OTE OIA Prominent Hill Web Eng

8/12/2019 OTE OIA Prominent Hill Web Eng

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The Prominent Hill operation comprises

both an open pit mine and a newly

developed underground operation with a

10Mtpa milling capacity. Prominent Hill

produces some of the worlds highest

grade copper concentrates. The site

is a fly-in/fly-out operation employing

approximately 1,200 employees and

contractors.

Simultaneous reline of SAG and ball mills completed

with zero harm at Prominent Hill

Organisation

Oz Minerals

Site

Prominent Hill, South Australia

Year

2010

Application

Copper-Gold concentrate

Challenge

Prominent Hills first simultaneous reline Shutdown and relining concurrent with other

major works on site

Working within high foot traffic footprint

Site had only one reline machine

Solution

Highly specialised Outotec team perform mill

relining and maintenance works

Result

Reline completed on time and on budget

Incident free (zero harm)

Pneumatic torque unit being used to tighten bolts.


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Installing a new shell lifter on the SAG mill using the reline machine.

Project overview

Prominent Hills high grade ore production guidance

for 2013 is between 90,000-95,000 tonnes copper and

130,000-150,000 ounces gold. The newer Ankata

underground mine produces ore with similar

metallurgical characteristics as the original Malu open

cut mine, allowing the two run-of-mine ores to be

blended together.

Prominent Hill engaged the specialised mill relining

capabilities of the former TME Group, now part of Outotecs

Services division, to perform the mills first dual shutdown

since installed in August 2008. Both the SAG and Ball mill

were scheduled for simultaneous relining to take place

early in 2010, to replace the worn liners.

Mill reline scope

As the mill liners had originally been installed by

the Outotec team (then TME), they were aware of

the technical specifications. A subsequent site

audit facilitated assessment of the worn linings,additional works required and any constraints in the

working area. Originally the client anticipated the

replacement of only the shell lifters, feed end lifters

and plates and discharge grates on the 34 SAG mill.

However, following inspection, the scope of works

was extended to include replacement of all the shell

plates, along with the discharge end outer grates.

The 24 ball mill also required feed end outer and

inner plates, as well as shell and discharge plates,

to be replaced.

Process

A team of 56 specialised personnel took part in the

reline works which involved the replacement and

removal of over 1200 parts, with each mill taking less

than 73 hours to complete. Skilled personnel and

purpose designed equipment are critical in reducing

reline time and ensuring safety.

Many of the mill reline personnel have worked together

for almost a decade and are all qualified specialists in

their field with a reputation for expediency, innovation

and safety. The reline team have worked on thecomplete range of mill types and lining configurations

for gold, copper, lead, zinc, uranium, nickel, diamond

and cement mills.


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The project managers worked closely with the client

to manage the critical path. This continual focus on

reducing reline incurred downtime ensured completion

within the planned shutdown schedule. This was

accomplished by expertise in planning, monitoring and

evaluating the shutdown timetable as well as utilising

Short Interval Control, a bespoke programme used

to track the progress of reline tasks. The programme

provided up-to-the minute information including parts

moved, time lost, estimated time of completion and

took all delays into account.

Challenges

To make optimal use of the shutdown period, Prominent

Hill scheduled two major maintenance works by other

teams to be carried out in addition to the relining project.

During the works, the mill deck was therefore subject

to high foot traffic and equipment congestion. As such,

it was critical to ensure that strict safety standards

were adhered to and a strong working relationship

forged with mill staff and the other work forces on

site. This had proven results in that the job was

completed without incident or injury to the teams

or equipment.

As site had only one mill reline machine available,

completion time would essentially have been doubled

if works had to be performed consecutively. To combat

this, the Outotec team worked around the clock to

complete the SAG mill and used a boom crane to remove

all of the dismantled lining from the ball mill until the

reline machine became available. Utilising available

resources in this way saved additional downtime and

ensured the project was completed to deadline.

Additional minor works were identified and completed

as the job proceeded, including assisting with the

isolations, set up on the mill and installation of the

Davit crane. Also, the discharge end and trunnions gaps

were filled with ceramic.

Safety first

Health and safety on-site is a primary objective for

any project and during the mill reline the Outotec

team ensured strict standards were adhered to. At thebeginning of each shift a pre-start and toolbox meeting

was held, with site safety inspections conducted per

shift. Prior to shutdown, safety performance was

discussed in detail and the actual shutdown closely

monitored, resulting in a safe procedure without

incident.

One area that existed within the former TME Group

was a Safety and Training operation. Transfer of the

licenses are due for completion in 2013, allowing the

Registered Training Organisation (RTO) capability to

be incorporated into Outotecs remit. This fast-track,

industry-specific training ensures highly qualified

personnel are always available and readily expedited

to site.

Results

Through efficient planning and a strong working

partnership with Oz Minerals and site, Prominent Hills

first simultaneous shutdown of the SAG and Ball mill

was executed on site with zero harm to personnel,

equipment or the environment.

Outotec was also on-site for the mill restart, completing

the retorque of the bolts for both mills after the first day

of operation.

Feedback from site was very positive, with Graham Dearing,Process Superintendent saying,

I would like to express my

congratulations to the team and

project manager on the completion

of a dual reline to the SAG and

Ball mills here at Prominent Hill

without incident. It was made even

more difficult by having to share

the mill deck with two other large

jobs taking place simultaneously.

The whole crew had a very positive

attitude throughout the day and

night shifts. Please pass on to the

guys and Supervisors my whole

hearted thanks for a fantastic

job. I look forward seeing them inaction again at Prominent Hill.


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Outotec provides leading technologies and services for the sustainable use of Earths natural resources. As the

global leader in minerals and metals processing technology, Outotec has developed many breakthrough technologies

over the decades. The company also provides innovative solutions for industrial water treatment, the utilization of

alternative energy sources and the chemical industry. Outotec shares are listed on NASDAQ OMX Helsinki.

Contact us at

[email protected]

www.outotec.com

Despite the downtime incurred due to only one available

relining machine, works were completed on schedule.

The reline machine and liner removal tools on-site

performed well with no issues, however, the Outotec

team also identified site equipment improvements that

would benefit future, long-term performance.

Scheduled maintenance services

Proactive maintenance ensures optimum grinding mill

operation and Prominent Hill ensure this by scheduling

maintenance shutdowns to be performed regularly

at 14 week intervals. Outotec has been contracted

to inspect and perform these future maintenance

and repair works.

Australia.

November2013.

Documents

OTE OIA Prominent Hill Web Eng