Tag Archives: Comminution

Kwatani breathes new life into scalping screens with rubber, polyurethane wear panels

Comminution of minerals, Equipment maintenance, Mineral processing, Mining equipment, Mining services, , , , ,

As mines move towards using one large scalping screen between primary and secondary crushers – rather than a modular approach using multiple smaller screens – Kwatani says it has found ways to triple the panel life in these single mission-critical units.

According to Kenny Mayhew-Ridgers, Chief Operating Officer of Kwatani, any downtime in this single-line stream would require the mine to store several hours of production. While some mines schedule regular weekly production halts during which an exciter or worn screen panels can be replaced, many operations are not so lenient, he said.

“The message from these mines is clear: the longer the scalper can run between maintenance interventions, the better,” Mayhew-Ridgers said. “Our research and development efforts, together with extensive testing in the field, have allowed us to extend the life of screen panels from eight weeks to over six months.”

While smaller screens use wire mesh screening media, Kwatani has evolved larger screens that use rubber or polyurethane screen panels. Although these panels present less open area, they deliver important advantages.

“Key to the success of our design is our integrated approach – which matches the panel design with that of the scalping screen itself,” Mayhew-Ridgers said. “This allows us to achieve a balance between screening area, aperture layout and screen panel life – a result based on a sound understanding of screen dynamics.”

Whereas wire mesh undergoes rapid wear from abrasive materials, the rubber or polyurethane panels are more wear resistant and deliver longer life, according to the company. The latter require gentler declines for effective stratification, but a key factor is the stiffness of the screen bed.

“The stiffness of the supporting structure must go hand-in-hand with the screen panel design to achieve our required results,” Mayhew-Ridgers said.

Polyurethane panels, while strong and lightweight, have screening apertures that tend to be too stiff for heavy-duty scalping applications. This leads to blinding. Rubber overcomes this problem, however, and also delivers improved wear life.

Kwatani has also developed a panel replacement system – with a fastening mechanism on the underframe – that improves safety and saves time, it says.

CMIC-backed novel comminution technology hits commissioning milestone

Comminution of minerals, Environmental, Mineral processing, Mining equipment, Mining industry recognition, Mining services, Sustainable mining, , , , , , , , , , , , , , ,

The Canada Mining Innovation Council’s (CMIC) Conjugate Anvil Hammer Mill (CAHM) and MonoRoll platform technology project has reached a new milestone with hot commissioning of the MonoRoll at COREM’s testing facility in Quebec, Canada.

CAHM is a platform technology advancing two technologies in parallel where both designs break particles in a highly efficient thin particle bed. CAHM, according to CMIC, provides a more efficient alternative to high pressure grinding rolls and SAG mills, while the MonoRoll variant is designed for finer grinds and to replace inefficient rod and ball mills.

In a recent post, CMIC said hot commissioning of the MonoRoll at COREM’s testing facility, using some of the 300 t of ore contributed by Agnico Eagle Mines, was now complete. Although the MonoRoll is being tested using hard rock, there is also significant interest from the iron ore, cement and aggregate industries, CMIC says.

It added: “Fabrication of the CAHM machine is underway and if the optimised discrete element method modelling results hold, we are confident that the MonoRoll and the CAHM are on track to achieve the following significant benefits in ore grinding:

  • “Reduce energy consumption by an estimated 50% compared to best available technology;
  • “Eliminate grinding media;
  • “Increase ore feed reduction ratio; and
  • “Simplify the comminution circuits.”

CMIC is leading a consortium including experts in comminution, product development, engineering and testing as well as six major hard-rock mining companies guiding the effort and participating as potential first adopters. Included among the consortium is CTTI, Hatch, Glencore Canada – XPS (Expert Process Solutions), COREM, Teck, Agnico Eagle, Newmont and Kinross.

The MonoRoll technology is one of only six finalists in Impact Canada’s Crush It! Challenge. Launched in October 2018, Crush It! challenged Canadian innovators to deliver game-changing solutions for cleaner, more efficient rock processing.

CMIC said: “The MonoRoll project is the only finalist developing a novel grinding mill, and if the project wins the C$5 million ($3.9 million) Grand Prize, the funds would be used to engineer a large-scale machine to test in active mining operations.”

Metso Outotec to help modernise Nornickel’s Talnakh processing plant

Base metals, Comminution of minerals, Equipment maintenance, Mine operation news, Mineral processing, Mining equipment, Mining services, , , , , , , , ,

Metso Outotec says it has signed an agreement to deliver its “industry-leading comminution equipment” to Norilsk Nickel’s refurbishment project at the Talnakh processing plant in Norilsk, Russia.

The contract includes delivery of one SAG mill and two ball mills with a total installed power of 36 MW, as well as two HP series pebble crushers. Metso Outotec will also supply spare parts and consumables, including metallic mill liners, and will supervise the installation of the equipment. The delivery is scheduled for 2022.

While the order value was not disclosed, Metso Outotec said the order has been booked in its December quarter 2020 orders received.

Sergey Dubovitsky, Senior Vice President, Strategy, Strategic Projects, Logistics & Procurement at Norilsk Nickel, said: “The modernisation of the Talnakh processing plant is one of the priority projects for Norilsk Nickel. Its implementation will significantly increase the volume and efficiency of production. To achieve this, we utilise the most modern technologies from Metso Outotec.”

Stephan Kirsch, President, Minerals business area, Metso Outotec, added: “We are pleased to continue our partnership with Norilsk Nickel. The supply of leading-edge equipment from Metso Outotec for the reconstruction of the comminution section at the Talnakh concentrator will enable an increase in the amount of ore processed. Our company has taken part in several projects with Norilsk Nickel to boost throughput rates of the processing facilities, and we are grateful for having been again selected to provide reliable solutions for a project as significant as Talnakh.”

Metso Outotec supports GTK Mintec’s pilot plant plans with new flotation cells

Comminution of minerals, Mineral processing, Mining equipment, Mining services, , , , , , ,

Metso Outotec is set to deliver new, smart flotation cells to GTK Mintec’s pilot plant in Outokumpu, Finland, as part of the survey’s modernisation and expansion program.

The delivery consists of around 20 pilot flotation machines and additional equipment, with GTK Mintec replacing existing flotation cells at its pilot plant.

The new flotation cells will support the improvement of the monitoring of beneficiation studies and process design, according to Metso Outotec.

“GTK and Metso Outotec promote sustainable and competitive mining technologies,” Stephan Kirsch, President of Metso Outotec’s Minerals business area, says. “We are pleased that GTK chose Metso Outotec’s leading-edge flotation technology for their test facilities.”

Jouko Nieminen, Head of the Circular Economy Solutions unit for the Geological Survey of Finland (GTK), said: “The test plant and laboratory in Outokumpu offer mining customers a comprehensive service package. The whole production process needed for a mineral deposit can be tested there on the scale required by the research problem.

“Through the flotation investment, our domestic and international customers can use state-of-the-art technology in research related to battery minerals and circular economy materials, for example.”

Weir adds aftermarket and service contract to Iron Bridge remit

Comminution of minerals, Equipment maintenance, Mineral processing, Mineral project development, Mining equipment, Mining maintenance, Mining services, Steel and iron ore, , , , , , , , , , , , , , , , ,

The Weir Group says it has won a £95 million ($127 million) order to provide aftermarket components and service to the Iron Bridge magnetite project in Western Australia.

The aftermarket contract follows Weir’s success in winning a record £100 million order for original equipment for the Iron Bridge project in 2019, including its Enduron® High Pressure Grinding Rolls (HPGRs, pictured) that, it says, will enable dry processing of ore and use at least 30% less energy than traditional alternatives.

The Iron Bridge magnetite project is a $2.6 billion joint venture between Fortescue Metals Group’s subsidiary FMG Magnetite Pty Ltd and Formosa Steel IB Pty Ltd located in the Pilbara region, around 145 km south of Port Hedland.

Both the aftermarket order and revenues will be recognised over the seven-year period of the agreement, which starts in 2022, in line with the 22 Mt/y project’s initial production.

Ricardo Garib, President of Weir Minerals, said: “This is another landmark order for Weir. Having helped design an energy and water efficient magnetite processing plant, we are delighted to provide operational support for Iron Bridge from 2022. It is an excellent example of the value that Weir’s innovative engineering and close customer support can create for all our stakeholders and reflects the key role we have to play in making mining operations more sustainable and efficient.”

Weir’s Enduron HPGRs are increasingly replacing conventional mills in comminution circuits, Weir says. In addition to their energy and water savings, they also reduce grinding media consumption, while their wearable components last longer, reducing maintenance costs. Additionally, HPGRs contribute significantly to carbon dioxide emission savings.

Stuart Hayton, Managing Director of Weir Minerals Netherlands, where the Enduron HPGRs are designed and manufactured, said: “This is an important project for Weir and for the broader mining industry. We know comminution is one of the most energy intensive parts of the mineral process and, with our Enduron HPGRs, we have a unique ability to offer significant cost, energy and water savings to customers around the world. As the mining industry evolves, we are commited to continuing to innovate, reducing miners’ costs and environmental impact.”

This latest contract award means Weir now has more than £200 million of orders from the Iron Bridge project including its Enduron HPGRs, GEHO® and Warman® pumps, Cavex® hydrocyclones and Isogate® valves.

To support the project and future growth, Weir says it will build a new service centre in Port Hedland, Western Australia, thereby providing employment and training opportunities in the area, with a particular emphasis on supporting greater Aboriginal representation in the broader mining workforce.

SGS to bring Glencore Technology’s Albion Process testing to Africa mining market

Base metals, Comminution of minerals, Metallurgy, Mineral processing, Mining services, Precious metals, , , , , , , , ,

SGS Minerals is to offer Glencore Technology’s Albion Process™ test work to mining companies in Africa after the two extended an agreement and certification related to the hydrometallurgical process.

While SGS already has a relationship with Glencore Technology through SGS Lakefield – through an agreement signed last year – the extension opens up the potential for more large packages of work of “high relevance and value”, Glencore Technology says.

“For Glencore Technology, it extends further the global reach of Albion Process test work as it has grown 300% in the last 12-24 months and is seen as uniquely viable in terms of capital costs, operational costs and project feasibility,” the company said.

The new test work locations will now include Randberg in South Africa, with other locations being discussed elsewhere around the world, according to Glencore Technology.

The Albion Process uses a combination of ultrafine grinding and oxidative leaching at atmospheric pressure to work. It also tolerates a more variable feed and lower grade than other processes, according to Glencore Technology, meaning it can make some projects feasible and profitable where alternative technologies could not. The sulphides in the feed are oxidised and valuable metals liberated, with the economic metals recovered by conventional downstream processing. Test work requires only small sample masses with no pilot plant, Glencore Technology says.

The process has produced high recoveries in refractory gold and in base metal concentrates at the six Albion Process plants in operation across the globe, according to the company.

Glencore Technology’s Paul Voigt said: “The extension to Africa has been under discussion for quite some time. We know the importance of local contact and context. It’s also part of a wider focus we have for the African continent.”

SGS’ Niels Verbaan, said: “This is a natural and highly relevant extension of our work with Glencore Technology on Albion Process test work. We look forward to a larger global footprint to help operations in Africa and the Americas, especially those with complex mineralogies, to get an objective opinion on process options.”

SGS is the third certified provider of test work, joining Core Resources in Australia and TOMS Institute in Russia.

Los Andes Copper commits to HPGR comminution route for Vizcachitas

Base metals, Comminution of minerals, Environmental, Mineral processing, Mineral project development, Mining services, Sustainable mining, Water management, , , , , , , , , ,

Los Andes Copper says additional comminution test work has confirmed the selection of high pressure grinding rolls (HPGR) circuit technology for use in the processing circuit at its Vizcachitas copper project in Chile.

The use of HPGR, and the adoption of the previously announced dry-stack tailings, reinforces the company’s commitment to the environment and designing a sustainable operation with low energy and water consumption, it said.

At early stages of the Vizcachitas prefeasibility study (PFS), HPGR technology had been identified as the most attractive grinding alternative, given the data obtained from preliminary test work conducted in 2009, and in 2017-2018. As part of the PFS metallurgical test work, four representative samples from the mine plan were sent to a laboratory for pressure bed testing. The results of this test work confirmed the equipment sizing and its performance for a PFS-level study.

The results provided specific energy consumption readings of 2.17 kWh/t in the case of a HPGR circuit, which results in a global specific energy consumption of the comminution circuit of approximately 14 kWh/t. As compared with the semi-autogenous grinding alternative, the HPGR showed a reduction of up to 20% in energy and up to 50% in grinding media consumption, Los Andes Copper said. These results confirm the advantages of adopting this technology at the project.

The comminution circuit at Vizcachitas, where the HPGR circuit will be incorporated, is a three-stage crushing circuit using a gyratory primary crusher, three cone crushers in open circuit and two HPGR as a tertiary stage arranged in a closed circuit followed by ball mills. Through this process, and in addition to the lower energy consumption, the use of HPGR will reduce dust emissions related to dry crushing due to the removal of coarse recirculation in the secondary crushing stage, the company said.

Fernando Porcile, Executive Chairman of Los Andes, said: “I am pleased that the results from the test work carried out to date have confirmed the advantages of using HPGR in terms of enhancing project economics, lowering energy consumption and increasing operational flexibility.

“The use of HPGR technology favours the stability of the dry stacked tailings operation, as well as reducing the environmental impact by minimising energy usage, water consumption and dust emissions.”

FLSmidth tackles the need for higher power, throughputs with new TSUV Mark 5 gyratory crusher

Comminution of minerals, Equipment maintenance, IoT, Mineral processing, Mining equipment, Mining maintenance, Mining services, Mining software, Sustainable mining, , , , , ,

FLSmidth has launched a new “digitally-enabled” gyratory crusher to, it says, deliver the lowest total cost per tonne of material processed, even when crushing the most challenging ore.

In response to the industry need for higher power crushing and throughputs for lower-grade ores, FLSmidth has developed the TSUV Mark 5 Top Service Gyratory Crusher, the world’s most opex- and capex-efficient gyratory crusher, it said.

FLSmidth’s latest generation gyratory crusher, the TSUV Mark 5, follows the success of the Top Service (TS) and Top Service Ultra Duty (TSU) models.

The unique top-service design prioritises safety, maintenance and efficient crushing performance, FLSmidth says. Unlike other gyratory crushers that require workers to get in underneath the crusher to perform high-risk maintenance, the TS range allows service and maintenance to be carried out from above, increasing speed, safety and simplicity. Additionally, the 100-plus tonne, fully-dressed main-shaft no longer needs to be guided into the eccentric assembly by hand. “Now, the shaft aligns automatically, dramatically reducing risk,” the company says.

All TS gyratory crushers are built for strength, durability and the ability to adapt to the various requirements of mine operators, but the TSUV design adds even more power, capacity and flexibility, to give mine operators a low total cost of ownership, according to FLSmidth.

The improved power handling capabilities of up to 1,500 kW allow miners to process more material as ore yields decline, enabling operations to remain competitive, while the crusher footprint has only nominally increased.

Optimised eccentric speeds ensure maximum throughput without incurring excessive wear rates, the company says. This is a finely balanced equation, based on extensive R&D work, which, together with the new service and operational features, gives operators the lowest possible cost per tonne of material processed, it explained.

“To offer even greater potential to optimise performance, the TSUV Gyratory Crusher is digitally enabled – giving operators more control over operations and availability,” FLSmidth says. “The ability to make fine adjustments to wear compensation, track equipment trends and instantly detect crusher obstructions will enable increased uptime, optimum equipment life and significantly reduce risk of unplanned downtime.”

The TSUV Gyratory Crusher can be connected to FLSmidth’s digital ecosystem, which provides operators with the benefits of both FLSmidth technologies and experience. A range of services is on offer, geared towards maintaining asset health and optimising performance, many of which can be carried out remotely, saving both time and money, the company says.

The TSUV Gyratory Crusher’s advanced control system gives operators a 24/7 view of performance metrics, enabling increased reliability, FLSmidth says. And, with further condition monitoring feedback and controls, maintenance can be more proactive, minimising the risk of unscheduled stops.

“Through a combination of all these features, the TSUV Gyratory Crusher achieves the lowest cost per metric tonne in operation of any crusher on the market and gives you the lowest total cost of ownership,” the company says. “This translates into a reduced environmental impact.”

Chris Reinbold, Head of Global Product Line Management, Senior Vice President, Mining, said: “We remain steadfast in our aim to reduce emissions from mining to zero by 2030. Increasing the sustainability of key equipment, like the gyratory crusher, is part of our core goal to invest in efficiency-focused R&D, to deliver the best available equipment to the minerals industry.”

Centerra Gold joins CEEC’s quest for eco-efficient comminution

Comminution of minerals, Environmental, Mineral processing, Mining services, Power supply for mines, Sustainable mining, Water management, , , , , , , , ,

Centerra Gold has become the latest miner to join the Coalition of Energy Efficient Comminution (CEEC) as a new sponsor.

Centerra, which follows in the footsteps of Hudbay Minerals in backing the not-for-profit organisation, is a Canada-based gold mining and exploration company with assets in Canada, the Kyrgyz Republic and Turkey. It is one of the largest Western-based gold producers in central Asia, and its Mount Milligan mine (pictured) is the first, large new operation in British Columbia in a generation.

The company’s vision is to build a team-based culture of excellence that responsibly delivers sustainable value and growth, according to CEEC.

CEEC CEO, Alison Keogh, said: “We are thrilled with Centerra’s decision to become a CEEC sponsor. Our sponsors work collaboratively to accelerate energy-efficient, productive mining processes. That’s vital for our industry and communities as we reduce impact, tackle costs and improve shareholder value.

“As a CEEC sponsor, Centerra helps CEEC provide industry with information and tools from experts and grow the network of committed professionals working to accelerate eco-efficient comminution and maximise the potential of their mineral resources and assets.”

Centerra Vice President and Chief Operating Officer, Daniel Desjardins, praised CEEC for its contributions towards environmental, social and governance (ESG) actions in the field and welcomed the opportunity to share information to advance business goals.

“Centerra’s financial and operational objectives are underpinned by a fundamental commitment to ethical and sustainable practices,” Desjardins said. “Our values are strongly aligned to CEEC’s mission for eco-efficient comminution; environmental, social and governance factors are our foremost priorities as we strive to continually improve the management of our operations.

“CEEC offers a pathway to share best practice and innovation in the international mining sector. We look forward to collaborating with like-minded organisations on shared challenges such as energy and water use.”

Centerra produced 783,308 oz of gold and 3,220 t of copper in 2019, making it one of the leading gold and copper producers based out of Canada.

The company’s major assets include the Kumtor Mine in the Kyrgyz Republic, which has produced more than 12.6 Moz of gold between 1997 and the end of 2019, and the long life, low-cost gold/copper Mount Milligan Mine, in British Columbia, Canada. The third operating mine, the Öksüt Gold Mine, in central Anatolia, Turkey, poured gold for the first time on January 31, 2020, after just 22 months of construction.

Metso Outotec ticks the TCO box with latest HRC HPGR design

Comminution of minerals, Mineral processing, Mining equipment, Mining maintenance, Mining services, Sustainable mining, Water management, , , , , , , , ,

The design and operating principle of Metso Outotec’s HRC high pressure grinding roll has been well proven since going commercial in 2014.

The elimination of the edge effect with a flange design brings with it high throughput, while the anti-skew assembly means customers find faster machine restarts and no downtime from skewing events.

These benefits have been proven at Freeport McMoRan’s Morenci mine, in Arizona, USA, with the company’s largest unit – a HRC 3000 – having now processed more than 120 Mt of ore at that operation. This HRC 3000 is still going strong.

Yet, there was room for improvement, hence the reason Metso Outotec has just released the HRC™e HPGR.

Christoph Hoetzel, Head of Grinding business line at Metso Outotec, explained the rationale for such an update.

“To enable this flange technology, it was very important to have a simple, mechanical solution that works under any circumstances,” he told IM. “Our solution with the HRC was the arch frame, which was a mechanical fix to keep the rolls parallel at all times.

“This, however, came with a compromise. You had to have access to both sides of the machine and, in general, the units were relatively heavy and tall.”

These attributes meant that, if the customer investigated the total installed cost of the HRC – especially if they were weighing the purchase of more than one unit – the cost sometimes outweighed the benefits.

“This was a case of where the economics did not match the sustainability and efficiency of the unit,” Hoetzel said.

Metso Outotec has listened to customer feedback with the HRCe.

“The enabling factor for the flange technology is a mechanical solution for eliminating skewing on the machine,” Hoetzel said. “We have now achieved this with a much simpler, compact design. This is really where the step change has come from.”

Now, when you look at the specifications of the HRCe, which comes with a large feed size acceptance of 60-120 mm and typical capacities of 1,810-6,930 t/h, the footprint is almost the same as other HPGRs on the market, according to Hoetzel.

“Yet, the unit benefits from the proven and reliable flange design of the original HRC,” he said. “You could, potentially, even use a smaller unit for the same application.”

By reducing the size and associated installation cost that comes with the HRC technology, Metso Outotec is suddenly levelling the HPGR playing field. The advantages the company spelt out back in 2014 when the HRC technology was originally publicised now come with no cost drawbacks.

With more miners looking for not only energy-efficient grinding solutions in their flowsheets, but processing options that reduce their water intake, HPGRs are increasingly being used in tertiary or quaternary crush applications, or in lieu of traditional SAG mills.

In this regard, an updated HPGR is coming to the market at just the right time.

Metso Outotec, cognisant of this trend, has also sought to offer the benefits of its HPGR technology to the wider market.

The mechanical skew control HPGR (High Pressure Grinding Roll) retrofit kit takes the key components responsible for minimising skew from the HRC and makes the technology more accessible without the major investment or need to acquire a new machine, according to the company. The technology can also be incorporated into non-Metso Outotec machines.

These latest product updates are in keeping with Metso Outotec’s defined purpose of “enabling sustainable modern life”, fitting the mineral processing reality that miners face today.

Hoetzel reinforced this message: “Customers should not have to choose between sustainability and lowest total cost of ownership with their machines. At Metso Outotec, we truly want to be the partner for positive change, which means we really need to combine both.

“With the HRCe, we think we have achieved that.”