Continuous Improvements in Mineral
Processing
Mining on Top – Stockholm
Minerals Engineering 2013 – Lucy England
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected ...
Delivering results for more than a century
130 years of experience and leadership in cement
100 years of rich experience i...
One Source Supplier

One Source

4
Sustainable Mining

5
New Product Investment

•

HPGR – Finished and tested

•

Semi Mobile Crushers

•

SX Reverse Mixer/Settler

•

Large Gyra...
Product Optimization Investments

•

Expand Gyratory Top Service Design

•

Mill Gear Optimization and Standardization

•
...
RESOURCE EFFICIENCY

8
Global Technology Center - Salt Lake City
Integrated Solutions & Capabilities
World Class Ore Characterization / Metallurg...
10
11
SAFETY AND ECONOMY

12
Primary Gyratory - History
First Generation (Mk I)
Traylor Type C (Bulldog)
Gyratory Crusher (1905 - 1950)
Second Generati...
Gyratory - Added Value in Design

1. Fuller-Traylor Bar-Type Spider

•

4-Bolt Attachment

• Simple Geometry
• Fast to Ins...
Gyratory - Added Value in Design

2. Fuller-Traylor Specialty Maintenance Tools

•

Concave Replacement Platforms

• Eccen...
Latest Developments
Top Service “TS” Design Gyratory

• Designed for Safe Maintenance
• NO Eccentric Cart Required
• NO La...
Fuller-Traylor®
Primary Gyratory Crushers
World’s Largest Gyratory
1600 x 3000 (63” x 118”), 1200 kW
Hudbay Minerals – Con...
Gyratory – Future Developments…?

New Concepts:
•
•
•
•
•
•

100+ Years of Experience
Benefit of Finite Element Analysis
B...
RESOURCE EFFICIENCY AND
ECONOMY

19
FLSmidth Research and Development:
Our Investment Improves your Recovery

20
FLSmidth Flotation Technologies

WEMCO
300 & 600

technologies

XCELL
350

Dorr-Oliver
300 & 600

The information containe...
600 Series SuperCell™

22
Final 600 Series Supercell Result:
600 series SuperCell™

Design Summary
Tank Summary:
Nominal Tank Volume: 600m3
Active T...
Effect of Bubble and Particle Size
Collision probability

•

Sutherland, 1948; Reay and Ratcliff, 1973; Flint and Howarth,...
Energy Barrier (E1)
Extended DLVO

theory

VE 

0r1r2 12  22 

r1  r2 

 212  1  e H
 2
ln 
2
1  ...
Tres  Trup

Tres  Trup





Transition from bouncing to penetrating particle is predicted by:
1/ 2

U 2   1
3...
Predicted Attachment Rate
- DO Rotor 300m3 Machine

Standard Stator

Attach Inside Stator

Attach Outside Stator

New Slot...
Hybrid Energy Flotation™

Standard energy
(standard
mechanism)
Easy floating
material.
Recovery is froth phase
controlled
...
Mixed Row Flotation
Hybrid Mechanism Flotation™

Standard mechanism
Easy floating material
Recovery is froth phase
control...
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected ...
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Continuous improvements in Mineral processing

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Mining On Top: Stockholm 2013
26-27 Nov 2013

Continuous improvements in Mineral processing – Lucy England, FLSmidth; Sales Manager - Northern Europe

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Continuous improvements in Mineral processing

  1. 1. Continuous Improvements in Mineral Processing Mining on Top – Stockholm Minerals Engineering 2013 – Lucy England
  2. 2. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 2
  3. 3. Delivering results for more than a century 130 years of experience and leadership in cement 100 years of rich experience in minerals Essentially “invented” the cement industry and fuelled major developments within minerals Unsurpassed expertise and know-how in both industries FLSmidth corporate 3 3
  4. 4. One Source Supplier One Source 4
  5. 5. Sustainable Mining 5
  6. 6. New Product Investment • HPGR – Finished and tested • Semi Mobile Crushers • SX Reverse Mixer/Settler • Large Gyratory Design • Vertical Stirred Mill • Deswick Fine Grinding Mill 6
  7. 7. Product Optimization Investments • Expand Gyratory Top Service Design • Mill Gear Optimization and Standardization • Larger Flotation Cells • Flotation Optimizations – coarse particle recovery and froth vision • Expand Cone Crusher Sizes • Larger AFP and other Pressure filter improvements • Sedimentation Optimization 7
  8. 8. RESOURCE EFFICIENCY 8
  9. 9. Global Technology Center - Salt Lake City Integrated Solutions & Capabilities World Class Ore Characterization / Metallurgical Lab Full-disciplined Engineering • Process Optimization • PFS/FS/DE • Flow Sheets, P&IDs, Layout Optimization • Civil/Structural • Mechanical/Piping • Electrical / Automation and Controls • 3D Models Experienced Project Management Staff • Cost Controls, Reporting • Procurement Specialists In-House Equipment Products Specialists • Comminution • Flotation • Dewatering / Filtration • ADR 9
  10. 10. 10
  11. 11. 11
  12. 12. SAFETY AND ECONOMY 12
  13. 13. Primary Gyratory - History First Generation (Mk I) Traylor Type C (Bulldog) Gyratory Crusher (1905 - 1950) Second Generation (Mk II) Traylor Type TC Gyratory Crusher (1950 – 1990) Third Generation (Mk III) Traylor Type NT Gyratory Crusher (1990 – Present) Fourth Generation (Mk IV) Traylor Type TS Gyratory Crusher (2005 – Present) 13 28 November 2013 Primary Gyratory 13 Crushers
  14. 14. Gyratory - Added Value in Design 1. Fuller-Traylor Bar-Type Spider • 4-Bolt Attachment • Simple Geometry • Fast to Install, Fast to Remove • Compact Lay-Down Areaxxxxx • Saves 10 Hours of Down Time per Main Shaft Change-out • Annually this equals 10 hrs x 4 persons x 3 changes per year = 120 man hours or 30 hours of additional annual production. Primary Gyratory Crushers 28 November 14 14
  15. 15. Gyratory - Added Value in Design 2. Fuller-Traylor Specialty Maintenance Tools • Concave Replacement Platforms • Eccentric Maintenance Carts • Provide Safe Work Area • Pre-Assemble Concaves While Plant is Operating • Reduces Crusher Down-time for Concave Replacement from 48 hours to 36 Hours. Primary Gyratory Crushers 28 November 15 15
  16. 16. Latest Developments Top Service “TS” Design Gyratory • Designed for Safe Maintenance • NO Eccentric Cart Required • NO Large Discharge Bin Doors • Replacement Times: 4 Hours Main Shaft Assembly 6 Hours Eccentric Assembly 10 Hours Outer Eccentric Bushing xxx • Safety Value….Less Exposure 125 Man-hours less for unscheduled Eccentric Bushing replacement. • Plant Design Savings +$ 400,000 Primary Gyratory Crushers 28 November 16 16
  17. 17. Fuller-Traylor® Primary Gyratory Crushers World’s Largest Gyratory 1600 x 3000 (63” x 118”), 1200 kW Hudbay Minerals – Constancia Copper 17
  18. 18. Gyratory – Future Developments…? New Concepts: • • • • • • 100+ Years of Experience Benefit of Finite Element Analysis Benefit of Solid Works 3D Modeling Modern Control Techniques Willingness for “Out of the box Thinking” Desire to “Break away from Traditional Ideas” Desires: • • • • • Increased Capacity (Not at Expense of OSS Setting) Increased Power (More efficiently utilized) More Maintenance Friendly New Materials for Increased Wear Life Improved Safety Features Constraints: • • • • Modern Day Foundry Capacities Modern Day Machine Shop Capacities Transportation Limitations Industry Reluctance to Accept New Ideas Primary Gyratory 18 Cruhers
  19. 19. RESOURCE EFFICIENCY AND ECONOMY 19
  20. 20. FLSmidth Research and Development: Our Investment Improves your Recovery 20
  21. 21. FLSmidth Flotation Technologies WEMCO 300 & 600 technologies XCELL 350 Dorr-Oliver 300 & 600 The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 28 November 2013 21
  22. 22. 600 Series SuperCell™ 22
  23. 23. Final 600 Series Supercell Result: 600 series SuperCell™ Design Summary Tank Summary: Nominal Tank Volume: 600m3 Active Tank Volume: 660m3 Diameter: 10870mm Overall Tank Height: 8415mm Wetted Height: 7720mm Aspect Ratio: 0.71 Drop height: 1200mm Manway Dimensions: 2400mm x 2400mm Tank Drain Size: (2) @ 18” Launder Width: 575mm (22.6”) Froth Surface Summary: Tank Surface Area: 92.8m2 Peripheral Launder Lip Length: 34.1m Number of Radial Launders: 16 Radial Launder Width: 300mm Total Radial Launder Lip Length: 68.8m Total Radial Launder Area: 9.6m2 Total Lip Length: 93.7m Effective Area: 59.5m2 Motor: Installed Motor HP: 1000 test Operation 450-900 HP VFD included 23
  24. 24. Effect of Bubble and Particle Size Collision probability • Sutherland, 1948; Reay and Ratcliff, 1973; Flint and Howarth, 1971; Weber and Paddock, 1983; Ahmed and Jameson, 1989; Luttrell and Yoon, 1989 r  Dp  Pc  A D    b 2 Ur Gaudin, 1931 Ut R  Rb elephant curve 24
  25. 25. Energy Barrier (E1) Extended DLVO theory VE  0r1r2 12  22  r1  r2   212  1  e H  2 ln  2 1  2  1  e H   VT  VE  VD  VH VD       ln 1  e 2H     A132 r1 r2  1  2bl  1   6 H r1  r2   1  bc H  r1 r2 K132 VH   6r1  r2 H  E  PA  exp   1   E  k   25
  26. 26. Tres  Trup Tres  Trup   Transition from bouncing to penetrating particle is predicted by: 1/ 2  U 2   1 3 1  h0  2    We  ln       Fr 2  Wes  hcr   26
  27. 27. Predicted Attachment Rate - DO Rotor 300m3 Machine Standard Stator Attach Inside Stator Attach Outside Stator New Slotted Stator 10 microns 150 microns 300 microns The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 28 November 2013 27 27
  28. 28. Hybrid Energy Flotation™ Standard energy (standard mechanism) Easy floating material. Recovery is froth phase controlled Low energy (larger High energy rotor, (standard low RPM) mechanism, Coarse high RPM) material Fine material The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  29. 29. Mixed Row Flotation Hybrid Mechanism Flotation™ Standard mechanism Easy floating material Recovery is froth phase controlled New mechanism New mechanism More blades Holes in stator Fine material Coarse material The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  30. 30. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. Title The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 28 November 2013 28 November 2013 30 30
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