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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: [email protected]
mailto:[email protected]:[email protected]