VERTIMILL Maintenance and Layout_Escondida Meeting-Aug 18.pptx

8/10/2019 VERTIMILL Maintenance and Layout_Escondida Meeting-Aug 18.pptx

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VERTIMILL ® Grinding Mills

This submittal is to be used bythe Recipient only for the

purpose for which it is provided. All documents, drawings,pricing, descriptions, literature,data, etc. contained herein(whether hard copy or

electronic) are ConfidentialInformation and are to be treatedas such by Recipient, to include,but not be limited to, protectingthe Confidential Information fromunauthorized disclosure or use.

VERTIMILL ® Grinding MillPresentation Outline

• Vertimill Overview• Maintenance Activities

• Layout Considerations

• New VTM-3000-WB at Newcrest Cadia

27-10-20143

The VERTIMILL ® Overview

10/27/20144

• > 330 Units Worldwide• > 175,000 kW Total power

• Unit Sizes from 15 to 3000 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

The VERTIMILL ®

Applications

• Grinding- Secondary - 6 mm to 75 µm- Tertiary - 400 µm to 75 µm- Regrind - 200 µm to 15 µm- Flue Gas Desulphurization - 6 mm

to 20 µm

• Lime Slaking- Flue Gas Desulphurization- Acid Neutralization- Additive

10/27/20145

Regrind Flue Gas Desulfurization

Lime Slaking Secondary and Tertiary

VERTIMILL ® Maintenance Activities

10/27/20146

• Grease Motor Bearings

• Change Motor Brushed

• Grease VTM Bearings

• Change Lube oil & filters• Change Screw Liners

VERTIMILL ® MaintenanceDesign Considerations

• Access for greasing all bearings• Access to mill motor brushes

• Access to lube skid

• Crane and Fork Lift capacity and access for screw liner changes

• Crane for recharging Vertimill with balls• Access for screw transport pockets

• Vertimill pier height for use of ball bins

10/27/20148

VERTIMILL ® MaintenanceDaily Activities

• Daily equipment walk-down by operators

• No daily maintenance required

• All maintenance and troubleshooting detailed in manual

10/27/20149

VERTIMILL ® MaintenanceSchedule

Mill SystemComponent

TaskDescription

TaskDuration

Interval Mill Condition forProcedure

System Overall Check 10 min Daily Operating

Mill Motor GreaseBearings 5 min 3000 hrs Operating or Stopped

Reducer Change Oil 4 hrs Yearly Mill Stopped

Mill Bearings Inspect GreaseSystem 5 min Weekly Operating or Stopped

Mill Internals Inspect 12-16 hrs TBD Mill Stopped

10/27/201410

VERTIMILL ® MaintenanceTypical Steps to Change Liners

1. Grind-out2. Ball discharge

- To floor

- Use of ball bins

3. Door opening

4. Liner/screw replacement- Inside mill

- Complete screw change out

5. Door closing

6. Ball loading- Use of ball bins

- Continuous system

10/27/201411

VERTIMILL ® MaintenanceOpen the Ball Discharge Port

• Loose all nucking nuts “A” • Back off jacking bolt “B” by one turn

• Tighten bolts “C” to push the shaft awayfrom the mill body and release the seal onthe ball discharge port

• Operate the valve by pulling the handleaway the mill body

• If necessary in step 2, turn bolt “B” morethan one turn

• To close, reverse the above by looseningbolt “C” and tighten bolts “B” to seal the

valve, then tighten nuts “A” to lock the bolts • Warning, do not open the valve with bolts

“B” beyond one and a half turns since largematerial can enter the sealing surface andmake it difficult to seal

VERTIMILL ® MaintenanceBall Discharge Using Bins – Option 1

• Ball Bins provide a clean andeasy way to handle media

• Manual discharge port

• Allows for easy loading andunloading of grinding media

10/27/201414

VERTIMILL ® MaintenanceBall Discharge To Floor – Option 2

VERTIMILL ® MaintenanceDoor Opening

• Remove the bolts in the access door flange,pump up the hydraulic door flange jackswith the pump provided with the screwtransport system. The jacks and plumbingshould have been previously filled with oiland the lines bled to remove any air.

• As the hydraulic jacks are being extended,the manual jacks installed at the hingepoints should be extended to keep the doorvertical and in the outer most position in thehinge slots as the door is opened.

• After the door is opened, wash theremaining balls out with high

• pressure hoses, or remove with shovels andrakes.

ManualJack

HydraulicJack

Most common options:• Winches

• Cranes

• Loader/Excavator

VERTIMILL ® MaintenanceScrew Liner Wear

10/27/201419

VERTIMILL ® MaintenanceDoor/Ball Charge Height

10/27/201420

VERTIMILL ® MaintenanceLiner Change Option 1

• Change liners inside the mill, most common solution

10/27/201421

VERTIMILL ® MaintenanceLiner Change Option 2

• Change Entire Screw

10/27/201422

VERTIMILL ® InstallationsLayout Examples

• Cerro Verde• Hibbing Taconite

• Los Pelambres

• Candelaria

• Codelco Andina• Esperanza

Not Recommended Layouts (Safety Issues):

• Escondida• Las Tortolas (Los Bronces)

10/27/201424

Cerro VerdeThree (3) VTM-1500-WBs

• No structure in front of millto allow easy crane accessfor screw insert and removal

• Modest pier height for easymaintenance

• Bins used for mediaaddition as well

10/27/201425

Cerro VerdeMedia addition – Same bin used for media handling

10/27/201426

Hibbing TaconiteTwo (2) VTM-1250-WB

10/27/201427

Los PelambresOne (1) VTM-1500-WB

10/27/201428

CandelariaOne (1) VTM-1250-WB

10/27/201429

Codelco AndinaTwo (2) VTM-1250-WB

10/27/201430

Minera EsperanzaTwo (2) VTM-1500-WB

10/27/201431

EscondidaFour (4) VTM-1500-WB (Not Recommended)

10/27/201432

Los BroncesThree (3) VTM-1500-WB (Not Recommended)

10/27/201433

Newcrest CadiaVTM-3000-WB

The 1 st VTM-3000-WB InstallationNewcrest Mining Ltd. Cadia Valley Operations

21 September 201035

Newcrest CadiaHigh Grade Concentrator Simplified Flow Sheet

21 September 201036

Secondary VTM-1250-WB

Tertiary VTM-3000-WB

Regrind VTM-1250-WB

Newcrest CadiaThe 1 st VTM-3000-WB

• Grinding Design• F80 – 150 µm

• P80 – 90µm

• 780 mtph

• Exceeded efficiency predictions

• Flotation Recovery High thananticipated

- Sharper particle size distribution

- Finer feed to flotation

• Tertiary circuit stabilizes feed torougher flotation circuit

21 September 201037

Newcrest CadiaOperation of Separating Tank

27-10-201438

VTM-3000-WB PerformanceSummary to Date

• No Installation complications

• No Mechanical complications

• No Process complications

• With in 3 days of the start of commissioning, the mill became anactive part of plant operations

• Improving Recovery

• Increasing capacity

• Project and Installation executed with efficiency, quality, andfunctionality of a typical smaller VTM project

• Original set of liners replaced on May 2011 after 9 months ofoperation (no complications in the replacement, it took 30 hours).

21 September 201039

VTM-3000-WB MaintenanceFirst Internal Inspection After 3 Months of Operation

21 September 201040

October, 2010

VTM-3000-WB MaintenanceFirst Liner Replacement on May 2011

21 September 201041

9 months of life

VTM-3000-WB MaintenanceFirst Liner Replacement on May 2011

10/27/201442

VTM-3000-WB MaintenanceTypical Steps to Change Liners

1. Grind-out – 8 hours2. Ball discharge

- To floor – 11 hours

- Use of ball bins

3. Door opening

4. Liner/screw replacement- Inside mill – 4 hours (2 diggers)

- Complete screw change out

5. Door closing

6. Ball loading- Use of ball bins – 5 hours (10 ton)

- Continuous system

Cadia Total Time: 28 hours

10/27/201443

VERTIMILL Maintenance and Layout_Escondida Meeting-Aug 18.pptx

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