Continuous improvements in Mineral processing
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The document outlines FLSmidth's advancements and innovations in mineral processing and mining, emphasizing their 130 years of expertise and new product investments like high-pressure grinding rolls and large gyratory crushers. It discusses design improvements in primary gyratory crushers that enhance safety, reduce downtime, and increase efficiency, showcasing the benefits of modern engineering techniques. Additionally, the document highlights ongoing research and development efforts aimed at optimizing resource efficiency and enhancing recovery in flotation technologies.
Continuous improvements in Mineral processing
- 1. Continuous Improvements in Mineral Processing Mining on Top – Stockholm Minerals Engineering 2013 – Lucy England
- 2. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 2
- 3. Delivering results for more than a century 130 years of experience and leadership in cement 100 years of rich experience in minerals Essentially “invented” the cement industry and fuelled major developments within minerals Unsurpassed expertise and know-how in both industries FLSmidth corporate 3 3
- 4. One Source Supplier One Source 4
- 6. New Product Investment • HPGR – Finished and tested • Semi Mobile Crushers • SX Reverse Mixer/Settler • Large Gyratory Design • Vertical Stirred Mill • Deswick Fine Grinding Mill 6
- 7. Product Optimization Investments • Expand Gyratory Top Service Design • Mill Gear Optimization and Standardization • Larger Flotation Cells • Flotation Optimizations – coarse particle recovery and froth vision • Expand Cone Crusher Sizes • Larger AFP and other Pressure filter improvements • Sedimentation Optimization 7
- 9. Global Technology Center - Salt Lake City Integrated Solutions & Capabilities World Class Ore Characterization / Metallurgical Lab Full-disciplined Engineering • Process Optimization • PFS/FS/DE • Flow Sheets, P&IDs, Layout Optimization • Civil/Structural • Mechanical/Piping • Electrical / Automation and Controls • 3D Models Experienced Project Management Staff • Cost Controls, Reporting • Procurement Specialists In-House Equipment Products Specialists • Comminution • Flotation • Dewatering / Filtration • ADR 9
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- 13. Primary Gyratory - History First Generation (Mk I) Traylor Type C (Bulldog) Gyratory Crusher (1905 - 1950) Second Generation (Mk II) Traylor Type TC Gyratory Crusher (1950 – 1990) Third Generation (Mk III) Traylor Type NT Gyratory Crusher (1990 – Present) Fourth Generation (Mk IV) Traylor Type TS Gyratory Crusher (2005 – Present) 13 28 November 2013 Primary Gyratory 13 Crushers
- 14. Gyratory - Added Value in Design 1. Fuller-Traylor Bar-Type Spider • 4-Bolt Attachment • Simple Geometry • Fast to Install, Fast to Remove • Compact Lay-Down Areaxxxxx • Saves 10 Hours of Down Time per Main Shaft Change-out • Annually this equals 10 hrs x 4 persons x 3 changes per year = 120 man hours or 30 hours of additional annual production. Primary Gyratory Crushers 28 November 14 14
- 15. Gyratory - Added Value in Design 2. Fuller-Traylor Specialty Maintenance Tools • Concave Replacement Platforms • Eccentric Maintenance Carts • Provide Safe Work Area • Pre-Assemble Concaves While Plant is Operating • Reduces Crusher Down-time for Concave Replacement from 48 hours to 36 Hours. Primary Gyratory Crushers 28 November 15 15
- 16. Latest Developments Top Service “TS” Design Gyratory • Designed for Safe Maintenance • NO Eccentric Cart Required • NO Large Discharge Bin Doors • Replacement Times: 4 Hours Main Shaft Assembly 6 Hours Eccentric Assembly 10 Hours Outer Eccentric Bushing xxx • Safety Value….Less Exposure 125 Man-hours less for unscheduled Eccentric Bushing replacement. • Plant Design Savings +$ 400,000 Primary Gyratory Crushers 28 November 16 16
- 17. Fuller-Traylor® Primary Gyratory Crushers World’s Largest Gyratory 1600 x 3000 (63” x 118”), 1200 kW Hudbay Minerals – Constancia Copper 17
- 18. Gyratory – Future Developments…? New Concepts: • • • • • • 100+ Years of Experience Benefit of Finite Element Analysis Benefit of Solid Works 3D Modeling Modern Control Techniques Willingness for “Out of the box Thinking” Desire to “Break away from Traditional Ideas” Desires: • • • • • Increased Capacity (Not at Expense of OSS Setting) Increased Power (More efficiently utilized) More Maintenance Friendly New Materials for Increased Wear Life Improved Safety Features Constraints: • • • • Modern Day Foundry Capacities Modern Day Machine Shop Capacities Transportation Limitations Industry Reluctance to Accept New Ideas Primary Gyratory 18 Cruhers
- 20. FLSmidth Research and Development: Our Investment Improves your Recovery 20
- 21. FLSmidth Flotation Technologies WEMCO 300 & 600 technologies XCELL 350 Dorr-Oliver 300 & 600 The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 28 November 2013 21
- 23. Final 600 Series Supercell Result: 600 series SuperCell™ Design Summary Tank Summary: Nominal Tank Volume: 600m3 Active Tank Volume: 660m3 Diameter: 10870mm Overall Tank Height: 8415mm Wetted Height: 7720mm Aspect Ratio: 0.71 Drop height: 1200mm Manway Dimensions: 2400mm x 2400mm Tank Drain Size: (2) @ 18” Launder Width: 575mm (22.6”) Froth Surface Summary: Tank Surface Area: 92.8m2 Peripheral Launder Lip Length: 34.1m Number of Radial Launders: 16 Radial Launder Width: 300mm Total Radial Launder Lip Length: 68.8m Total Radial Launder Area: 9.6m2 Total Lip Length: 93.7m Effective Area: 59.5m2 Motor: Installed Motor HP: 1000 test Operation 450-900 HP VFD included 23
- 24. Effect of Bubble and Particle Size Collision probability • Sutherland, 1948; Reay and Ratcliff, 1973; Flint and Howarth, 1971; Weber and Paddock, 1983; Ahmed and Jameson, 1989; Luttrell and Yoon, 1989 r Dp Pc A D b 2 Ur Gaudin, 1931 Ut R Rb elephant curve 24
- 25. Energy Barrier (E1) Extended DLVO theory VE 0r1r2 12 22 r1 r2 212 1 e H 2 ln 2 1 2 1 e H VT VE VD VH VD ln 1 e 2H A132 r1 r2 1 2bl 1 6 H r1 r2 1 bc H r1 r2 K132 VH 6r1 r2 H E PA exp 1 E k 25
- 26. Tres Trup Tres Trup Transition from bouncing to penetrating particle is predicted by: 1/ 2 U 2 1 3 1 h0 2 We ln Fr 2 Wes hcr 26
- 27. Predicted Attachment Rate - DO Rotor 300m3 Machine Standard Stator Attach Inside Stator Attach Outside Stator New Slotted Stator 10 microns 150 microns 300 microns The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 28 November 2013 27 27
- 28. Hybrid Energy Flotation™ Standard energy (standard mechanism) Easy floating material. Recovery is froth phase controlled Low energy (larger High energy rotor, (standard low RPM) mechanism, Coarse high RPM) material Fine material The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
- 29. Mixed Row Flotation Hybrid Mechanism Flotation™ Standard mechanism Easy floating material Recovery is froth phase controlled New mechanism New mechanism More blades Holes in stator Fine material Coarse material The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
- 30. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. Title The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 28 November 2013 28 November 2013 30 30