Pad

DEFLECTOR PAD & WEAR

CONE

DEFLECTOR PAD & WEAR

CONE

OUTER BOWL / CON LAUNDER

OUTER BOWL

OUTER BOWL

OUTER BOWL

OUTER BOWL

PORTED HUB

BEARINGS

ROTOR ASSEMBLY

CONCENTRATE LAUNDER

CONCENTRATE LAUNDER

DRIVEN PULLEY

BELT GUARD

GREASE LINES

ROTATING UNION

ROTATING UNION

KNELSON CONCENTRATORS
SAFETY CONSIDERATIONS

SAFETY CONSIDERATIONS
ALWAYS LOCK OUT/ISOLATE electrical
and water sources for machine as per mine-site
policy.
ALWAYS ensure rotating assembly has come
to a complete stop when shutting down
machine.

SAFETY CONSIDERATIONS
NEVER operate concentrator with inspection
door open or unsecured.
NEVER operate unit with emergency stop
disabled or not functioning.

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.

SAFETY CONSIDERATIONS

ALWAYS use an anti-seize compound on

fasteners, and be sure fasteners are proper
thread type.
NEVER weld or torch cut on machine.

SAFETY CONSIDERATIONS

NEVER run concentrator without water flow.

NEVER use impact tools on stainless steel
fasteners.

KNELSON CONCENTRATORS
FLUIDIZATION WATER

FLUIDIZATION WATER
Normal concentrating flow rate is 300 to 450
US gal. per min. or 68.1 to 102.2 m3/hr (G4
Cone).
Normal concentrating flow rate is 180 to 270
US gal. per min. or 40.9 to 61.3 m3/hr (G5
Cone).
Normal flushing flow rate is 10% to 20%
higher.

FLUIDIZATION WATER

Normal concentrating operating pressure range

is 9 to 13 pounds per square inch or 62 to 90
kilo pascal.
Normal filter differential pressure range is 4 to
8 pounds per square inch or 28 to 56 kilo
pascal.

FLUIDIZATION WATER
Pressure Gauges & Readings
Depending on concentrator age and model
Knelson uses two different pressure gauges.
There is Gauge Pressure (PSIG).
There is Absolute Pressure (PSIA).

FLUIDIZATION WATER FILTER

30 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

ROTARY UNION
MECHANICAL SEAL
A B

A: Rotating seal face.

B: Stationary seal
face.
C: Stationary spring
assembly.

CONE SCALING
The biggest maintenance concern is the scaling
of the concentrating cone from untreated
fluidization water that precipitates calcium
carbonate.
Most gold mills use a filtered process water as
the concentrator fluidization water.

CONE SCALING
Precipitation of the carbonate salts results most
often either from energy change or pH shock or
a combination.
pH shock occurs when the fluidization water
meets the high pH (because of lime addition)
slurry inside the concentrate cone.

CONE SCALING
Scale will build on the edges of the rings, this
can cause recovery losses and needs to be
addressed with regular cleaning but is not too
serious for the operation of the Knelson.
Energy change can be any form, (heat) such as
strip circuits, (pressure) such as filter presses,
(agitation) such as pumps and the Knelson
Concentrator.

CONE SCALING

Scale formed from the agitation is much more

serious for the Knelson, because of its
formation in the fluidization holes and around
the outer diameter of the cone.

CONE CLEANING
MECHANICAL
Use the special tool
and bits supplied
with your machine to
clear the fluidization
holes.
NEVER use a power
drill.

CONE CLEANING
BIO-DEGRADABLE DESCALER
Knelson descaler
removes scale in less
time and without the
hazards of chemical
acids.
Cleaning usually
takes 4 hours in a
50% solution of
water and descaler.

CONE CLEANING
CHEMICAL
A dunk tank and
agitator used at
Alumbrera for acid
cleaning concentrate
cone.
Cleaning usually takes
6 hours in a weak (up to
10%) solution of
sulphuric acid.

CONE CLEANING

Example of weld
failure from
hydrochloric acid.

KNELSON CONCENTRATORS
PREVENTIVE
MAINTENANCE

DAILY PM SCHEDULE
Grease the Bearing Cap Fittings located on the
Upper Frame. Always follow lubrication
schedule (5 grams). Always CHECK GREASE
TYPE.
VISUALLY INSPECT the machine for:
Unusual or excessive vibration
Water leaks
Slurry spillage

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.

WEEKLY PM SCHEDULE

Grease Rotating Union fitting on Upper Frame.

Always follow lubrication schedule (12 grams).
Always CHECK GREASE TYPE.
Grease Bearing fittings on Upper Frame.
Always follow lubrication schedule (16 grams).
Always CHECK GREASE TYPE.

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.

WEEKLY PM SCHEDULE
Isolate (Lock Out) unit and check by probing
with wire/rod that the 18 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.

WEEKLY PM SCHEDULE

Remove filter screen and clean, ensure proper

reassembly.
Check that the drive belt and sheaves are in
good condition and are not suffering wear.

Grease the bearing cap fittings

Grease the bearing cap fittings
Grease the bearing cap fittings
Grease the bearing cap fittings

Top Bearing Top Cap, 5 shots

Top Bearing Bottom Cap, 5 shots
Bottom Bearing Top Cap, 5 shots
Bottom Bearing Bottom Cap, 5 shots

Visually inspect the machine for unusual or excessive vibration

Visually inspect the machine for water leaks
Visually inspect the machine for slurry spillage
Open water filter drain for 3 seconds and check for solids/discoloration
Check that fluidizing water pressure and filter differential are indicating normally
Record top bearing temperature
Record bottom bearing temperature
Grease the fitting for the Rotary Union, 12 shots
Grease the fitting for the Top Bearing, 16 shots
Grease the fitting for the Bottom Bearing, 16 shots
Check feed screen & ensure screen is not blinded off, pressure wash as required
Check feed screen & ensure all water sprays are unplugged and positioned properly
Remove lids and observe operation
Remove lids and observe concentrate draining sequence
Remove water filter screen & clean if necessary
Check by using a hole probe that the 18 x 1/8" silt bleed holes (outboard of the
concentrate cone bolts) are clear. Unit must be locked out
Look at/feel rings in concentrate cone for scale build up & polyurethane wear/damage.
Unit must be locked out
Check the deflector pad and wear cone for wear/damage. Unit must be locked out
Check that the drive belt & sheaves are in good condition. Unit must be locked out
Initials:
Note:
All greasing must be done while concentrator is running & at operational temperature
Please list comments on back of the sheet
The longer the intervals are between cone cleanings the more important it becomes to have regular inspections of the wear parts
Calibration of instrumentation at least every two years
Ensure instrument air quaility is not compromised
Check electrical connections for tighness every year
Recommended motor greasing twice a year

Sunday

Saturday

Friday

Thursday

Wednesday

Tuesday

Monday

PM SCHEDULE

For Week Starting: _________________

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.

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.

MONTHLY PM SCHEDULE

Replace worn parts before structural damage

can occur. Some components can be returned to
Knelson Concentrators and be refurbished in
our exchange program.

CRITICAL WEAR ZONES

CRITICAL WEAR ZONES

ZONE DESCRIPTION
A
B
C
D
E
F
G
H
I

SUGGESTED
INSPECTION
INTERVAL

WEAR SKIRT IMPACT ZONE

MONTHLY

CONCENTRATE CONE TOP FLANGE

MONTHLY

CONCENTRATE CONE LOWER RINGS

MONTHLY

FEED TUBE NOZZLE

QUARTERLY

DEFLECTOR PAD CENTER

MONTHLY

DEFLECTOR PAD UNDERSIDE & EDGES

MONTHLY

TAILINGS LAUNDER OUTLET

QUARTERLY

TAILINGS LAUNDER BOTTOM SURFACE

QUARTERLY

DISCHARGE WEAR CONE

MONTHLY

AREAS OF WEAR

Elusive
deflector pad
wear.

AREAS OF WEAR

Deflector pad wear.

AREAS OF WEAR

Deflector pad wear.

AREAS OF WEAR

Example of worn
wear cone.

AREAS OF WEAR

Example of worn
wear skirt.

ABUSIVE WEAR

Excessive wear to
concentrate cone.

ABUSIVE WEAR

Worn beyond repair.

ABUSIVE WEAR

A closer view.

ABUSIVE WEAR

Worn beyond repair.

ABUSIVE WEAR

Closer look at
previous picture.

MONTHLY PM SCHEDULE

In-frequent removal of the concentrate cone

requires monthly inspections of not only the
wear parts but the rotor housing water jacket.

MONTHLY PM SCHEDULE

With the unit isolated and drained of water,

remove one of the inspection doors located on
the rotor housing and inspect for solids in the
water jacket and scaling on the concentrate
cone.

MONTHLY PM SCHEDULE

If there are excessive solids in the water jacket,

the filter system may have failed, or inadequate
water flow during the operating cycle may have
allowed solids to pass through the concentrate
cone fluidizing holes. A check of the operating
sequence and controls may be necessary.

MONTHLY PM SCHEDULE

Excessive scaling or sediment will block the

fluidizing holes in the concentrate cone and descaling/cleaning will be necessary of both cone
and rotor housing.

MONTHLY PM SCHEDULE

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.

QUARTERLY PM SCHEDULE

In addition to the PM requirements of monthly

inspections the following needs to done at least
quarterly.
Inspect the wear areas of the feed tube and
nozzle. The tailings launder wall, floor and the
discharge area to piping.

QUARTERLY PM SCHEDULE

If any metal is exposed it must be repaired or

replaced immediately.
Replace worn parts before structural damage
can occur. Some components can be returned to
Knelson Concentrators and be refurbished in
our exchange program.

QUARTERLY PM SCHEDULE

Remove the belt guard and check High Torque

Drive (HTD) belt for wear and alignment.
Check both sheaves for excessive wear. If the
flange on the drive sheave is worn or missing
then it should be replaced, as it is essential to
maintain alignment.

PREVENTIVE MAINTENANCE

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 with a new or refurbished unit. The
removed union can be sent to Knelson as part of
our exchange program.

PREVENTIVE MAINTENANCE

Before the unit is put back into service, observe

it through a flushing cycle before introducing
feed. Also visually inspect vibration mounts and
check for any abnormal vibration.

PREVENTIVE MAINTENANCE

Recommend dedicated storage for special tools,

small parts, grease guns, etcetera in a location
close to the concentrators.

KNELSON CONCENTRATORS
TROUBLESHOOTING

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.

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.

TROUBLESHOOTING
EXCESSIVE VIBRATION
Check for concentrate build up in the cone
rings.
Excessively worn parts will cause the rotor
assembly to be unbalanced. Such as lining wear
so extreme that metal is visible.

TROUBLESHOOTING
EXCESSIVE VIBRATION
Worn bearings.
Carcass of drive belt damaged or separating.
Vibration isolator damaged or separating.

TROUBLESHOOTING
EXCESSIVE VIBRATION
Hard piping not allowing machine to move
properly.
Screen hopper on unit using non-screen hopper
vibration isolators.

TROUBLESHOOTING
EXCESSIVE WATER PRESSURE
Concentrating cone fluidization holes plugging
off.
Ball valve improperly set.
Check ICS set points.

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.

TROUBLESHOOTING
PREMATURE WEAR
Feed particles oversized.
Tramp steel >6 mm not being eliminated from
the feed.

KNELSON CONCENTRATORS
AUTOMATION

MAINTENANCE CHECKPOINTS

Check condition of proximity switches for

spacing and wear from slurry accumulating on
the drive sheave.
Instrumentation calibration check every 2
years.

AUTO PIPING
Actuator &
Positioner

Pressure
Transmitter

Differential Pressure
Transmitter

Segmented Ball
Valve

Filter Screen

Magnetic Flow
Transmitter

CRITICAL SPARES - AUTO PIPING

Magnetic flow meter
Gauge pressure transmitter
Inductive proximity switch
Differential pressure transmitter
Control valve c/w actuator and transducer

CONTROL VALVE ASSEMBLY

POSITIONER

ACTUATOR

VALVE

TROUBLESHOOTING
CONTROL VALVE
Most common problem occurs with air supply.
Dirty air plugs filters and reduces pressure &
volume.
Causes pilot valve in positioner to stick or seize.

TROUBLESHOOTING
CONTROL VALVE
Is full range of signal reaching the valve?
Too much loop resistance or bad connection
will prevent signal from reaching 20 Ma.
Move positioner pilot valve by hand to see if
valve responds.

TROUBLESHOOTING
CONTROL VALVE
Valve oscillation
First step is to put control loop in manual and
ensure valve stays in set position.
Make small step changes and check that valve
is responding smoothly.

TROUBLESHOOTING
CONTROL VALVE
Valve oscillation
If two or more small step changes in the same
direction are required and then there is a
jump.
Most likely cause is a sticking pilot valve in the
positioner.

TROUBLESHOOTING
CONTROL VALVE
Valve oscillation
A sticking valve, from scale, damage, etc.
Least likely is a sticking actuator.
Excess vibration can cause mechanical problems
in the positioner

TROUBLESHOOTING
ACTUATOR
Valve does not stroke when air pressure applied.
First check for wear on the coupling.
Next most likely causes are damage to the valve
seat, scale on the ball or build up behind the
ball.

TROUBLESHOOTING
ACTUATOR
Dirty air can seize the actuator.
Remove the coupling between the actuator and
valve and check actuator stroke.
Each time actuator is removed ensure proper
stop adjustment when re-installed.

TROUBLESHOOTING
FEED/BYPASS VALVE
Most common problem occurs with air supply.
Dirty air plugs inlet filters and reduces pressure
& volume.
Low air pressure can appear to be a sticking
valve.

TROUBLESHOOTING
FEED/BYPASS VALVE
Is the solenoid valve working?
If valve is energizing you can usually hear it
click.
If not, the solenoid coil may have burnt out. A
common cause for that is water in the wiring
conduit.

KNELSON CONCENTRATORS
PARTS EXCHANGE
PROGRAM

PARTS EXCHANGE PROGRAM

ROTARY UNIONS

BEFORE

AFTER

PARTS EXCHANGE PROGRAM

CONCENTRATE CONES

BEFORE

AFTER

PARTS EXCHANGE PROGRAM

ROTOR ASSEMBLIES

BEFORE

AFTER

PARTS EXCHANGE PROGRAM

MACHINE REBUILDS

THE END