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Proven Results

Hot Thickener Optimization with Advanced Process Control

March 1, 2026

The Challenge

A potash operation’s hot thickener suffered from limited visibility into critical process parameters such as bed depth and settling rates. To protect equipment, operators ran the thickener conservatively—pumping lower‑density slurry to tailings to avoid excessive bed levels and rake torque. This approach increased tailings flow and led to unnecessary product losses through saturated brine.
The Solution

The Solution

Spartan Controls implemented the SpartanPRO™ Thickener APC to automatically optimize underflow pumping rates while continuously monitoring key constraints, including rake torque, line velocities, and pumping limits.

Using a model predictive control (MPC) strategy, the solution managed slow process dynamics and multiple constraints while maximizing underflow density. A low‑rate recirculation line was also leveraged to further reduce tailings losses.

The Value

The APC solution delivered improved thickener stability and material recovery, particularly on the underflow line to tailings:
 
  • 8% increase in average tailings underflow solids content
  • $2.5M per year reduction in saturated brine losses
  • 25% reduction in overall tailings flow
  • 50% reduction in high rake torque events
The hot thickener APC has remained the site’s standard operating mode since deployment in 2016, delivering sustained long‑term performance.

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