COMMINUTION

DISINTEGRATION

John Chadwick looks at new

machines and ideas in the constant
battle to bring comminution costs,
especially energy consumption,
down and raise breaking efficiency

The first Siemens gearless mill drive with a frozen charge shaker

J
KMRCs Z. Pokrajcic1, explains the the observed strength approaches the high The SAG mill was converted to an AG mill
comminution process remains inherently intrinsic strength of the solid. and the ball mill was converted to a pebble mill
inefficient. It is understood that 85% of the Pokrajcic says energy cuts can be achieved to decrease liner and media consumption.
energy used is dissipated as heat, 12% is by purposely targeting the comminution energy Existing mill sizes were reduced.
attributed to mechanical losses and only 1% of at specific problematic size fractions such as the When the performance of this new ABC-
the total energy input is used in size reduction critical size material in the primary mill and the HPGR-PM circuit was compared to the original
of feed material. very fine fraction in the secondary mill. Through SABC circuit, (based on JKSimMet and mass
Another aspect of comminution which the use of more efficient comminution devices balancing predictions) it was observed that the
contributes significantly to the energy intensity such as HPGR (high pressure grinding rolls) a new circuit produced both finer and steeper
of the process is the consumption of media and product size distribution that is narrower in size product size distribution, which promoted better
mill liners. The quantity of energy necessary for range can be generated. This size distribution flotation performance some 2% increase in
the fabrication of the media and/or liners from contains less material in the coarse fraction to gold recovery.
extraction, to transport, to manufacture and aid overall mineral liberation and less material in Direct energy comparisons show that the
assembly is considered part of the total energy the fine fraction to minimise the effects of ABC-HPGR-PM circuit had an operating work
utilisation of the comminution process. This is slimes. index of 15.9 kWh/t compared to 24.3 kWh/t
also quite an energy intensive process and JKMRC made eco-efficient modifications to for the base case SABC circuit. This is a
opportunities to minimise steel consumption in an existing SABC (SAG mill with recycle significant energy saving greater than 8 kWh/t
comminution circuits should be realised. crushing and a single stage ball mill). First, a for the whole circuit. Comparing indirect energy
The third factor which contributes significantly pre-crush stage using HPGR was introduced to consumption, again the ABC-HPGR-PM out
to the energy intensity of comminution circuit is minimise the generation of critical size material performed the standard SABC circuit with a
the chosen grind size. As the target product size in the primary mill. The aim was to reduce a 79% saving in indirect energy based on media
decreases the energy required to achieve the portion of the feed material below critical size and liner wear alone. The SABC circuit
product size increases significantly. As the and generate more fines to decrease the load in consumed 3,535 kW while the new circuit
particles become smaller their strength and the primary mill. Not all of the feed material consumed 753 kW. These figures are based on
therefore their resistance to breakage increases. was pre-crushed to allow for sufficient abrasion 6 kWh/kg required to manufacture the grinding
For small particles as internal flaws are depleted, breakage in the primary mill. consumables.

30 International Mining OCTOBER 2009

Processs Solutions

Perfecting the Process.

Process Technology Service Solutions
Unique combination of tools and technologies. Optimize the reliability and availability of your
Process optimization equipment or plant.
Process automation Metso offers a complete portfolio of solutions.
A proven track record of productivity Maintenance strategy and implementation
improvements. Life cycle service contracts
515% production increases in existing plants Field service
Over 1% improvement in metal recovery Safety, health and environment
Education and training
Wear and spare parts

metso.com email: minerals.info@metso.com

 COMMINUTION

FLSmidth Minerals has been looking at

different crushing combinations and says that
while traditional crushing circuits such as
gyratory/cone, jaw/cone, two-stage or three-
stage low-speed sizing, and two-stage
impactors are still the norm, in recent years FLS
has been working on hybrid circuits that
combine various crushing technologies into a
single circuit when special circumstances exist.
In today's market many of the typical
applications have already been addressed and
quite often the newer applications involve
special circumstances such as working with wet,
sticky, clay-like feed, or trying to achiev a
relatively small final product while controlling
fines generation.
FLS has several crushing technologies within
its catalogue which enables it to offer good FLS says today the crushing circuit should be Pennsylvania Crusher says its Mountaineer Sizer is
overall solutions. It says that while some viewed with an open mind to new possibilities. designed for primary or secondary sizing of coals,
companies have one or two crusher types, FLS No longer is the crushing circuit limited to a industrial minerals, and ores with minimum fines
has globally-recognised gyratory crushers, low- single crushing method (compression, impact, generation. Its rolls are linked via gearing in the drive
speed sizers, jaw crushers, cone crushers, or sizing). Combination circuits may provide the system to ensure product size and it is of single drive
hammermills, and feeder-breakers. By having best alternative, especially if special conditions motor and reducer design. It employs standard drive
these various crusher types FLS can mix and exist. components and has an integral base for foot-
match crusher types for customised crushing In addition to hybrid crushing circuits, FLS has mounted drive components. The company also says it
solutions instead of trying to adapt a single type proven solutions for crushing high-work index is an extremely rugged, high capacity machine. The
of machine to a specific application that has ores and can provide plant designs with varied Mountaineer crushing chamber is lined with heavy
certain objectives. That one-machine-fits-many- levels of mobility. duty liners. The sizing rolls are offered in a variety of
applications way of thinking brings about The addition of FLSmidth Excel, with its tooth patterns to suit the application. Side reflectors
compromise from both the supplier and the Raptor line of cone crushers, has provided FLS prevent oversize material by-pass and clean mud off
purchaser. The FLS approach to any project is, with a product offering to complement its the rolls
and has always been, to meet the end-user's combination of complete mineral processing
objectives with the best combination of crusher solutions. As it has done with the cement smooth integration into an automated plant
types to minimise upfront capital cost [and] industry, FLS is now doing for the mining environment. FLSmidths Automation
delivery time, and provide the specified end industry - offering complete mineral processing Technology is available on multiple platforms,
product for the application. plants through its innovative 'One Source' and the cone crusher automation package was
Examples of FLS' latest crushing circuits program. developed specifically to meet the unique
include: These Raptor crushers join other industry- requirements and expectations of the mineral
A primary impactor followed by a low speed leading products from FLS, including Traylor processing engineer, Excel says.
sizer primary gyratory crushers, ABON sizers, Fuller
A primary low-speed sizer followed by a grinding mills and pumps, hydrocyclones, New crushers
secondary cone crusher flotation cells, thickeners and filter presses, to There is a new jaw crusher now available in the
A primary gyratory crusher followed by deliver a great combination of technologies. Sandvik CJ200 series the CJ208. This is a
secondary and tertiary sizers Excel Crushers shipped its first cone crusher, crusher for customers who do not want to
A primary jaw crusher followed by secondary the Raptor XL400, in February 2005. Before the compromise between lightweight and heavy-
and tertiary low speed sizers. end of 2005, FLS had purchased a 50% interest duty equipment, mobile and stationary
Depending on the customer's goals, these in the venture with the goal of developing of applications, and process flexibility and easy
circuits were designed around objectives such as full line of Raptor cone crushers dedicated to operation. The new Sandvik CJ208 is the
minimising fines and dust while getting the serving the minerals industry. Whilst the XL300 smallest member of the family, but this does not
most reduction ratio, or being able to reliably was already in development, the FLS investment reflect in anyway on its performance.
crush feed with wet and sticky properties. drove the fast-track engineering of the Raptor Sandviks CJ200 series offers a combination
Hybrid crushing circuits work very well when XL1100, a 3-m diameter, 895 kW cone crusher. of lightweight equipment and heavy-duty
special conditions need to be addressed and By the summer of 2006, FLSmidth had received crushing applications, offering superior cost
they give more flexibility with the product for orders for a total of nine XL1100 cone crushers efficiency. The optimised crushing chamber
downstream processes. An example of this before the first casting had even been poured. provides a high reduction ratio and capacity.
involves a low-speed sizer ahead of the SAG mill Now FLSmidth Excel has added the XL600 and The frame of Sandviks CJ200 series of jaw
at a gold mine. The orientation of the teeth in XL900 cone crushers. crushers is all-welded. The clear advantage of a
the sizer was configured to deliver the best size Raptor cone crushers come packed with welded frame is that it is equally strong in all
and shape of feed to the SAG mill, thus features aimed at maximising performance, directions and ensures excellent durability
optimising the SAG mill performance. reducing maintenance requirements and against shock loads. In turn, this minimises the

32 International Mining OCTOBER 2009

 THE HAVER SCREENING GROUP
A reliable partner since 1930

WORLDWIDE SOLUTION INNOVATOR

IN MINERAL PROCESSING

Systems and Services

for
Classifying Washing Pelletizing

North America: W.S. TYLER Screening Group, Canada

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South America: HAVER & BOECKER Latinoamericana, Brasil

Phone: + 55 19 3879-9100 E-mail: haverhbl@haverbrasil.com.br Internet: www.haverbrasil.com.br

Europe, Africa, Asia: HAVER & BOECKER Machinery Divison, Germany

Phone: + 49 251 9793-0 E-mail: niagara@haverboecker.com Internet: www.haverboecker.com
 COMMINUTION

risk of mainframe failure, as seen with a bolted At present, the Flexifeed

design. Furthermore, the design of the deep mantle is only available for
symmetrical crushing chamber maximises feed the Sandvik CH440 cone
size, capacity and reduction. crusher in combination
The CJ200s heavy-duty capacity makes it an with EC, C and MC
excellent choice for stationary applications. But concaves.
its compact, low-weight and easy-to-install
design also makes it ideal for use in mobile Better jaw
applications. Its bolted feet enable the Sandvik crushers
crusher to be used as a stationary unit with zero Telsmith says that recent
degree inclination or on a mobile unit with 5 advances in jaw crusher
inclination. design it has developed are
The Sandvik CJ208 and the other members yielding greater productivity
of the 200 series are available with a range of through reductions in
optional equipment, such as automatic bearing maintenance and unplanned
lubrication, feed hopper, intermediate downtime. The application
protection plate and a complete drive package, of computer technology and
including motor, bracket, pulley, belt and hydraulics technology is
flywheel/belt protection. The CJ200 series has allowing the modern Telsmith
low energy and operating costs thanks to its jaw crusher to operate
optimised flywheels, For example, the CJ208 reliably in 24 hour
model requires only a 55 kW motor to crush the operations, while processing
hardest material with the smallest feed greater quantities of ore than
openings. ever before.
Sandvik has also recently launched an Telsmith engineers have
innovative, patented and tested mantle - the adapted advanced hydraulic systems and Modern hydraulic jaw crusher designs have been
Sandvik Flexifeed FF mantle. This crushing Programmable Logic Controllers into the crusher evolving since Telsmith introduced the model 3858
mantle has a patented design featuring a to yield new benefits not previously available on hydraulic jaw crusher in 1999
variable intake in the upper section. Although jaw crushers. Combined, the company says,
the feed opening is narrower in some sections these benefits yield greater reliability, increased push button controls to clear the crusher,
of the intake, capability is maintained. The operating hours and the confidence to operate typically in 15 minutes. Hydraulic cylinders
mantle and pockets rotate during crushing, thus at 100% production speed at all times, retract the pitman slightly - allowing ore to fall
facilitating the passage of top-size material delivering greater efficiency and productivity. deeper into the crushing chamber. Powerful
through the chamber. Hydraulic chamber clearing: Any time a hydraulics then push the pitman forward,
The extension of the mantle means that more crusher stops while full of ore it must be cleared crushing the ore. As the pitman retracts again,
crushing takes place in the upper section of the before it can restart. This has historically meant crushed ore falls onto the belt below. Repeating
chamber, while large stones can still be crushed anywhere from four to eight hours of the process several times clears the chamber
where there is no extension. This translates into unplanned downtime as well as service people while yielding properly sized material for the
maximum utilisation of the chamber and more putting themselves at risk of next stage in the process. Start-up can typically
even wear throughout the entire chamber. injury. Telsmith begin within 15 minutes.
The proven benefits resulting from tests chamber clearing Hydraulic overload relief: Tramp iron or
performed at customers facilities are clear: uses hydraulic any uncrushable material, including clay, can
Liner life is 20-50% longer, cylinders and overload a crusher and cause premature failure
depending on the of internal parts. Overload relief allows the
application, as a result of setting to open when an overload condition
optimised utilisation occurs. In the automatic mode, the PLC will re-
Reduction ratio is increased set the crusher and provide feedback to the
by approximately 5% operator, and/or automated control system,
Production levels are maintained allowing them to take appropriate action for
throughout the mantles life the process downstream.
Top-size capability is Hydraulic adjustment: Adjusting a jaw
maintained. crusher setting has typically involved adjusting
wedges or installing shims as well as adjusting
tension rod springs. This process requires
Sandvik's CJ200 series jaw maintenance crew preparation and anywhere
crushers' wide range of from 20 to 60 minutes of crusher downtime.
applications includes the The hydraulic adjustment system provides the
possibility of producing a 0-40 operator remote push button control and
mm final product in one virtually eliminates downtime for setting
crushing stage adjustment. The PLC provides feedback on the

34 International Mining OCTOBER 2009

 COMMINUTION

ME Elecmetal automated epoxy operator to run the crusher at tighter settings to

backing pump to assist in the make finer feed for the mills. ROI is less than
replacement of wear three months in most cases.
components in crushing The Tramp Release System will help owners
equipment meet OSHA/MSHA safety requirements and
significantly increase the run time of the
crusher setting and liner crushers thereby increasing daily production.
wear tracking for The system can be added in the field without
maintenance planning. removing any major components.
ME Elecmetal has added an automated epoxy
Turbocharged backing pump to its product line to assist in the
crushers replacement of wear components in crushing
Sam Sawant, President of equipment. Mounted to a frame allowing the
Innotech Solutions notes use of large volume epoxy containers, it is
Symons cone crushers [Metso add on kit that capable of pumping up to 11.4 litres/min. The
Minerals] have been the workhorses in the allows the crusher to absorb pump uses disposable applicator tips that mix
mining industry for the last 80 years. They are higher power and use this additional the two part epoxy, eliminating the need for
amazing crushers with proven reliability and power to crush more ore and/or lower the P80 of repetitive hand mixing of smaller containers.
durability in the toughest crushing the discharge. Based on our field experience, the The applicator/mixing tips also minimise
applications. Now, he explains, Innotech crusher production increases as much as 20%. The exposure to fumes that may develop from the
Solutions, with its worldclass crusher expertise, ROI on this investment is typically less than six mixing process.
has been able to turbocharge these crushers to months. The unit includes a self contained heater to
substantially increase their performance. The Rotating Feed Distributor for the tertiary facilitate quicker pumping and curing of the
Innotech has also developed several add-ons for crushers is one of the most significant add-ons. epoxy, and is accessible by fork truck from all
these crushers that improve their operational This device homogenises the feed by sides. It has certified lifting rings to allow for
safety and ease of automation. Thus, he says, distributing it 360 around the cavity, overhead crane movement and is available with
for a fraction of the cost of a new expensive eliminating segregation. This, Sawant says, the option of being mounted on a trailer for
replacement crusher, a very good crusher now causes even crushing around the cavity, relocating to different crusher sites. According
becomes the best crusher. eliminates crusher abuse, increases liner life up to John Sellars, ME Elecmetals Vice President of
Turbocharging is accomplished with a simple to 20%, reduces power draw and allows North American Sales, Not only will the pump

36 International Mining OCTOBER 2009

 COMMINUTION

increase equipment availability, when used in According to Jonathan Allen, Metso Manager The Vertimills carbon footprint much smaller
combination with our non-hazardous backing Stirred Mills, the Vertimill has been proven to than other technologies, offering both direct and
epoxy and larger volume containers, it offers a provide energy savings ranging from 30% to indirect (use of less grinding media that takes
safer, more environmentally responsible option greater than 50% compared with traditional energy to produce) energy savings. Allen believes
for crushing operations. ball mills. By using the best available that the environmental impact of a concentrator
technology, he says, companies are going to is significantly decreased by using Vertimills. In
Vertimills save money/energy be able to save millions of metric tons of the future, he says, it is extremely likely that
Metso has mature, green technology to meet carbon. At a time when everyone is focused on more sites will adopt this technology for more of
demands to cut energy costs and public limiting their footprint, this is not an their grinding needs to increase their profitability
pressure to be environmentally conscious. The insignificant factor in choosing a mill. and decrease their environmental impact.
company syas that operating with higher The Vertimills improved grinding energy
energy efficiency, the Vertimills, total cost of efficiency is due largely to the effect of its High pressure grinding
ownership is almost always significantly less vertical arrangement, which maximises attrition HPGRs are increasingly becoming a part of hard
than a traditional horizontal ball mill solution, grinding and eliminates wasteful impact rock processing due to their energy efficiency,
lowering processing costs and improving breakage. More efficient grinding is also ability to induce micro-cracks and preferential
profitability while reducing carbon emissions. obtained by using finer media. The Vertimill can liberation, coupled with high throughput and
Since 1978, more than 300 Vertimills have been be charged with a smaller media top size, high reduction ratio.
sold globally, with 76 of those in the last three creating an overall smaller size distribution. A With more than 250 Polycom installations in
years alone, giving it the largest installed base small change in media size can have a big different industrial sectors, Polysius says it is
of any stirred milling technology." impact on the total grinding surface area, the worldwide market leader for this
Available in standard sizes from 15 to 2,240 explains Allen. In general, a Vertimill size technology. This comminution system offers
kW, the Vertimill has a relatively large practical distribution has greater than three times the numerous benefits that Polysius list as:
operating range, handling feed sizes from 6 mm surface areas of an equivalent ball mill grinding Low operating costs, in comparison to other
and grinding to sub 20 microns products. charge. For an initial conservative comparison, systems both power consumption and costs
Mechanically, it is a very simple machine with the Vertimill is evaluated as 30% more efficient for wear parts are significantly lower
advantages that include reduced energy and than a ball mill for coarser applications (P80 > High throughput rates: an HPGR can replace
media consumption, long wear life, reduced 200 m) and 35% for fine grinding applications several crushers
maintenance and high availability, lower (P80 < 200 m); but field surveys show that Metallurgical advantages in the downstream
installation cost in less floor space and greater greater energy improvements can be achieved, process stages
operational safety. according to Metso. Shorter delivery and commissioning times

FOR SALE NEW/UNUSED CRUSHING & MILLING EQUIPMENT

MAJOR PROJECT &
UPGRADE OPPORTUNITY
PRIMARY LONG LEAD EQUIPMENT ITEMS - SURPLUS TO PLANNED PRODUCTION
PACKED & CRATED
IMMEDIATE DELIVERY
EX PERTH WESTERN AUSTRALIA

MANUFACTURER DELIVERED AUGUST 2009

FULL DETAILS ON WEB AT: www.Minasco.com.au

Geoff Fields - Mob: 61-419-377 939 Robert Fields - Mob: 61-439-321 476
69 Evans Street, SUNBURY VIC 3429 AUSTRALIA
Ph: +61-3-9740 8933 Fx: +61-3-9740 9211 E-Mail: Geoff.Fields@minasco.com.au

OCTOBER 2009 International Mining 37

 COMMINUTION

Metso Vertimills at Cerro Verde

than can be achieved with other systems.

Polycom units are designed for throughput
rates in excess of 3,000 t/h. The mill feed
material can be dry or moist and with particle
sizes ranging from below 1 mm to more than
75 mm. If required, the material can be dried in
screens or air separators in a closed circuit
grinding system.
Kppern says its HPGRs are operation- and
maintenance-friendly. Easy separation of drive
and rolls together with the Kppern hinged
frame allow for quick roll removal and
replacement. The wear parts of the gravity
feeder can be replaced easily from the outside.
The roller surfaces are provided with a wear-
resistant Hexaduur liner produced by powder
metallurgical technology.
JKMRC has a project2 to determine whether a
series of HPGR units could be used to perform
most of the grinding duty in a process plant,
increasing the amount of breakage performed
in these machines. Such a circuit could
substantially reduce the energy and grinding
media used and therefore reduce the carbon
footprint of new processing plants.
To date, HPGRs have been installed as single
unit, either in open circuit or closed circuit with

Turbocharge Your Symons Crushers

Symons Cone crushers are still considered best in the

mining applications because of their ruggedness and
reliability. Innotech, with their world class crusher expertise,
can modernize and Turbocharge your Symons crushers
at a fraction of the cost of new crushers to increase the
Mill feed tonnage and or make it ner. Your investment
should be returned in less than one year, based on our
track record. We can also supply fully reconditioned and
modernized Symons crushers at attractive prices.

1-888-827-0011 X14
ssawant@theinnotechsolutions.com
www.TheInnotechSolutions.com
Symons is a registered trademark of Metso Minerals Corp.

38 International Mining OCTOBER 2009

 COMMINUTION

a screen. A single HPGR unit is typically limited to around 3 kWh/t,

compared with SAG mills which may have energy inputs exceeding 10
kWh/t, and therefore despite being less efficient can generate a finer
product.
The samples were crushed to minus-32 mm top-size and processed in a
three-pass HPGR circuit. Test work was carried out on two large pilot-scale
Kppern HPGRs at AMMTEC in Perth. In each case, up to three passes of
the HPGR were used. The energy consumption and product size was
measured for each stage in the flow sheets to determine the energy
efficiency of circuit. Comminuting
Initial data showed the three-HPGR circuit produces a broad product
size distribution, but also that the magnitude of size reduction reduces your maintenance
with subsequent passes. Two passes were found to be effective; however
the third pass continues to generate fines without substantially reducing expenditure
the top size. The result is a flatter or broader product size distribution.

Optimised circuits
Process audits are an excellent way to benchmark current performance,
review current operating and production targets, says Richard Jenner
Outotecs Account Manager for Service and After Sales Minerals
Processing Technologies Australia. They are also extremely useful in
identifying projects to meet or exceed budget targets and business goals.
A process audit will answer the tough questions that threaten your
sustainability:
How do I get that extra 3% yield?
How can I reduce water consumption?
How can I reduce my power usage without reducing productivity?
What gains can be achieved without capex?
Where can I spend my limited capex for maximum returns?
The scope of a process audit will depend on your needs, and can range
from basic to detailed, with either a narrow single process stage focus or
broader site wide perspective. Depending entirely on the scope, a process
audit may include:
Site-wide mass, energy and water balance
Overall and unit efficiency of existing plant (grinding, thickeners and
flotation)
Mechanical condition of existing plant (grinding, thickeners and
flotation)
Identification of bottlenecks and root cause analysis of performance
issues Kppern roller presses have been proven successful
Corrective actions and improvement opportunities identification all over the world in plants for the energy-saving high
Budgets, scoping, engineering, contracts, implementation, and gains! pressure comminution of cement clinker, limestone and
A skilled process audit team will approach your operation from a blast furnace slag as well as various ores and minerals.
number of perspectives to determine your needs, including: metallurgical, For the comminution of abrasive materials the patented
process, mechanical, operation, maintenance, and personnel training. Hexadur wear protection of rollers is available.
Particle size distribution and electricity consumption are the two main
concerns for any grinding circuit. A process audit in the grinding circuit
will: Kppern Quality made in Germany.
Determine optimum particle size distribution for maximum recovery State of the art technology
Outline a process for efficient mill control Process technology know how
Determine any potential for reduced power consumption. High plant availability
Automation is another area which can quickly yield results if the correct Quick roller replacement
process and technology are in place. But the basics of spares, service,
maintenance and training are also important Jenner explains:
Am I carrying enough critical spares to stay online?
Do I know the lead times for critical spares that I dont carry?
Is my preventative maintenance program suitable?
Do my operators have the skills to run my plant optimally?
Do we know how to effectively troubleshoot process upsets? www.koeppern.de
Answering no to any of these questions represents a risk to the

OCTOBER 2009 International Mining 39

 COMMINUTION

sustainability of your operation. Not only will a Low risk of vibration in

process audit answer these questions, but will the gear unit
outline the corrective actions necessary to foundation
achieve sustainability, Jenner concludes. Easy installation as
AMIRA notes that declining metal prices well as easy access for
brought a renewed focus by member service and
companies on improved production efficiency. maintenance
Its Project P1003, Energy Efficient Grinding and Easy replacement of
Liberation, will enhance practical application of rotating parts
the industrys expanding knowledge of the Integrated oil system
complex relationship between mill type, Direct lube oil return
grinding media and final grind size on cost- from the girth gear to
efficient recovery. the integrated lube oil
It has two interdependent components: tank prevents
1. Application of stirred milling to mainstream contamination of oil
grinding for rougher recovery Minimum oil flow in
2. Application of stirred milling to regrinding the girth gear guard
for cleaner circuits. Simple foundation for
(Terry.Braden@amira.com.au) gear unit, motor and
auxiliary drive
Successful lateral thinking A tooth safety factor
FLSmidths MAAG Gear AG entered the market of at least 2,3 (AGMA)
with its own integrated side drive in 2003. The Calculated bearing
design is based on state-of-the-art technology service life of 80,000
and enhanced the already tried and tested hrs.
design which is available on the market. It was One of the major
developed to save cost and space for mills with benefits of the MAAG
integrated side drive, such as ball, market and Gear LGD system is the
drive mills (FTG/SAG mills). torque split between the
The first LGD, put into operation five years two pinions. It ensures
ago is still running smoothly in line with the that the total torque to
customer request. Since then over 20 LGDs have the mill is always equally
been delivered and are in operation. In this year distributed from both pinions. Any deviations in Polysius Polycom HPGR breaking copper ore. The
13 more will be installed and commissioned. torque between the two pinions is automatically company claims 60% of the high-pressure grinding
The success of the LGD is based on its design. equalised by axial adjustment of the intermediate rolls installed in the minerals industry are from
It is positioned 40 under the mill which shaft triggered by the deviations in the axial Polysius
demands a compact type of construction and forces. A crowned toothing between the pinion
leads to lower building and foundation costs as and the pinion shaft enables the pinions to self The LGD unit is a three stage spur gear with
a lot of space is saved. The new position of the align. This ensures full tooth contact even at a load distribution. It drives the various mill types
side drive is combined with many additional smaller run out of the girth gear and directly via the pinions of the two output shafts
advantages: compensates pitch errors. and reduces the speed of the mill drive motor
to the pre-determined speed of the mill. The
Process audits are
important casing is cast and comprises three different parts
which are horizontally divided into the lower,
middle and upper parts.
In contrast to other lateral drive equipment
suppliers, no separate oil tank is needed. The
LGD has an integrated lube oil system in the
lower casing to lubricate all the teeth and
bearings. The pinions of the upper and lower
output shaft as well as the girth gear of the ball
mill are lubricated via the output shaft. With the
LGD gearbox positioned partly below the mill, it
is possible to return the lubrication oil directly
from the girth gear guard to the gearbox.

Worlds largest GMDs

Earlier this year ABB won an order from Minera
Chinalco Per to deliver and install three
complete gearless mill drive (GMD) systems for

40 International Mining OCTOBER 2009

 COMMINUTION

the Toromocho porphyry copper project. world's largest ball mills at 28'x44' (8.5 m by factor. Where small motors, e.g. for handheld
Toromocho is in central Peru, approximately 140 13.4 m). The grinding line is being designed to devices, have an electrical efficiency as low as
km east of Lima in the historic Morococha handle in excess of 120,000 t/d. The 10%, large motors in the MW range offer
mining district. ABB says its GMDs for equipment is scheduled to be shipped in the about 95%. Thus, it makes sense to install
Toromocho will be the largest such systems fourth quarter of 2010, co-ordinating with the fewer big machines instead of many smaller
worldwide, to be installed at the highest altitude owner's construction schedule to meet the ones. This reduces the fixed capital, but
where gearless mill drive systems ever have been targeted initial plant start-up. increases the operational risk with lower
installed. The region has a steep topography FLS says that in order to reduce mineral redundancy. The efficiency gain can be in the
with elevations over the deposit ranging from processing costs and increase throughput, ore range of 10% and more, depending on the
4,700 m to over 4,900 m above sea level. producers have moved towards increasingly specific conditions.
ABBs scope of supply consists of three larger mill sizes. FLSmidth grinding mills are The way torque is applied to the mill is also
complete GMD systems including transformers, designed using the latest technology available in important. It is best to apply it directly as with a
ring motors and containerised E-houses. One the industry. Strain gauging has been used to GMD. Here magnetic interaction turns the mill
system will be installed on a 12.2 m SAG mill verify the predicted stress levels to ensure directly without mechanical interaction. Each
with a power of 28 MW. The SAG mill will be success of the heavy duty rotating equipment. mechanical contact, each reduction stage,
equipped with the new ABB 18-pulse With over 3,000 grinding mills supplied, introduces losses and introduces maintenance
cycloconverter. The other two GMD systems will FLSmidth holds a leading position in large requirements. As GMDs are tailor made pieces
be installed on 8.5 m ball mills rated with a grinding mill technology. of equipment these machines are economically
power of 22 MW. The company provides expert analysis of data feasible above about 10 MW of power. Below
FLSmidth Minerals will supply the SAG mill using Bond Work Index as well as other ore this power a geared solution is more feasible,
and two ball mills. It says the SAG mill will be characteristics available to correctly size and apply where a minimum of reduction stages is ideal.
the largest in the world at 40x26' (12.2 m by grinding mills in the most efficient manner. It Consequently a high pole, slow speed solution,
7.9 m). Accompanying the SAG mill will be the offers a wide variety of comminution equipment, possibly with permanent magnet rotor, is the
including SAG, AG, rod, ball, pebble and vertical best solution under these circumstances. The
roller mills, as well as the hydraulic roll press. power gain for a direct drive compared to
Besides the optimal tuning of process geared solution is in the 5% range depending
parameters it is imperative that energy on the project configuration.
consumption be as low as possible. Even in The fixed speed solution is the most efficient
good times, unnecessary energy consumption for the drive. Unfortunately the parameters may
diminishes profit. The main parameters vary, i.e. with changes in ore quality or at partial
influencing energy consumption for mill drive load. If so, an adjustable speed solution will
applications are machine size, torque improve the overall efficiency; even if a frequency
transmission, variable speed, cooling and converter is needed. These converters consist of
electrical design, ABB explains. electrical switching elements, which introduce
For motors, economy of scale is an important little additional loss. Generally, cycloconverters are
slightly better than Voltage Source or Line
FLSmidth's LGD integrated side drive was developed Commutated Inverters. Anyhow, the whole drive
to save cost and space for mills system has to be evaluated because the output
of cycloconverters tends to have more harmonic
content. The estimated increase in overall
efficiency for a variable speed solution is 1 to 3%.
The cooling circuit; minor electrical design
features like optimisation of the current density
in the windings and application of Roebel bars
for GMDs influence the efficiency less than 1%
each, at a relatively high investment. Finally it is
important to note there is little margin to
optimise modern transformer losses; they
contribute less than 1%.
When considering energy optimisation,
reduced consumption is one important part, but
the mine should also be analysed for free
energy. For example a down-hill conveyer could
generate some megawatts.
Finally it is the decision of the owner to
balance investment with operational cost for the
specific site opportunities.
For the first time in 40 years of gearless mill
drive (GMD) history, ABB recently completed a
stator rewinding on site. This was undertaken

42 International Mining OCTOBER 2009

 COMMINUTION

Efficiency of a 13.5 MW Gearless Mill Drive:

Source ABB

GD. In normal operation the charge starts sliding

after the mill reaches an angle of between 40
and 70 and the load torque decreases.
This decrease in torque is monitored and
used by the frozen charge protection to stop
the mill before falling frozen charge damages it.
This prevents damage but does not
automatically eliminate the frozen charge.
Frequently, the material does not break up and
remains stuck to the mills shell. Only labour-
intensive mechanical efforts with jackhammers
or pressurised water jets can remove the firmly
attached charge. This is time consuming work,
which causes loss of production.
With the help of the frozen charge shaker
function integrated in the SimineCIS Mill GD
system, deposits can be loosened by causing the
mill to move systematically. To do this, the
operating personnel initiate the mill drives frozen
charge shaker mode from the local control desk.
Defined forward and reverse movements of the
mill lift the charge to a less critical angle and
move the mill in a harmless range with varying
speed and acceleration. The angle and
13,500 kW movement are designed to break the frozen
charge and remove it from the mill body. The
motor is the same as that used for grinding. The
frozen charge shaker avoids production from
on a SAG mill stator at Minera Escondida, the efficiently. This reduces maintenance times and being interrupted for frozen charge removal and
world's largest copper mine. In a joint effort, costs considerably. prevents mill damaged and simultaneously
engineers from ABB in close co-operation with Rio Paracatus Morro do Ouro mine is an reduces maintenance times considerably. Given
its suppliers and Minera Escondida started the open-pit operation owned by Kinross Gold. It is that production is worth thousands of dollars per
design process. Within six months, this team near the historical gold mining city of Paracatu, hour, maintenance cycles costing several million
produced a complex and detailed engineering around 220 km to the southeast of the capital, dollars can be avoided.
design. The new stator winding material was Brasilia. Rio Paracatu is the largest active single At the Equinox operations in Zambia, Siemens
manufactured at Alstom factories and the gold mine in the world in terms of ROM (run- equipped two ore mills on the Lumwana copper
equipment from Switzerland and Spain was of-mine) processing, Siemens reports, and uses mine with gearless SimineCIS Mill GD drive
finally shipped to Antofagasta, Chile, on a modern technology to increase its production. systems. The frozen charge shaker function will
Boeing 747 cargo aircraft specially chartered for As part of an expansion project, Siemens also be used there. And across the Atlantic, at
this occasion. supplied the GMD system with 20,000 kW of Los Bronces, part of Anglo Americans Chilean
For training purposes, a stator dummy was rated power. With a diameter of approximately operations, Siemens supplied a 22 MW GMD for
manufactured in Santiago de Chile. Expert site 12 m and a length of around 7 m, the new SAG a 12.2 m SAG mill and two 16.4 MW GMDs for
staff from 13 countries were trained to become mill was one of the largest mills in the world. two 7.9 m ball mills. Los Bronces will be one of
familiar with all possible special conditions. On When maintenance has to be carried out, the biggest copper and molybdenum mines in
July 1, some 300 people started work, on three grinding mills have to be shut down for several the world. The GMDs are designed to provide
shifts. Under this experienced team, the hours or even days. In this time, the remaining mill drives with the lowest possible power
rewinding job for the SAG mill was mill charge can easily solidify, firmly attaching consumption and are equipped with the frozen
accomplished according to schedule. itself to the shell of the mill the frozen charge shaker function. IM
charge. When the mill is restarted, there is a
Frozen charge shaker danger that the frozen charge will not detach References
In December 2008, Siemens started up the itself from the mill shell immediately, but will 1. Pokrajcic Z, Energy Efficient Comminution Circuits
worlds first ore mill with the frozen charge initially be lifted up by the mill and then dropped A modified grinding strategy and the selection of a
shaker function at the Rio Paracatu gold mine. from a great height. The resulting damage to the target product size, CSRP08 (Centre for Sustainable
With the help of this solution, which is mill can be severe. To detect firmly attached Resource Processing), 2nd annual conference, Brisbane,
integrated in the SimineCIS Mill GD GMD, charge in good time and switch off the mill, Australia, November 2008
charge that has become frozen to the mills Siemens developed a frozen charge protection 2. Hilden M. and Powell M, Multiple-pass High
inside shell can be removed quickly and function for GMDs of the type SimineCIS Mill Pressure Grinding Rolls Circuits, CSRP08

44 International Mining OCTOBER 2009