Thickener optimizer

Last updated Aug 2026

Improve thickening performance by controlling the key variables of a thickener, including underflow density, the overflow solids content, and the thickener inventory level.

Improved performance, greater process stability and lower flocculant costs through advanced process control.

Sustained higher underflow density

Helps maximize thickener throughput and downstream dewatering efficiency

Improved overall thickener performance

Uses advanced multivariable, model-based control to optimize operation

Stabilized process with variable feed

Maintains stable operation despite changes in feed flow rate and slurry characteristics

Reduced flocculant consumption & costs

Optimizes reagent dosing, lowering operating costs

Benefits

The Thickener optimizer overcomes the challenges of conventional single-loop controllers, and combines a multivariable, model-based controller with in-depth process knowledge to stabilize and optimize thickener performance.

Sustained higher underflow density
Improved overall thickener performance
Stabilized thickening process with variable feed
Reduced flocculant consumption and cost
Reduced operator time for manual work

Operation

Improving process stability is the key to process control. Thickening is, by nature, a slow process with multiple variables influencing process performance. For example, when the feed mass flow and its properties change, timely adjustments are needed to maintain a stable output. This requires a good understanding of process dynamics and overall process behavior.

Traditionally, thickener controls are implemented as single-loop controllers in plant control systems. Based on our experiences from numerous thickener installations, this approach has several drawbacks, which easily lead to sub-optimal process performance. The Thickener optimizer overcomes these limitations, and combines our thickening experience with a multivariable, model-based controller. The Thickener optimizer is based on our proven proprietary APC platforms.

The Thickener optimizer controls:

Underflow density
Overflow solids content
Thickener inventory level

The Thickener optimizer utilizes measurements available from the process, and manipulates the underflow pumping rate and flocculant dosage to maintain a stable process. Information from the thickener feed line – the input flow rate and slurry density – is used when available. To avoid critical rake loads, the rake torque is also taken into account.

Applications: