Process Engineers - Who We Are

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Process Engineers & Equipment Corporation is a family-owned business which specializes in sand classification, fine sand recovery, water clarification, and sludge dewatering systems. These systems are designed to recover salable products while reducing operating costs by eliminating costly tailings ponds.

We have manufacturing facilities in Spokane and Wisconsin and have installed equipment in more than 100 plants throughout the United States, providing packaged systems with overall system responsibility, complete engineering and field services, along with turn key installation.

We differentiate ourselves from others by providing personal service throughout the United States. In business since 1993, our team of dedicated employees, which has a combined industry service of over 100 years, will do whatever it takes to deliver quality products in a timely manner.

We have a complete in-house wet lab to provide free analysis for your application. These tests also allow us to provide you with flow diagrams, detailed performance projections, and pay-back studies. We also provide parts, technical services, chemicals, and service options. We use FLSmidth cyclones, GIW slurry pumps, Tsurumi submersible pumps, CFS density separators and sand classifiers, and plate presses from TPH.

We specialize in:
  • Slurry and water pumping systems
  • High capacity water clarifiers; 100' diameter and 23,000 gpm
  • Design and installation of sand recovery systems
  • Design and manufacture of structural supports
  • Pre-plumbed and skid mounted polymer delivery systems
  • Automated systems
  • On-site testing
  • Frac sand systems with up to 1,000 tph
  • Mobile water treatment systems

Sand Processing and Recovery Systems

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Process Engineers designs custom recovery systems and we specialize in slurry and water pumping systems. Typical applications include pumping tailings with a GIW slurry pump through FLSmidth hydrocyclones, both of which are sized to each specific application (flow rate, TPH, desired recovery). Recovered sand can be further dewatered using a high frequency screen with a urethane deck.

CYCLONES – Process Engineers provides cyclones manufactured by FLSmidth which come complete with metal housings, rubber liners, cyclo-stack sand dewatering boot and siphon control. The recovered sand is generally blended back into the sand product. The fines overflow is typically fed to a high capacity water clarifier.

DENSITY SEPARATORS – Process Engineers provides density separator sand classifiers. Density separators are a very accurate way to classify sand and are able to make a very specific cut to maximize desirable sand products.

STRUCTURAL – Process Engineers designs and manufactures custom structural supports for cyclone systems. We also design rubber lined manifolds for material splitting to multiple units and bulk material handling hose for conveying sand slurry between pumps and cyclones.

SLURRY PUMPS – Process Engineers represents Georgia Iron Works (GIW) slurry pumps.

SUBMERSIBLE PUMPS – Process Engineers offers Tsurumi pumps for this application.

The Process Engineers high capacity water clarifier/thickener separates fine particle solids (typically passing 200 mesh/74 micron or finer) by adding a treatment polymer to the incoming slurry from a cyclone, screw classifier, sand classifier and/or storm water. The polymer attaches to the solids in the slurry causing them to clump together and gain enough mass to drop out of solution via gravity. The mud settles to the bottom of the tank and is raked to the center where a thickening cone maximizes slurry density before being pumped out. As the solids settle out, a rising current of clean water is collected in an overflow weir (can be cleaner than 50 NTU depending on application). These systems recycle over 90% of the water in the system for future use.

Process Engineers have some of the largest capacity clarifiers in the country -- 100' diameter and 23,000 gpm.

Filter Presses

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Belt filter presses use a series of belts and rollers to compress underflow slurry pumped to the belt filter press from a high capacity water clarifier. The standard Process Engineers belt filter press is three meters wide and is sized to handle up to 25 (US) dry tons per hour of solids. The water pressed out of the mud is collected below the unit in a sump and is returned back to the clarifier for a closed loop water cycle, minimizing the loss of water with the dewatered solids. Dewatered solids have a cake dryness of up to 60-70% solids by weight, depending upon the characteristics of the solids, making the product conveyable and/or truckable to an off-site location or to be used as back fill/reclaim in the mine.

Plate presses use hydraulic pressure to compress porous membranes full of slurry between dozens of plastic plates. Dewatered solids have a cake dryness of 70% to 80% solids by weight.

Mobile Systems

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Process Engineers designs and builds custom mobile water treatment plants utilizing a trailer mounted clarifier and belt or plate filter press system. These units minimize on-site installation due to piping and wiring already being installed and they offer the highest possible solids capture rate.

Chemical Systems

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Process Engineers make-down systems are custom designed to each application based on material, projected use and specific project needs. Our dry system is typically used for higher tonnage applications while our wet, emulsion systems are designed for lower tonnage applications. Systems can come pre-plumbed and skid mounted.

DRY SYSTEMS – The dry powder is volumetrically added to an educator via a wetting cone (shown top left). The automated system has three alarms to prevent spills: a flow switch to ensure adequate water flow through the educator, a bin level sensor to ensure dry product availability for the process and a plug sensor in the wetting cone to prevent spills from plugs.

EMULSION SYSTEMS – Typical applications involve diluting a emulsion from a tote to a specific concentration for injection into a process. The skid mounted system is custom designed to accommodate the mixing and agitation needs of the specific application.

AUTOMATION – Process Engineers offers an Auto-Dose system. It consists of a sensor that monitors the size of flocculated material in the center feedwell of a clarifier. After establishing a set point for optimal flocculation, the process controller sends a speed signal to the dosing pump increasing and decreasing depending on demand to minimize usage. pH and flow related automation are also available.

Technical Services

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Process Engineers is proud to provide technical services to our clients. We are committed to providing highly qualified technicians who will make sure your process utilizes the best chemistry and equipment to optimize your process. Rates for services will be negotiated upon contract initialization.

These services include full system audits and process optimization studies. Regularly scheduled quality control sampling and testing will be performed to ensure your process is applying optimal water chemistry and dosage rates. A detailed report will be submitted upon the completion of each round of testing. Our lab capabilities allow us to screen multiple polymers and additives to determine the optimal product specific to your material. We are also able to analyze settling rates, water clarity, residual treatment presence, pH monitoring and control, metal contaminant mitigation and monitoring and any other test that may be specific to your application or process.

Many clients who discharge water are subject to strict discharge requirements by local agencies and municipalities. Process Engineers provides detailed treatability studies to ensure that irregular discharge does not lead to issues with permitting. We can give you the tools to demonstrate your commitment to adhering to compliance regulations.

In addition to process testing, clients will be made aware of the latest instrumentation and automation equipment. Process Engineers will recommend equipment upgrades based on system and regulatory requirements. All system related equipment will be presented and quoted with a payback study where applicable.