Stirred milling machine development and application expansion
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Mining On Top: Stockholm 2013 26-27 Nov 2013 Stirred milling machine development and application expansion – Graham Davey, Metso Minerals; Senior Process Manager
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Stirred milling machine development and application expansion
- 1. Mining on Top - Stockholm Stirred Grinding Mill Development and Application Expansion Graham Davey Process Manager
- 2. Contents Current offering Efficiency and application range development Machine development and where we are going Key project updates
- 3. Metso Stirred Milling Goals • What we know and what we don’t know • We rely on operations and projects to give us feedback • Learn more together • Ask the right questions • Circuit Design, Optimization and Modelling • Maintenance Best Practices and Strategies • Update on the technology and future developments 3 © Metso
- 4. Contents Current offering Efficiency and application range development Machine development and where we are going Key project updates 4
- 5. Stirred milling Design goals Lowest total cost of ownership Energy efficiency Sustainability © Metso Ease of operation Grinding media consumption 5 Minimal maintenance CAPEX
- 6. VERTIMILL® grinding mill Overview • Over 420 units worldwide • Over 270,000 kW total power • Unit sizes from 15 to 4500 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 6 © Metso
- 7. VERTIMILL® grinding mill Components and features Motor Low speed coupling Gear reducer Thrust bearing Reducer pedestal Driver shaft Feed chute Upper body Ball port Lower body Dart valve operator Screw with liners Separating tank Magnetic lining Recycle hose Recycle pump Access door Drain 7 © Metso Product elbow
- 8. VERTIMILL® grinding mill Lowest total cost solution • Low operating cost - Energy efficient - Reduced media consumption - Long wear life • Low installation cost - Simple foundation - Quick installation - Less floor space • Improved process performance • Higher recovery • Higher availability • Greater operational safety 8 © Metso
- 9. Stirred Media Detritor Overview • Primarily for fine and ultra fine grinding • Low density media: sand or ceramic • Optimum grinding intensity for optimum wear life • >170 units by Metso SMD-185-E 9 © Metso SMD-355-E SMD-1100-E
- 10. Contents Current offering Efficiency and application range development Machine development and where we are going Key project updates 10
- 11. Stirred milling Design goals Lowest total cost of ownership Energy efficiency Sustainability © Metso Ease of operation Grinding media consumption 11 Minimal maintenance CAPEX
- 12. Vertimill Energy Efficiency Primary Reasons • High Shear Energy - Generally accepted to be more efficient • Minimal Impact - Wasted ball mill energy with balls impacting balls and balls impacting liner - Also contributes to higher ball wear • Retention of Fine Media - Vertical arrangement keeps the fines in the mill - 12 © Metso Fine media will float out of a ball mill (will wear out pumps and screens fast too)
- 13. Striving to full understanding of the VERTIMILL and ball mill power relationship Specific Energy (kWh/mt) “30-50% more efficient than a Bond Ball Mill” • True in most cases • Over simplification 10 •Function of the feed size, product size, and material grindability • How far coarse and how fine can we go? • Efficiently • Practically 100 P80 (microns) Bond Ball mIll Power 13 © Metso 1000 VTM Power • How do we determine this relationships for all ore types?
- 14. Contents Current offering Efficiency and application range development Machine development and where we are going Key project updates 14
- 15. Stirred milling Design goals Lowest total cost of ownership Energy efficiency Sustainability © Metso Ease of operation Grinding media consumption 15 Minimal maintenance CAPEX
- 16. Current/Planned Development Activities VTM-6000 (or larger!) VTM-10 Pilot Unit Stirred Milling Bench Scale Equipment Intermediate VTM Sizes VTM-75-WB Portable Pilot Plant VTM Liner Handler Automated Media Discharge SMART Equipment Automated Media Reloading Standard Layouts 16 © Metso • Bigger mills at economical prices • Enable secondary grinding • Create multiple VTM Pilot units to be distributed into third party facilities • Looking for WA partner to take a unit • New Test in development with the JKMRC • Jar mill continued development • Fill in our product offering for improved project economic • VTM-2250-WB and VTM-3750-C • Available for Extensive field trials • Integral device for faster liner handling • Included features to remove grinding media • Hydraulic Actuated valve • Integrate water flush lines • Condition Monitoring and advanced process control • Standard unit supervisory control to reduce installation cost and time • Faster media addition during operation and after mill relining • Reduce project engineering cost • Incorporates beset practices in maintenance and operation
- 17. Creating the VTM-3000-WB from the VTM-1500-WB Previous Scale up Considerations • Wanted to Keep existing Vertimill advantages: - Machine Simplicity - Long Wear Life - Grind Efficiency • Challenges - Torque and Availability of Drive Components - Wear Minimize Capital Cost Maintainability The VTM-3000-WB was the most successful development and new machine for Metso in recent memory 17 © Metso
- 18. VTM-6000-C And beyond • What we want to provide - Lower CAPEX, enable use of large machines VTM-4500 equal or better OPEX Shorter mill deliveries Smaller wear components • Will use innovative and new to metallic mineral processing drive concepts • Will be shorter overall height than VTM-4500-C • Ready to offer by Dec 2013, target delivery of 1Q15 18 © Metso
- 19. Current/Planned Development Activities Stirred Media Detritor SMD-E SMD-3300-E Simulation and Modeling SMD-1100- E Field Trials and Validation SMD Impeller Arm wear materials 19 © Metso • Completion of the E Series Product Line • E series improves wear life, maintainability and reduces cost • Next Larger size SMD • Ready for the market in 1Q 2014 • DEM and PEPT Work to further optimize the SMD operation • Continued co-development with Imerys • Extensive field program jointly with Anglo Platinum to put the SMD-1100E through its paces • Continued development on impeller material for specific applications • Bench scale impeller wear test rig • Advantage of pin is new machines immediately test various materials
- 20. Stirred milling testing capabilities CIS NAM EMEA APA Jar Mill SMD-0.75 SAM SAF USMT KW-3 SMD-P 20 © Metso
- 21. VERTIMILL® grinding mill Standard Layouts • Takes the full experience of the Metso team • Incorporates different strategies for maintenance • Saves times and cost 21 © Metso
- 22. VERTIMILL® development activities Not ready to show VTM Liner Handler Automated Media Discharge © Metso • Hydraulic Actuated valve • Integrate water flush lines Automated Media Reloading 22 • Integral device for faster liner handling • Included features to remove grinding media • Faster media addition during operation and after mill relining
- 23. Contents Current offering Efficiency and application range development Machine development and where we are going Key project updates 23
- 24. Northlands’ Resources Kaunisvaara Project Five (5) VTM-3000-WB One (1) VTM-4500-R
- 25. Vertimill Multi Unit Arrangement Kaunisvaara Advantage • Trend is for single stage ball mill to save CAPEX, but this limits flexibility • Additional space has been left for a 5th Vertimill in the Sahavaara Line • Only the Mills that are required will be run, saving: - Energy – each mill operated at optimum efficiency - Wear and Parts • Vertimills Enabled a change in Mining Schedule - Original Plan was to have line 1 with Tapuli Ore, line 2 with Sahavaara Ore - All ore now planned to be tapuli, delayed delivery of one mill - Conversion of one unit to VTM-4500-R to have greater capacity than plan • Design = F80 300 microns to a P80 of 34 microns. • Schedule for Review by JKMRC 25 © Metso
- 26. Northlands Screw 15 months expected wear life 26 © Metso
- 27. VERTIMILL® & Stirred Media Detritor Barrick Lake Cowal Gold sulphide concentrate • Design grinding duty: - F80: 150 microns - P80: 15 microns - Bimodal size distribution - Reduction ratio: 10 • Customer requested single stage VERTIMILL® • Metso provided an optimal media size and reduction ratio solution of two stage grinding Mills are exceeding grinding performance targets 27 © Metso
- 28. VERTIMILL® & Stirred Media Detritor Barrick Lake Cowal (cont.) Alternative two stage grinding Grind water Cyclone overflow • First stage Scalping cyclone overflow - One VTM-1000-WB - F80: 150 microns - P80: 40 microns - 12 mm steel media • Second stage - Two SMD-355 in series - F80: 40 microns - P80: 15 microns - 3 mm ceramic or sand media • Overall specific energy reduced through: - Optimum technology - Efficient media Underflow SMD product SMD feed Mill discharge Circuit feed Metso VERTIMILL® Dilution water Cyclone feed Dilution water 28 © Metso Metso Stirred Media Detritors Scalping cyclone feed Final product
- 29. Mining on Top - Stockholm Stirred Grinding Mill Development and Application Expansion Graham Davey Process Manager