KC-MD3 User Manual Rev 4.0 - 201710 - EN

User Manual
Model KC-MD3
™
Knelson Concentrator Manual Discharge
FLSmidth Ltd.
650-700 West Georgia • Vancouver • British Columbia • V7Y 1A1 • Canada
Tel +1 604 888 4015 • Fax +1 604 888 4013 Revision Number 4.0 EN
Parts and Service: knelsonparts@flsmidth.com • Website: www.flsmidth.com (2017/10)
© 1992-2017 FLSmidth A/S. All Rights Reserved.
This manual is provided for informational use only and is subject to change anytime without notice.
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copyright, patent, or trademark.
Although the specifications, features, illustrations, equipment, and other information contained in this
manual are based on information available at time of issue, and while FLSmidth makes all reasonable
efforts to ensure the information is correct, accuracy cannot be guaranteed and FLSmidth makes no
warranties or representations as to its accuracy and assumes no responsibility or liability for any
errors or inaccuracies.
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Table of Contents
List of Figures ............................................................................................. 5
List of Tables............................................................................................... 5
Section 1: Important Safety information ..................................................... 7
Defining safety hazards/conditions ............................................................................... 7
General safety hazards................................................................................................ 8
Section 2: Introduction ............................................................................... 9

About the Knelson Concentrator ................................................................................... 9
When to use an Knelson Concentrator ..........................................................................12
Section 3: Installation ............................................................................... 15

Receiving .................................................................................................................15
Components .............................................................................................................16
Positioning................................................................................................................17
Assembling poly-hose assembly/spray gun ...................................................................17
Connecting the water supply and discharge hose ...........................................................17
Determining the water supply ..............................................................................18
Connecting the power supply ......................................................................................19
Confirming jumper settings ..................................................................................20
Confirming rotor rotation ............................................................................................22
Storing the concentrator ............................................................................................22
Section 4: Operation ................................................................................. 23

Getting ready............................................................................................................23
Startup procedure .....................................................................................................24
Monitoring machine operation .....................................................................................25
Monitoring fluidization-water operating pressure.....................................................25
Monitoring rotor speed ........................................................................................25
Testing methodologies defined ....................................................................................26
Shutdown procedure ..................................................................................................27
Emergency stop procedure .........................................................................................27
Section 5: Maintenance ............................................................................. 29

Rotary union .............................................................................................................29
Greasing the rotary union ....................................................................................30
Replacing the rotary union ...................................................................................30
Concentrating cone ....................................................................................................36
Removing the concentrating cone .........................................................................36
Installing the concentrating cone ..........................................................................38
Maintaining rotor housing O-ring .................................................................................39
KC-MD3 User Manual Rev 4.0(2017/10) 3

Inspecting/cleaning the fluidization holes .....................................................................40
Cleaning the water supply filter screen .........................................................................41
Inspecting V-belt tension ............................................................................................42
Maintaining the rotary locking pin assembly ..................................................................43
Appendix A – E-GRG Test .......................................................................... 45

Appendix B – GAT Test .............................................................................. 53
Appendix C – One Pass GRG Test .............................................................. 57
Appendix D – Two Pass GRG Test .............................................................. 63
Appendix E – Drawings ............................................................................. 71
Appendix F – Facts and Figures ................................................................. 73
Weights and measures .........................................................................................................73
Conversion factors...............................................................................................................73
Grease equivalency list (For manual lubrication ONLY) .............................................................74
Useful formulas ...................................................................................................................74

List of Figures
Figure 2-1 Example of a G5 concentrating cone ........................................................................... 9
Figure 2-2 KC-MD3 concentrating cone ....................................................................................... 9
Figure 2-3 Fluidization process .................................................................................................10
Figure 2-4 Slurry component weight vs. acceleration ...................................................................10
Figure 2-5 Slurry flow ..............................................................................................................11
Figure 2-6 Concentrating bed ...................................................................................................12
Figure 3-1 KC-MD3 Components ...............................................................................................16
Figure 3-2 Permanent magnet motor nameplate showing voltage and current requirements .............20
Figure 3-3 VSD panel doors showing location of four bolts............................................................20
Figure 3-4 VSD jumper J1 and J2 locations.................................................................................21
Figure 3-5 Correct clock-wise rotor rotation................................................................................22
Figure 4-1 Location of STOP switch on the VSD ...........................................................................27
Figure 5-1 Rotary union ...........................................................................................................29
Figure 5-2 Location of grease fitting on rotary union....................................................................30
Figure 5-3 Removing the fluidization hose from the rotary union inlet fitting...................................31
Figure 5-4 Bracing the rotor housing .........................................................................................32
Figure 5-5 Threading rotor housing off the rotary union shaft .......................................................32
Figure 5-6 Removing the bolt from the rotary union bracket .........................................................33
Figure 5-7 Using wedge to release the rotary union .....................................................................33
Figure 5-8 Location of 2-3 mm clearance between housing and locking pin ....................................34
Figure 5-9 Applying Loctite to rotor housing threads ....................................................................34
Figure 5-10 Threading rotor housing onto the rotor union shaft ....................................................34
Figure 5-11 Tightening the rotor housing onto the rotary union ....................................................35
Figure 5-12 KC-MD3 Concentrating cone ....................................................................................36
Figure 5-13 Removing screen and feed funnel ............................................................................36
Figure 5-14 Location of rotary-locking pin ..................................................................................37
Figure 5-15 Illustrating clockwise direction to loosen cone-locking ring ..........................................37
Figure 5-16 Illustration of locking pin slotted into rotor housing notch ...........................................37
Figure 5-17 Removing the cone-locking ring ...............................................................................37
Figure 5-18 Removing concentrating cone ..................................................................................38
Figure 5-19 Hand-tightening cone-locking ring by turning it in a counter-clockwise direction ............38
Figure 5-20 Seating O-ring into rotor housing groove ..................................................................39
Figure 5-21 Using hole-cleaning tool to unplug fluidization hole ....................................................40
Figure 5-22 Water supply hose filter screen................................................................................41
Figure 5-23 Removing belt guard assembly ................................................................................42
Figure 5-24 Location of rotary locking pin assembly below rotor housing........................................43
List of Tables
Table 4:1 Test methodologies by stream ....................................................................................26

Section 1: Important Safety information
This manual contains important safety information about the
Knelson Concentrator Manual Discharge Model KC-MD3. Read and
understand the safety symbols and hazards defined in this section
before installing, operating, or maintaining this machine.
Any use of the concentrator other than described in this manual

requires prior written approval from FLSmidth. Failure to comply
with these conditions will automatically release FLSmidth from any
responsibility or liability as per the “Machinery Directive,” “EMC
Directive,” and “Low Voltage Directive.”
Defining safety hazards/conditions

Defined below are symbols and signal words used throughout this
manual. These specifications are intended to alert and inform users
of specific hazards and conditions when operating or working around
the concentrator and provide instruction on how to take
precautionary action or other appropriate action.
WARNING indicates a hazardous situation, which if not avoided,

could result in death or serious injury.
CAUTION indicates a hazardous situation, which if not avoided,

could result in minor or moderate injury.
NOTICE information considered important but not hazard-related,

such as a risk of machine damage.

General safety hazards
WARNING: Understand these safety hazards before installing,

operating, or maintaining the concentrator to avoid a hazardous
situation that could result in death or serious injury.
• Only trained and qualified personnel should install, operate, or

maintain the concentrator.
• All wiring connections must be properly isolated. Verify voltage
and wiring are correct and match the nameplate on the motor.
• Always disconnect the concentrator from the plant water system
before maintenance.
• Always follow the LOCKOUT/TAGOUT procedure when performing
maintenance on the concentrator.
• Never operate concentrator with screen pan or feed funnel
removed. Rotating parts hazard – removing these parts during
operation could result in serious injury.
• Wear personal protective equipment (PPE), including ear and eye
protection, when working around the concentrator.
• Keep pathways around work area clear. Remove any tripping
hazards.
• Always use correct lifting techniques when handling buckets of
slurry.

Section 2: Introduction
The Knelson Concentrator is a centrifugal gravity separator that
combines a high-g centrifugal force with a patented fluidization
technology to produce unequalled performance in the recovery of
free target heavy mineral. This section provides a brief overview
about the concentrator and the various applications. For more
information, contact a Knelson Concentrator specialist at FLSmidth
About the Knelson Concentrator

The central component for processing slurry is the concentrating
cone. The cone is composed of a highly wear resistant polyurethane
compound. The conical shape incorporates a series of rings that
increase in diameter from the bottom of the cone to top of the cone.
Around the circumference of each ring are a series of fluidization

holes. The precise size, number, and location of these holes results
from extensive research and on-going product development.
FLSmidth produces application specific cones. The profiles are

designated as G4, G5, G6, and G7. The larger model concentrators
typically use a G5 or G6 profile (See Figure 2-1), whereas the
smaller, lab-sized concentrator (i.e. KC-MD3) uses a G4 profile. See
Figure 2-2.
Figure 2-1 Example of a G5 concentrating cone Figure 2-2 KC-MD3 concentrating cone

During machine operation, water flows up the rotor shaft into a
water cavity formed between the concentrating cone and rotor
housing.
As the cavity reaches capacity, water is forced through the

fluidization holes into the concentrating cone tangential to the
movement of the cone wall. See Figure 2-3.
Figure 2-3 Fluidization process
The concentrator’s rotor assembly, as viewed from above, spins in a

clockwise direction at a predetermined speed. As illustrated in Figure
2-4, the rotational speed creates a centrifugal acceleration of up to
200 g, compared to the 1 g force employed by conventional gravity
concentrating devices such as mineral jigs, shaking tables, and
sluice boxes.
Figure 2-4 Slurry component weight vs. acceleration

Feed slurry enters the unit through a stationary feed funnel. The
slurry flows down the feed funnel to the bottom of the cone where
centrifugal force drives it outward to the cone wall. See Figure 2-5.
Figure 2-5 Slurry flow
As the solids reach the wall, they fill each ring starting from the
bottom. Once each ring reaches capacity, a concentrating bed is
established and water simultaneously injected from the water cavity
fluidizes this bed.
The fluidization-water flow-rate is optimized during the

commissioning of the concentrator. Variables affecting the flow-rate
include particle size distribution, overall gangue density, and size of
the gold being targeted.
Optimal fluidization occurs when the inward flow of water through

the concentrating bed balances the outward force of the slurry. This
enables fine-grained target heavy mineral particles to sink into the
bed through interstitial trickling. See Figure 2-6.
As long as the fluidization-water flow-rate stays unchanged, the

selection and concentration of high specific gravity particles, and the
rejection of low specific gravity particles, will continue.

Figure 2-6 Concentrating bed
At the conclusion of the concentrating cycle, the concentrating cone

is removed from the rotor housing and the concentrates are washed
out with the supplied clean-out wand for subsequent inspection. For
full scale concentrators, the concentrate is flushed automatically.
When to use an Knelson Concentrator

A Knelson Concentrator should be an integral part of any type of
mineral processing system. Use the concentrator whenever there is
an opportunity to recover “free-milling” or “native” target heavy
mineral particles.
Use the concentrator when:
• samples from an alluvial deposit contain traces of free target

heavy mineral
• visible gold has been detected in drill cores by geologists
• metallurgical test work has confirmed presence of free target
heavy mineral in ore
• free target heavy mineral losses have been detected in mill
tailings streams
• occasional assay “spikes” are observed in mill final tails samples
• high target heavy mineral “inventory” has been detected in any
closed grinding circuit

• free target heavy mineral has been detected when relining mills,
cleaning sumps and at other collection points
Use the concentrator to:
• recover alluvial target heavy mineral recovery

• recover primary target heavy mineral from mill grinding circuits
• recover by-product target heavy mineral from base metal
grinding circuits
• recover gold from flotation concentrates
• recover target heavy mineral from tailings re-treatment
• recover secondary target heavy mineral in concentrate upgrading
operations
• recover other high specific gravity minerals and metals such as
platinum, silver, and mercury

Section 3: Installation
Carefully read and follow the instructions in this section and refer to
the drawings provided to prepare the KC-MD3 for operation.
Receiving
The KC-MD3 is factory shipped assembled in a wooden crate
protected by custom fit packaging. Included separately with the
shipment are the following items:
• Spray gun
• Clear poly-hose assembly
• Clean-out wand assembly
• Fluidization hole cleaning tool
• Extra filter hose strainers (quantity two)
Depending on the requirements at time of ordering, the shipment

may also include the following optional items:
• Lubrication kit (grease tube, grease gun hose c/w dispenser)
• Commissioning spare parts kit
Upon delivery, check the packing list to ensure all items listed are
included and in good condition. If any items are missing or
damaged, then make a note on the bill of landing and notify
FLSmidth.
Keep the wooden crate and custom fit packaging for future use.
These items will protect the KC-MD3 during a move or during long-
term storage. For specific storage instructions, refer to Section 3.8.
It is important to follow these instructions to maintain the life of the
machine and for warranty protection.

Components
Shown in Figure 3-1 are some of the key components of a KC-MD3
Knelson Concentrator.
2
6
3 7
8
4
10
Item Description
Flexible steel gooseneck connection with
1
nozzle
2 Motor
3 Hose coupling connection, or hose barb
4 Rotary union
Flexible poly hose connection – use with
5
spray gun and clean-out wand
6 Fluidization-water valve
7 Needle valve
8 Pressure gauge
9 Flow meter
10 Reduce port ball valve
Figure 3-1 KC-MD3 Components

Positioning
Position the KC-MD3 on a reasonably level surface. If operating the
concentrator in a lab, place it on a table or a counter. If operating
the unit in the field, position the unit on a small piece of plywood to
create a level surface. Whether in the lab or in the field, the unit
does not require positioning on an absolute level surface or bolting
down.
When considering a location ensure there is enough space to

manage the collection and removal of the tailings and water
discharged from the tailings outlet.
Assembling poly-hose assembly/spray gun

Connect the female end of the clear poly-hose assembly provided to
the male connector on the manifold. Use the quick coupler plug on
the spray gun and connect to the quick coupler socket on the other
end of the poly-hose
Connecting the water supply and

discharge hose
CAUTION: Always use flexible hose for the inlet and outlet piping
to avoid damaging the concentrator.
The KC-MD3 requires two flexible hoses: one hose to supply

fluidization-water to the concentrator, and one hose to discharge
tailings from the concentrator into a bucket or other tailing system.
For the water supply choose a flexible hose. Connect the hose to the
¾” hose coupling located on the manifold, or attach the hose barb
to hose coupling and attach the hose to the hose barb.

For the tailings discharge, choose a rubber hose with a 2” inner
dimension to fit over the outside of the tailing pipe on the tailing
launder.
During operation, the KC-MD3 produces low vibration. Four rubber

vibration isolators mounted on the base of the concentrator helps to
reduce but not eliminate this movement. For this reason, use a
flexible and preferably short hose when connecting the water supply
hose and the tailings discharge hose. A short flexible hose will allow
for minor unobstructed movement during operation.
If using a long hose is unavoidable, support the weight to a

maximum of 600 mm (24”) from the connection to avoid adding
excessive weight to the machine.
Determining the water supply
The quality, source, and temperature of the fluidization-water supply

are important elements to consider before operating the KC-MD3.
Refer to the information in this section when determining the water
supply.
CAUTION: Failure to provide fluidization-water of adequate

quality could void all warranties.
Quality
The water supply should be clean and free of suspended sediments

or organics to avoid sediment build-up inside the water cavity.
Excessive sediment can lead to plugged fluidization holes and
disturb the rotor assembly’s dynamic balance. This condition could
reduce recovery times and/or cause damage to the machine.
Therefore it is important that suspended sediments be given a
chance to settle out of the water before entering the KC-MD3 piping
system. Note: the water does not have to be crystal clear.
Also certain water chemistries can cause scale build-up. For

example, water containing high pH levels or low-solubility salts such

as gypsum (calcium sulfate), barite (barium sulfate), and calcite
(calcium carbonate). Scale build-up inside the water cavity can lead
to plugged fluidization holes. If this occurs, follow the instructions in
Section 5 to remove and clean the concentrating cone.
Source
Domestic water is the preferred water source, if available. If not

available, pre-clean the water and allow large sediments to settle
out prior to use. If using re-circulated water, ensure the water
source is free from excessive amounts of suspended solids.
FLSmidth does not recommend using salt water as the water supply.
This is due to the susceptibility of corrosion to the steel components
on the KC-MD3.
Temperature
Use cold to lukewarm water for testing. The use of hot water may
expand the concentrating cone making it difficult to remove from
the rotor housing
Connecting the power supply
WARNING: Connect the power supply in accordance with local

codes.
The KC-MD3 comes equipped with a 1/4 HP [0.19kW], permanent

magnet (PM) 90V DC electric motor wired to a variable speed drive
(VSD). The control features on the VSD include LEDs for power ON,
overload (OL) and STOP. It also includes an electronic START-STOP
switch.
The power supply automatically adjusts for a line input of 115 or

208/230 VAC. Users must attach a suitable plug on-site to suit their
outlet.

Confirming jumper settings
The VSD is configured at the factory to match the motor voltage and
current requirements as described on the motor nameplate.
Figure 3-2 Permanent magnet motor nameplate showing voltage and current requirements
The FLSmidth default configuration is that the armature voltage is

set to 90V on the J1 jumper and the motor current is set to 2.5A
on the J2 jumper. These jumpers are accessible by removing the
cover of the VSD.
1. Remove the four bolts on the VSD panel shown in Figure 3-5.
Figure 3-3 VSD panel doors showing location of four bolts

2. Inspect the jumper settings at the locations shown in Figure
3-4.
Figure 3-4 VSD jumper J1 and J2 locations
For more information about the motor and the VSD, refer to the
manufacturers’ manuals provided.

Confirming rotor rotation
The correct direction of rotor rotation is clockwise as viewed from
the top. See Figure 3-11. Confirm rotation at initial start-up and
correct, if necessary, by referring to information on the motor
nameplate.
Figure 3-5 Correct clock-wise rotor rotation
Storing the concentrator

During the interval when the concentrator is not in use:
• Flush and drain all piping when storing the concentrator for an
extended period (more than one month) and when exposing the
machine to freezing conditions.
• Storage of rubber and urethane parts can be at temperatures
down to -60 C, but keep out of direct sunlight.
• Before resuming machine operation:
− Inspect for signs of corrosion, sediment or scale build-up and
remove. If excessive, contact a Knelson Concentrator
specialist at FLSmidth for more information.
− If storing the machine for more than three months, then
lubricate the rotary union bearings.

Section 4: Operation
Operation of the KC-MD3 is relatively simple. However, being aware
of some fundamental concepts will allow for smoother operation and
better optimization of the concentrator.
This section provides general instruction on how to prepare, startup,

and shutdown the concentrator. It also provides concepts and
strategies to monitor and optimize machine performance. To achieve
optimal results and to avoid rework, it is important to adhere to
these instructions and to the test methodologies provided in the
Appendices.
Getting ready
After completing the installation requirements including connecting
the fluidization-water supply, the piping and the power, follow the
general instruction in this section to get ready for operation.
Understand the sample requirements
Prior to start-up, understand the sample requirements and assemble

the applicable materials and apparatus. Have available, buckets for
tailings and feed sample, pans for drying concentrates and tailings,
and other apparatus.
Prepare the sample
Before initial start-up and prior to every test, it is important to first

prepare the sample. For guidelines on how to prepare a sample,
refer to the test methodologies provided in the Appendices.
Clean the machine
Before starting the KC-MD3 it should be free of any residual

concentrate from the previous test. Use the cleaning tools provided
with the concentrator and refer to the steps below to ensure the

interior and exterior surface are free of material, and that the unit is
properly reassembled before operation.
To clean the machine:
1. Remove the screen pan, feed funnel, cone-locking ring, and

concentrating cone. For instructions, see Section 5.2.1.
2. Inspect the cone’s fluidization holes and clean as needed using

the hole-cleaning tool provided. See Section 5.4.
3. Remove and inspect the rotor housing O-ring. Inspect for tears
or cracks; replace if damaged. When installing ensure the O-
ring is properly seated. See Section 5.3
4. Reinstall the concentrating cone ensuring it is locked in-place.

See Section 5.2.2.
5. Position the feed funnel and screen pan in-place.
Startup procedure
1. Ensure the reduce port ball valve located under the rotor
housing is closed.
2. Have empty buckets in place to catch the tailings launder run-

off.
3. Open the full port ball valve to turn ON the fluidization-water

and use the flow meter to set the flow rate to 3.5 L/min.
NOTICE: Water provides lubrication to the rotary union and seal

surfaces. Rotating the rotary union without water may damage the
union and/or seals.
4. Wait until the water is flowing through the tailings launder. It

may be necessary to adjust the needle valve.
5. Set VSD to required speed then START the machine.

Monitoring machine operation
To ensure the KC-MD3 is operating properly, it is important to
monitor the fluidization-water operating pressure and rotor speed.
Monitoring fluidization-water operating

pressure
The KC-MD3 requires a concentrate fluidization-water supply of

approximately 0.7-7.0 Lpm (0.2-1.6 USgpm) at a minimum
operating pressure of 55-69 kPa (8-10 psi).
CAUTION: To avoid equipment damage, the maximum operating

pressure should not exceed 414 kPa (60 psi).
The concentrator is equipped with a 0-70 kPa (0-10 psi) pressure

gauge. During operation the operating pressure should not increase
dramatically (when comparing separate cycles) during the
optimization process. A dramatic increase in pressure indicates
fluidization holes are plugged. Plugged holes could ruin the
optimization process.
NOTICE: It is normal for the operating pressure to raise 7-20 kPa

(1-3 psi) over the course of a cycle.
Monitoring rotor speed
The KC-MD3 has been designed to operate at 1450 RPM (60 G’s +-
2%). With a variable speed drive the machine may operate up to
2050 rpm (120 g). The rotor’s operating speed should not be
exceeded unless the rotating assembly is specifically re-balanced for
higher speeds and the manufacturer has been consulted prior to this
modification. Only use genuine FLSmidth, Knelson Concentrator
parts.

Testing methodologies defined
There are three industry standard test methods that can be
conducted using the KC-MD3. These test methods are defined as:
• Extended Gravity Recoverable Gold (E-GRG) - This test is

used to determine the amenability of an ore to the utilization of
batch gravity concentration technology.
• Gravity Amenability (GAT) - This test is used to determine the
amenability of an ore to the utilization of continuous gravity
concentration technology.
• Gravity Recoverable Gold (GRG) Stream Test - This is used
when testing a plant stream, as opposed to an ore. The test can
be conducted as a one-pass test or a two-pass test depending on
the stream.
Determining which test to use depends on the sample to be tested.

Differing samples from within a mineral processing circuit will have
specific processing requirements. To determine which processing
method is suitable to the sample, cross-reference the information
provided in Table 4:1 to the applicable procedure in the Appendix.
For more information, contact FLSmidth.
Table 4:1 Test methodologies by stream

Typical Sample Refer to
Stream Test
Weight (kg) Appendix
Ore, free Gold determination E-GRG 30-50 A
Ore, or plant stream for Gold associated sulphides GAT 1-10 B
Cyclone Underflow GRG One-Pass 10-15 C
Primary Knelson Tailings GRG One-Pass 10-15 C
Primary Knelson Feed GRG One-Pass 10-15 C
Flash Flotation Tailings GRG One-Pass 10-15 C
Flash Flotation Concentrates GRG One-Pass 10-15 C
Alluvial GRG One-Pass 20-100 C
Cyclone Overflow GRG Two-Pass 10-15 D
Flotation Concentrates GRG Two-Pass 10-15 D
Final Tailings GRG Two-Pass 50-100 D
GRG Two-Pass with
Rougher Concentrate 20-30 D
Intermediate Grind

Shutdown procedure
The shutdown procedure varies, depending on the test
methodology. For this reason, refer to the processing method
provided in the Appendices.
In general, follow the shutdown procedures in the sequence

provided to prevent concentrate particles from migrating into and
plugging the fluidization holes. If the machine is not shutdown
properly the results could destroy the test. However, the test may
be repeated as long as the entire sample can be recovered from
within the system (i.e. tailings launder, or concentrating cone).
Emergency stop procedure

The KC-MD3 is equipped with a 1/4 HP, 90V DC electric motor wired
to a variable speed drive (VSD).In case of emergency, either use the
STOP switch on the VSD to turn OFF the power to KC-MD3 or unplug
the VSD power cord from the power outlet. See Figure 4-1.
Figure 4-1 Location of STOP switch on the VSD

Section 5: Maintenance
The KC-MD3 is easy to use and requires minimal maintenance over
its anticipated life. For continued reliability and cost efficient
operation follow the maintenance instructions in this section.
Rotary union
The rotary union is a precision mechanical device that transfers
pressurized water from static piping outside the KC-MD3 to the
rotor. See Figure 5-1. Micro-lapped sealing surfaces and anti-friction
bearing enable the rotary union to supply water at a constant
pressure while rotating at high speeds.
Figure 5-1 Rotary union
A small amount of water must always be present in the rotary union

to lubricate the sealing surfaces. A slight squealing sound may be
apparent while the union’s seals are being seated or replaced.
If water is leaking from the rotary union brass housing it must be

replaced. To order a new rotary union, contact a Knelson
Concentrator specialist at FLSmidth. To remove/install a
replacement rotary union see Section 5.1.

Greasing the rotary union
The rotary union is factory shipped pre-greased. To replenish the

grease, pump one (1) shot into the grease fitting located on the
union support frame after every 150 hours of operation. See Figure
5-2. Only grease the bearings while the unit is operating and
preferably when at a normal operating temperature. The
recommended grease is Shell Gadus® S4 V600AC 1.5.
CAUTION: To avoid premature bearing failure, do not over grease.

Many bearing failures occur because the heat generated by the
churning of the surplus grease results in grease softening and the
eventual breakdown of the lubrication film.
Figure 5-2 Location of grease fitting on rotary union
Replacing the rotary union
CAUTION: Always LOCKOUT power before maintaining the

concentrator.

Follow the steps in this section for instruction on how to replace the
rotary union in the KC-MD3.
To remove the rotary union:
1. Ensure power to the KC-MD3 is LOCKED OUT.
2. Remove the screen pan and feed funnel from the top of the
tails launder. Remove the concentrate cone. See Section 5.2.1.
3. Remove the two-piece belt guard assembly. See Section 5.6.
4. Loosen the clamps that secure the piping to the KC-MD3 and
remove the fluidization hose from the rotary union by grasping
the collar on the union inlet fitting and pulling the collar
towards the inlet fitting and the hose away from the inlet
fitting. See Figure 5-3.
NOTICE: By loosening the piping clamps it allows the piping to

swivel out when removing the fluidization hose from the rotary
union inlet fitting.
Figure 5-3 Removing the fluidization hose from the rotary union
inlet fitting
5. Remove the drive belt.
6. Using a 10 mm wrench (or equivalent) as a brace, install the

open end of the wrench into locking notch located at the
bottom of the rotor housing and brace the other end of the
wrench to the bottom of the piping bracket. See Figure 5-4.

Figure 5-4 Bracing the rotor housing
7. Use a 7/8” thin profile wrench to loosen the nut at the top of
the rotary union and thread the rotor housing off the rotary
union shaft. See Figure 5-5.
Figure 5-5 Threading rotor housing off the rotary union

shaft

8. Remove the bolt from the rotary union bracket and using a
wedge or flathead screwdriver, insert into the split in the rotary
union bracket to release the rotary union. See Figures 5-6 and
5-7.
NOTICE: Measure the height the rotary union is held in the bracket
before removing to ensure proper orientation of the replacement
union).
Figure 5-6 Removing the bolt from the rotary union bracket Figure 5-7 Using wedge to release the rotary union
To install the rotary union:
NOTICE: If installing a new rotary union, reuse the fittings from the
old rotary union.
1. Install the new rotary union into the union bracket while
ensuring it is at the correct height in the bracket.
NOTICE: Typically when the rotor housing is installed onto the

rotary union, the bottom edge of the rotor housing will clear the
rotary locking pin by 2-3 mm. See Figure 5-8.

Figure 5-8 Location of 2-3 mm clearance between
housing and locking pin
2. Tighten the bolt on the bracket.
3. Apply a small amount of Loctite # 242 to the threads of the

rotor housing and thread onto the rotary union shaft. See
Figure 5-9 and 5-10.
Figure 5-9 Applying Loctite to rotor Figure 5-10 Threading rotor housing onto the
housing threads rotor union shaft
4. Use a 10 mm wrench as a brace to tighten the rotor housing

onto the rotary union. Position the wrench in the opposite
direction as first used in the disassembly procedure and use a
7/8” wrench to tighten the rotary union nut. See Figure 5-11.

Figure 5-11 Tightening the rotor housing onto the rotary
union
5. Install the drive belt.
6. Install the fluidization hose by pushing the hose into the rotary
union inlet fitting. Tighten the piping clamps.
7. Install the belt guard assembly.
8. Install the concentrate cone and cone-locking ring. Install the

feed funnel and material screen.
9. Turn ON the water supply and check for leaks.
NOTICE: Avoid premature damage to the rotary union seal

surfaces; DO NOT operate the concentrator without water in the
union.
At all times a small amount of water must be maintained in the

rotary union to keep the seal surfaces lubricated. When new, the
seals may squeal slightly while seating.

Concentrating cone
Collecting residual concentrates in the cone is a significant step in
the testing process. After each sample, it is important to inspect the
concentrating cone (See Figure 5-12) for plugged fluidization holes
and to clean the holes if needed. See Section 5.4. Inspection and
cleaning is only possible with the cone removed. To remove and
install the cone, follow the instructions in Section 5.2.1 and 5.2.2.
Figure 5-12 KC-MD3 Concentrating cone
Removing the concentrating cone
1. Remove the screen pan and the feed funnel from the top of the
machine as shown in Figure 5-13.
Figure 5-13 Removing screen and feed funnel

2. Remove the cone-locking ring. Use one hand to push the rotary
locking pin up against the bottom of the rotor housing (See
Figure 5-14), then use the other hand and slowly turn the
cone-locking ring (See Figure 5-15) until the locking pin slots
into the notch. See Figure 5-16.
Figure 5-14 Location of rotary- Figure 5-15 Illustrating Figure 5-16 Illustration of
locking pin clockwise direction to loosen locking pin slotted into rotor
cone-locking ring housing notch
3. Continue to turn the locking ring clockwise as shown in Figure

5-17, until the locking ring becomes loose; then remove the
ring.
Figure 5-17 Removing the cone-locking ring
4. Remove the O-ring from its groove. Inspect for damage;

replace if necessary. See Section 5.3.

5. Remove the concentrating cone from the rotor housing. See
Figure 5-18.
Figure 5-18 Removing concentrating cone
Installing the concentrating cone
1. Install the concentrating cone.
2. Hand-tighten the cone locking ring by turning it in a counter-

clockwise direction as shown in Figure 5-19, while holding the
rotary locking pin in-place.
Figure 5-19 Hand-tightening cone-locking ring by turning it

in a counter-clockwise direction
3. Install the screen funnel and screen pan.

Maintaining rotor housing O-ring
Located in the groove of the rotor housing is an O-ring. See Figure
5-20. When properly seated and undamaged this ring provides a
watertight seal between the rotor housing and the concentrating
cone. A watertight seal helps to keep the water and concentrate
from entering the rotor housing water cavity.
Frequent removal of the lock ring to access the concentrating cone

to collect residual sample provides opportunity to inspect the O-ring
for tears or cracks and to replace if damaged.
For ease of removal and reinstallation, apply a small amount of non-

hardening silicone gel to the O-ring while disassembled. This
preventative action will reduce the risk of tearing damage and help
to extend its service life.
Figure 5-20 Seating O-ring into rotor housing groove

Inspecting/cleaning the fluidization holes
The fluidization holes allow the transfer of water from the water
cavity into the rings of the concentrating cone. This transfer is
essential to maintain proper fluidization of the concentrate bed
during operation. Over time, depending on frequency of operation
and water quality, solids and scale build-up will plug the fluidization
holes and cause the fluidization process to slow or stop, and thus
reduce recovery.
For this reason inspect the fluidization holes after each sample. To
clean plugged holes, use the hole-cleaning tool provided and follow
the instruction below.
To clean the fluidization holes:
1. Remove the concentrating cone. See Section 5.2.1.
2. Inspect each fluidization hole for sediment or scale build-up to

determine if cleaning required. See Section 5.4.
3. Align the hole-cleaning tool provided with the angle of each

plugged fluidization hole. See Figure 5-21.
Figure 5-21 Using hole-cleaning tool to unplug fluidization hole
4. Gently turn the hole-cleaning tool, keeping the tool at the same
angle as the hole, and clear the plugged fluidization hole.

Cleaning the water supply filter screen
The water supply filter screen, shown in Figure 5-22 helps to keep
large sediments from entering the water cavity. Find this easy to
clean screen located where the water supply hose connects to the
manifold.
To clean the screen:
1. Detach the hose from the manifold and remove the screen from
the hose.
2. Scrape/rinse off any particles that many have accumulated.
3. Inspect the screen for damage and replace if needed.
4. Reassemble the screen to the hose and attach to the manifold.
Figure 5-22 Water supply hose filter screen

Inspecting V-belt tension
CAUTION: Before performing any inspection or adjustment of the

V-belt or any other part of the concentrator, lockout and disconnect
the power supply.
The steps to inspect the V-belt are:
1. Lock out the power supply by pulling the plug
2. Remove the belt guard assembly. See Figure 5-23.
a. Remove the two 1/2" fasteners from both sides of the belt
guard.
b. Remove the two 3/8" fasteners from the underside of the

belt guard.
Figure 5-23 Removing belt guard assembly
3. Check the belt tension. It should deflect approximately 10mm

(3/8") at mid-span between the cone and the motor sheave
when applying moderate thumb pressure to the side of the belt.
4. If necessary, adjust or replace the belt.

Maintaining the rotary locking pin
assembly
Once weekly, apply light oil to the rotary locking pin to protect it
from rust and to ensure it continues to function with ease. See
Figure 5-24.
Figure 5-24 Location of rotary locking pin assembly

below rotor housing

Appendix A – E-GRG Test
1.0 Safety first
WARNING: Before beginning this test, read the safety precautions

outlined in Section 1 in this KC-MD3 User Manual.
2.0 Overview
The KC-MD3 is used to determine the amenability of an ore type to
gravity concentration. It uses centrifugal forces to selectively
separate free gold and other heavy minerals from the ore. The GRG
value of an ore sample provides an indication of the amenability of
the ore to gravity concentration. The GRG testing scheme is based
on the fact that progressive size reduction allows for the
determination of the precious metal recovery as liberated without
over-grinding and smearing coarse precious metal particles.
The GRG test consists of three sequential liberation and recovery

stages. The progressive grinding (as opposed to testing only at final
grind) is necessary in order to obtain an accurate GRG value with an
indication of the size distribution of the GRG. It also limits smearing
of coarse gold particles that may be present in the as-crushed
sample.
3.0 Sample requirement

The sample should be free of the usual pitfalls of gravity testing,
such as gold traps or the use of samples from circulating loads that
are non-representative of steady-state operation. If using plant
samples they should be obtained over a reasonable amount of time
to average out day-to-day variations.
The ideal samples for this test are composite samples from:
• Drill core
• Crusher product (if it is fine enough for representative sampling)
• Primary mill discharge (not from within the circulating load)
4.0 Flowsheet
Receive coarse
sample
US12# (1.7mm)
Crush
Split sample
1. 2.
Grind Test (10 kg) E-GRG Test (20 kg)
Sub-sample- Screen and assay

Grind 2 min MD3 Test KC Conc.1
Screen fractions
(Stage 1)
Sub-sample-
Grind 10 min KC Tails 1 Sub-sample- Screen
Screen
Sub-sample- MD3 Test Screen and assay

Grind 13 min Grind KC Conc.2
Screen (Stage 2) fractions
Sub-sample- KC Tails 2 Sub-sample- Screen

Grind 15 min
Screen
MD3 Test Screen and assay

Grind KC Conc.3
Tails (Stored) (Stage 3) fractions
Sub-sample- Screen
KC Tails 3
and assay fractions
Tails Disposed
Tails (Stored)
Tails Disposed

5.0 Apparatus and Materials
• Jaw Crusher
• Sweco Screen
• Riffle Splitter
• Agitator
• KC-MD3
• Buckets- for tailings and feed sample
• Compressed air (for removing dust)
• Oven
• Rod Miill (available from FLSmidth)
• Filter Press
• Pans for drying concentrates and tailings
• Screens for screen analysis
6.0 Procedure
Sample Preparation
Coarse wet samples should be dried at 60-150°C prior
to any sample preparation. If mercury (Hg) is known to
be in the samples, the samples must be dried at 50°C
or less to avoid mercury vapors.
Stage crush sample in its entirety to 98-100% passing
1.7 mm.
Split sample into appropriate size for testing purposes.
A 10-kg portion is required for the grind test and a 20-
kg portion is used for the E-GRG test. Any remaining
sample shall be kept as storage.
If less than 30-kg is available sample is spilt into three
representative portions and the processing is completed
following the general outline. Note: If 25kg or less is
available omit the grind portion of the test procedure as
outlined in Section 6.2.
Grind Test
A grind test requires 10kg based on a 10kg mill.
Smaller mills will require smaller feed masses.
Follow the instructions for mill in use.
Graph the screen analysis data obtained and use to
determine grind times necessary to obtain the required
p80 values for the E-GRG test.
Machine Start-up & Stage 1 processing

Ensure KC-MD3 (including feed funnel, launders, water
jacket, concentrating cone, and tailings line) is clean.
No material should be present on any interior or
exterior surfaces.
Set machine parameters to standard settings; rotation
to correspond to a force of 60 G’s and 3.5 litres/min
fluidization water.
Record dry sample mass on appropriate record sheet
(~20 kg for an E-GRG).
Slowly feed sample into feed funnel, feed rate should be
~500-800g/min of solids.
Sub-sample gravity tails during processing. The tails are
cut at consistent intervals until all of the feed has been
processed and should be between 150-200g. See
Section 6.6 for tails handling procedure.
Shutdown machine as outlined in Section 6.5.
Remove concentrating cone and carefully rinse
concentrate into the gold pan using the cone washing
wand. Ensure any material in water jacket is combined
with concentrate. See Section 6.7 for concentrate
handling procedure.
Prior to Stage 2 and Stage 3 processing the Bulk KC-
MD3 Tailings is to be ground for the appropriate length
of time as determined in the grind time analysis.

Sample processing- Stage 2 & 3
Grind bulk tails from previous stage of processing at
60% solids for appropriate length of time as determined
in the grind time analysis. Target grinds are p80=250
microns for Stage 2, and p80=75 microns for Stage 3.
fluidization water.
Slowly feed ground tailings sample into feed funnel,
feed should be at a rate of ~500-800g/min of solids.
Stage 2 Tailings: Sub-sample gravity tails during
processing. The tails are cut at consistent intervals until
all of the feed has been processed and should be
between 150-200g. See Section 6.6 for tails handling
procedure.
Settle, decant, and regrind the bulk tailings as
determined by the grind analysis before stage 3
processing.
Stage 3 Tailings: Tailings should be sampled as per
section 6.4.4; however, a 200-300g sub sample is
required. Filter the entire tails. Dry. Follow Section 6.6
for processing tailings.
Shutdown machine as outlined in Section 6.5.
wand. Ensure any material in water jacket is combined
with concentrate. See Section 6.7 for concentrate
handling procedure.
Repeat Section 6.4 for Stage 3 processing
Final bulk tails are stored once third stage processing is
complete.

Machine Shut-down
Simultaneously, turn OFF fluidization water using ball
valve located on top piping and the motor.
Allow rotor housing to come to complete stop.
Remove feed funnel. Wash any material on underside of
feed funnel into tailings.
Remove cone locking ring (recall left-hand thread). Any
sample on cone locking ring should be washed into
concentrate container.
wand. If material is present in fluidization water holes,
clean accordingly.
Place empty container under drain valve at the bottom
of the rotary housing.
Open drain valve at the bottom of the rotary housing
and allow water jacket to empty.
Clean water jacket with fresh water.
Open fluidization water valve for 2 seconds then close
valve. This ensures any solids that may have gotten
into the water jacket are removed from the system.
Allow water jacket to completely drain and close drain
valve at the bottom of the rotary housing.
Combine the material collected from the drain valve
with concentrate into the gold pan.
Thoroughly wash out KC-MD3 tailings launder and
piping line into tailings bucket.
Wash out the tailings container to ensure there is no
residual material.
Store KC-MD3 tailings for further processing or storage.

Gravity Tails Sub-samples: Screen Analysis
and Assay
Stage 1&2: Wet screen sample at 38 microns.
Record the mass (either of the +400# or entire
sample). Dry screen the oversize through the following
mesh sizes (in microns) 1700, 1180, 850, 600, 425,
300, 212, 150, 106, 75, 53, 38, 25, pan. Weigh and
record all screen fraction weights.
The first and second pass screen fractions can be re-
combined and stored as reference samples.
Stage 3: The cut bulk tailings sub-sample is filtered,
dried and weighed in its entirety.
Record the dry weight of total sub-sample.
Cut a representative portion ~30-50g from the total
sub-sample. This is considered a bulk sub-sample for
QA/QC.
The remainder of the sample (up to 200g) is used for
screen analysis to determine actual p80. Each fraction
is assayed. If the remaining sample is greater than
200g, representatively split out 200g for screen analysis
and store the remaining as reference.
Wet screen sample at 25 microns.
Dry screen oversize through the following mesh sizes
(in microns) 1700, 1180, 850, 600, 425, 300, 212, 150,
106, 75, 53, 38, 25, pan. Weigh and record all screen
fraction weights.
Stage 3 screen fractions must be weighed and placed in
separate clean, dry, labeled sample bags. If the tailings
weight is less than 2g, record weight then combine with
the next fraction for assay purposes.
Combine the –25 micron wet and dry screens and
representatively cut 2 samples from the –25 micron
fraction if the mass is greater than 30g. The sample

may need to be pressed and rolled using a rolling pin to
remove any lumps.
All products are sent for Au assay (or other PGM
assays). The bulk stage 3 tails and –25 duplicates are
QA/QC samples.
Determine the p80 of the tails sample prior to sending
the sample for assay. If the p80 is greater than 85µm,
recombine the last stage tails and concentrate. Grind
and re-process the sample through the KC-MD3.
(Ensure to include all concentrate, tailings and
reference samples).
Concentrate Samples: Screen Analysis and

Assay
Wet screen the concentrate at 25 microns. Decant
water. Do not filter as there will be losses. Dry and
weigh each fraction.
Dry screen the 25 micron oversize through the following
mesh sizes (in microns) 1700, 1180, 850, 600, 425,
300, 212, 150, 106, 75, 53, 38, 25, pan.
Place each concentrate fraction into its own clearly
labeled vile. All stages of the concentrate are screened
to -25 microns. Concentrates shall be screened to the
top fraction as determined by the corresponding tails
screen analysis or technician’s judgment.
Weigh each fraction of concentrate separately and
record weight.
Knelson concentrates are assayed to extinction for Au
(or other PGM assays).
Knelson feed and tailings are assayed for Au (or other
PGM assays).

Appendix B – GAT Test
1.0 Safety first

outlined in Section 1 in this KC-MD3 User Manual.
1.0 Overview
The KC-MD3 is used to determine the amenability of an ore type to
gravity concentration.
The multi-pass GAT test is used to generate mass pull/recovery

profiles, to determine amenability to full scale processing with the
KC-CVD. The feed mass is smaller than for the E-GRG to obtain a
larger mass pull to recovery ratio. The number of passes is
dependent on numerous variables including sample type and
composition, particle size, etc. Typically, four to six passes are used.

• Jaw Crusher
• Sweco Screen
• Riffle Splitter
• Agitator
• KC-MD3
• Buckets- for tailings and feed sample
• Compressed air (for removing dust)
• Oven
• Rod Mill (available from FLSmidth)
• Filter Press and filter paper
• Pans for drying concentrates and tailings

3.0 Procedure
Sample preparation
Split sample into the appropriate size for testing
purposes.
Multi-pass samples require 1-5 kg, depending on grade
and ore characteristics. The mass as well as the particle
size (p80) used for testing should be determined with
an FLSmidth Process Engineer. Typically, if a CVD
scoping test is performed, 1-5 kg is used.
Grinding
Grinding may or may not be required, depending on the
test program.
Grinding samples should be at approximately 65%
solids.
If extra sample of the same size used for testing is
available, perform a grind test with the extra sample to
more accurately determine the grinding time needed to
obtain the target particle size.
After processing with a KC-MD3, a sub-sample shall be
taken for screen analysis determination, to determine
the actual particle size (p80).
Sample Processing
Weigh the sample and record the feed weight, if
ground, dry the tailings to determine mass. If sample is
in slurry form, dry tailings afterwards and add all of the
weights together to obtain a feed weight for mass
balances.
Ensure KC-MD3 (including feed funnel, launders, water
jacket, concentrating cone, and tailings line) is clean.
No material should be present on any interior or
exterior surfaces.

fluidization water, or other as required by the test
program.
Slowly feed sample into feed funnel, feed rate should be
~500-800g/min of solids.
Turn OFF the motor (switch) and fluidization water (ball
valve) simultaneously.
Allow rotor housing to come to a complete stop.
Remove feed funnel. Wash any material on underside of
feed funnel into tailings.
Remove cone locking ring. Any sample on cone locking
ring should be washed into concentrate cone.
Remove concentrate cone and carefully rinse
concentrate into a pan using the cone washing wand. If
material is present in fluidization water holes, clean
accordingly.
Place empty container under drain valve at the bottom
of the rotary housing.
Open drain valve at the bottom of the rotary housing
and allow water jacket to empty.
Clean water jacket with fresh water.
Open fluidization water valve for 2 seconds then close
valve. This ensures any solids that may have entered
the water jacket are removed from the system.
Allow water jacket to completely drain and close drain
valve at the bottom of the rotary housing.
Combine the material collected from the drain valve
with concentrate into the gold pan.
Thoroughly wash out KC-MD3 launder and tailings line
into tailings bucket.
If not panning, decant excess water and the dry
concentrate. If required, either pan the concentrate (if
required) into pan con and pan tails. Pan con should be
about 5-10g, the remaining material in pan tails. Ensure
to label each concentrate stage differently.
Weigh conc and assay as required. If requiring gold
analysis, the concentrates must be assayed to
extinction, only the Pt, Pd, and Ag can also be analyzed.
If requesting other elements, the material does not
have to be analyzed to extinction.
Repeat steps 6.3.2 to 6.3.19 until the total number of
passes are performed (as per test program).
Sub-sample gravity tails during last processing stage.
This is to be performed for each processing stage. The
tails are cut at consistent intervals until all of the feed
has been processed and should be 150-300g.
Filter and dry and weigh the tailings sample. Split out
30-50g for a sub-sample. The remaining can be wet
screened at 25µm, then dry screened from 1700 (or top
size, as appropriate) to -25µm (combine the two –25µm
fractions) to determine a particle size analysis (P80) of
the sample, or it can be stored for future reference. The
mass of a particle size analysis for sieving should be
over 100g, but no more than 250g.

Appendix C – One Pass GRG Test
1.0 Safety First

outlined in Section 1 in this KC-MD3 User Manual and adhere to the
additional messages below.
• Use ventilation system while riffling and removing dry fractions.

Use dust mask or half mask respirator as appropriate.
• Read and understand any MSDS that may accompany samples.
• Ensure to take necessary precautions for materials with
hazardous substances.
2.0 Overview
This procedure is for one-pass GRG tests with size by size analysis
of the concentrate and tailings.
Typical samples include:
• Cyclone Feed
• Cyclone Underflow
• Primary Circuit Knelson Feed
• Primary Circuit Knelson Tailings
These samples will contain both gravity recoverable gold (GRG) and
gold that is not gravity recoverable. In order to distinguish between
the GRG and non-GRG, the KC-MD3 is used to capture the GRG in
the sample. (GRG is considered to be larger than 15 microns and
‘free’).

3.0 Flowsheet
One-Pass Test
(15kg)
Screen sample at Weigh and store

850µm +850µm
MD3 Test (Stage 1) Screen and assay

KC Conc 1
60G, 3.5L/min Au
Screen and assay

Tails 1 Sub-sample Au
Tails (Stored) 3
months
Tails Disposed

• KC-MD3
• 850µm vibrating screen (20#) (larger diameter) to remove
tramp metal from concentrates. Note this screen should be
reserved for high grade samples only.
• Riffle with pans (if required to decrease sample size)
• Vibrating screen motor for wet screening
• Pre-labeled whirl pack bags or sample containers
• Screens for wet and dry screening conc and tails, from 850µm
to 25µm, √2 series, 8” diameter
• Fresh water source
• Pans for drying
• Filter paper and pressure filter(s)
• Rolling pin
• 20L buckets to collect tailings
• Slurry sample cutter

5.0 Procedure
The mass of the sample can vary between 10-25kg (dry

weight), depending on the grade and GRG content.
Typically, 15kg is used for testing. Whenever possible, dry
the sample first then screen at 850µm to remove any
tramp metal and coarse particles. If dry screening is
performed, ensure to wet screen the oversize to ensure
the finer particles are washed through. Ensure to record
the dry masses of the +850µm and minus (-)850µm
portions of the sample (or total dry mass of the sample
and the -850µm portion).
The +850µm portion: Dry and weigh the +850µm, reserve

50 to 100g of oversize (in case assaying is required).
Discard remaining oversize.
The -850µm portion: Combine -850µm portions from wet

and dry screening. Record dry mass of sample.
Re-pulp the -850µm fraction to ~60% solids (w/w) for

testing.
Ensure there are enough tailings buckets (15 of 20L pails).
Turn on the water control valve (completely open) and

motor of the KC-MD3. Set the G-force to 60G’s (on the
speed control), and set the water flow to 3.5L/min. Adjust
the water flow using the water flow valve (on side of
machine) as needed to achieve flow rate. Depending on
the coarseness of the sample, a higher fluidization water
flow rate may be required. Duplicate testing utilizing
different fluidization water flow rates may be required.
Slowly process the -850µm fraction in its entirety through

the KC-MD3 (ensure the tailings are collected, a person
may be needed to take a tailings sub-sample as well as to

change the tailings buckets). The feed should be feed
consistently and at a rate of ~600 to 700g/min.
During processing, take representative cuts from the

tailings stream using a slurry sample cutter.
Approximately 200 to 300g of dry tailings is required.
Take tailings sub-sample throughout the entire processing
of the sample.
Ensure to change the tailings buckets once ¾ full.
After the sample is processed, gradually turn OFF the

fluidization water first, then turn OFF the motor.
Remove the concentrate from the cone, using the cone-

wash wand, into a pan/bucket. If there are any solids
present in the KC-MD3 fluidization holes, clean with the
tool provided with the machine. Ensure the fluidization
water line is drained and free of solids. Collect the solids
and add to the concentrate from the cone.
KC-MD3 Concentrate: Wet screen the concentrate at

25µm in its entirety. Allow particles to settle. Decant
water (as much as possible) and dry the oversize and
undersize, separately. Dry screen the oversize using the
following screens 850µm, 600µm, 425µm, 300µm,
212µm, 150µm, 106µm, 75µm, 53µm, 38µm, 25µm.
Combine the dry screened 25µm undersize with the 25µm
undersize wet screened portion.
Place each fraction in pre-labeled containers and weigh.

Record weights (ensure to tare/zero the sample
container).
Assay each fraction of the KC-MD3 concentrates for Au (or

other precious metals) TO EXTINCTION.

KC-MD3 Tailings: Filter (dewater) the bulk tailings sub-
sample and dry. Once dry, weigh, then split out a 30-50g
sub-sample (use a rolling pin to break up clumped
particles as needed). This sub-sample is for bulk assay
(QA/QC- to compare with the calculated tails value).
The remaining tailings sub-sample (ensure this portion is

over 100g) is to be weighed, then wet screened at 25µm
(500#). Filter and dry the undersize and decant and dry
the oversize, separately.
Dry screen the oversize using the following screens

850µm, 600µm, 425µm, 300µm, 212µm, 150µm, 106µm,
75µm, 53µm, 38µm, 25µm. Combine the dry screened
25µm undersize with the 25µm undersize wet screened
portion.

Record masses (ensure to tare/zero the sample
container). Assay each fraction of the tails for Au, (do NOT
assay to extinction).

Appendix D – Two Pass GRG Test
1.0 Safety First

outlined in Section 1.0 of this KC-MD3 User Manual and adhere to
the additional messages below.
• Use ventilation system while riffling and removing dry fractions.

Use dust mask or half mask respirator as appropriate.
• Read and understand any MSDS that may accompany samples.
• Ensure to take necessary precautions for materials with
hazardous substances.
2.0 Overview
This procedure is for samples which have a fine and narrow particle
size distribution.
Typical samples with the recommended mass include:
• Cyclone Overflow (15-20kg)

• Flotation Concentrate or Tailings (10-20kg)
• Final Tailings (50-100kg)
• Regrind Circuit Knelson Feed (15-20kg)
• Regrind Circuit Knelson Tailings (15-20kg)
Sample size and methodology varies, depending on the stream,

grade and GRG content. These streams may contain both gravity
recoverable gold (GRG) and gold that is not gravity recoverable.
In order to distinguish between the GRG and non-GRG, the KC-MD3

is used to capture the GRG in the sample. (GRG is considered to be
larger than 15 microns and ‘free’).

3.0 Flowsheet
There are two flowcharts for the Two-Pass GRG test. The flowsheet
in Section 3.1 includes a step for regrind. Choose this methodology
for samples when wanting to determine if there is additional GRG
available when additional grinding is employed.
The flowsheet in Section 3.2 does not include a regrind step. Choose
this methodology for Cyclone Overflow, Final Tailings, Regrind
Circuit Knelson Feed, and tailings samples.
Flowsheet - Two-pass GRG Test with Regrind
Two-pass GRG Test

w. Regrind
Screen at 850µm.
Store +850µm
Process -850µm

KC Conc 1 Au to extinction
60G, 3.5L/min,
Grind to P80 <50µm

KC Conc 2
150G, 3.5L/min Au to extinction
Screen and assay

Tails (Stored) 3
months
Tails Disposed

Flowsheet - Two-pass GRG Test (no regrind)
Two-pass GRG Test
Screen at 850µm.
Store +850µm
Process -850µm

KC Conc 1
60G, 3.5L/min, Au to extinction

KC Conc 2
150G, 3.5L/min Au to extinction
Screen and assay

Tails (Stored) 3
months
Tails Disposed

• KC-MD3
• 850µm vibrating screen (20#) (larger diameter) to remove
tramp metal from concentrates. Note this screen should be
reserved for high grade samples only.
• Riffle with pans (if required to decrease sample size)
• Vibrating screen motor for wet screening
• Pre-labeled whirl pack bags or sample containers
• Screens for wet and dry screening conc and tails, from 850µm
to 25µm, √2 series, 8” diameter
• Fresh water source
• Pans for drying
• Filter paper and pressure filter(s)

• Rolling pin
• 20L buckets to collect tailings
• Slurry sample cutter
5.0 Procedure
Usually 10 to 100kg (dry weight) is recommended for

testing, depending on grade and GRG content. Please
refer to Section 2.0 for typical samples with recommended
sample masses.
It is easiest to dry the sample first. Record dry sample

mass. Pre-screening at 850µm may not be required as the
sample should be finer than 850µm.
Re-pulp the sample to approximately 60% solids (w/w).
Turn on the water control valve (completely open) and

motor of the KC-MD3. Set the G-force to 60G’s (on the
speed control), and set the water flow to 3.5L/min. Adjust
the water flow using the water flow valve (on side of
machine) as needed to achieve flow rate.
Slowly process the sample through the KC-MD3 (ensure

the tailings are collected. The feed should be feed
consistently and at a rate of ~600-700g/min.
Ensure to change the tailings buckets once ¾ full.
After the sample is processed, gradually turn OFF the

fluidization water first, and then turn OFF the motor.

tool provided with the machine. Ensure the fluidization

water line is also free of solids. Collect the solids and add
to the concentrate from the cone.
KC-MD3 Concentrate: see step 5.1.17 for KC-MD3

concentrate processing.
Allow the bulk tailings to settle; the use of a settling agent

may be helpful.
REGRIND ANALYSIS ONLY: Grind the sample in its

entirety to a P80 of less than 50µm or to what the
anticipated P80 of the regrind circuit will be.
Once the sample has settled, decant/siphon the excess

water.
Prepare for the second pass, set the KC-MD3 to 3.5L/min

and 150G’s.
Slowly process the sample through the machine.
During processing, take representative cuts from the

tailings stream using a slurry sample cutter.
Approximately 200 to 300g of dry tailings is required.
Take tailings sub-sample throughout the entire processing
of the sample.
After the entire sample has been processed through the

KC-MD3, gradually turn OFF the fluidization water
first, and then turn OFF the motor.

spray tool provided with the machine. Ensure the
fluidization water line is also free of solids by turning on
the water fluidization ball valve fully open and allow water

to enter the water jacket and then shut OFF. Collect the
solids and add to the concentrate from the cone.
KC-MD3 Concentrate processing (Stages 1 & 2): Wet

screen the concentrate at 25µm. Allow particles to settle.
Decant water (as much as possible) and dry the oversize
and undersize.
Dry screen the oversize using the following screens (top

size may vary, depending on size distribution) 850µm,
600µm, 425µm, 300µm, 212µm, 150µm, 106µm, 75µm,
53µm, 38µm, 25µm. Combine the dry screened 25µm
undersize with the 25µm undersize wet screened portion.

container). Assay each fraction of each stage concentrate
Au (or other precious metals) TO EXTINCTION.
KC-MD3 Tailings (Stage 2): Filter (dewater) the bulk

tailings sub-sample and dry. Once dry, weigh, then split
out a 30 to 50g sub-sample (use a rolling pin to break up
clumped particles as needed). This sub-sample is for bulk
assay (QA/QC- to compare with the calculated tails value).
The remaining tailings sub-sample (ensure this portion is

over 100g) is to be weighed, then wet screened at 25µm
(500#). Filter and dry the undersize and decant and dry
the oversize, separately.
Dry screen the oversize using the following screens (top

size may vary, depending on size distribution) 850µm,
600µm, 425µm, 300µm, 212µm, 150µm, 106µm, 75µm,
53µm, 38µm, 25µm. Combine the dry screened 25µm
undersize with the 25µm undersize wet screened portion.

container). Assay each fraction of the tails for Au or other
precious metals, (do NOT assay to extinction).

Appendix E – Drawings
Included in this section is a general arrangement drawing and a
specification sheet specific to the KC-MD3 Knelson Concentrator.
The general arrangement drawing lists part descriptions and part
numbers.
When ordering spare parts please specify the Part Number and
provide the Machine Serial Number.
For additional support, contact FLSmidth Parts and Service at

knelsonparts@flsmidth.com.

Appendix F – Facts and Figures
Weights and measures
Weight Equivalent
1 troy ounce = 480 grains (gr)
1 troy ounce = 20 pennyweights (dwt)
1 troy ounce = 31.1 grams (g)
1 troy pound = 12 troy ounces
1 avoirdupois pound (lb) = 16 avoirdupois ounces
1 avoirdupois pound (lb) = 14.58 troy ounces
1 short ton (tn) = 2000 avoirdupois pound
1 short ton (tn) = 907.2 kilograms (kg)
1 part-per-million (ppm) = 1 gram per tonne (g/tonne)
1 gram (g) = 15.43 grains (gr)
1 gram (g) = 0.643 pennyweights (dwt)
1 kilogram (kg) = 32.15 troy ounces
1 tonne (t) = 32 154 troy ounces
1 tonne (t) = 2205 avoirdupois pounds (lb)
1 tonne (t) = 1000 kilograms (kg)
Conversion factors
To convert from… To… Multiply by:
troy ounce/ton gram/tonne 34.29
gram/tonne troy ounce/ton 0.02917
litres gallons (US) 0.2642
gallons (US) litres 3.785
gallons (UK) litres 4.546
litres/second (L/s) ft3/min 2.119
litres/second (L/s) USgpm 15.85
litres/second (L/s) m3/min 0.06
cubic feet per minute (ft3/min) USgpm 7.481
cubic meters’ per hour (m3/hr) L/s 0.472
cubic metres per hour (m3/hr) USgpm 4.403
cubic metres per hour (m3/hr) L/s 16.67
gallons (US)/min (USgpm) L/s 0.06309
gallons (US)/min (USgpm) ft3/min 0.1337
gallons (US)/min (USgpm) m3/hr 0.2271
ft·lb N·m 1.355818
in·lb N·m 0.112985

Grease equivalency list (For manual lubrication ONLY)
Grease Brand Grease name

Shell GadusRail S2
Mobil Unirex N3
Mobil Mobilgrease XHP 223
FAG/Schaeffler Arcanol VIB3
Useful formulas
∅#, ∗ #
#
% & ∅#, ' ∅ , ∅
,

( & ∅#, )
#
∗ ∅* , ∗ +#

(∅#, & ∅* , )
Where: Where:
# , /"

∅#, !"
∅*, !" -

#
-"!" , /" ∅ , !"
+#
. / /, 01 /" ∅
, !"
33 & 2

+789 :. :3<= ∗ ∗ 4 5
2

33 & 2
2
33 ∗ ∗ 4 & 5
% & '
+8>* ∗ 4 5
2

Where: Where:
"!" , /" 2

6 !"
+789 / , !/0
+8>* / , 01 /"

2
6 !"

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User Manual

Section 2: Introduction ............................................................................... 9

Section 3: Installation ............................................................................... 15

Section 4: Operation ................................................................................. 23

Section 5: Maintenance ............................................................................. 29

KC-MD3 User Manual Rev 4.0(2017/10) 3

Appendix A – E-GRG Test .......................................................................... 45

KC-MD3 User Manual Rev 4.0(2017/10) 4

KC-MD3 User Manual Rev 4.0(2017/10) 5

Any use of the concentrator other than described in this manual

Defining safety hazards/conditions

WARNING indicates a hazardous situation, which if not avoided,

CAUTION indicates a hazardous situation, which if not avoided,

NOTICE information considered important but not hazard-related,

KC-MD3 User Manual Rev 4.0(2017/10) 7

WARNING: Understand these safety hazards before installing,

• Only trained and qualified personnel should install, operate, or

KC-MD3 User Manual Rev 4.0(2017/10) 8

About the Knelson Concentrator

Around the circumference of each ring are a series of fluidization

FLSmidth produces application specific cones. The profiles are

KC-MD3 User Manual Rev 4.0(2017/10) 9

As the cavity reaches capacity, water is forced through the

Figure 2-3 Fluidization process

The concentrator’s rotor assembly, as viewed from above, spins in a

Figure 2-4 Slurry component weight vs. acceleration

KC-MD3 User Manual Rev 4.0(2017/10) 10

Figure 2-5 Slurry flow

The fluidization-water flow-rate is optimized during the

Optimal fluidization occurs when the inward flow of water through

As long as the fluidization-water flow-rate stays unchanged, the

KC-MD3 User Manual Rev 4.0(2017/10) 11

At the conclusion of the concentrating cycle, the concentrating cone

When to use an Knelson Concentrator

Use the concentrator when:

• samples from an alluvial deposit contain traces of free target

KC-MD3 User Manual Rev 4.0(2017/10) 12

Use the concentrator to:

• recover alluvial target heavy mineral recovery

KC-MD3 User Manual Rev 4.0(2017/10) 13

• Clear poly-hose assembly

• Clean-out wand assembly

• Fluidization hole cleaning tool

• Extra filter hose strainers (quantity two)

Depending on the requirements at time of ordering, the shipment

• Lubrication kit (grease tube, grease gun hose c/w dispenser)

• Commissioning spare parts kit

KC-MD3 User Manual Rev 4.0(2017/10) 15

3 Hose coupling connection, or hose barb

10 Reduce port ball valve

Figure 3-1 KC-MD3 Components

KC-MD3 User Manual Rev 4.0(2017/10) 16

When considering a location ensure there is enough space to

Assembling poly-hose assembly/spray gun

Connecting the water supply and

The KC-MD3 requires two flexible hoses: one hose to supply

KC-MD3 User Manual Rev 4.0(2017/10) 17

During operation, the KC-MD3 produces low vibration. Four rubber

If using a long hose is unavoidable, support the weight to a