GROUPE K AT O S p e c i a l i s t S e r v i c e
to the Minerals Processing
Industry

PUBLICATIONSFor users interested in more detailed information on mixing
EKATO offers its ‘Handbook of Mixing Technology’ whichamong other important topics describes the fundamentals ofmixing and many mechanical aspects. Various papers have been
written, presented and published by EKATO, in particular for minerals
processing:■ POX autoclaves –New advances in impeller design for highly abrasive ores

■ Innovation in agitation technology for autoclave applications■ Considerations and methodologies for the design of gassed
agitated CSTR’s■ Agitator start-up in settled bed conditions■ Systematic characterization of the mixing process for theBIOX® reactor■ Mechanical seals and seals supply systems for high pressure
autoclave applications■ Increasing safety and reliability of autoclaves by a simplified risk
analysis procedure of mechanical seals and supply systems

www.ekato.com

GROUPE K AT O S p e c i a l i s t S e r v i c e
to the Minerals ProcessingIndustry■ EKATO, for over 75 years, has successfully designed andmanufactured industrial agitators utilized in many global industrialmarkets. One of these global industry sectors is minerals processing
where hydrometallurgical processes utilize agitation.

CN Detox
BioleachPOX■ A significant contribution to our success and recognition inthis demanding industry is ‘added value’. EKATO`s uniquecapabilities to conduct pilot scale tests with ore from yourspecific geological region in our Technical Center extends ourengineering capabilities far beyond the normal industry limits ofagitation and differentiates us from the traditional agitatormanufacturers.
■ Technology development is the foundation of our reputation andreference of operational sites which employ process routes such as
HPAL, POX, CIL / CIP, Bioleach, CN Detox, etc.

Feed Tanks

Atmospheric Leach

Sulphide Precipitation
Lime / Limestone Storage

Neutralization

CIL / CIP

HPAL

Manganese Removal

Aluminum Hydroxide■ Thousands of customers have already found the benefits that
optimization of their proprietary production processes delivers byconducting tests in our R&D facilities and implementing therecommendations.

GROUP

Te c h n i c a l C e n t e r F a c i l i t i e s■ Where the specific detail of the application or the product data is
unknown, for the owner and operator, it can be beneficial to back up
the classical agitator design by testing in a controlled environment.
The objective is ’optimized design with reduced risk‘.
EKATO’s primary Technical Center is located in Schopfheim,
Germany, where more than 20 engineers are available to support
you. In our state of the art facility testing is possible using
your original products or representative model substances.
The capabilities of the test equipment ranges between 500 ml up to
100 m³, although the typical test range against which reliable results
can be achieved is between 50 liters and 1 m³.
A multitude of vessel arrangements and shapes including autoclave
vessels are available or can be assembled for sizes which can beconfidently used as the basis for scale-up.

Depending on the flow sheet requirements or specific mixing task
many critical data points and values can be recorded during testing
to determine the characteristics of the product ensuring a complete
understanding of how the process will behave at full scale conditions,e.g.:■ mixing time
■ mass transfer■ feed locations■ process simulation■ rheological properties■ particle size distribution■ solids settling curves■ flow velocities or pumping rates■ power numbers ungassed / gassed■ forces acting on impellers and shaft■ solids suspension homogeneity■ residence time distributions (solid / liquid)■ particle characterization by microscope■ surface phenomena, e.g. entrainment ofpowders into a liquid■ validation of CFD models

I m p e l l e r Ty p e sGROUP■ As an agitator manufacturer dedicated to process technology
development through proven trials and results we have an
extensive range of impellers available which are essential for
successful applications.
In the event that creativity and innovation is required to fulfill theprocess requirements of the application our technical staff has thecapability to develop new impeller types.
Depending on the application, from our extensive knowledge andoperational experience for standard suspending tasks the hydrofoil
type EKATO VISCOPROP is the impeller of choice, or in processes
where a gas phase is added to the slurry the widefoil type EKATO
ISOJET-B would offer significant advantages.

■ For HPAL or POX autoclave
applications the EKATO EPAL orEPOX-R impellers are designed tofulfill very specific mixing tasks whileconsidering the full scale operationcosts. Many other impeller types
are available, including complex
draft tube designs, where the EDTC
impeller offers advantages compared
to standard designs.

GROUP

Engineering Services■ Additional engineering services
Include technical reviews of equipment or operations which influence
the process performance. Often overlooked, interrelations such as
the vessel geometry or feed / discharge locations have a significant
impact on the process itself or mechanical design of the equipment.
Deliverables and expectations are tailored to suit client needs andrequirements determined by the scope of the project. Results ofthe testing or engineering study will be summarized in a technicalreport illustrating the options for the operator to secure market
driven competitive advantages. Clients are welcome to witness thetesting activities, or tests can be recorded digitally and supplied ona DVD.

■ Testing / engineering studies
Making use of the resources in the well equipped TechnicalCenter and its experienced minerals processing engineers dedicatedto the industry, EKATO has the competence to support end-users orengineering companies. This service extends to the design of
new or improvement of existing processes to achieve optimum
efficiency, cost efficiency or increased reliability. Engineeringstudies range from a basic one day test to an extensive research
project.
Depending on the nature of the testing program original
concentrate samples can be utilized. If samples are not available
most product characteristics and mixing tasks can be simulated
by model substances. Both methods allow for an accurate andsafe full scale design.

■ Consulting on site
Our capabilities are not limited to the Technical Center. Consultancy
services or test programs can be provided on site. A review ofequipment or an audit of operations focusing exclusively on
enhancements to agitation technology leads to a comprehensive
report and recommendations to any modifications.

Additional Services

In addition to already mentioned services, EKATO canprovide a wide range of additional services and knowhow, such as:■ design of gas sparger types and feed locations■ feed pipe dimensions and locations, as e.g. slurry
and sulphuric acid feed pipes in HPAL applications■ discharge locations, dimensions of dip or riser pipes■ CFD (Computational Fluid Dynamics) and FEA(Finite Element Analysis) simulations■ mechanical calculations as the determinationof forces acting on vessel internals■ increase life-time of equipment by reducing
abrasion or application of coatings■ restart strategies or consulting for processes
operated at high solids concentrations■ optimized draft tube geometries to reduce pressure
drops and therefore required power inputs■ increase life-time of the mechanical seals byrevamping with mechanical seals from EKATO ESD■ thermographic measurements■ training at your office or plant site

GROUP