C1000-R3.

Installation, Operations, and Maintenance Manual

Introduction

1.1 Who is Sepro Mineral Systems?

SEPRO MINERAL SYSTEMS CORP. is a Canadian company operating internationally in the mining and
metals industries. Sepros core business for the last 25+ years has been manufacturing mineral processing
equipment including Falcon Centrifugal Gravity Concentrators for fine gold and mineral recovery, largescale ore scrubbers and agglomeration drums, smaller duty grinding mills, Sepro-Sizetec screens for coarse
particle separation and Sepro-Atalay screens for fine particle separation in addition to metallurgical testing
and process consulting. Basic services range from evaluative studies through equipment design, fabrication
and commissioning. Sepro is committed to providing state-of-the-art equipment and process solutions for
new and existing projects worldwide.
Thank you for purchasing your own Falcon Concentrator.

C1000 Continuous Concentrator

Sepro Mineral Systems Corp.

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C1000-R3.1

Installation, Operations, and Maintenance Manual

1.2 The Continuous Concentrator

Recovering FINE metals and minerals from process streams has always been difficult. With the Falcon C
series, its design simplicity and 300 G-force, this has made the historically impossible process possible.
Designed to never stop, it continuously produces concentrate yielding weight recoveries as high as 40%.
The primary objective with this series is to maximize recovery and reduce weight to subsequent down
stream processes. This makes the units perfect for scavenging or pre-concentrating streams, as it uses no
elutriation water and produces concentrates that are de-slimed and de-watered (+70% solids by mass).
One moving part and top grade component materials such as 316 stainless steel, rubber, polyurethane,
tungsten carbide and ni-hard, mean that you can look forward to greater than 95% operational availability
as well as low operating costs.
The Falcon model C concentrator is normally utilized where separation of a relatively small amount of
fine heavy material (underflow) from a relatively large amount of lighter gangue is required.
The Falcon model C works for many minerals and metals:

Scavenging FINE gold and sulphides from leach or flotation tailings

Pre-concentrating before the leach to maximize leach performance
Scavenging FINE tantalum and tin from plant tailings
Removing ash and sulphides from coal
Scavenging FINE iron ore from LIMS tailings
Pre-concentrating of old gold and silver tailing dumps
Pre-concentrating and de-sliming heavy mineral deposits
Pre-concentration before flotation or leach rejecting light undesirables

1.2.1 How it Works

The feed stream particles are subjected to gravitational forces of up to 300 Gs and are segregated
according to effective specific gravity along the smooth spinning rotor wall. The heaviest layers are
continuously bled off at a controlled rate through a series of unique plane mass flow hoppers and patented
throttling nozzles.
The high Gs permit effective recovery of even very fine particles (below 10 microns). This unit requires
no feed interruptions or added process water. The adjustable fraction of heavy particles bled off are
effectively de-slimed and partially de-watered.
Feed capacity
Feed density
Feed particle size

Sepro Mineral Systems Corp.

4 sizes to 110 t/h solids

45% solids maximum
#20 (1mm) mesh maximum recommended

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C1000-R3.1

Installation, Operations, and Maintenance Manual

1.3 Description
Frame:

All-welded construction, mild steel with epoxy paints to ensure long life of
the unit. The design and construction minimize normal operating vibrations.

Launders / Lid:

All-welded construction, mild steel with rubber linings and epoxy paint to
ensure long life of the unit.

Rotating Assembly::

Machined shaft, rotor base, rotor bowl, and underflow discharge head. All
components contacting slurry are 316 stainless steel and/or rubber lined,
designed for easy replacement. This assembly is effectively the only moving
part.

Drive:

VFD, motor, belts and sprockets.

Control:

PLC, Operator Interface, and communications.

1.3.1 Process
Feed is screened at approximately 1 mm depending on the application, and is introduced as slurry through
a central vertical feed pipe, and then accelerated by an impeller. Rapid stratification according to specific
gravity occurs as the material is driven up the stratification zone, under the influence of an immense
gravity field. The size of the field is varied by changing the rate of revolution of the rotor with the variable
frequency drive.
Once in the retention zone, the concentrated heavy fraction is withdrawn continuously through a series of
plane mass flow hoppers distributed evenly around the perimeter of the rotor.
The flow of heavy fraction or underflow is controlled by the Falcons patented throttling nozzles. This
heavy solid fraction is deposited in an annular launder, which is provided with two opposing discharge
points. Water can be added in the launder to dilute this stream which is normally >70% solids.
The lighter solid fraction or overflow and most of the associated process water flow upward and are
discharged into an outer launder and ultimately conducted away from the machine.

Sepro Mineral Systems Corp.

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C1000-R3.1

Installation, Operations, and Maintenance Manual

1.3.2 Figure 1.3.1

Process Schematic
SLURRY FEED

RUBBER LINED LID

FEED PIPE

LIGHTS

LIGHTS

HIGH

HEAVIES

RETENTION

STRATIFICATION

HEAVIES

IMPELLER

LAUNDERS

THROTTLING NOZZLES (30)

COMPRESSED AIR SUPPLY
(Introduced at Rotating Union)

All this is done through the Automation Package or AutoPac, strongly recommended on all production
units. The AutoPac includes a programmable variable frequency drive (VFD), PLC control, dynamic
braking, a pneumatic proportional valve (PPV), vibration switch and solenoids.
These are control various operating parameters including acceleration ramp, centrifugal field, deceleration
ramp, throttling nozzle pressure (heavy fraction discharge), automatic rinsing, and others. An external
operator interface with a 4-line display screen enables the user to program many of these operating
parameters without opening the enclosure.

Sepro Mineral Systems Corp.

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