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Mill Performance Improvement Through Practical Innovation

Dr. Sanjeeva LatchireddiChief Process Engineer

Turbo Pulp Lifter TPLTM

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Outline

Turbo Pulp Lifter TPLTM What is TPLTM?

Material Transport in AG/SAG Mills Material Transport Problems Effect of Material Transport Problems Process Benefits

Cortez Experience Cortez Grinding Circuit Cortez SAG Mill

Pre-TPLTM

and Post-TPLTM

resultsTPLTM Operational Trends Contact Information

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Turbo Pulp Lifter TPLTM

What is Turbo Pulp Lifter (TPLTM) ?

TPLTM is a complete grate discharge system forAG/SAG mills.

TPLTM is a proven technology which ensures themaximum performance of AG/SAG mills byeliminating the material transport problems.

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BREAKAGE

DISCHARGE

END (DE)

Material Transport in AG/SAG Mills

TPLTM replaces the DE

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Material Transport Problems

Grinding

Chamber Pul

p

Lift

er

Water

Ore

Discharge

Short-circuitingPebbles/slurry

Slurry Pooling

Slurry Flow-back

Slurry Carry-over

Gra

te

Pebbles Flow-back

Pebbles Carry-over

Pebble Pooling

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Effects of Material Transport Problems

Increased rock:ball ratio

Increased charge loading

Inefficient grinding !!!

Reduced flow gradient

Slurry Pooling

andPebble pooling

Limited Capacity

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Eliminates all the material transport problems.

Significantly increases flow-gradient. Allows particles to stay just enough time to be broken to

grate size, leading to lower loads.

Ensures good grinding conditions with lower grinding

energy per ton.

Efficient operation at all operating range of mill speeds.

Process Benefits with TPLTM

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Ensures the mill gives true response for anychanges in ore characteristics or process

parameters.

Operator friendly smooth mill operation.

Significantly improves wear life.

Process Benefits with TPLTM

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Cortez Experience

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Cortez Grinding Circuit

Cortez Grinding Circuit

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Cortez SAG Mill

Cortez Gold Mines, Nevada, USA

SAG Mill 26-ft x 12.5-ft with Radial pulp lifters

Only the DE was changed

Grate size kept same at 2.75 inches.

Grate openings changed to LONG SLOT from SQUARE

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Pre and Post-TPL operation (Same Ore)

Mill Feed Rate, MTPH : 343 420

Mill Load (Ball-9.08%) :23.5 12.7

SAG Mill Power draw, kW : 2915 1884

SAG Specific Energy, kWh/t : 8.48 4.48

BM Specific Energy, kWh/t : 10.5 7.96

Plant Operating Wi, kWh/t : 17.5 13.2

Cost of Power, US$/Month : 189K 121K

Pre-TPL Post-TPL

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Post-TPL OperationTrends at CGM

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SAG Mill Power draw

SAG Power

0

500

1000

1500

2000

2500

3000

3500

J 04F0

4M04A0

4M04J 0

4J 0

4A0

4S0

4O04N04D04J 0

5F0

5M05A0

5M05J 0

5J 0

5A0

5S0

5O05N05D05J 0

6F0

6M06A0

6M06J 0

6

Pre_TP

L

Post_TP

LW1W

2W

3W

4W

5W

6W7W

8W

9W

10W

11W

12

Months / Weeks of operation

SAGP

ower,kWh

2580

2080J an 2004 - J une 2006

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SAG Feed TPH

TPH

0

100

200

300

400

500

600

700

J 04F0

4M04A0

4M04J 0

4J 0

4A0

4S0

4O04N04D04J 0

5F0

5M05A0

5M05J 0

5J 0

5A0

5S0

5O05N05D05J 0

6F0

6M06A0

6M06J 0

6

Pre_TP

L

Post_TP

LW1W

2W

3W

4W

5W

6W7W

8W

9W

10W

11W

12

Months / Weeks of operation

MillThroughput,tph

409

503

J an 2004 - J une 2006

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SAG Specific Energy

SAG S.E.

0

2

4

6

8

10

12

J 04F0

4M04A0

4M04J 0

4J 0

4A0

4S0

4O04N04D04J 0

5F0

5M05A0

5M05J 0

5J 0

5A0

5S0

5O05N05D05J 0

6F0

6M06A0

6M06J 0

6

Pre_TP

L

Post_TP

LW1W

2W

3W

4W

5W

6W7W

8W

9W

10W

11W

12

Month / Week of operation

SAG

SE,kWh/t

6.3

4.2

J an 2004 - June 2006

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BM Specific Energy

BM S.E.

0

2

4

6

8

10

12

J 04F0

4M04A0

4M04J 0

4J 0

4A0

4S0

4O04N04D04J 0

5F0

5M05A0

5M05J 0

5J 0

5A0

5S0

5O05N05D05J 0

6F0

6M06A0

6M06J 0

6

Pre_TP

L

Post_TP

LW1W

2W

3W

4W

5W

6W7W

8W

9W

10W

11W

12

Month / Week of operation

BMSE,kWh/t

8.4

7.0

J an 2004 - J une 2006

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Product size, P80 (% -200#)

% -200#

0

10

20

30

40

50

60

70

80

90

J 04F0

4M04A0

4M04J 0

4J 0

4A0

4S0

4O04N04D04J 0

5F0

5M05A0

5M05J 0

5J 0

5A0

5S0

5O05N05D05J 0

6F0

6M06A0

6M06J 0

6

Pre_TP

L

Post_TP

LW1W

2W

3W

4W

5W

6W7W

8W

9W

10W

11W

12

Months / Weeks of operation

%200#Passing 70.6 71.7

J an 2004 - J une 2006

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Plant Operating Wi

Plant Operating Wi

0

2

4

68

10

12

14

16

18

20

J 04F0

4M04A0

4M04J 0

4J 0

4A0

4S0

4O04N

04D04J 0

5F0

5M05A0

5M05J 0

5J 0

5A0

5S0

5O05N

05D05J 0

6F0

6M06A0

6M06J 0

6

Pre_TP

L

Post_TP

LW

1W

2W

3W

4W

5W

6W7W

8W

9W

10W

11W

12

Months / Weeks of operation

PlantO

peratingW

i,

kWh/t

15.1

11.4J an 2004 - J une 2006

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Average Post-TPL Performance

Mill Feed Rate, MTPH : + 20%

SAG Mill Power draw, kW : - 15-20%

SAG Specific Energy, kWh/t : - 30-40%

BM Specific Energy, kWh/t : -15-20%

Plant Operating Wi, kWh/t : - 20-25%

Savings on SAG Power, US$/month : + 60K

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Daily Operator Views

We could never run STEADY and with CONFIDENCElike this before with the old design for fear of the SAGmill getting quickly out of control.

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Conclusion

TPLTM significantly increases the energy efficiency ofAG/SAG mill.

TPLTM allows the mill to operate at its maximumpossible capacity.TPLTM allows steady and smooth operation.

All AG/SAG mill applications will significantly benefitwith TPLTM. Can be precisely designed to handle the given

capacity.

Can be easily retro-fitted to existing mills.

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Contact Information

Dr. Sanjeeva LatchireddiChief Process Engineer

Outokumpu Technology Inc.

10771 E Easter Ave. Suite 120, Centennial CO 80112

USA

Phone +1 303 792 3110 x224 | Mobile +1 303 408 1691

Email: sanjeeva.latchireddi@outokumpu.com

mailto:sanjeeva.latchireddi@outokumpu.commailto:sanjeeva.latchireddi@outokumpu.com