SAMPLE PAST PROJECTS
Optimization – Mine Tailings
Seven large filter presses were not performing in a gold tailings application in Mexico. There were numerous problems, including significant mechanical, process and reliability issues. Success was achieved by spending time on-site working hands-on together with plant maintenance & operations personnel. Valuable information was then brought back to management and together we devised solutions that were implemented by the customer in the field. The equipment is now performing at the “nameplate” production rate.
Troubleshooting – Mineral Concentrate
A fast acting minerals filter press was only a few years old and was having reliability issues, including leaking filter plates and damaged filter cloths, resulting in a bottleneck for the entire copper concentrate mine. Troubleshooting this system required working closely with maintenance and operations personnel at the mine to repair the equipment and implement sustainable cycle operating parameters. A preventative maintenance schedule was implemented and a list of recommended improvements was provided. This filter is now running reliably and exceeding production requirements.
Technical Support – Chemical Recycling
Ten (10) filter presses of various sizes and OEM manufacturers operate throughout this zinc recycling plant. Equipment and process issues require ongoing assistance, both on-site service and remote support. Design upgrades, and occasionally a major overhaul, have been required over the years. As a result, filter press reliability and performance are steadily improving, allowing the plant to steadily increase production.
Commissioning – Mineral Concentrate
Serial #1 & 2 of these new, largest of their kind tower filters were installed at a remote iron ore mine in South America. There were numerous problems with this new product, including significant mechanical, process and political/personnel challenges. The best progress was made by spending time on-site working hands-on together with field-service engineers and plant maintenance & operations personnel. Valuable information was then brought back to the OEM engineering group and together we devised solutions that are being implemented by the customer in the field.
Retrofit Upgrade – Chemical Processing
A filter press had been in operation for 20-yrs in a corrosive sulfuric acid application and the OEM of the equipment had since gone out of business. The sidebars/rails had corroded so much that they were at risk of structural failure. 3D CAD drawings were created from field measurements and site photos. By creating accurate drawings and working closely with fabricators, a new set of stainless steel clad filter press sidebars were produced and efficiently installed, and are now expected to outlast the original set.
Large Installation – Mine Tailings
Eighteen (18) large filter presses were installed across three frac sand mines in the United States, under a fairly aggressive schedule. Work was performed closely with the on-site installation team, including OEM representatives, plant owners and the engineering firm, to ensure efficient and accurate assembly, testing and commissioning of the equipment.
Equipment Audit and Redesign – Chemical Processing
Serial #1 of this new, high-tech filter for a highly corrosive application was held up in the shop after failing the customer acceptance testing. There were numerous problems with the acid waste filter, most significantly mechanical design issues. A critical understanding was established by spending time talking to the people who designed the equipment, the people who did the fabrication and assembly as well as the people who tested the equipment in the shop. Redesign concepts were created by working together and then detailed solutions were found by running both physical tests and virtual finite element analysis (FEA). These solutions have since been implemented and successfully tested, allowing the customer to accept and ship the filter.
Equipment Expansion – Mineral Concentrate
An emergency expansion of multiple filtration systems was required for a lead & zinc circuit at a gold mine in Mexico. The customer was losing a lot of money because the filtration system had become the bottleneck for the entire lead and zinc circuits. Success was achieved by working closely with engineering, procurement and manufacturing personnel. Together we were able to significantly cut the delivery time for these custom expansion parts from the originally estimated six months to having the system up and running in just under three months. The installation was successful and the filtration system is no longer the mine’s bottleneck.
Equipment Upgrade – Mineral Concentrate
Specialized iron ore filtration equipment in the field needed support with documentation and instructions for subcontractors to both bid from and to actually perform this major product retrofit in the field. The job was located in Brazil and the retrofit was too large and time-consuming to be left to on-site, word-of-mouth communication. A valuable instruction manual was produced by working closely with engineering, field-service and technical writing personnel. The final product was delivered in multiple languages and included step-by-step instructions supplemented with invaluable photos, drawings and CAD images.
Manufacturing – Food Processing
A Chinese customer required Chinese manufacturing for their new corn starch filter, with a tight delivery schedule, even though this equipment had never been made in China. With the short delivery time, multiple new manufacturers within numerous industrial areas of China had to be brought up to speed quickly. Success was achieved by working closely with engineering, procurement and manufacturing personnel. We were able to meet the customer’s needs and ship a quality filter within their deadline.
Sales Support – Food and Pharmaceutical
Managed booth for an OEM at a corn starch technology conference located in the Midwestern United States. Was able to successfully address questions, provide valuable insight and connect potential customers with the appropriate OEM sales personnel by leveraging extensive experience with filters and equipment in this market.
PLC Programming – Allen Bradley
A number of issues with the PLC logic and touchscreen interface of this new filter press were delaying commissioning and making it difficult to train operators. Changes to the ControlLogix & PanelView code allowed for clear communication between the filter press and plant DCS. Adjustments to the PanelView code allowed operators and maintenance personnel to better understand the operation and service of the press.