frank peter van der meer_1
Post on 02-Apr-2018
219 Views
Preview:
TRANSCRIPT
-
7/27/2019 Frank Peter Van Der Meer_1
1/20
Excellent
Minerals
Solutions
PILOT HPGR CAMPAIGN AT
THE CODELCO EL
TENIENTE COPPER MINE
F.P. van der MeerR. DickeP. Morales
H. Elgueta M.P. Negroni
-
7/27/2019 Frank Peter Van Der Meer_1
2/20
Excellent
Minerals
Solutions
Location: Codelco El Teniente plant, near Rancagua,
89 km south of Santiago, Chile.
Plant Capacity: 137,000 tpd.
Reserves ca. 2.5 billion tons grading ca. 0.84%.Ore Type/Mineralogy: Porphyry copper & molybdenite mineralogy.
with copper- and sulphide rich breccia
(Biotite, Tourmaline, Anhydrite).
UCS 90-140 MPa
Production: approximately 430,000 t/y refined copper
Processing Scheme: SAG and conventional milling, followed by
flotation, thickening and filtration
CODELCO EL TENIENTE COPPER OPERATION
-
7/27/2019 Frank Peter Van Der Meer_1
3/20
Excellent
Minerals
Solutions
REASONS for ON-SITE PILOT WORK
1. Variability testing of different ore types
where representative testing of smaller ore samples abroad is limited,
and costs for transport and testing for multiple ore samples is high.
Samples tested included El Teniente, Andina and Chuquicamata ores.
2. Testing for periods of extended operation
to provide an impression of the operability of a roller press,
acquaintance of the operation, and evaluating availability.
3. Test the operation in a continuous closed circuit
4. Realistic indication forwear rate on roll surface and cheek plates
5. Provide a possibility of on-site determination ofdownstream effects
(such as the reduced ball mill energy input and improved metallurgy)
6. Confirmation tests of initial small scale results (at KHD laboratories)
on a semi-production scale.
-
7/27/2019 Frank Peter Van Der Meer_1
4/20
Excellent
Minerals
Solutions
ARRANGEMENT of PILOT HPGR at EL TENIENTE
Nominal Capacity: 40-60 t/h
Circulating load : 50-60 %
Operating gap approximately 32 mm (1)
6.0 MM
Closed circuit 6 mm dry screening
-
7/27/2019 Frank Peter Van Der Meer_1
5/20
Excellent
Minerals
Solutions
SUMMARY of PILOT HPGR KEY DATA
Stud-Lined Rolls
-
7/27/2019 Frank Peter Van Der Meer_1
6/20
Excellent
Minerals
Solutions
GENERALIZED PILOT HPGR SET-UP FLOW SCHEME
-
7/27/2019 Frank Peter Van Der Meer_1
7/20
Excellent
Minerals
Solutions
PILOT HPGR SET-UP at EL TENIENTE
Feed Chute
Pilot HPGR
Discharge
Conveyor to
6 mm screen
Screen OS
recycle
conveyor
-
7/27/2019 Frank Peter Van Der Meer_1
8/20
Excellent
Minerals
Solutions
PARAMETERS TO BE RECORDED & MEASURED(1 second interval from data logger):
Power consumption (kW) , both motors
Movable roll position; operating gap, left and right
Hydraulic pressure; left and right
Feed rate; from weigh-belt feeder or from sample weight and test duration
SAMPLES TO BE TAKEN
Fresh feed
HPGR effective feed including recycle
HPGR products. Centre and Edge.
Screen oversize (recycle)
Screen undersize
PRODUCT ANALYSES
Particle size distribution
Moisture
Density (SG)
Bulk density
Flake size, proportion and strength
PILOT HPGR TEST DATA COLLECTION
AUXILIARY MEASUREMENTS
Roll surface and lateral wall wear, desagglomeration, screen efficiency
E ll
-
7/27/2019 Frank Peter Van Der Meer_1
9/20
Excellent
Minerals
Solutions
EXAMPLES OF HPGR TEST DATA SERIES
Codelco Andina Ore
E ll t
-
7/27/2019 Frank Peter Van Der Meer_1
10/20
Excellent
Minerals
Solutions
EXAMPLE OF TEST RESULTS
El Teniente and Andina ores
Effect of Pressure on Specific Energy and Specific Throughput
E ll t
-
7/27/2019 Frank Peter Van Der Meer_1
11/20
Excellent
Minerals
Solutions
EXAMPLES OF TEST RESULTS
HPGR Centre Discharge
with ca. 10 % flakes
Weak flakes;
disintegrate upon handling
Average Feed & Product Size Distributions
E ll t
-
7/27/2019 Frank Peter Van Der Meer_1
12/20
Excellent
Minerals
Solutions
EXAMPLE OF TEST RESULTS
El Teniente and Andina ores
Effect of Pressure on Product Size
E cellent
-
7/27/2019 Frank Peter Van Der Meer_1
13/20
Excellent
Minerals
Solutions
Projected roll surface wear life
from wear rate measurements
indicates
7,500 to 12,000 operating hours
for Stud-Plus Lining
Optimized conditions ensure
a strong autogenous roll coating
ROLL SURFACE WEAR
Excellent
-
7/27/2019 Frank Peter Van Der Meer_1
14/20
Excellent
Minerals
Solutions
OBSERVATIONS ENCOUNTERED
Gap skew from feed segregation
and material flow hindrance in feed chute
Shallow feed chute did appear to
limit material passage
at freezing conditions
A wider chute and insulation
did achieve better flow conditions
Mass flow calculations from belt cuts
difficult to reconcile with actual throughput
Weigh belt or feeder more reliable
Sufficient spares, maintenance and
availability of support personnel essential
Excellent
-
7/27/2019 Frank Peter Van Der Meer_1
15/20
Excellent
Minerals
Solutions
COMPARISON OF PERFORMANCEAverage Results
Excellent
-
7/27/2019 Frank Peter Van Der Meer_1
16/20
Excellent
Minerals
Solutions
CRUSHING CIRCUIT SPECIFIC ENERGY COMPARISON
Ch 2
Ch 3
Mda.Bolas
Conventional Crushing HPGR
Mda.
Bolas
Ch 2
Ch HPGR
Courtesy of Codelco
AND: Additional savings in
reduced ball mill energyand finished product generated
in HPGR discharge
Excellent
-
7/27/2019 Frank Peter Van Der Meer_1
17/20
Excellent
Minerals
Solutions
COMPARISON OF PERFORMANCE
average results for Andina, El Teniente and Chuquicamata
with copper ores at similar conditions
Excellent
-
7/27/2019 Frank Peter Van Der Meer_1
18/20
Excellent
Minerals
Solutions
INDICATION OF FULL SCALE CAPACITIESof average results for Andina and El Teniente ores
for a specific pressure of 3.0-4.0 N/mm
Excellent
-
7/27/2019 Frank Peter Van Der Meer_1
19/20
Excellent
Minerals
Solutions
CONCLUSIONS and OBSERVATIONS
Andina, El Teniente and Chuquicamata ores were amenable to HPGR
with performance parameters near average of other copper ores
Andina was slightly harder than El Teniente and Chuquicamata
with higher energy input and lower specific throughput
HPGR offers a lower energy consumption in the crushing circuitof average 18 % against SAG milling and 6-10 % against conventional crushing
No differences were observed in flotation response
Presently projected or available HPGR unit sizes
do facilitate maximum unit capacities of up to 3,000-4,000 tons per hour
Wear rates measured indicate roll surface life of 8,000 to 12,000 operating hours
Control and arrangement of a homogenous feed supply is essential
Pilot plant design needs attention equivalent to a production facility
Preparation in sampling, mass rate measurement, feed supply is critical
Excellent
-
7/27/2019 Frank Peter Van Der Meer_1
20/20
Excellent
Minerals
Solutions
I THANK YOU FOR YOUR KIND ATTENTION.
If you have any questions, I would be happy to answer these.
top related