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Presentación de Raúl Noriega y Juan Collao, Metso

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Presentación de Raúl Noriega y Juan Collao, Metso en foro “Nuevas Tecnologías que Revolucionan la Minería”

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Presentación de Raúl Noriega y Juan Collao, Metso

  1. 1. Metso HRC™ state-of-the-art HPGR technology
  2. 2. © Metso© Metso Content 2 • HPGR basics - Advantages over SAG mill • The HRC™ key innovations - Reducing edge effect through the use of flanges • HRC™ advantages over traditional HPGR’s • An even better HRC™ coming soon • Conclusions
  3. 3. © Metso© Metso HPGR basics 3 © Metso© Metso
  4. 4. © Metso© Metso Metso HRC™ 7 © Metso© Metso
  5. 5. © Metso© Metso This is the Metso HRC™ HPGR 8 Feed system Main hydraulic cylinders Patented Arch-Frame assembly Drive train assembly reducer, cardan shaft, safeset coupling, motor & VFD Base frame assembly Stabilizing cylinders for positioning and maintenance
  6. 6. © Metso© Metso HRC™ HPGR product line 9 Model Name Roll Dimensions Diameter (mm) x Width (mm) Maximum Installed power (kW) Maximum Installed power (HP) Nominal Roll Speed (RPM) Top size (mm)* Typical Capacity (tph)* HRC™800 740 x 400 2 x 110 kW 2 x 147 HP 30.2 18 86 - 120 HRC™1000 1000 x 625 2 x 260 kW 2 x 349 HP 25.8 25 211 - 295 HRC™1450 1450 x 900 2 x 650 kW 2 x 872 HP 21.4 36 530 - 742 HRC™1700 1700 x 1000 2 x 900 kW 2 x 1207 HP 19.1 43 723 - 1012 HRC™2000 2000 x 1650 2 x 2100 kW 2 x 2816 HP 19.1 50 1650 - 2310 HRC™2400 2400 x 1650 2 x 3000 kW 2 x 4023 HP 19.1 60 2376 - 3326 HRC™2600 2600 x 1750 2 x 3700 kW 2 x 4962 HP 19.1 65 2958 - 4141 HRC™3000 3000 x 2000 2 x 5700 kW 2 x 7644 HP 19.1 75 4500 - 6300 *Varies per application, capacity based on nominal equipment speed and a specific throughput of 250 - 350 ts/m3h, values do not include circulating load
  7. 7. © Metso© Metso20 © Metso© Metso HRC™ Advantages
  8. 8. © Metso© Metso Advantages: Better Performance • HRCTM shows an improvement in grinding performance due to flanged rolls  Reduced edge effect. • Table shows typical improvements observed at pilot and industrial scale. • Reliable flange operation has only been proven in a machine fitted with anti- skew. • Metso is the only OEM who has a proven solution for reliable operation of flanges and anti-skew. 21 Variable Proven Benefits compared with Traditional HPGR Specific Capacity + 20% Fresh Feed + 20% Gap + 25% Specific Energy - 10% Circulating Load - 40% Product Size P80 -10%
  9. 9. © Metso© Metso Advantages: Improved Wear Life • Uniform wear through roll length, no bathtub effect or premature studs failures (no wash out) like conventional HPGR’s • Typical HRC3000 wear performance (for copper ore): • Rolls: 15,000-20,000 hours (6,000-9,000 hours typical for HPGR’s) • Flanges: 8,000 hours • Edge blocks: 8,000 hours Flanged roll after 16,200 operating hours in copper ore application 22
  10. 10. © Metso© Metso Advantages: Reduced CapEx and OpEx • The HRC3000 is the largest and proven HPGR available in the market and it’s capable to process up to +100 KTPD of fresh feed. • HRC3000 can effectively reduce the amount of auxiliary equipment compared with multiple HPGR lines resulting in… • Lower CapEx and OpEx of the plant due to smaller and simpler building • Less maintenance man-hours required and less equipment to be maintained • Better dust control due to less transfer points and bins 23
  11. 11. © Metso© Metso Advantages: Increased Reliability and Availability • Crushing circuit will require less auxiliary equipment with one HRC3000: • Less conveyor belts, feeders, chutes, bins and transfer points • Complexity is reduced therefore it can obtain higher availability due to less auxiliary equipment needing maintenance: • Example: Tripper car in the feed bin • We estimate 2 additional points (%) in run time of the circuit compared with a circuit of multiple HPGR’s Typical Layout with Multiple HPGR’s Layout for One HRC3000 24
  12. 12. © Metso© Metso Advantages: 2ry Crusher in Open Circuit • The HRC3000 has a 3 meter diameter roll which means larger feed gap than smaller HPGR’s. • Larger feed gap means that bigger rocks can be fed to the machine therefore secondary circuit can be arranged in open circuit reducing the footprint in the plant even further. • Additionally the MP2500 is the largest cone crusher available. It was specially designed to reduce plant footprint and consequently CAPEX as it can replace two MP1250’s 25 One MKIII 6089 One MP2500 One HRC3000 Two BM 27 x 44 CAPEX Saving Circuit for ~100 ktpd
  13. 13. © Metso© Metso Advantages: +5 years of continuous operation 26 • Average Roll speed of 15-16 rpm of 21 rpm max. This is ~30% available capacity • 92% availability • Almost 20,000 hours of tire life • It’s the largest HPGR operating in mining application - 10.000 20.000 30.000 40.000 50.000 60.000 70.000 80.000 90.000 Averagedailythroughput(mtpd) HRC3000 Throughput
  14. 14. © Metso© Metso28 We are making the HRCTM even better © Metso© Metso
  15. 15. © Metso© Metso The same HRC™ advantage - operating with flanges 29 Even crushing force reduces the tire wear: • promoting even wear across the width of the tires • allows for innovative carbide stud compositionReduced circulating loads in closed circuit applications: • potential to design auxiliaries (screens, conveyors) for lower recycle rate • alternatively, potential for a smaller aperture on the screens, generating a finer product Increased breakage rates provide higher energy efficiency Higher specific throughput increases unit capacity Finer product in open circuit applications: potential to be applied in broader range of applications © Metso© Metso
  16. 16. © Metso© Metso Arch Frame replaced with new Anti-Skew Assembly (Patent Pending) • CapEx eliminated • CapEx eliminated • Maintenance requirement reduced Next Generation HRC™ The same performance but lowered total CapEx cost 30 Transport Cart eliminated Stabilizing cylinder eliminated
  17. 17. © Metso© Metso Next Generation HRC™ Delivering lowered total CapEx cost 31 • Total CapEx reduced • ~80% of the components / assemblies are the same • Floor space reduced • Total height reduced • Foundation requirement reduced
  18. 18. © Metso© Metso Next Generation HRCTM • HPGR technology offers a better efficiency and OpEx than SAG mill circuits. • Better Total Cost of Ownership and financial returns, specially in large plants and hard ores • Major differences are anti-skew system and flanged rolls that allows following advantages: o Best process performance o Reduced wear life o Larger Machine  Reduced CapEx and Higher Reliability • The same performance of the Patented Arched Frame design; new Anti-Skew Assembly (Patent Pending) and flanged rolls. • Optimized to deliver lowered total CapEx Conclusions 32 Compared with SAG mills Compared with Conventional HPGRs

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