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

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
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
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
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
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
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
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
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
POLYCOMs for Tertiary Crushing in Large Concentrators

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
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
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
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
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
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
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
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
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
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
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
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
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
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
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. 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