Presentation on SABC Draft Editorial Policies 10 October 2003.
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HPGRs in Hard Rock Applications
A Technology Broke Barriers
Egbert Burchardt & Rilmar Ojeda
First Approach of HPGRs to the Copper Industry
metallurgically
considered as a big
success!
widely percepted as a
failure due to
unresolved wear issues!
Cyprus Sierrita
1994 – 1996
POLYCOM 22/13
Growth of HPGRs in Minerals Applications
Diamonds
Iron ore
Hard rock
Latest Trends in Copper / Mineral Ore Processing
traditional SABC circuit
New ore bodies have often been harder and lower grade
=> ultimate need to
to build high capacity concentrators
■ to minimise operating cost
in order to make these projects feasible at all
=> application of the most energy efficient technologies required
in order to mininise energy and consequently wear cost!
Energy requirements of SAG
Mills are about 4 to 16 kWh/t
Freeport – Cerro Verde, Peru
First Copper Concentrator built on HPGR technology
Freeport -
Cerro Verde
Design capacity: 108,000 mtpd
in operation since 2006
(> 120.000 tpd achieveable)
Freeport –
PTFI Grasberg
Freeport – PTFI
Grasberg, Indonesia
First quaternary HPGRs
in a brownfield copper application
Quaternary crushing mode
brownfield installation
Objectives:
1. capacity increase @ same grind
2. higher recovery @ finer grind
2 x POLYCOM 20 / 15
2 x 1,800 kW (each)
Sierrita – quaternary – open circuit
Bagdad – tertiary – closed circuit
Freeport – Sierrita Mine and Bagdad Mine, USA
LOI for largest HPGRs ever built - brownfield copper applications
Testwork for Sierrita Mine
suggested potential to:
reduce BM energy
by up to 22 %
■ increase throughput
by up to 25 %
2 x POLYCOM 26/18
1 x POLYCOM 26/18
2 x 3,300 kW (each)
3,000 – 3,600 tph
(design)
LOI was cancelled in
2008 due to
economical crisis
Freeport –
Sierrita Mine
Bagdad Mine
Anglo Platinum – Mogalakwena North, RSA
First Platinum Concentrator built on HPGR technolgy
Anglo Platinum –
Mogalakwena North
Newmont – Boddington Gold Mine, Australia
First Gold Concentrator built on HPGR Technolgy
96.000 tpd plant
4 x POLYCOM 24/17
2 x 2,800 kW (each)
> 2.100 tph
(design each)
up to 3,000 tph
start-up in 2009
AngloGold Ashanti – Tarkwa Mine, Ghana
First commercial HPGR for heap leaching of gold ore
AngloGold Ashanti –
Tarkwa Mine
In operation since 2009
Freeport –
Cerro Verde
Anglo Platinum –
Mogalakwena North
Freeport –
Grasberg
Newmont –
Boddington Gold Mine
Goldcorp Inc. – Penasquito, Mexico
First HPGR for pebble crushing in a hard rock application
Goldcorp Inc –
Penasquito
Start up in 2010
Operating Plants & Upcoming Installations
Vale –
Salobo Project
Anglo Ferrous –
Minas Rio ProjectBKM – Assmang (2008)
Northam Platinum (2008)
Gindalbie –
Mt. Karara
Moly Mines –
Spinnefex Ridge
Future Trends in Mineral Ore Processing:
Reduction of CO2 emissions to avoid global warming
introduction of CO2 certificates would translate into available power;
available power and required energy translates into maximum capacity
CO2 certificates may limit the capacities of future concentrators
Drastic need to reduce energy consumption even more!
Studies to minimise energy input with HPGRs
More revolutionary concepts may be required!
Future Trends in Mineral Ore Processing
Shortage of water and minimised energy requirements
Could favour
heap leach applications
less energy required
● no wet grinding or wet flotation process required
HPGRs have the potential to elevate the lower recoveries!
■ dry grinding applications
Future Trends in Mineral Ore Processing
Dry HPGR grinding of
hard limestones
BWI up to 16 kWh/mt
320 – 370 tph capacity
Fineness: 80 – 85 % < 90 µm
10.5 to 11.5 kWh/t energy input(HPGR, fan, separator and bucket elavator)
50 % grinding energy required
as compared to ball mill
Future Trends in Mineral Ore Processing
Dry grinding:
saves energy & water,
reduces CO2 emissions!
HPGRs in Hard Rock Comminution
A Technology Broke Barriers
Questions?