VERTIMILL Maintenance and Layout_Escondida Meeting-Aug 18.pptx

8/10/2019 VERTIMILL Maintenance and Layout_Escondida Meeting-Aug 18.pptx

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VERTIMILL ® Grinding Mills



This submittal is to be used bythe Recipient only for the

purpose for which it is provided. All documents, drawings,pricing, descriptions, literature,data, etc. contained herein(whether hard copy or

electronic) are ConfidentialInformation and are to be treatedas such by Recipient, to include,but not be limited to, protectingthe Confidential Information fromunauthorized disclosure or use.



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VERTIMILL ® Grinding MillPresentation Outline

• Vertimill Overview• Maintenance Activities

• Layout Considerations

• New VTM-3000-WB at Newcrest Cadia

27-10-20143



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The VERTIMILL ® Overview

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• > 330 Units Worldwide• > 175,000 kW Total power

• Unit Sizes from 15 to 3000 HP

• Feed Size from 6 mm

• Product Sizes to 15 µm• Low Intensity = Low Wear

• High Density media

• Media Size Matched with Grind

38 – 5 mm



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The VERTIMILL ®

Applications

• Grinding- Secondary - 6 mm to 75 µm- Tertiary - 400 µm to 75 µm- Regrind - 200 µm to 15 µm- Flue Gas Desulphurization - 6 mm

to 20 µm

• Lime Slaking- Flue Gas Desulphurization- Acid Neutralization- Additive

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Regrind Flue Gas Desulfurization

Lime Slaking Secondary and Tertiary

Other



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VERTIMILL ® Maintenance Activities

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• Grease Motor Bearings

• Change Motor Brushed

• Grease VTM Bearings

• Change Lube oil & filters• Change Screw Liners



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VERTIMILL ® MaintenanceDesign Considerations

• Access for greasing all bearings• Access to mill motor brushes

• Access to lube skid

• Crane and Fork Lift capacity and access for screw liner changes

• Crane for recharging Vertimill with balls• Access for screw transport pockets

• Vertimill pier height for use of ball bins

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VERTIMILL ® MaintenanceDaily Activities

• Daily equipment walk-down by operators

• No daily maintenance required

• All maintenance and troubleshooting detailed in manual

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VERTIMILL ® MaintenanceSchedule

Mill SystemComponent

TaskDescription

TaskDuration

Interval Mill Condition forProcedure

System Overall Check 10 min Daily Operating

Mill Motor GreaseBearings 5 min 3000 hrs Operating or Stopped

Reducer Change Oil 4 hrs Yearly Mill Stopped

Mill Bearings Inspect GreaseSystem 5 min Weekly Operating or Stopped

Mill Internals Inspect 12-16 hrs TBD Mill Stopped

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VERTIMILL ® MaintenanceTypical Steps to Change Liners

1. Grind-out2. Ball discharge

- To floor

- Use of ball bins

3. Door opening

4. Liner/screw replacement- Inside mill

- Complete screw change out

5. Door closing

6. Ball loading- Use of ball bins

- Continuous system

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VERTIMILL ® MaintenanceOpen the Ball Discharge Port

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VERTIMILL ® MaintenanceOpen the Ball Discharge Port

13

• Loose all nucking nuts “A” • Back off jacking bolt “B” by one turn

• Tighten bolts “C” to push the shaft awayfrom the mill body and release the seal onthe ball discharge port

• Operate the valve by pulling the handleaway the mill body

• If necessary in step 2, turn bolt “B” morethan one turn

• To close, reverse the above by looseningbolt “C” and tighten bolts “B” to seal the

valve, then tighten nuts “A” to lock the bolts • Warning, do not open the valve with bolts

“B” beyond one and a half turns since largematerial can enter the sealing surface andmake it difficult to seal



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VERTIMILL ® MaintenanceBall Discharge Using Bins – Option 1

• Ball Bins provide a clean andeasy way to handle media

• Manual discharge port

• Allows for easy loading andunloading of grinding media

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VERTIMILL ® MaintenanceBall Discharge To Floor – Option 2

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VERTIMILL ® MaintenanceDoor Opening

• Remove the bolts in the access door flange,pump up the hydraulic door flange jackswith the pump provided with the screwtransport system. The jacks and plumbingshould have been previously filled with oiland the lines bled to remove any air.

• As the hydraulic jacks are being extended,the manual jacks installed at the hingepoints should be extended to keep the doorvertical and in the outer most position in thehinge slots as the door is opened.

• After the door is opened, wash theremaining balls out with high

• pressure hoses, or remove with shovels andrakes.

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17

ManualJack

HydraulicJack



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Most common options:• Winches

• Cranes

• Loader/Excavator

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VERTIMILL ® MaintenanceScrew Liner Wear

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VERTIMILL ® MaintenanceDoor/Ball Charge Height

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VERTIMILL ® MaintenanceLiner Change Option 1

• Change liners inside the mill, most common solution

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VERTIMILL ® MaintenanceLiner Change Option 2

• Change Entire Screw

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VERTIMILL ® InstallationsLayout Examples



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VERTIMILL ® InstallationsLayout Examples

• Cerro Verde• Hibbing Taconite

• Los Pelambres

• Candelaria

• Codelco Andina• Esperanza

Not Recommended Layouts (Safety Issues):

• Escondida• Las Tortolas (Los Bronces)

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Cerro VerdeThree (3) VTM-1500-WBs

• No structure in front of millto allow easy crane accessfor screw insert and removal

• Modest pier height for easymaintenance

• Bins used for mediaaddition as well

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Cerro VerdeMedia addition – Same bin used for media handling

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Hibbing TaconiteTwo (2) VTM-1250-WB

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Los PelambresOne (1) VTM-1500-WB

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CandelariaOne (1) VTM-1250-WB

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Codelco AndinaTwo (2) VTM-1250-WB

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Minera EsperanzaTwo (2) VTM-1500-WB

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EscondidaFour (4) VTM-1500-WB (Not Recommended)

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Los BroncesThree (3) VTM-1500-WB (Not Recommended)

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Newcrest CadiaVTM-3000-WB



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The 1 st VTM-3000-WB InstallationNewcrest Mining Ltd. Cadia Valley Operations

21 September 201035



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Newcrest CadiaHigh Grade Concentrator Simplified Flow Sheet

21 September 201036

Secondary VTM-1250-WB

Tertiary VTM-3000-WB

Regrind VTM-1250-WB



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Newcrest CadiaThe 1 st VTM-3000-WB

• Grinding Design• F80 – 150 µm

• P80 – 90µm

• 780 mtph

• Exceeded efficiency predictions

• Flotation Recovery High thananticipated

- Sharper particle size distribution

- Finer feed to flotation

• Tertiary circuit stabilizes feed torougher flotation circuit

21 September 201037



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Newcrest CadiaOperation of Separating Tank

27-10-201438



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VTM-3000-WB PerformanceSummary to Date

• No Installation complications

• No Mechanical complications

• No Process complications

• With in 3 days of the start of commissioning, the mill became anactive part of plant operations

• Improving Recovery

• Increasing capacity

• Project and Installation executed with efficiency, quality, andfunctionality of a typical smaller VTM project

• Original set of liners replaced on May 2011 after 9 months ofoperation (no complications in the replacement, it took 30 hours).

21 September 201039



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VTM-3000-WB MaintenanceFirst Internal Inspection After 3 Months of Operation

21 September 201040

October, 2010



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VTM-3000-WB MaintenanceFirst Liner Replacement on May 2011

21 September 201041

9 months of life



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VTM-3000-WB MaintenanceFirst Liner Replacement on May 2011

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VTM-3000-WB MaintenanceTypical Steps to Change Liners

1. Grind-out – 8 hours2. Ball discharge

- To floor – 11 hours

- Use of ball bins

3. Door opening

4. Liner/screw replacement- Inside mill – 4 hours (2 diggers)

- Complete screw change out

5. Door closing

6. Ball loading- Use of ball bins – 5 hours (10 ton)

- Continuous system

Cadia Total Time: 28 hours

10/27/201443



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Documents

VERTIMILL Maintenance and Layout_Escondida Meeting-Aug 18.pptx