hpgr huasco

7/27/2019 HPGR HUASCO

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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


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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)


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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


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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


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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


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Process Flow Sheet at CMH Los Colorados

Chart 7


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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


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Edge Wear Observation

Chart 9

Can significantly reduce wear life

Leads to increased bypass

Hinders effective gap control Leads to less efficient comminution


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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


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Chart 11

Roll Wear Roll Surface Quality Development


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Chart 12

Proven KHD Stud-Lined Roll Surface Wear Life.

Comparison of Guaranteed and Achieved Values


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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


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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 %


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10 years successful operation! To Be Continued!

Thank you foryour attention !

Any Questions ?

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