Upload
angel-canales-alvarez
View
238
Download
0
Embed Size (px)
Citation preview
7/27/2019 HPGR HUASCO
1/16
SUCCES AND RELIABILITY of HPGR CRUSHING
at COMPAA MINERA HUASCO in CHILEDr.-Ing. E. Matthies, F.P. van der Meer KHD Humboldt Wedag, Germany
C.P. Westermeier, V.H. Gallardo Compaa Minera Huasco, Chile
7/27/2019 HPGR HUASCO
2/16
7/27/2019 HPGR HUASCO
3/16
Replace Tertiary and Quaternary Crusher with only OneUnit
Higher Overall Throughput for Crushing & Grinding
Reasons for Installation of HPGR at Los Colorados
Chart 3
p m se a er a repara on or owns ream rocess zeDistribution)
Higher Percentage of Fines between -3mm +45m
Low Energy Consumption: 0.76 kWh/t up to 1.46 kWh/t
(depending on ore type and applied press force)
7/27/2019 HPGR HUASCO
4/16
Pilot Scale HPGR Testing
Pilot Testing of allrelevant parametersrequired (open &closed circuit) On-Site
Confirmation PilotTesting at KHDCologne, Germany
Including:
Chart 4
ar a on o ore ype
Variation of feedmoisture content
Variation of operatingpressure
Variation of roll speed
Wear testing Flake &
Desagglomerationtesting
Bond ball mill WI tests
7/27/2019 HPGR HUASCO
5/16
Roller Press RP 16-170/180
Roll diameter: 1700 mm
Roll width: 1800 mmFeed material: Coarse Iron Ore
Feed moisture content: 0-1%
Ball Mill W before RP: 9-14 kWh/t
Humboldt Wedag HPGR at Los Colorados
Chart 5
Feed size 0-63 mm
Final grain size: < 6.35 mm (55..70 %)
Throughput: up to 2,000 t/h
Spec. energy cons.: < 1.2 kWh/t
Spec. press force: Average 3.5-4 .0 N/mm, max 5.0 N/mm
Installed power: 2 x 1,800 kW
Status of roll wear life: > 14,600 operating hours
7/27/2019 HPGR HUASCO
6/16
HPGR PERFORMANCE and PRESSURE.
Wi (kWh/t)
Bond Wi Comparison CMH Los Colorados Iron OreIn Dependence of Pressure Applied
COMPARISON OF BOND BALL MILL WI, ORE TYPE M1:MINERAL SECTOR B LOS COLORADOS
Chart 6
UNTREATED ORE(Quatern. Crusher Discharge)
10.70 kWh/t
HPGR DISCHARGE 8.08 kWh/tDIFFERENCE 2.62 kWh/t
% REDUCTIONw.r.t. CONE CRUSHER PRODUCT
24.5 %
Operating Pressure 40 barPeripheral Speed 1,11 m/s
7/27/2019 HPGR HUASCO
7/16
Process Flow Sheet at CMH Los Colorados
Chart 7
7/27/2019 HPGR HUASCO
8/16
Stud-Lined Roll Surface
after 6 Months of operation
Good flat wear profile
Competent autogenous
wear layer
Chart 8
Accelerated edge wear
Old Design: reweldable edgesegments
7/27/2019 HPGR HUASCO
9/16
Edge Wear Observation
Chart 9
Can significantly reduce wear life
Leads to increased bypass
Hinders effective gap control Leads to less efficient comminution
7/27/2019 HPGR HUASCO
10/16
Edge Wear KHD Solution Replaceable Lateral Studs
Maintained EdgeRim
Optimal ParallelAlignment of RollSurface
Minimal MaterialBypass
Reduced Downtime
Chart 10
ImprovedAvailability
Pre-longed RollSurface Wear Life
7/27/2019 HPGR HUASCO
11/16
Chart 11
Roll Wear Roll Surface Quality Development
7/27/2019 HPGR HUASCO
12/16
Chart 12
Proven KHD Stud-Lined Roll Surface Wear Life.
Comparison of Guaranteed and Achieved Values
7/27/2019 HPGR HUASCO
13/16
7/27/2019 HPGR HUASCO
14/16
The KHD HPGR at CMH Los Colorados provides a reliable operation atan excellent performance for a track record time of over 11 years.
Machine and process optimized to improve maintenance and availability > 94% Zero bearing problems
High classification efficiency of HPGR product (no deagglomeration required)
Roll surface wear life increased to > 14,600 hours today
Observations, Experience, Key Data, Conclusions
Chart 14
Lower energy consumption (-25%) from a reduced Bond WI and high fines volumein the product
Improved concentrate quality at constant yield in downstream magneticseparation
The demonstrated success led to installation of HPGR in CMPs El Romeral plant,for similar crushing duty as Los Colorados
7/27/2019 HPGR HUASCO
15/16
New KHD HPGR DESIGN
RP Swing Frame and Gearbox Support
Minimized change-out time
Chart 15
No deformation tojoints
Minimal cranerequirements
increase availability
to 95-97 %
7/27/2019 HPGR HUASCO
16/16
10 years successful operation! To Be Continued!
Thank you foryour attention !
Any Questions ?
Chart 16