Mining On Top: Stockholm 2013 26-27 Nov 2013 Continuous improvements in Mineral processing – Lucy England, FLSmidth; Sales Manager - Northern Europe

1. Continuous Improvements in Mineral
Processing
Mining on Top – Stockholm
Minerals Engineering 2013 – Lucy England

2. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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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
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4. One Source Supplier
One Source
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5. Sustainable Mining
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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
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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
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8. RESOURCE EFFICIENCY
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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
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12. SAFETY AND ECONOMY
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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)
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28 November 2013
Primary Gyratory
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Crushers

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
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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
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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
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17. Fuller-Traylor®
Primary Gyratory Crushers
World’s Largest Gyratory
1600 x 3000 (63” x 118”), 1200 kW
Hudbay Minerals – Constancia Copper
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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:
•
•
•
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Modern Day Foundry Capacities
Modern Day Machine Shop Capacities
Transportation Limitations
Industry Reluctance to Accept New Ideas
Primary Gyratory
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Cruhers

19. RESOURCE EFFICIENCY AND
ECONOMY
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20. FLSmidth Research and Development:
Our Investment Improves your Recovery
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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
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22. 600 Series SuperCell™
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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
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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
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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 

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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 

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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
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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. 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. 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
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