Tag Archives: Weir Minerals

Weir Minerals expands Linatex rubber manufacturing facility in Malaysia

Equipment maintenance, Mining consumables, Mining equipment, Mining services, Sustainable mining, , , , , , , ,

Weir Minerals, the sole producer of Linatex® premium rubber products, has expanded its rubber manufacturing facility in Batu Caves near Kuala Lumpur, Malaysia, doubling production capacity and enabling faster delivery times to customers.

The site, which sits on 18 acres (7.3 ha), has been expanded to include a new Continuous Rubber Process (CRP2) facility, a new Banbury mixer to manufacture masticated dry rubber and additional rubber presses to support the growth within this area of the business.

The modern manufacturing facility features state-of-the-art equipment that produces Linatex rubber products, a leading rubber used to protect equipment in mining, minerals processing and industrial applications for the global Weir Minerals network. The £13 million ($14 million) investment enhances Weir Minerals’ position as a global supplier, enabling the company to meet the increasing demand for premium rubber products and support its worldwide customer base, it said.

The new facilities were inaugurated by the President of Weir Minerals, Ricardo Garib, Vice President Operations of Weir Minerals, Richard Hinsley, and Managing Director of Weir Minerals Malaysia, Stephen Frendt.

Frendt said: “Our site manufactures Linatex rubber sheet and moulded rubber products for process equipment used in mining and industrial applications. This expansion will allow us to service the growing demand in the market – not just now but for years to come.

“The investment in the CRP2 allows us to increase the production capacity for the high wear and abrasion resistant Linatex rubber sheet. The Rubber Mixing Process expansion, on the other hand, is an upstream vertical integration of the supply chain in which masticated dry rubber compounds such as R55 are manufactured and distributed worldwide from the facility here at Weir Minerals Malaysia.”

The investment is a testament to the company’s focus on material technology, it says, ensuring that Weir Minerals’ customers have access to the best elastomers and supporting continuous product development.

The CRP2 control room at Weir Minerals Malaysia

Garib added: “Linatex is a vulcanised natural gum rubber, which is produced through a unique liquid phase proprietary process. Manufactured from a renewable resource, the final product is 95% natural rubber made from the highest-quality latex. Our rubber manufacturing facility is
very significant to Malaysia and to Weir Minerals globally, and continues to showcase our dedication to the environment and sustainable practices.”

In line with Weir Minerals’ dedication to sustainable solutions and practices, the Linatex rubber manufacturing process already has the lowest energy consumption compared with other rubber suppliers to the industry, it claims. A new renewable solar energy system has been installed on site in Batu Caves to further lower the power used in the rubber production process. The solar panels will reduce greenhouse gas emissions by almost 900 t CO2e/y, the company estimates.

Weir Minerals says it is also committed to further sequestering carbon by planting new trees on site and ensuring the natural surroundings are rehabilitated and preserved. All-local tree species were selected for this project after consultation with the local town council.

Hinsley said: “Sustainability is an inherent part of Linatex production, starting with latex being a natural and renewable resource sourced directly from the Hevea Brasiliensis trees, to working with ‘green’ suppliers, to manufacturing. The Continuous Rubber Process has minimal waste, and even mixing requires less energy compared to other rubbers.

“Sustainability is also an important part of our supply chain: we have been investing in Malaysia for a long time, employing local workers, providing community support and partnering with local suppliers, some of whom have been with us for over 30 years.”

Weir and Swiss Tower Mills align on energy efficient comminution pathway

Comminution of minerals, Environmental, Mining equipment, Mining services, Sustainable mining, , , , , , , , , ,

The Weir Group has announced a new alliance with Swiss Tower Mills Minerals (STM) in which Weir will market STM’s vertical stirred grinding mills for coarse grinding applications worldwide.

Integrating vertical stirred grinding mills into Weir’s minerals processing flowsheet will provide customers substantial improvements in throughput and energy efficiency, helping them to meet their productivity and sustainability goals, Weir says.

STM’s vertical stirred grinding technology is proven for energy efficient comminution in the mining market with more than 80 units currently operating in the hard-rock mineral processing industry across the globe, according to the company. It is used within the comminution segment of the minerals processing circuit as part of a series of crushing and grinding processes that create the fine particles from which minerals can be extracted through flotation.

Comminution, as has been well documented, is one of the most energy intensive parts of the mine, accounting for 25% of the final energy consumption of an average mine site.

Weir says it is already a leader in comminution technologies, offering solutions such as Enduron® high pressure grinding rolls (HPGRs) to drive down energy consumption by around 40% for customers.

This new alliance with STM takes things to the next level, offering the mining and minerals industry a proven low energy alternative to traditional high energy consuming tumbling mills, it said. Combining and integrating these energy-efficient technologies into a single, optimised flowsheet will deliver significant reductions in energy use, driving down costs and carbon emissions.

In order to prove the most beneficial flowsheet for specific projects, STM has already supplied two vertical test mills to the Weir Minerals HPGR test facility in Venlo (Netherlands). This will put Weir and STM in the unique position to provide clients combined energy efficient grinding test work of HPGR followed by STM’s vertical stirred mill, they said.

Ricardo Garib, Weir Minerals Divisional President, said: “Weir and STM share the same vision of enabling primary resource providers to produce resources in the most sustainable manner. This is a perfect match of best-in-class technology providers. Integrating STM mills with Weir’s comminution products, which includes Enduron HPGRs and Enduron screens, will improve throughput and help bring substantial reductions in carbon emissions.

“This is a real win-win.”

Fritz Moser, STM Chairman, said “Both the HPGR and the STM vertical stirred mills provide significant energy savings compared to conventional grinding technologies. Our new supply agreement with Weir will enable us to fast track the roll out of an innovative flowsheet using STM mills in conjunction with Weir’s Enduron HPGR.”

Weir Minerals and Eriez Flotation team up to expand coarse particle flotation market reach

Base metals, Comminution of minerals, Environmental, Metallurgy, Mineral processing, Mining equipment, Mining services, Sustainable mining, , , , , ,

Weir Minerals and Eriez Flotation have announced a cooperative agreement to design and develop coarse particle flotation (CPF) systems.

Coarse particle flotation facilitates more efficient separation, while also reducing water and energy consumption and producing safer tailings. It has been proven at the likes of Anglo American’s El Soldado mine, Newcrest’s Cadia operation and Capstone Mining’s Pinto Valley operation, among others.

“This cutting-edge technology is a step-change improvement over conventional flotation systems,” Eric Bain Wasmund, Ph.D., Professional Engineer, Vice President of Eriez Global Flotation Business, said.

The cooperation allows both companies to better connect the Eriez equipment with the slurry classification and conveying expertise of Weir Minerals, according to Ricardo Garib, Division President of Weir Minerals.

“As mining companies look to optimise their plant and processes while also reducing their carbon footprint, we’ll see CPF being more widely adopted,” he said.

“We have an Integrated Solutions team – made up of a diverse range of product experts, process engineers, design engineers and materials scientists, among others – that works closely with miners to deliver reliable solutions that help solve their specific problems. In the current regulatory environment and with an increased focus on ESG issues, miners are being asked to produce more with less and CPF systems are a vital technology that allows them to do that.”

Eriez’s leading products include the HydroFloat® Separator for coarse particle mineral concentration, which delivers the capacity of a density separator while maintaining the selectivity of a flotation device. Using a novel aeration system to disperse fine bubbles into a fluidised-bed environment, the HydroFloat Separator significantly increases the selective recovery of coarse particles by applying flotation fundamentals to gravity separation.

Garib added: “Weir Minerals has a long history of innovative engineering and we’re excited to partner with a company like Eriez because its technology perfectly complements the solutions Weir Minerals currently provides. Ultimately, it’s about delivering the best outcomes for our customers.

“We’re proud of the work we do to harness the latest technologies to efficiently process the minerals that will be essential for a future in which mass electrification will play a vital role in the transition to a low carbon economy.”

Weir Minerals provides slurry pipeline operators with predictive maintenance tool

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Weir Minerals is launching Synertrex® IntelliWear™, a new digital wear monitoring system for spools and hoses in slurry pipelines.

Developed by the Weir Minerals digital specialists in Chile, the intelligent system addresses the increasing demand for optimisation and safety within the mining industry, the company said.

With the continual move towards digital solutions, Weir Minerals recognised the need to support customers with their ongoing maintenance. The company has now developed a solution that enables mine sites to monitor the condition and wear performance of their hoses and spools via a network of smart sensors connected to their DCS (Digital Control System).

“Equipment health is of the utmost importance, with many operators looking to streamline their operations for increased productivity and reduced downtime,” the company said. “The Synertrex IntelliWear monitoring system allows pipeline operators to check their equipment in the critical wear areas and perform predictive maintenance prior to any unplanned disruptions and downtime.”

With planned repair and replacement of equipment, the benefits to customers are invaluable, according to Weir Minerals.

“Unscheduled stops are reduced – leading to reduced costs of operation and maintenance,” it said. “Most importantly, safety on site is increased, as spools and hoses are replaced prior to failure, thus removing the risk of slurry leakage which can cause injury to workers on site and the environment.”

Eduardo Putz, Synertrex and Mechatronics Champion, Latin America, says the Synertrex IntelliWear monitoring system enables customers to have much more control over their equipment.

“With smart sensors they are able to analyse wear life, plan maintenance and control stock,” he said. “The ability to prevent non-scheduled maintenance further supports our customers in their sustainability goals.”

The Synertrex IntelliWear system has been developed and rigorously tested in a range of slurry conditions and mill circuit arrangements, according to Putz, with the company confident the platform will deliver a significant positive impact on customers’ operations.

The system is comprised of an intelligent digital sensor integrated into Weir Minerals’ Linatex® and Vulco® hoses and spools. A central control panel captures information in a single location, and a dashboard allows for visualisation and analysis of the equipment data via Synertrex.

“Digitalisation enables our customers to continue their normal operational duties, while large amounts of data is automatically analysed and interpreted in the background via the Synertrex platform,” Putz said.

A conductive wire is installed in the rubber lining at various levels of thickness. As the lining wears, it activates sensors to indicate the extent to which the rubber liner has been worn and in turn how much life is left.

A digital traffic light system has been developed to enable quick visual identification of the condition of the hose or spool. Less than 50% wear is green, between 50% and 70% wear is yellow, greater than 75% wear is red – indicating it is time for preventative maintenance. The conductive wire is installed along the entire Linatex or Vulco spool or hose, throughout its diameter.

The central monitoring panel collects data from the sensors in the field and sends it to the Synertrex platform, which allows operators or maintenance personnel to view it. Information collected can also be uploaded to the cloud to be viewed on a live dashboard, which is automatically updated every two minutes. The intelligent system enables operators to view real-time wear information from any device remotely – ensuring continual monitoring and better control over their equipment, Weir Minerals says. This control allows for optimisation, improved performance and the elimination of unwanted operating conditions.

Synertrex IntelliWear is available across the Weir Minerals network initially in the Americas, Africa and Asia Pacific.

Weir Minerals taps XMPro digital twin solution for Synertrex development

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Weir Minerals has announced a new partnership with XMPro, a digital twin platform, to enable intelligent equipment and services and support miners to achieve higher performance while also reducing the environmental footprint of their operations, the mining OEM says.

The XMPro platform – as a part of the Synertrex® digital ecosystem – will facilitate the delivery of event intelligence, predictive analytics and real-time insights, Weir Minerals said. It allows for data orchestration and value creation from multiple sources, including sensors, miners’ digital ecosystems and data only available to Weir Minerals as an OEM, like maintenance data and 3D engineering models, it said.

The platform identifies critical events by applying artificial intelligence and predictive analytics, which will provide Weir Minerals’ customers with the next generation of predictive services and recommended actions. XMPro facilitates easy collaboration between reliability engineering and operations by providing real-time information and equipment insights, viewed via mobile devices and the Synertrex intelligence web portal, according to the company.

Weir Minerals also recently signed a digital partnership framework for strategic cooperation with AVEVA, an end-to-end pioneering industrial software provider. 

Ole Knudsen, Weir Minerals, Director Digital, said: “XMPro takes an actionable and collaborative approach to data that closely aligns with our Synertrex digital ecosystem. It is a platform ensuring maximum customer value from all the data we collect, ranging from equipment and process data to the in-house data we have access to as an OEM. We see the multiple data source approach as essential to build the holistic digital twins providing ‘intelligence’ to our customers in terms of insights, predictiveness and recommendations allowing for a proactive approach to maintenance planning and execution.

“Within the foreseeable future, we see these platforms and the building of the multiple data-source digital twins providing even more value for Weir Minerals and our customers, which is enabled by closing the loop between real-time operations, equipment design and manufacturing.”

Pieter van Schalkwyk, CEO XMPro, said: “The partnership between Weir and XMPro creates a unique opportunity for mining companies to accelerate their digital transformation journey for complex assets. It combines Weir’s deep domain expertise and rich asset information models with XMPro’s class-leading real-time, operational digital twin platform. This combination provides unique insights, prescriptive maintenance and operations recommendations for users of Weir’s extensive range of mining equipment.

“It has been a pleasure working with Weir’s engineering team, who are not only deep domain experts on mining processes but also have a clear vision of their roadmap for digital solutions that provide real-time operational intelligence for the overall mining value chain. We are excited that XMPro is the platform that Weir chose to deliver these capabilities to end-users.”

Weir Minerals and AVEVA team up to offer secure access to Synertrex IIoT hub

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Weir Minerals has signed a digital business framework with industrial software provider, AVEVA, with an aim to use the AVEVA PI System™ as the data foundation for the OEM’s Synertrex® digital ecosystem.

Weir Minerals intends to use the AVEVA PI System to collect, contextualise and analyse data streams wihtin the context of Synertrex, its advanced Industrial Internet of Things (IIoT) platform.

The objectives of the agreement include:

  • Digitally enabling the mining industry by simplifying data access and data sharing with easy and secure on-premises or cloud integration between Weir Minerals and its customers;
  • Establishing the data foundation for technologies, such as artificial intelligence, to optimise equipment and processes and thereby maximising sustainable performance; and
  • Pioneering new and innovative digital solutions supporting our common customers digital transformation and adoption of intelligent solutions.

The use of AVEVA PI, along with AVEVA Data Hub, a cloud-native hub for aggregating and contextualising on-premises and remote data, will offer the mining industry a unique solution for securely connecting mining operators with Weir Minerals as an OEM, the company said.

The business model will provide a variety of flexible integration solutions – from on-premise to cloud – that will make it easier for miners to integrate with the Weir Minerals’ Synertrex digital ecosystem. It uses a secure and simplified approach to access and share real-time and historical operations data, according to the company.

These shared ecosystems will provide miners and Weir Minerals with full data transparency and an easy-to-access, real-time 360° view of all Synertrex-enabled equipment and processes. They will also be the basis of the further development of digital twins and predictive algorithms, which will provide decision makers with recommended actions and real-time decision support, Weir Minerals said. This will lead to less power and water consumption and extended equipment life.

Ole Knudsen, Weir Minerals, Director Digital, said: “The AVEVA PI System is an established industrial data management solution that is currently used by nine of the top ten Fortune 500 mining companies. The proven and secure PI System enables us to build a series of Asset Framework templates for our equipment, making it a secure yet simple plug and play exercise to connect our equipment to our customers’ digital ecosystems. This will enable the critical first steps of a structured and standardised data approach.

“With the addition of the new AVEVA Data Hub and Weir Minerals’ Synertrex solutions, we’re in a unique position as an OEM to offer our customers a real game-changing approach to a flexible data sharing strategy. This will be the foundation of our data and intelligence driven digital optimisation solutions; this is how Weir Minerals will transform and enable more sustainable mining operations.”

Rónán de Hooge, AVEVA’s Executive Vice President of Information Management, added: “We’re very excited to work with Weir Minerals to deliver mining operators smart analytics to drive industrial transformation. AVEVA’s ability to collect real-time performance data in any location and deliver it securely to the Synertrex platform will give operators new insight into the health of their assets and help them optimise maintenance and avoid costly downtime.

“AVEVA is deeply committed to providing industrial companies with an open platform that is their trusted system of record for industrial data. Our products help companies harvest diverse types of critical industrial data across their distributed environments, enrich it with contextual information, and make it easily available to the people, applications and tools that will deliver transformation and sustainability.”

Weir Minerals’ Vulco rubber compound proves its mill lining worth

Comminution of minerals, Equipment maintenance, Mineral processing, Mining consumables, Mining maintenance, Sustainable mining, , , , , ,

Close to four years after release, Weir Minerals Vulco® 67 rubber compound is providing exceptional wear life and reliability in mill lining systems, according to the OEM.

These abrasion- and impact-resistant rubber compounds have been developed with advanced technologies by the Weir Minerals’ team of expert engineers and material scientists who are continually refining Vulco rubber products to keep them at the forefront of mill lining systems technology, the company says.

Having identified a need for higher-wearing rubbers for mill lining systems, the material science experts commenced developing an industry leading, premium-grade rubber compound with superior wear life and performance in mill lining applications. The result was the Vulco R67 rubber – a material manufactured with proprietary new compounds and innovative methods of processing to deliver outstanding wear life and longer uptime, Weir Minerals says.

Extensive field research, compound testing and site trials were conducted to ensure it was not only able to withstand severe abrasion in typical mill system applications, but that it is best in class, the company said.

“In fact, it has been the most wear-resistant rubber compound that Weir Minerals has ever developed for mill lining applications,” Weir Minerals said. “The R67 compound boasts a high hardness, elongation, tensile and tear strength, and is suitable for lifter bars, head/shell plates and grates. When it’s utilised in conjunction with metal cap mill liners, the result is a versatile, economical and efficient product that weighs up to 50% less than steel alone.

“The added benefit is a lighter product that’s faster, easier and safer to install.”

Revolutionising wear lining

Since its launch in 2018, many mining operators from around the globe have implemented the R67 compound into their mill lining systems, according to Weir Minerals. They have reported as much as 20-40% improvement in wear life, which is resulting in fewer mill lining replacements and longer mill campaigns. This reduction in shutdowns has a dual benefit of increased cost savings and improved plant availability.

With a liner that can run significantly longer, operators have experienced a wide range of benefits including:

  • Improved wear life;
  • A measurable reduction in mill downtime;
  • Increased uptime and processing;
  • Easier and safer installations; and
  • Reduced maintenance costs.

In-field success

Extensive global trials and commercial installations in the market have resulted in several successful outcomes across a variety of different grinding applications.

As an example, a high-grade nickel and copper mining project in the US had a problem where the liners in one ball mill were wearing out too quickly, leading to continued downtime and reduced processing. The operation was looking for a product significantly superior to the elastomer it was using. Initially there was reluctance from the mine, as it had loyalty to its original mill supplier, however after Weir Minerals conducted a series of trajectory simulations and discrete modelling – to optimise the design and deliver the best process performance for the mill – it agreed to trial the R67 liners.

At the end of the trial, the R67 showed 30-40% better performance than the incumbent liners and the customer installed a full set of R67 liners in its mill.

Another trial in the US took place in an iron ore mine with several dozen ball mills in operation. Here, Vulco R67 liners delivered a 17% increase in life compared with the failed shell plates from the mine’s original mill lining system supplier. The company has since installed a complete shell liner in its ball mill.

Moving to Chile, a copper mine was keen to trial the R67 compound to see if it could improve the wear time of a competitor rubber liner. After a three-month trial, all liners were physically measured showing the Vulco R67 liners fully worn wear life projected from the actual wear would be 80% longer compared with the incumbent liners.

Another copper processing plant in Chile trialled R67 composite liners in its SAG mill against two other compounds commonly used in the industry. After 12 months, there was a 48% and 62% wear life improvement on the other liners – proving the R67 composite liners could withstand the highly abrasive environment.

Vulco R67 mill liners are made exclusively at Weir Minerals facilities in North and South America, Australia and South Africa, with plans to expand production into more regions in the future.

Weir Minerals updates Trio live-shaft cone crusher range with TC84XR

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

Weir Minerals has upgraded its range of Trio® TC live-shaft cone crushers, incorporating the latest technology to ensure it remains integral to flowsheets long into the future, the OEM says.

The Trio® TC84XR features all the robust design elements that have made live-shaft crushers a fixture of the mining and sand and aggregate industries for generations, but updated it with new smarts, according to Weir Minerals.

Mark Utecht, Weir Minerals’ Director of Comminution Engineering, said: “The Trio TC cone crushers’ live-shaft design has been proven to perform in heavy-duty secondary and tertiary crushing applications. We wanted to build on this strong foundation. My team followed a comprehensive design process – we’ve reviewed and tested every inch of this crusher. While the TC84XR may seem familiar on the outside, we’ve upgraded its design and control functionality. The motor is larger and it has a much higher crushing capacity compared to equivalent sized crushers.

“The result: we now have an incredibly robust, powerful and technologically advanced crusher that is easy to operate, has a low wear rate and uses less energy, which ultimately lowers operating costs.”

While many OEMs have made the decision to discontinue their live-shaft cone crushers, Weir Minerals says it has resisted this trend, believing that, because every mining and sand and aggregate operation is different, there can’t be a one-size-fits all approach.

There are some applications and situations where pedestal (fixed-shaft) style crushers may be the more appropriate solution, which is why Weir Minerals continues to manufacture the premium Trio TP pedestal style machine, it said. Weir Minerals claims to be the only global equipment manufacturer offering both the TC live shaft and TP fixed shaft style machines.

“The combination of the Trio TP and TC fixed and live-shaft cone crushers ensures that Weir Minerals continue to offer their customers the right technology, regardless of their site structure, operating conditions or application,” Utecht said.

Trio live- and fixed-shaft cone crushers are made for modern mines and quarries with advanced hydraulics, wear resistant material and the latest technology, according to the company.

Ekkhart Matthies, Weir Minerals’ Global Application Director, said: “This is really exciting for our customers, as they now have a real choice. The combination of our TC and TP series allows us to have an honest conversation with our customers on the options available to them and make a technological recommendation which truly meets their needs.”

Replacing existing live-shaft style machines on site with the Trio TC84XR crusher is now a straightforward process because it has very similar dimensions and is a comparable weight to its live-shaft predecessors, Weir says. And because it produces the same product, downstream changes aren’t required, which isn’t the case when replacing a live-shaft style machine with a fixed-shaft style machine.

“In other words, there is no need to re-design existing circuits,” the company said.

Technology upgrades

The recent technology upgrades in the Trio TC84XR crusher have improved its safety, functionality and reliability, according to the OEM.

Matthies explained: “At Weir Minerals, we understand and appreciate the important role live-shaft cone crushers play in today’s challenging crushing applications. Combining decades of experience and first-hand customer feedback with innovative designs, the highest quality materials and latest in control technology, we believe that our new Trio TC84XR cone crusher is the most reliable and robust live-shaft cone in the market today.”

Engineered to perform in the most extreme applications, the Trio TC84XR crusher is robust and easy to maintain and operate, according to the company. It reliably delivers high crushing force and high horsepower in primary, crushed ore and quarry rock applications.

The ability of the TC84XR crusher to handle variable feed and crush pebbles is also partly a result of its large motor; it’s been designed with higher power capability than comparable cone crushers. Ultimately, this translates to a higher potential crushing force and, therefore, increase in production, Weir said.

Another feature that allows it to handle variable feed, as well as deal with tramp material safely, is the fully-automated tramp-release and setting recovery system. The tramp release hydraulics can also be used to safely clear the crushing chamber should a sudden disruption in plant power cause a shutdown of the cone crusher.

The socket assembly has been redesigned to improve sealing, which has optimised functionality and manufacturability by reducing the machining setups of the socket and seal rings, it said. The Weir comminution team has also redesigned the countershaft assembly to remove welding and machining, while simultaneously improving venting and the dust seal.

The Trio TC84XR crusher, like the range of TP series cone crushers, can be fitted with ESCO® wear parts, designed with superior ESCO alloys, which can be custom designed based on specific requirements.

Kışladağ and Weir Minerals on the HPGR-backed gold recovery trail

Comminution of minerals, Environmental, Metallurgy, Mine operation news, Mineral processing, Mining consumables, Mining equipment, Mining services, Power supply for mines, Precious metals, Sustainable mining, , , , , , , , , , , , , ,

The story that led to the installation of a Weir Minerals Enduron® high pressure grinding roll (HPGR) at Eldorado Gold’s Kışladağ heap leach operation in Turkey is a fascinating read, as well as a great example of the benefits of using such technology.

Back in March 2018, Eldorado announced it would suspend mining to evaluate processing options for the operation. This decision followed extensive laboratory tests that indicated gold recoveries would continue to trend downwards around the base of the open pit where mining was underway.

This suspension, plus further engineering and test work, led to the company advancing the potential development of a mill project. The transition away from its heap leaching roots to a possible mill and carbon-in-leach (CIL) process would have added significant capital costs and shortened the mine life significantly.

Before making this significant capital decision, Eldorado paused to take time to undertake the necessary technical work and sought the technical collaboration of Weir Minerals on a solution.

“It was a very challenging period,” George Burns, President & CEO of Eldorado Gold Corporation, told IM. “Kışladağ is a cornerstone asset in our portfolio. It required collaboration with our geologists, metallurgists, site teams and technology providers, including Weir, working together on a solution.”

(Credit: Eldorado Gold)

In late 2018, results showed increased recoveries from an extended leach cycle. Following a deeper understanding of the geometallurgical drivers of the sulphide component of the deposit, improved heap leach recoveries were realised by optimising the metallurgical conditions. With these improved recoveries confirmed, the heap leach plan was revised in early 2019. Eldorado announced plans to resume mining, crushing, stacking and heap leaching at Kışladağ, and suspended plans to build the processing plant.

The decision came following metallurgical test work on the material placed on the heap leach pad in 2018. Gold recovery had increasingly exceeded expectations throughout the year, providing a new, positive heap leaching outlook beyond the near term. At the same time, Eldorado worked with Weir Minerals on the potential use of an HPGR at the operation.

HPGR creates a finer particle size, which helps to liberate the gold particles, resulting in increased recoveries.

An improved understanding of the leaching process on its low-grade ore and the potential of this cost-effective grinding addition provided it with the confidence to continue heap leaching beyond the short-term time horizon previously envisaged.

“Our collaboration with Weir on this effort is an excellent example of how Eldorado collaborates with technology leaders and seeks out solutions,” Burns said. “We believe this is a strength of the company’s core business values. We are agile and flexible ‒ a good example in both business and operations to find innovative, technical solutions and demonstrate prudent capital discipline. Ultimately, the solution was the best technical and economic decision for Eldorado.”

Testing, testing, testing

“The relationship between Weir Minerals’ and Kışladağ goes back to 2013,” Bjorn Dierx, Global Product Manager Enduron HPGR, told IM.

The OEM had been provided with samples on several occasions to investigate different flowsheet possibilities.

“The benefits of HPGR in heap leaching recovery were known by the site’s crew,” he said.

Enduron technology was tested at the quaternary crushing stage before heap leaching, in the quaternary crushing stage before ball milling and at the tertiary crushing directly before heap leaching.

All the time, the mine operator, Tuprag, Eldorado Gold’s subsidiary in Turkey, was evaluating the impact on gold recovery.

Although HPGR in closed circuit with screening was also tested, most of the test campaigns were focused on a configuration with so-called ‘Partial Product Recycling’ (PPR), according to Serhat Onol, Weir Minerals Senior Process Engineer.

“This system includes splitter plates underneath the rolls which ‘cut’ a proportion of the product discharge and reverts this back to the HPGR head feed,” he explained. “This recycle stream can be adjusted online to adapt the product grind towards the downstream requirements.”

PPR is not an option for every application but for Tuprag – due to the feed and desired product size – all specifications showed it was the best route.

“The hybrid solution with screening serves to increase the flexibility and to control the circulating load to the HPGR,” Onol said.

With capacity rates of around 4,200 t/h at Kışladağ, the screening area requirement was reasonably high, he explained.

“The hybrid solution uses screening only for the recirculating stream: the centre product of the HPGR reports to downstream leaching, whereas the rest is recirculated,” he said. This not only removes the fines re-entering the HPGR and, thus, reduces the circulating load, but also avoids the over-grinding of fines before leaching.

The PPR option, itself, is a very flexible operation, with the adjustable discharge splitter plates providing the best circuit flexibility in terms of throughput and product size, according to Onol.

(Credit: Eldorado Gold)

Great expectations

With the main driver of the HPGR installation being an improved gold recovery scenario, leading to an increased heap leach life, the pressure has been on Weir Minerals to come up with the goods.

The final flowsheet, which includes a 2.4 m diameter by 2.2 m long Enduron HPGR with the capacity to process 4,200 t/h, is much simpler than the existing circuit, according to Dierx, with less equipment to maintain, control and monitor.

“A single Enduron HPGR will replace all of the five existing tertiary crushers of which liners would have an average lifetime of circa-one month with a crusher availability of 85%,” he said. “The HPGR tyres have a wear life close to 18 months, with the HPGR achieving a high asset availability of more than 95%.

“Additionally, as a result of the HPGR combined with the hybrid PPR system, the existing four tertiary screens are also being decommissioned.”

Not only has the HPGR alleviated the use of this equipment, it is also set to boost that bottom line gold recovery.

“During testing, it was determined that the circuit configuration and HPGR operating conditions, such as pressure, have a direct influence on the gold recovery,” Dierx said. “The current expectation is that the average recovery increase after the commissioning of the Enduron solution will be approximately 4%.”

This could bring gold recovery to approximately 56%, as was declared in a 2020 press release from Eldorado that highlighted a 15-year mine life at Kışladağ with an average annual production of 160,000 oz.

In action

One of the largest brownfield HPGRs Weir Minerals has ever installed has just processed its first material at Kışladağ, which is testament to the hurdles both the Weir Minerals and Tuprag teams overcame during the height of the COVID-19 pandemic.

“Despite the challenges we faced during the pandemic, we were able to fully install the machine, including pre-commissioning, in only 22 weeks,” Dierx said.

(Credit: Eldorado Gold)

This was achieved by minimising the amount of work carried out on site via pre-site testing and modular HPGR assembly.

“As the available footprint in existing sites is limited, the unique Enduron design (length:diameter ratio) not only improves the grinding efficiency but also allows for easier implementation with less civil requirements,” Dierx said.

The machine has the potential to be digitally connected to the Weir Synertrex® IoT platform where operators can benefit from direct access to maintenance specialists, who will be monitoring performance and provide necessary operating guidance.

And the Weir Minerals team is confident more Enduron HPGR installations will follow the one at Kışladağ.

“We are very proud of the product’s recognition by our customers as the Enduron HPGR has been selected for all major greenfield HPGR projects in the hard-rock space,” Dierx said. “Despite all the key Enduron differentiators, it is not only merely about the product but particularly the wider experience across Weir Minerals in both the upstream and downstream processes via our wide product portfolio.

“Particularly in these brownfield applications, the system is not operating in a vacuum and every process change influences how the overall circuit works. This requires tacit knowledge, which Weir Minerals holds across their global teams.”

Eldorado’s Burns concluded: “We are pleased to implement a solution that increases gold recovery and supports a 15-year mine life at Kışladağ, allowing Eldorado to continue to provide employment and economic opportunity in the region, as well as provide a solid foundation for future growth.

“Kışladağ has been the cornerstone asset of Eldorado for over a decade, producing over 3 Moz of gold and generating significant value for all stakeholders during that period. This project is a testament to our exceptional team and technology partners working together to execute in challenging circumstances during the pandemic.”

Weir Minerals expands the Cavex 2 hydrocyclone range with 650 model

Base metals, Comminution of minerals, Equipment maintenance, IoT, Mineral processing, Mining equipment, Water management, , , , , ,

Weir Minerals, building on over 20 years of Cavex® hydrocyclone experience, has added the Cavex 2 650 to its product line, with the cyclone set to deliver unparalleled results, the company says.

The release follows the recent launch of the Cavex 2 hydrocyclone, which brought with it the introduction of a LIG+™ inlet and chamber design that, the company says, produces a more stabilised flow pattern, further reduces turbulences and friction throughout the hydrocyclone and provides up to 30% additional capacity.

The latest 650 model has undergone years of research, lab testing and in-field testing to ensure it can withstand the rigours of heavy-duty industrial and abrasive applications. It also addresses the continual demand for increased operational and circuit capacity, and offers customers process improvements combined with digital technology, Weir Minerals said.

“It is important to note that enhancements of the hydrocyclone performance go hand in hand with improving the environmental footprint of the equipment,” the company said.

“By reducing bypass returning to the mill, fewer fines are returned back to the mill in a closed-circuit milling process, thus reducing the need for energy to be used to further process particles that are already small enough to move on to the next stage. This frees up mill capacity, previously used up with fine particles, for the size reduction of larger particles.”

As a hydrocyclone that can make a finer separation, the Cavex 2 650 can operate at a lower pressure for further energy savings or a higher feed density for water savings, while maintaining the existing cut size from the hydrocyclone, according to the company.

And, finally, using equipment with a higher volumetric capacity requires fewer units to be installed upfront as well as fewer consumable spare parts used over the life of the hydrocyclone.

Significant benefits to mining customers include:

  • Increased operational and circuit capacity up to 30%;
  • Maximised plant recovery by reducing the quantity of misclassified particles with an average improvement of the alpha parameter of more than 10%;
  • Improvements in bypass with an average of over 15%;
  • Opportunity to retrofit Cavex 2 650 cyclone into existing cyclone cluster footprints;
  • Less turbulence during the separation process due to the LIG+ inlet and elongated chamber design;
  • Enhanced performance with a Synertrex®-enabled monitoring system, which can detect roping or blockage conditions in advance for continuous, efficient operation of the hydrocyclone; and
  • Improvement of environmental footprint.

To satisfy all process conditions and slurry types, the Cavex 2 650 hydrocyclone comes with a range of material technology options including Linatex® premium rubber, R55 rubber, neoprene for high levels of hydrocarbon and ceramic.

The Cavex 2 650 hydrocyclone can be customised to suit almost any application with a variety of spigots, vortex finders and cone angles, according to the company.

These new hydrocyclones have already been put to the test, with the latest Cavex 2 650 hydrocyclone trial taking place with a customer in Chile. The testing was conducted in a large copper ore mine which had a SAG mill in a closed circuit with the cyclone cluster. The trial tested one Cavex 2 650 in a six-place cluster of existing Cavex cyclones and saw an improvement of up to 48.5% in circulating load and 31.7% in water bypass versus the original cluster, according to Weir Minerals.

A lab water test with the same hydrocyclone fittings as above also yielded positive results: a 211 mm inlet and 260 mm vortex finder delivered 16% more capacity at 100 kPa, and 17% more capacity at 250 kPa.

“These improvements in efficiency and bypass translate to increased savings for brownfield sites where the existing hydrocyclones do not have enough capacity and are maxed out, while greenfield projects benefit from savings in capital expense,” the company said.

The Cavex 2 650 hydrocyclone is the second in a range of standard sizes that Weir Minerals is planning to release, with more sizes in development to expand the current product range.