More Related Content Similar to Stirred milling machine development and application expansion (20) More from Mining On Top (20) Stirred milling machine development and application expansion1. Mining on Top - Stockholm
Stirred Grinding Mill Development
and Application Expansion
Graham Davey
Process Manager
3. Metso Stirred Milling
Goals
• What we know and what we
don’t know
• We rely on operations and
projects to give us feedback
• Learn more together
• Ask the right questions
• Circuit Design, Optimization
and Modelling
• Maintenance Best Practices
and Strategies
• Update on the technology and
future developments
3
© Metso
5. Stirred milling
Design goals
Lowest total cost of ownership
Energy efficiency
Sustainability
© Metso
Ease of operation
Grinding media consumption
5
Minimal maintenance
CAPEX
6. VERTIMILL® grinding mill
Overview
• Over 420 units worldwide
• Over 270,000 kW total power
• Unit sizes from 15 to 4500 hp
• Feed size from 6 mm
• Product sizes to <15 µm
• Low intensity = low wear
• High density media
• Media size matched with grind
38 – 5 mm
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7. VERTIMILL® grinding mill
Components and features
Motor
Low speed coupling
Gear reducer
Thrust bearing
Reducer pedestal
Driver shaft
Feed chute
Upper body
Ball port
Lower body
Dart valve operator
Screw with liners
Separating tank
Magnetic lining
Recycle hose
Recycle pump
Access door
Drain
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© Metso
Product elbow
8. VERTIMILL® grinding mill
Lowest total cost solution
• Low operating cost
- Energy efficient
- Reduced media consumption
- Long wear life
• Low installation cost
- Simple foundation
- Quick installation
- Less floor space
• Improved process performance
• Higher recovery
• Higher availability
• Greater operational safety
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9. Stirred Media Detritor
Overview
• Primarily for fine and
ultra fine grinding
• Low density media:
sand or ceramic
• Optimum grinding
intensity for optimum
wear life
• >170 units by Metso
SMD-185-E
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SMD-355-E
SMD-1100-E
11. Stirred milling
Design goals
Lowest total cost of ownership
Energy efficiency
Sustainability
© Metso
Ease of operation
Grinding media consumption
11
Minimal maintenance
CAPEX
12. Vertimill Energy Efficiency
Primary Reasons
• High Shear Energy
-
Generally accepted to be more
efficient
• Minimal Impact
-
Wasted ball mill energy with balls
impacting balls and balls impacting
liner
- Also contributes to higher ball wear
• Retention of Fine Media
- Vertical arrangement keeps the fines in
the mill
-
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Fine media will float out of a ball mill
(will wear out pumps and screens fast
too)
13. Striving to full understanding of the VERTIMILL
and ball mill power relationship
Specific Energy (kWh/mt)
“30-50% more efficient than a
Bond Ball Mill”
• True in most cases
• Over simplification
10
•Function of the feed size, product
size, and material grindability
• How far coarse and how fine can
we go?
• Efficiently
• Practically
100
P80 (microns)
Bond Ball mIll Power
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© Metso
1000
VTM Power
• How do we determine this
relationships for all ore types?
15. Stirred milling
Design goals
Lowest total cost of ownership
Energy efficiency
Sustainability
© Metso
Ease of operation
Grinding media consumption
15
Minimal maintenance
CAPEX
16. Current/Planned Development Activities
VTM-6000 (or larger!)
VTM-10 Pilot Unit
Stirred Milling Bench Scale
Equipment
Intermediate VTM Sizes
VTM-75-WB Portable Pilot Plant
VTM Liner Handler
Automated Media Discharge
SMART Equipment
Automated Media Reloading
Standard Layouts
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© Metso
• Bigger mills at economical prices
• Enable secondary grinding
• Create multiple VTM Pilot units to be distributed into third party facilities
• Looking for WA partner to take a unit
• New Test in development with the JKMRC
• Jar mill continued development
• Fill in our product offering for improved project economic
• VTM-2250-WB and VTM-3750-C
• Available for Extensive field trials
• Integral device for faster liner handling
• Included features to remove grinding media
• Hydraulic Actuated valve
• Integrate water flush lines
• Condition Monitoring and advanced process control
• Standard unit supervisory control to reduce installation cost and time
• Faster media addition during operation and after mill relining
• Reduce project engineering cost
• Incorporates beset practices in maintenance and operation
17. Creating the VTM-3000-WB from the VTM-1500-WB
Previous Scale up Considerations
• Wanted to Keep existing
Vertimill advantages:
- Machine Simplicity
- Long Wear Life
- Grind Efficiency
• Challenges
-
Torque and Availability of Drive
Components
-
Wear
Minimize Capital Cost
Maintainability
The VTM-3000-WB was the most successful development and
new machine for Metso in recent memory
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18. VTM-6000-C
And beyond
• What we want to provide
-
Lower CAPEX, enable use of large machines
VTM-4500 equal or better OPEX
Shorter mill deliveries
Smaller wear components
• Will use innovative and new to metallic mineral processing drive
concepts
• Will be shorter overall height than VTM-4500-C
• Ready to offer by Dec 2013, target delivery of 1Q15
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19. Current/Planned Development Activities
Stirred Media Detritor
SMD-E
SMD-3300-E
Simulation and
Modeling
SMD-1100- E Field
Trials and Validation
SMD Impeller Arm
wear materials
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• Completion of the E Series Product Line
• E series improves wear life, maintainability and reduces cost
• Next Larger size SMD
• Ready for the market in 1Q 2014
• DEM and PEPT Work to further optimize the SMD operation
• Continued co-development with Imerys
• Extensive field program jointly with Anglo Platinum to put the SMD-1100E through its paces
• Continued development on impeller material for specific applications
• Bench scale impeller wear test rig
• Advantage of pin is new machines immediately test various materials
21. VERTIMILL® grinding mill
Standard Layouts
• Takes the full experience of the
Metso team
• Incorporates different strategies
for maintenance
• Saves times and cost
21
© Metso
22. VERTIMILL® development activities
Not ready to show
VTM Liner
Handler
Automated
Media
Discharge
© Metso
• Hydraulic Actuated valve
• Integrate water flush lines
Automated
Media
Reloading
22
• Integral device for faster liner handling
• Included features to remove grinding
media
• Faster media addition during
operation and after mill relining
25. Vertimill Multi Unit Arrangement
Kaunisvaara Advantage
• Trend is for single stage ball mill to save CAPEX, but this limits
flexibility
• Additional space has been left for a 5th Vertimill in the Sahavaara
Line
• Only the Mills that are required will be run, saving:
- Energy – each mill operated at optimum efficiency
- Wear and Parts
• Vertimills Enabled a change in Mining Schedule
- Original Plan was to have line 1 with Tapuli Ore, line 2 with Sahavaara Ore
- All ore now planned to be tapuli, delayed delivery of one mill
- Conversion of one unit to VTM-4500-R to have greater capacity than plan
• Design = F80 300 microns to a P80 of 34 microns.
• Schedule for Review by JKMRC
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27. VERTIMILL® & Stirred Media Detritor
Barrick Lake Cowal
Gold sulphide concentrate
• Design grinding duty:
- F80: 150 microns
- P80: 15 microns
- Bimodal size distribution
- Reduction ratio: 10
• Customer requested single stage
VERTIMILL®
• Metso provided an optimal media
size and reduction ratio solution
of two stage grinding
Mills are exceeding grinding
performance targets
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28. VERTIMILL® & Stirred Media Detritor
Barrick Lake Cowal (cont.)
Alternative two stage grinding
Grind water
Cyclone overflow
• First stage
Scalping cyclone overflow
- One VTM-1000-WB
- F80: 150 microns
- P80: 40 microns
- 12 mm steel media
• Second stage
- Two SMD-355 in series
- F80: 40 microns
- P80: 15 microns
- 3 mm ceramic or sand media
• Overall specific energy reduced through:
- Optimum technology
- Efficient media
Underflow
SMD product
SMD feed
Mill discharge
Circuit feed
Metso VERTIMILL®
Dilution
water
Cyclone feed
Dilution water
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Metso Stirred Media Detritors
Scalping cyclone feed
Final
product
29. Mining on Top - Stockholm
Stirred Grinding Mill Development
and Application Expansion
Graham Davey
Process Manager