BRADKEN MOLINOS

8/10/2019 BRADKEN MOLINOS

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September 3-5, 2008. Santiago, Chile

to Improve the Wear Life in SAGto Improve the Wear Life in SAGMill Feed End LinersMill Feed End Liners

Craig FaulknerBradken, Australia


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Contents Introduction

SAG Mill - FE Liner Optimisation and Design

Summary

Conclusion

September 3-5, 2008. Santiago, Chile 2


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Introduction Cadia Valley Operations (CVO) consists of two

distinct processing plants

Cadia Hill - Low Grade Plant

Ridgeway - High Grade Plant


16,300 tpd @ 2.4g/t Au and 0.8% Cu

Annual Production:

35,000 t Cu

290,000 oz Au


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Ridgeway Operation Semi-Augeounous Grinding

32ft Dia. x 16ft Long SAG Mill

700 t/h new feed

6500 kW

14.5 EGL


. .

62.6 78.6% critical

28% Mill volume

13% Ball charge

125mm Dia. Balls 50mm grate aperture

15mm trommel aperture

Steel liners ( 417 tonne)


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FE Liner Optimisation & Design The Drivers

Liner life

Combat excessive wear

Reduce reline times per annum

Improve profitability



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Feed End Liner Design Original Design

Typical lifter liner (OEM) design

Three row setup (throat, middle & outer)*Note Throat liner missing from image



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Feed End Liner Design Original Design

High wear through joint

Both parts changed-out together

Liner life 120 days (avg.)

2.0 Mt processed



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Feed End Liner Design Intermediate Design change

Reduce the length of middle liner

Extend outer to cover full charge volume Increase lifter thickness (40mm) to improve wear life

Reduction in liner bolts from 160 to 128 per reline (20%)



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Feed End Liner Design Intermediate Design change

Liner life - 4.4 months & 2,122,801 tonnes

Extra thickness to lifter bar (25mm) Change in CTR bolt position

Extra liner mass



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Composite Liner Design Design Criteria

CAD Modeling incorporating DEM output

Achieve 6 month liner life Review alternative wear materials

Safe and Easy to install


Survive SAG milling environment

Manufacturability


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Composite Liner Design White-iron insert Chrome Moly liner



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Composite Liner Design Implementation

Risk

Trial installation 13-03-07 Inspection & Wear monitoring



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Composite Liner Design Liner Inspection

Wear monitoring 31-05-07

Liner predictions



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Composite Liner Design Full Implementation

Set installed 13-11-07

White-iron performance Liner results



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Liner Inspections


18-02-08 (3.0 months) 30-04-08 (5.5 months)


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Liners removed 20-05-08

6.2 months life (189 days) 2,985,348 tonnes milled



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Composite Liner Analysis Wear Analysis Chrome-moly liner

Laser scanning

Mass reduction Rate of wear


Part No. Material Installed Removed

Life

(Days)

Life

(Months)

Installed

Tonnes

Removed

Tonnes

Period

Tonnes

Tonnes

per Day

BK53212A Chrome-moly 24/07/2007 13/11/2007 112 3.7 29,184,335 30,973,378 1,789,043 15,974


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Composite Liner Analysis Wear Analysis Chrome-moly liner

Mass New 1974

Worn 1420

Mass Reduction Kg's 554

% 28%

Installed Height mm 395

Removed Height mm 150

Material Worn mm 245

mm per MT 136.94


.


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Composite Liner Analysis Wear Analysis

Feed End Liner Analysis

300

350

400

450

ss

2500000

3000000

3500000

d


0

50

100

150

200

250

0 112 189

Days in Service

LinerThickn

0

500000

1000000

1500000

2000000

TonnesM

ill

CrMo WI Composite CrMo - Tonnes WI Composite - Tonnes


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Summary Results

Achieved 6 month relines

Reduction in one reline per year Reduced overall annualised reline times by 24 hours

Increased wear life by 68.75%


Liner Description uan y

Per Set

ner ass

Per Set (kg's)

ange-ou me

Per Set (Hours)

ear e

(Months)

nnua se

Change-out Time (Hours)Feed End

Middle Liner 16 24,000 4.53 3.8 14.3

Outer Liner 32 44,880 9.07 3.8 28.668,880 43

REVISION 2

Liner Description uant ty

Per Set

ner ass

Per Set (kg's)

ange-out me

Per Set (Hours)

ear e

(Months)

nnua se

Change-out Time (Hours)

Feed End

Middle Liner 16 10,816 4.53 42.7 1.3

Composite Outer Liner 32 62,080 9.07 6 18.172,896 19


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Conclusion



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Acknowledgements Bradken

Newcrest Mining Cadia Valley Operations


Notice:The Design and Technical information as detailed in this document is the exclusive property of the Bradken Pty. Ltd. and its relatedentities. It is issued on the strict condition that except with our written permission it must not be reproduced, copied or communicated toany third party nor be used for any purpose other than that stated in the particular enquiry or contract with which it is issued.

THANK YOUTHANK YOU

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