00 Workshop Chile - May 2009 - HPGR Summary

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C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt
High Pressure Grinding Roll POLYCOM

Process, Design &
Experiences in Various Applications
TKT Workshop Santiago - May 06, 2009
Egbert Burchardt
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Growth of HPGR References Over Time
> 35 in diamonds
> 45 in iron ore
> 30 in hard rock
12 copper
11 gold
3 platinum
5 molybdinum
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HPGR References
References:
Gold Corp. Minera
Penasquito
POLYCOM 24/17
2 x 2,500 kW
> 2.000 tph
HPGR for Pebble Crushing
separate pebble crushing circuit
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HPGR References
References:
FMI PTI Grasberg (2)
Northam Platinum
UG2 Plant
Anglo Ferrous Minas Rios Project (3)
HPGR in Quaternary Application
open circuit or edge recycle
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HPGR References
References:
Anglo Platinum Mogalakwena North
HPGR in Tertiary Application
normal closed circuit dry screening
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HPGR References
References:
FMI - Cerro Verde (4)
Newmont / Anglo
Boddington (4)
Moly Mines
Spinefex Ridge (3)
Vale Salobo (2)
Gindalbie Metals
Karara Magnetite (2)
HPGR in Tertiary Application
normal closed circuit wet screening
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SAG Mill Circuits

Disadvantages of SAG Mills
SAG circuits are sensitive
to changes in ore properties
Feed size control is essential
Pebble crushing is difficult
to control and expensive
Difficult to balance SAG and BM Circuit
Longer project implementation

Higher risk in project schedule (castings)
Longer ramp up compared to a HPGR
More complex control required

Higher risk in liner replacement
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SAG Mill Sizing

Today, SAG mills
are sized based on
SPI Test
(Minnovex)
Drop Weight Test
(JK / SMCC)
A * b /
DWI
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SAG Mill Circuits
16 kWh/t
4 kWh/t
SAG Mill Energy Input

varies between
4 to 16 kWh/t
A * b = 25
A * b = 80
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SAG Mill Sizing
No strong relation between

A * b Parameter and Bond Index
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SAG Mill Sizing
A* b = 28 to 75
suggests
energy input
between 5 to 15 kWh/t
throughput
+/- 50 % variation
without blending!
Deposit with extreme variation of
A * b Parameters
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HPGR Circuit
Sensitivity of
HPGR circuits
treating various ores
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Sizing of HPGR Circuit

Determination of
circulation factor
=>
Required
HPGR throughput capacity
Selection of
Roll dimensions and speed
based on specific throughput
in order to achieve required throughput
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Sizing of HPGR Circuit
HPGR throughput is a function of

roll dimensions, speed and specific throughput
HPGR throughput is adjusted by the roll speed
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Definition of HPGR Products
Fineness of HPGR discharge

(is mainly controlled by
grinding force and breakage properties)
Fineness of HPGR circuit

mesh size of closing screen)
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Fineness of HPGR discharge
Suggests SAG energy between 8 and at least 16 kWh/t
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Variation of HPGR Discharge Fineness
No significant fineness variation for A* b from 19 to 36
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HPGR Circuit - Variation of Circulating Factor
For producing a < 6 mm circuit product:

Circulation factor may vary between
1.6 and 2.0
if
HPGR discharge varies between
at a screen efficiency of
55 70 % < 6 mm
90 %
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Product Fineness of HPGR Circuit
< 2 mm
< 11 mm
< 6 mm
HPGR circuit fineness

mesh size of closing screen)
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Variation of HPGR Circuit Fineness
HPGR circuit fineness

Usually does not vary much for most ores
(diagram shows < 8 mm product of 6 individual ore types from one deposit)
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HPGR Circuit Performance

Stable HPGR circuit performance due to
relative low variation of circulating load
low variation of specific throughput for most ores
Low variation of the HPGR circuit fineness
stable ball mill performance

(better product size and throuhput control)
stable operation of flotation circuit
improved flotation recovery
HPGR is considered to be the Big Equalizer!
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HPGR Circuits
HPGR Control Parameters
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Higher Grinding Forces

higher fineness of HPGR discharge
higher circuit throughput
higher energy input
limited influence on circuit product fineness
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Throughput Control
Belt feeders control
filling level of HPGR
Motor speed is adjusted
according to level
in BM screen bin
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SAG Mill vs. HPGR Circuits
Scoping Study
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Assumptions
SAG Mill Steel Wear = 0,050 kg / kWh
Ball Mill BWI = 16 kWh/t
Ball Mill Steel Wear = 0,025 kg / kWh
Ball Mill P80 = 150 m
Steel Ball Cost
Energy Cost = 0,07 US$/kWh
= US$ 1.000 / ton
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HPGR Technology
Experiences in several applications
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Freeport Grasberg, Indonesia

2 x POLYCOM 20/15
2 x 1,800 kW
single pass
feed < 20 mm
1,200 -1,400 tph
in operation since 05 / 2007
Throughput:
design throughput exceeded
Tyre lifetime
>> 12,000 hours
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Freeport Grasberg, Indonesia

2 x POLYCOM 20/15
2 x 1,800 kW
single pass
feed < 20 mm
1,200 -1,400 tph
HPGR in Quaternary Application
Throughput:
Tyre lifetime
>> 12,000 hours
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Anglo Platinum - Mogalakwena North, South Africa

POLYCOM 22/16
2 x 2,800 kW
circuit feed < 60 mm
circuit product < 8 mm
HPGR: 2,200 tph
Circuit:1,100 tph
Throughput:
Tyre lifetime
> 12,000 hours
(based on current wear condition)
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HPGR for replacement of Tertiary and Quaternary Crushers
One HPGR replaces several

tertiary and quaternary crushers!
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Freeport Cerro Verde, Peru
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4th HPGR was commissioned in middle of December 2006

Nameplate capacity was achieved first time in early May 2007
Nameplate capacity - on a monthly average - was achieved in July 2007
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Even without any previous operating experience with HPGR plants,

the start-up time of the Cerro Verde Concentrator
was shorther or within the time frame required for conventional technology!
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Daily Production Rates: Design 108,000 tpd Achieved average 113,000 tpd
Maximum instantaneous plant capacity between 110,000 and 130,000 tpd
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SAMPLING CAMPAIGN AT CERRO VERDE
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SAMPLING CAMPAIGN AT CERRO VERDE
Sampling of 3 sections
under the Polycom
rollers
left
centre
right
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Performance Summary
Achieved throughput rates were as predicted
Fineness of HPGR discharge was according to

predictions based on simulations
Circulation factors in HPGR circuit were as predicted
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Performance Summary
Cakes in HPGR discharge broke up easily

and did not cause any screening problems
Moisture content in + 6 mm screen oversize is less

than 4 %
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Finding:
CV ore body is highly abrasive and
more abrasive than initially tested!!
Challenge:
How to get 6,000 hours roll life
on an extremely abrasive ore??
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Roll Wear Parameters
Abrasiveness of Ore
&
Wear Protection Design
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Roll Wear Parameters
Parameters influencing wear rate & lifetime

Process
& Operation
Ore Properties
mineralogy
hardness
HPGR wear index
top feed size

feed size / gap ratio
truncated feed
moisture
grinding pressure
roll speed
Design
stud
composition
stud length
stud diameter
stud pattern
tyre properties
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Determination of HPGR Wear Index
ATWAL
abrasion testing unit provides HPGR wear index
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Ore Abrasiveness and Wear Life

Cyprus Sierrita
1996
First commercial scale HPGR

in a high wear application
Newmont Lone Tree
2002
Pilot Plant Application
Anglo Platinum PPL Plant
2004
Pilot Plant Application
Cerro Verde
since 12 2006
Freeport - Grasberg
since 05 2007
Anglo Platinum PPL Rust
since 03 - 2008
Northam Platinum
since 05 2008
Anglo Gold / Newmont

Boddington
start up 2009
Vale Salobo
start up 2010
Moly Mines Spinefex Ridge
start up 2010
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Determination of Industrial Wear Rate

industrial wear rate =
k1 * k2 * HPGR wear index
k1:
application factor (feed size, force, moisture, etc.)
k2:
wear material factor
wear index
determined by abrasion testing
usuable stud length

Lifetime ~
----------------------------------------------------industrial wear rate * roll speed
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Finding:
CV ore body is highly abrasive and
more abrasive than initially tested!!
Challenge:
How to get 6,000 hours roll life
on an extremely abrasive ore??
Outlook:
Design modifications indicate the
potential to achieve 6,000 hours!!
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Summary
Succesful HPGR references are in operation.
Metallurgical performance of HPGRs met or
exceeded the design criteria.
Robust scale-up procedures are availabe.
HPGRs are more competitive than SAG Mills
for the comminution of hard ores.
The harder, the better for HPGRs!
HPGR wear protection is further advancing.
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Thank you for your attention!
Questions?

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Page 1

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

High Pressure Grinding Roll POLYCOM

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

Growth of HPGR References Over Time

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

HPGR for Pebble Crushing

separate pebble crushing circuit

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

HPGR in Quaternary Application

open circuit or edge recycle

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

HPGR in Tertiary Application

normal closed circuit dry screening

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

HPGR in Tertiary Application

normal closed circuit wet screening

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

SAG Mill Circuits

Longer project implementation

More complex control required

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

SAG Mill Sizing

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

SAG Mill Circuits

SAG Mill Energy Input

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

SAG Mill Sizing

No strong relation between

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

SAG Mill Sizing

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

Sizing of HPGR Circuit

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

Sizing of HPGR Circuit

HPGR throughput is a function of

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

Definition of HPGR Products

Fineness of HPGR discharge

Fineness of HPGR circuit

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

Fineness of HPGR discharge

Suggests SAG energy between 8 and at least 16 kWh/t

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

Variation of HPGR Discharge Fineness

No significant fineness variation for A* b from 19 to 36

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

HPGR Circuit - Variation of Circulating Factor

For producing a < 6 mm circuit product:

1.6 and 2.0

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

Product Fineness of HPGR Circuit

HPGR circuit fineness

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

Variation of HPGR Circuit Fineness

HPGR circuit fineness

C:\Daten\EBU\00 Workshop Chile\Workshop Chile - May 2008.ppt

HPGR Circuit Performance

relative low variation of circulating load

low variation of specific throughput for most ores

Low variation of the HPGR circuit fineness

stable ball mill performance

stable operation of flotation circuit