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Mining On Top: Stockholm 2013 26-27 Nov 2013 Continuous improvements in Mineral processing – Lucy England, FLSmidth; Sales Manager - Northern Europe
Citation preview
Continuous Improvements in Mineral
Processing Mining on Top – Stockholm
Minerals Engineering 2013 – Lucy England
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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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
Delivering results for more than a century
3 FLSmidth corporate
presentation 2013
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One Source
One Source Supplier
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Sustainable Mining
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New Product Investment
• HPGR – Finished and tested
• Semi Mobile Crushers
• SX Reverse Mixer/Settler
• Large Gyratory Design
• Vertical Stirred Mill
• Deswick Fine Grinding Mill
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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
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RESOURCE EFFICIENCY
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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
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SAFETY AND ECONOMY
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Fourth Generation (Mk IV)
Traylor Type TS
Gyratory Crusher (2005 – Present)
Third Generation (Mk III)
Traylor Type NT
Gyratory Crusher (1990 – Present)
First Generation (Mk I)
Traylor Type C (Bulldog)
Gyratory Crusher (1905 - 1950)
Second Generation (Mk II)
Traylor Type TC
Gyratory Crusher (1950 – 1990)
13 28 November 2013 Primary Gyratory Crushers
Primary Gyratory - History
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Gyratory - Added Value in Design
14 28 November
2013
Primary Gyratory Crushers
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.
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Gyratory - Added Value in Design
15 28 November
2013
Primary Gyratory Crushers
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.
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Latest Developments
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2013
Primary Gyratory Crushers
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
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Fuller-Traylor®
Primary Gyratory Crushers
World’s Largest Gyratory
1600 x 3000 (63” x 118”), 1200 kW
Hudbay Minerals – Constancia Copper
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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”
Constraints:
• Modern Day Foundry Capacities
• Modern Day Machine Shop Capacities
• Transportation Limitations
• Industry Reluctance to Accept New 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
Primary Gyratory Cruhers
Gyratory – Future Developments…?
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RESOURCE EFFICIENCY AND ECONOMY
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FLSmidth Research and Development: Our Investment Improves your Recovery
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
FLSmidth Flotation Technologies
28 November 2013
21 technologies
WEMCO 300 & 600
Dorr-Oliver 300 & 600
XCELL 350
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600 Series SuperCell™
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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
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Effect of Bubble and Particle Size
2
b
p
cD
DAP
elephant curve
Collision probability • Sutherland, 1948; Reay and Ratcliff, 1973; Flint and Howarth, 1971; Weber and Paddock,
1983; Ahmed and Jameson, 1989; Luttrell and Yoon, 1989
Gaudin, 1931
R
UtUr
r
Rb
R
UtUr
r
Rb
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Energy Barrier (E1)
HDET VVVV
Extended DLVO theory
k
AE
EP 1exp
H
H
H
E
ee
e
rr
rrV
2
2
2
2
1
21
21
2
2
2
1210
1ln1
1ln
2
Hbc
bl
rrH
rrAVD
1
211
6 21
21132
Hrr
KrrVH
21
13221
6
26
2 We U 2
1/ 2
1
Fr23
1
Wes
ln
h0
hcr
Tres Trup
Tres Trup
Transition from bouncing to penetrating particle is predicted by:
27 28 November 2013 27
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Predicted Attachment Rate
- DO Rotor 300m3 Machine
10 microns 150 microns 300 microns
Standard Stator
New Slotted Stator
Attach Inside Stator Attach Outside Stator
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Hybrid Energy Flotation™
Standard energy (standard mechanism) Easy floating material. Recovery is froth phase controlled
High energy (standard mechanism, high RPM) Fine material
Low energy (larger rotor, low RPM) 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.
Mixed Row Flotation
Hybrid Mechanism Flotation™
Standard mechanism Easy floating material Recovery is froth phase controlled
New mechanism More blades Fine material
New mechanism Holes in stator 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.
28 November 2013 30
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
Title 30
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