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Two services lead to an effective recycling systemMinera Los Pelambres improves their process water management

A consultative process helped to meet recommendations made by the local Water Resources Authority and to set up a future proof model of process water management in the mining industry. This not only shows a high level of corporate responsibility but also a good measure of public transparency.

Customer challenge Serious drought conditions have forced Minera Los Pelambres to take steps to optimize fresh water consumption from its reservoirs. These actions are in response to the recommendations and rules set in place by the local Water Resources Authority. They undertook a three month fl ow meter audit as well as a 1-year nuclear density meter calibration audit, in order to ensure quality process management.

During kick-off meetings, it was agreed that any installed fl ow instru-ment would not pass the audit test if the comparison test against the master meter exceeded 5%.

The Los Pelambres copper deposit, located 200 km north of Santiago and 45 km east of Salamanca in the Choapa Province, was discov-ered by one of Chilean copper’s founding fathers, William Braden, in the 1920s. Today’s project, the world’s fi � h-largest copper mine, was started by Antofagasta Holdings in the 1990s.

“Endress+Hauser provided services which allowed Minera Los Pelambres to produce water management reports which are based on the highest monitoring and metering standards.”

Carmen Gloria Salinas,Water Engineer,Minera Los Pelambres,Chile

The solution Endress+Hauser audited diff erent areas of the plant, because one of the key areas for improvement was diagnosed to be the tailings process. This is a complex process involving many tanks, pipes and large reservoirs. 60-65% of the water used in the tailings reprocessing plant is recycled or caught up in the process. Measurements were performed where there were existing fl ow meters and at predetermined critical fl ow points in the plant’s water distribution and recycling system.

Also the W@M Portal (asset infor-mation management system) was set up by Endress+Hauser to centralize up-to-date information about the installed base and documentation such as calibration certifi cates (including operational manuals, spare parts and the radiometric licensing permits from local government authorities).

Optimizing fresh water consumption is one of the main challenges for Minera Los Pelambres.

Carmen Gloria Salinas, Water Engineer, Minera Los Pelambres

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service and user manuals. Other on-site findings also concluded that at some measurement points the opera-tional principle of the meter was not suitable and an alternative flow calculation principle should be adopted.

Life Cycle Management The W@M Portal is allowing effective management of the installed instruments throughout the asset’s life cycle. Minera Los Pelambres has easy access to up-to-date field instrument data and documentation at any computer, lap top or tablet which is connected to the internet.

After the first few months using Endress+Hauser’s web-based tool, the need to install a density measurement to determine water recycling effectiveness became quite clear.

The results • Controlled fresh water consumption via precise monito-

ring of each flow meter•Accurate records with regards to calibration, servicing

and radiometric source licensing• Customized reports for meeting the Water Resources

Authority’s recommendations

In order to ensure operational continuity and efficient water balance, a multi-disciplinary group was established.

Solution components

Prosonic Flow 93T• Ultrasonic clamp-on system (outside the pipe)• Accurate and cost-effective flow measurement• Without need to interrupt the process• Bidirectional and causes no pressure loss

W@M Portal• Access to information about installed devices• Automatic device documentation• Traceability of maintenance events• Easy integration into existing CMMS systems • Hosted by Endress+Hauser - no local installation

required

Audit details The mass balance water audit consisted of comparing the flow values from the installed flow devices in the plant against the readings from Endress+Hauser meters which have been verified to measure at specified tolerances. A final list was created and 52 measuring instruments were targeted for accuracy verification.However to effectively complete the water flow and stock audit it was decided that a total of 65 flow measurement points would be tested. The reference meter selected for the tests was the portable Endress+Hauser Prosonic Flow 93T. This flow device easily clamps on to any pipe line size up to four meters and is able to accurately measure liquid flow rates through the pipe walls by sending an array of ultra-sonic signals into the water stream and determining the volume flow by calculating the signals’ time of flight through the medium.

Additional service Among the flow meters evaluated during the audit were a number of magnetic insertion and other flow meters not supplied by Endress+Hauser. In these cases, the calculation of water flow accuracy was expanded to include a configuration and installation verification of the meter using the manufacturer’s own