Process Equipment

Paterson & Cooke’s skills and experience enable us to develop new technology for mining and mineral process applications, as well as design and supply specialised Pilot Plant facilities.

Differential Pressure Density Meter

Application Area
Technical Data

To effectively control slurry pipeline systems, the density of the slurry has to be known. The typical hurdles in measuring density in slurry pipelines include, but are not limited to, equipment availability due to pipeline size, the hassle of nuclear licenses when nuclear densitometers are used and the measurable density range. The Differential Pressure Density Meter (DPDM) alleviates all of these hurdles as it is available for a wide range of pipe sizes, and pipe liner materials. The DPDM is particularly useful for measuring low slurry densities like thickener feed slurries where nucleonic densitometers do not perform well. Because the DPDM operates without a nuclear source, the need for stringent nuclear licenses and associated requirements is mitigated. The DPDM only requires an inline flow measurement device, like an electromagnetic flow meter, to function.

The DPDM is used to measure the density of a variety of fluids and slurries. It is especially well suited on thickener feed lines where large bore piping is used in combination with low slurry densities.

Nominal Size: DN150 to DN1200
Density Range: 1000 to 4000 kg/m3
Flow Rate Range: 20 to 1400 l/s (Dependant on Size and Density)
Process Fitting: Any Standard Flange Arrangements
Maximum Line Pressure: 20 bar
Operating Voltage: 100 to 240 VAC (50/60Hz) or 24 VDC
Operating Temperature: 0 to 90 °C (Dependant on liner material)
Materials of Construction: DPDM tube - most metals or metal/liner combinations available in the industry
Signal converter - IP65 rated polycarbonate enclosure

Dewatering Bin (Patented)

Application Area
Technical Data

Dewater low density settling slurries fast and effectively.

Many mineral and mining processes transport dilute slurry initially, but then have to deal with the burden of the excess liquid by over sizing downstream process equipment. Dredging or offshore mining operations typically produce a dilute product stream that requires dewatering before introducing it to the process plant.

Paterson & Cooke has developed and patented a coarse solids dewatering bin that separates the solids and liquids from a dilute slurry stream. The size of the separated solid particles can range from fine sand to coarse gravel. The size fraction that reports to the overflow can be adjusted and the coarse fraction reports to the bin underflow. The Dewatering Bin design offers a wet bin storage facility where the settled solids are stored without agitation and extracted when required at a controlled rate and concentration using a custom designed fluidiser.

The Dewatering Bin is most commonly used in dredge operations where large volumes of low density slurry have to be dewatered before reporting to a processing plant.

Diameter: Size is determined by process requirements, typically 1m to 10m diameter.
Feed Density Range: Typically less than 1.15 kg/m3
Flow Rate Range: Dependant on Size and Density.
Materials of Construction: Most metals or metal/liner combinations available in the industry

Compact Splitter (Patented)

Application Area
Technical Data

Effective splitting and diversion of a slurry stream.

Many mining process require that a slurry feed stream is diverted equally to downstream processes. Typically, a launder will discharge to a central distribution box that splits the flow in several directions. It is difficult to control the flow split after the distributor, as downstream conditions influence the distribution of the flow. To overcome such problems, Paterson & Cooke has developed a Compact Splitter that provides an equal split to outlets. A riser pipe delivers flow to a specially designed pressurised splitter that provides an even distribution of material to each outlet.

The Compact Splitter can be used anywhere where one slurry stream has to be split into multiple streams of equal flow.

Inlet Diameter: Any size
Number of Outlets: Dependant on inlet diameter, maximum of 6 outlets
Outlet Diameter: Dependant on inlet flow rate and number of outlets
Materials of Construction: Cast Iron

Settling Slurry Viscosity Test Rig

Application Area
Technical Data

Settling slurry rheology measurement made easy.

Slurries that consist of fine heavy particles often behave as non-Newtonian fluids while all particles are in suspension. Such slurries include Ferro Silicon (FeSi) which is used as separation media in Dense Media Separation (DMS) processes. The rheology of such slurries cannot be measured with a Rotational Viscometer (RV) as the slurry behaves as a settling slurry as soon as the fluid stops moving. This phenomenon makes it very difficult to conduct slurry rheology control on DMS processes.

Paterson & Cooke has designed a Settling Slurry Viscosity Test Rig (SSVTR) that ensures the slurry stays in suspension and a standard RV can be used to measure rheology data.

The SSVTR is used in conjunction with a Rotational Viscometer to measure the rheology of settling slurries.

Particle Top Size: Less than 1 mm
Materials of Construction: Mild steel or Stainless steel

Mobile Metallurgical Sampler

Application Area
Technical Data

On line efficiency monitoring tool to improve plant performance.

Product recovery is dependent on the efficiency of the mining tools and also the process efficiency of the treatment plant. Loss of valuable product can occur due to inefficient screens (oversize and undersize), poor dense material separation (DMS) or through tailings. Paterson & Cooke has developed a mobile on-line metallurgical sampler to determine the potential loss of valuable material, measure the particle size distribution of dilute process streams or to determine process/screening efficiencies. The Metallurgical Sampler is designed to eliminate the difficulty of getting a representative sample of large flow, low density streams.

To get a representative sample of any large flow, low density slurry stream, e.g. underflow of screening process.

Operating Principle: Compressed air
Flow Rate Range: 0.38 to 18.9 l/s
Process Fitting: Flanged, DN40, SANS 1123 Table 1000/3 for sampling point
10 mm quick connector for compressed air connection
Maximum Line Pressure: 8 bar
Operating Voltage: N/A
Operating Temperature: -10 to 50 °C
Materials of Construction: Frame and canisters – Aluminium
-5 mm filter and filter bag holder – Stainless steel
Pump – Polyethylene
Flow meter body – IP65 rated polycarbonate enclosure

Large UCS Test Rig

Application Area
Technical Data

Testing compressive strength of large concrete cylinders.

Unconfined Compressive Strength (UCS) testing is currently one of the most common test procedures to assess the shear strength of backfill. The strength is typically estimated by casting specimens from a proposed mix design and crushing them in a laboratory while measuring displacement and load. Specimens are typically of smaller sizes, 150 mm in diameter by 300 mm in height, which poses a problem when large aggregate is added to the backfill sample. This is why Paterson & Cooke has designed and built a large UCS test machine able to test specimens up to 300 mm in diameter by 600 mm in height. The larger UCS machine allows the user to test large cylinders containing aggregate up to 75 mm in diameter.

To determine the unconfined compressive strength of large aggregate, backfill mixtures used in the mining industry.

Nominal Sample Size: Up to 620 mm high x 300 mm diameter
Maximum Compressive Force: 75 tonnes
Load Cell Safe Overload Capacity: 100 tonnes
Operating Voltage: 400 V, 3-phase with neutral
Operating Temperature: 10 to 60 °C


Application Area
Technical Data

A fluidiser is an apparatus used to extracted saturated solid or thickened material from a storage device such as a wet bin or thickener. Paterson & Cooke supply custom designed fluidisers for client-specific applications. We can also custom-size a unit from our standard range or design a fluidiser from scratch.

For the extraction of saturated solid or thickened material from a storage device.

Customised for client requirements.