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Process Optimization &
Performance Improvement

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Case Study

Thickener and Settling Efficiency Revamp at Coal Prep Plant

Challenge

Thickeners underperforming, high polymer usage, excessive underflow dilution, and multiple downstream pump issues.

ENG Solution

After a 2-week audit, ENG redesigned the chemical addition points, introduced staged flow redirection, and modified the delivery polymer program. A new rake drive torque monitoring system was recommended and installed by client, and the sludge pumping schedule was optimized and integrated into the process DLC.

Results

  • Polymer dosage reduced by 35%

  • Underflow solids improved from 19% to 24%

  • Pump reliability improved, reduced pressures on slurry line

  • ROI realized within 7 months

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