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Presentación de Egbert Burchardt, Thyssenkrupp

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Presentación de Egbert Burchardt, Thyssenkrupp foro Voces Mineras “Nuevas Tecnologías que Revolucionan la Minería”

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Presentación de Egbert Burchardt, Thyssenkrupp

  1. 1. Egbert Burchardt Grinding Technology – Mineral Processing Santiago de Chile I 28.08.2019 Voces Mineras: Nuevas Tecnologias Que Revolucionan La Minera POLYCOM HPGRs An Innovative and Matured Comminution Tool for the Mining Industry
  2. 2. 2 POLYCOM Principles ….. between two counterrotating rolls which are fed from the top. One of the rolls is fixed. The second roll is floating and pushed by a hydraulic system towards the fixed roll. The ore is ground in a HPGR by introducing high grinding pressures into a material bed …..
  3. 3. 3 POLYCOM Hard Rock Applications and References (Copper / Gold / Iron / Platinum) Pebble crushing in greenfield concentrators Partial pre-crushing for up-grades of existing SABC plants by de-bottlenecking the SAG mill
  4. 4. 4 POLYCOM 20/15 – 2 x 1,750 kW 1,061 tph < 10 mm closed circuit product KAZ Minerals – Bozshakol Start-up in 2016 KAZ Minerals – Aktogay Start-up in 2017 KAZ Minerals – Aktogay 2 Start-up in 2020 POLYCOM for Pebble Crushing in SABC Circuits Bozshakol Plant capacity: 3,425 tph (75.000 tpd) 1 x SAG mill Ø 12.2 x 7.9 m EGL – 28 MW 2 x Ball mill Ø 8.5 x 13.4 m EGL – 22 MW
  5. 5. 5 POLYCOM Hard Rock Applications and References (Copper / Gold / Iron / Platinum) Tertiary crushing in greenfield concentrators Quaternary crushing for up-grades of existing crushing & grinding plants by de-bottlenecking the ball mills
  6. 6. 6 2 x POLYCOM 20/15 – 2x 1.800 kW Freeport in operation since 2007 PTFI Grasberg > 15 % plant capacity increase due to HPGRs Refer to Paper SAG 2011: EFFECTS OF HPGR INTRODUCTION ON GRINDING PERFORMANCE AT PT FREEPORT INDONESIA’S CONCENTRATOR Quaternary Crushing for Concentrator Up-grades
  7. 7. 7 SPCC - Toquepala 1 x POLYCOM 24/17 – 2 x 2,650 kW Start-up during 2nd quarter 2018 Situation: ball mill bottleneck due to harder ore => production dropped from 60 ktpd to as low as 51 ktpd Approach: re-crushing of the complete crusher product to produce finer BM feed Achievement: plant production was brought back to more than 60 ktpd Quaternary Crushing for Concentrator Up-grades
  8. 8. 8 Freeport Cerro Verde copper 108.000 tpd 4 x POLYCOM 24/17 5.0 MW each Start up in 2006 Newmont Boddington gold 97.000 tpd 4 x POLYCOM 24/17 5.6 MW each Start up in 2009 Anglo Platinum Mogalakwena platinum 20.000 tpd 1 x POLYCOM 22/16 5.6 MW Start up in 2008 POLYCOMs for Tertiary Crushing in Large Concentrators
  9. 9. 9 POLYCOMs for Tertiary Crushing in Large Concentrators
  10. 10. 10 Freeport - Cerro Verde 360.000 tpd copper concentrator Cerro Verde 1 (2006) 120,000 tpd 4 x POLYCOM 24/17 – 5.0 MW 4 x Ball Mills Ø 7.3 x 11.0 m EGL – 12 MW Cerro Verde 2 (2015) 240,000 tpd 8 x POLYCOM 24/17 – 5.0 MW 6 x Ball Mills Ø 8.2 x 14.6 m EGL – 22 MW POLYCOMs for Tertiary Crushing in Large Concentrators
  11. 11. 11 POLYCOM Performance Results Copper Concentrators Plant Peru Plant Chile achieved (design) achieved (design) POLYCOM circuit product mm < 5.5 < 8 Higher throughput capability tpd > 35,000 (27,000) > 40,000 (28,000) (each POLYCOM 24/17 @ circuit product size and 92 % utilization) Lower energy consumption kWh/t < 2.7 (3.2) < 2.5 (2.9) (@ circuit product size) Longer roll life h > 10.000 (6,000) > 7.000 (6,000)
  12. 12. 12 POLYCOM vs. SAG Mill Based Plants Cons • POLYCOM HPGRs require a more complex material handling system and screening ⇒ higher capex Pros POLYCOM HPGRs are • more energy efficent than SAG mills (the harder, the higher is the POLYCOM efficiency! ⇒ lower opex in terms of energy and wear • less sensitive against ore variability ⇒ higher average plant capacity (due to less fluctuations) ⇒ higher recovery (due to stable flotation at uniform feed size and rate) Trade-off: Capex vs. Opex & Production
  13. 13. 13 POLYCOM vs. SAG Mill Based Plants Case Study – Energy Consumption +/- 0.4 kWh/t Axb values between 70 (soft) and 25 (competent) • SAG mill energy varies between 4 kWh/t [@ Axb = 70] and 11 kWh/t [@ Axb = 25] • POLYCOM energy 2.7 kWh/t in average (variation of about +/- 0.4 kWh/t for various copper ores at same T80)
  14. 14. 14 POLYCOM vs. SAG Mill Based Plants Case Study – Opex Axb values between 70 (soft) and 25 (competent) • SABC operating cost(*) varied between 1.7 and 2.6 US$/t in the study • up to 1 US$/t lower opex(*) for a HPGR based circuit • up to 19 MW less power supply required for HPGR plant (*) energy and wear of comminution equipment)
  15. 15. 15 POLYCOM Maintenance Requirements • scheduled maintenance between 160 and 185 hours per year (~ 2 % of time) • roll unit replacement is longest maintenance duty (~ 36 – 48 hours) • manual inspection of roll surface can be avoided by on-line roll measurement
  16. 16. 16 POLYCOM Operating Cost based on one roll unit change out per year w/o energy cost and spare parts Rolls and cheek plates about 90 % Manpower / labour about 8 % Importance of rolls and cheek plates!
  17. 17. 17 POLYCOM Design and Innovation Wear Protection System Cheek plates seal the gap towards the roll edges about 2,500 to 3,000 hours lifetime 1st generation – light design 3rd generation – heavy duty design System • Cheek plates
  18. 18. 18 System • Cheek plates • Roll surface POLYCOM Design and Innovation Wear Protection System Lifetime of the rolls is between 6,000 hours and more than 20,000 hours in hard rock depending on ore abrasiveness, ore toughness and feed size. Properties of the wear material must match ore properties => data base required!
  19. 19. 19 POLYCOM Design and Innovation Wear Protection System System • Cheek plates • Roll surface • Roll edge and side protection 1st generation – glued edge blocks 3rd generation – bolted edge blocks can be replaced individually prevents early roll damage and maximizes roll life.
  20. 20. 20 On-line monitoring of roll surface by continuous laser measurement - POLPROTECT Laser sensor moves along roll width (top) within a rubber sealing (right hand) Achievements: • permanent info about wear on roll surface ⇒ operating conditions can be adjusted to meet scheduled change out time • detection of broken studs or edge blocks ⇒ indicator of tramp metal or excessive oversized feed POLYCOM Maintenance Requirements Condition Monitoring of Roll Surface
  21. 21. 21 POLYCOM Design and Innovation Use of „Flanges“ on POLYCOMs cheek plates and flanges seal the gap towards the roll edges flanges attached to rolls Initial perception: skew must be mechanically suppressed in order to avoid that roll touches flanges => heavy and expensive design
  22. 22. 22 POLYCOM Design and Innovation Use of „Flanges“ on POLYCOMs cheek plates and flanges seal the gap towards the roll edges flanges attached to rolls field trials proved: flanges on POLYCOMs work w/o implemented skew suppression if applying roll parallel control as well as protective electrical and mechanical interlocks
  23. 23. 23 Use Of Flanges on POLYCOM HPGRs pilot test with flanges on MAGRO (Ø 950 x 350 mm) • more uniform pressure distribution along roll width • 30 % higher specific throughput • 25 % lower specific energy input (per pass) • small increase (2 – 3 %) in product fineness @ 6 mm long term field trials with flanges on POLYCOM 24/17 • 15 to 20 % higher specific throughput • 0 to 10 % lower specific energy input • no significant increase in product fineness
  24. 24. 24 Summary • more than 400 polycom® HPGR references with more than 50 in hard rock applications • polycom® circuits: more energy efficient and less sensitive to ore variability than SABC circuits ⇒ constant high throughput, low operating cost and reduced CO2 footprint • successful up-grades of existing crushing and grinding circuits with polycom® HPGRs ⇒ higher revenue due to increased plant throughput and recovery • low opex: polycom® offers longer roll life, higher throughput and requires less energy than original design figures specified • high availability due to robust design, low maintenance needs, long roll life and fast roll change-out • polycom® can be equipped with flanges to increase throughput w/o the need of mechanical skew suppression
  25. 25. Egbert Burchardt Grinding Technology – Mineral Processing Santiago de Chile I 28.08.2019 Voces Mineras: Nuevas Tecnologias Que Revolucionan La Minera POLYCOM HPGRs An Innovative and Matured Comminution Tool for the Mining Industry

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