End-user benefits 

Multotec customers benefit by knowing what to expect from the ore body. The test work confirms the expected upgrade or informs the customer to reconsider the project as the requirements cannot be met. Multotec’s test work:

• Tests the material behaviour on equipment as per conceptual design
• Determines if material can be upgraded as per customers’ requirements
• Indicates what yields and recoveries can be expected
• Evaluates potential losses of valuable materials to tails
• Records abnormalities of material behaviour on equipment

Additional test work benefits 

• Confirming achievable improved throughput rates on existing plants
• Certainty when upgrading or changing mineral processing flow sheets
• Confirming achievable recoveries and efficiencies by conducting comparative equipment performances
• Spiral results cannot be easily predicted using mathematical modelling only, test work is required
• Brownfield applications can improve plant efficiencies

R&D pertaining to test work

Multotec’s R&D plays a fundamental role in product development and in refining existing technologies. This contributes to the Multotec Group maintaining exceptional quality products and high performance standards. Mineral samples (of the above-mentioned commodities) are received from other countries and tested to prove their efficiencies and effectiveness in their specific applications.

In the interests of advancing the industry and its relevant material sciences, Multotec disseminates test results and related R&D technical data to industry. Additionally, the Group’s R&D facilities, including its laboratory facilities, are made available for specific research work for mining houses, universities, plants, OEMs and individual customers.

Laboratory facilities include:

• Sample drying
• Wet and dry screening for particle size distribution analysis
• Fine particle size distribution analysis
• Sample splitting by means of rotary splitters

Test work facilities and services

Multotec provides the following test work facilities and services for customers and non-customers alike:

Spiral Test Work 

Extensive work has been done concerning spiral applications and Multotec has developed a range of spiral models for gravity concentration. They are designed for use of different applications for a variety of minerals that include Gold, Copper, Iron ore, Chrome, Mineral sands, Tin, Coal and Lithium.

Cyclone Rigs

A variety of cyclone configurations according to specific configurations such as classification and dewatering.

Water Purification of Mine Effluents

Built on the foundation of continuous ion exchange, Multotec uses the Clean-iX process, developed by Australian company CleanTeQ. The platform for metals recovery and process water treatment is similar; the technology is branded Clean-IX for metals recovery and CIF® (Continuous Ionic Filtration) for process water treatment. The laboratory test work includes:

• Resin screening tests
• Ion exchange equilibrium isotherms and kinetics
• Column loading and elution tests

Multotec has a 1 m³/h 2-stage test rig for piloting the Clean-iX / CIF® technology

Magnetic Separation Test Work

High intensity separators are used to recover fine, weak magnetic particles from slurries. Medium and low intensity separators are used to recover weak and strong magnetic particles respectively.  Magnetic rolls are used to purify or concentrate dry, granular materials. Multotec offers the following magnetic separators for test work:

• Laboratory Scale Wet High Intensity Magnetic Separator
• Multotec Wet High Intensity Magnetic Separator (50-200 kg/h pilot scale capacity
• Wet & Dry Drum Medium Intensity Magnetic Separator
• Wet & Dry Drum Low Intensity Magnetic Separator
• Magnetic Roll Separator

Filtration Test Work

Typical in-house and on-site filtration test work includes:

• evaluating dewatering characteristics
• monitoring filterability, filtrate quality, solids dryness, flux and discharge characteristics 
• determining of solids density, particle size distribution and solids concentration

Centrifuge Test Work

This is conducted on Multotec’s state-of-the-art Centrilab.

In-house and on-site centrifuge test work includes:

• determining of solids density, particle size distribution and solids concentration
• conducting laboratory centrifuge tests to determine the sample behaviour in the centrifuge, moisture content and optimum operation condition
• sedimentation and filtration type tests

Screen Test Work

Multotec developed a screen test rig for screening media product development and optimising screening media selection according to client requirements. The rig consists of 3 platforms:

• Vibrating screen test platform for slurry drainage tests, wet and dry sizing tests, product development tests and plant screen simulations.
• Static screen test platform with adjustable inclination for drainage tests
• Sieve bend screen test platform for drainage tests

Laboratory equipment for screen test work consists of several Multotec customised test rigs designed to improve development cycles. The test rigs can be adapted to assist clients with rapid prototyping in other areas and consist of:

• Flotation rig to test elastomer wear surfaces on wet ends
• Wear abrasion rig to compare sliding abrasion characteristics of various metals in wet and dry environments according to ASTM 65 test requirements
• Trommel rig to test screen surfaces, scroll designs and feed arrangements
• Drain test rig to better understand screening properties in a controlled environment

Wear Linings Test Work 

Experienced, high-quality, independent in-house ceramic testing and wear characterisation is offered to clients. This test work is used by mineral processing customers, universities, power plants and service providers. The scope of this test work consists of:

• Mechanical testing using Vickers indentation hardness tests and 3-point bending tests
• Metallographic preparation for cutting, grinding and polishing samples
• Heat treatment includes firing or annealing in a laboratory kiln or muffle furnace and bottom loading furnace up to 1 600° C
• Non-destructive testing for cracks with dye-penetration tests, fluorescent light inspection and sound velocity tests for alumina materials
• Wear rate testing of airborne wear rate tests (fused alumina media)

Test work service delivery

To ensure test work information gathered can be replicated in real-time mineral processing, Multotec’s full plant-sized testing facility uses the identical equipment to be installed.

If the required equipment is unavailable, Multotec partners with laboratories like SGS (Geneva-based multinational providing inspection, verification, testing and certification services) and Mintek (the South African autonomous research and development organisation specialising in mineral processing, extractive metallurgy and related technology).

In return, these laboratories use Multotec’s facilities for services they are unable to offer from their own laboratories. Essentially, it is a quid pro quo arrangement which benefits the mineral processing industry as a whole. Additionally:

• Multotec’s facility is used to assist and support the market in general, it is not used only for Multotec customers.
• The service is offered on a local and global level and, depending on the requirements, Multotec staff and equipment (where possible) will conduct tests in the relevant country.
• Once test work is complete, Multotec’s service extends to commissioning and plant support.

There is a nominal charge for test work conducted. However, these costs can be offset against the invoice if Multotec’s equipment is ordered as a result of their test work.

In addition to our test work offering, Multotec’s service offering includes technical capabilities, training, field service maintenance and condition monitoring.

3D prototyping

To produce prototypes for customers quickly and effectively, Multotec makes use of 3D printing in its own 3D printing facility – bringing designs to life. A prototype can be produced within 24 hours, and allows for physical and visual interaction during concept development. The 3D printed parts are used as pattern to produce a mould for products – like screen panels for example. The subsequent mould is used to make screen panels from the required polyurethane material.

Full sized prototypes can be tested on Multotec’s testing rigs to prove or disprove their practical application before tooling stage begins. Where fine tuning and minor adjustments need to be incorporated into the prototype, reprinting can be done in a short period of time.

3D prototyping aids with continuous improvement to existing tooling, simplifying the process to validate the design and functionality before make the steel parts. Multotec is capable of printing objects of various sizes using 2 types of heat lamination 3D printers, and has invested in an extruder to extrude cords to the same specifications used in the manufacturing process.