LiDAR optimisation of belt press filter flocculant dosing

The move away from tailings dams in minerals processing has led to an increase in dry tailings disposal using Belt-Press Filters (BPFs) for coal tailings dewatering, especially in Australia and North America. Typically, BPF flocculation control involves operators manually monitoring and adjusting parameters based on the filter profile via direct observation or CCTV, which can be limited by camera quality and operator availability. To reduce monitoring needs and maintain manageable filter cake, over-flocculation is common, though it raises operational costs, with estimated over-spends of $36,400 annually per filter on typical Bowen Basin coals. Optical colourimetric systems have been developed to optimise flocculant dosing by measuring the filter cake, though they have limitations such as image blinding due to sunrise/sunset and build-up on lenses. This project examined the use of 3D camera and LiDAR technologies to measure the surface profile of the filter cake on a belt press filter and identify the relationship with flocculant dosing levels. Data from these technologies can help develop a more effective flocculant dosing control strategy, minimising costs and maintaining operational efficiency.