Efficient sedimentation is the backbone of any mineral processing plant. By ensuring solids and liquids are effectively separated, sedimentation optimises resource recovery and reduces operational inefficiencies.
Traditional sedimentation methods often struggle to keep up with the demands of modern processing plants. That’s where MechProTech’s Hi-Rate Thickener comes in—a robust solution designed to enhance performance, minimise costs, and eliminate sedimentation bottlenecks.
What Is a Hi-Rate Thickener?
Hi-Rate Thickeners are advanced sedimentation equipment designed to accelerate the settling process of solids in slurry. Unlike conventional thickeners, they use flocculants and specialised feed well designs to optimise sedimentation. This results in:
- Faster separation of solids from liquids.
- Reduced slurry volume.
- Clear overflow for recycling or disposal.
Their application is critical in mineral processing, water treatment, and chemical processing, where efficient solid-liquid separation can dramatically improve plant efficiency.
How Do Hi-Rate Thickeners Work?
Hi-Rate Thickeners streamline the sedimentation process through these steps:
Slurry Feed
The slurry enters the thickener through a feed well, where it’s evenly distributed to avoid localised overload.
Flocculation
Flocculants (chemical agents) are added, binding fine particles into larger flocs that settle faster due to increased weight.
Settling
Under gravity, solids settle to the tank’s bottom, while the clear liquid, or supernatant, remains on top for collection.
Rake Mechanism
Mechanical rake arms rotate slowly, sweeping the settled solids toward the tank’s central outlet for discharge
Efficient Separation:
The result is a concentrated slurry at the bottom and a clear liquid at the top, ready for reuse or further processing.
Why Choose MechProTech’s Hi-Rate Thickener?
MechProTech, a leading South African OEM equipment manufacturer, has redefined sedimentation efficiency with its Hi-Rate Thickener. Here’s how it stands out:
1. Innovative Design
Bolt-Together Tank Design: Designed for easy transport and on-site assembly, these tanks accommodate various site layouts with a maximum width of 3.9m and a height of 4.7m.
Full and Half-Radius Rake Arms: Engineered with MechProTech’s high-efficiency constant velocity rakes, the arms ensure consistent sedimentation and prevent blockages.
2. Advanced Control Mechanisms
Variable Speed Drive (VSD): Operators can adjust rake speed to match process requirements, with built-in torque warnings for enhanced safety.
Mechanical Lift Mechanism: The rake lift system adjusts to varying slurry densities, preventing overload and ensuring uninterrupted operations.
3. Durable Construction
High-Quality Materials: The tank floor and side walls are constructed from 6mm mild steel plates coated with a two-coat epoxy system for enhanced corrosion resistance. The bridge, walkway, and support columns are made from mild steel, with hot-dip galvanised finishes to ensure long-lasting durability.
Flow-Efficacy Feed Well: A rubber-lined tangential feed system promotes efficient slurry and flocculant mixing, enhancing performance.
Hi-Rate vs. Conventional Thickeners
| Feature | Conventional Thickeners | Hi-Rate Thickeners |
| Sedimentation Speed | Slower, relies on gravity alone. | Faster, uses flocculants and mechanical aids. |
| Sedimentation Speed | Limited by slower settling rates. | Handles larger slurry volumes efficiently. |
| Applications | Low-complexity operations. | High-throughput, demanding environments. |
Hi-Rate Thickeners are ideal for modern mineral processing plants where speed, efficiency, and reliability are non-negotiable.
Applications of Hi-Rate Thickeners
Hi-Rate Thickeners are invaluable across industries, including:
Mining and Mineral Processing
For tailings disposal, concentrate thickening, and ore beneficiation..
Water Treatment Plants
For removing suspended solids, achieving cleaner, recyclable water.
Chemical Processing
For maximising product recovery in solid-liquid separation processes.
Benefits of MechProTech’s Hi-Rate Thickener
Choosing MechProTech means investing in:
- Optimised Sedimentation
Faster settling rates reduce slurry volume and clarify overflow, streamlining operations. - Lower Maintenance Costs
Bolt-together design and robust materials minimise wear, reducing maintenance time and costs. - Custom Solutions
These thickeners can be tailored to meet specific plant requirements with modular designs.
Ready to Elevate Your Plant’s Efficiency?
MechProTech’s Hi-Rate Thickener is built to meet the rigorous demands of modern mineral processing. With unparalleled reliability and efficiency, it’s the ultimate solution for your sedimentation needs.
Contact MechProTech today to discover how our equipment can transform your operations and help you achieve peak performance.