Download HPGR in the Iron Ore Industry

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HPGR in the Iron Ore Industry
Mineral Engineering Technical Services Pty Ltd
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Presented by Karri Dorrington,
Process Engineer
> Mineral Processing
W: www.metsengineering.com
E: [email protected]
> Engineering Design > Training > Specialist Services
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• ACKNOWLEDGEMENTS
This document is a dynamic record of the knowledge and experience of personnel at Mineral
Engineering Technical Services. As such it has been built upon over the years and is a collaborative
effort by all those involved. We are thankful for the material supplied by and referenced from various
equipment manufacturers, vendors, industry research and project partners.
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Key Attributes
Pragmatic, efficient, complete engineering through
quality, personalised & exceptional service delivery
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Working globally since 1988
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Dynamic and innovative niche consultancy
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Dedicated team providing customised service
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Specialist in mineral processing & engineering projects
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Unique solution finder
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A division of Midas Engineering Group
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Outline
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What is HPGR?
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Benefits of HPGRs
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Iron ore types around the globe
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HPGR use in the iron ore industry
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HPGR in iron ore plant design
•
Testwork
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What is HPGR
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High Pressure Grinding Rolls (HPGR)
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Similar to the typical fixed roll crusher
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Force applied to push one roll towards the fixed roll
and raise pressure between the rolls
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Force on the material mainly compressive
Source: Mine Engineer Website (2012)
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Introduces micro cracking – favourable for further comminution
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Higher reduction ratios than fixed rolls
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HPGR
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Reduced power consumption hard ores – 10 to 15%
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Requires secondary crushed feed
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Reduced BWI
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Replaces SAG mill-smaller ball mill
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CAPEX similar
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10% moisture in feed
Source: Technomine Website (2012)
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HPGR
Source: World of Mining Professionals Website (2012)
Source: Weir Minerals Website (2012)
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HPGR vs Cone Crusher
•
HPGR and Cone Crusher Product
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Benefits to Magnetic Separation
80
70
HPGR Coarse Cob
Magnetic Recoverey, %
Cone Coarse Cob
60
50
40
100
30
HPGR Coarse Cob
90
20
Cone Coarse Cob
80
10
0
MgO
Al2O3
SiO2
Fe
Wt.
Assay, %
70
60
50
40
30
20
10
0
MgO
Al2O3
SiO2
Fe
Wt.
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HPGR vs Cone Crusher
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More even size distribution
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Finer size distribution
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Lower magnetic recovery of gangue minerals such as MgO, Al2O3 and
SiO2
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Lower mass recovery
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Typically a higher iron grade (and other metallics)
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Iron Ore Types Around the World
Russia:
Hematite
Canada:
Hematite, Magnetite
USA:
Hematite, Magnetite
China:
LG Hematite
East Africa:
Itabirite, Hematite
India:
LG Itabirite
Brazil:
Itabirite, Hematite
South Africa:
Hematite, Magnetite
Australia:
Hematite, Magnetite
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HPGR in Iron Ore Processing
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Applied to iron ore industry mainly for regrinding of pellet feed to
improve properties in the pelletising process
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Over time has been applied to other iron ore processes to improve
concentrates
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Australia
−
−
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South Africa
−
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Magnetite (Karara)
Vanadiferous, Titaniferous Magnetite (Future: Mount Peake)
Hematite (Khumani)
Brazil
−
Itabirite (Samarco)
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Karara Project
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JV project
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Long life magnetite concentrate operation (30+ years)
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Low-grade magnetite to produce a high-grade premium concentrate
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Have issues getting the power efficiency to the SAGs and therefore
optimum operating
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2011 installation of HPGR
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Installed downstream of the secondary crusher
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HPGR significantly lifted feed rates
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Karara Project
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Karara Project
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Mount Peake Project – FS Underway
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Polymetallic ore body
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Two stage HPGR installed after the secondary crusher
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Lower operating cost
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Efficient in producing the required feed size (two stages required)
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Micro-cracking
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Reduced mass recovery on coarse cobbing
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Changes to the process – HPGR still beneficial
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Mount Peake Project (Scoping Study)
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Khumani Mine
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High grade hematite deposit in South Africa
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Formally BKM Project (Bruce, King and Mokaning)
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10 Mt export quality iron ore per annum increasing to 16 Mt
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Civil construction began in 2006
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December 2007 first delivery to Bruce primary crusher
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Late 2007 construction of jigs and HPGR
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HPGR utilised to reduce middlings particle size
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Khumani Mine
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Khumani Mine
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Single HPGR located after Jigging of the Lump
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Size reduction from -32.0 +6.0 mm to -6.0 mm
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More efficient than cone crusher
Source: International Mining (2008)
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Samarco Project
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JV between BHP Billiton and Vale
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Low grade itabiritic ore
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Ore Reserve = 451 Mt (wet) as of 2008
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Conveyor belts transport the ore to the beneficiation plant, whilst a
396 km slurry pipeline transports the pellet feed to the pellet plant on
the coast
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HPGR prior to grinding, de-sliming and flotation
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Samarco Project
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Samarco Project
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Samarco Project
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HPGR Plant Design
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Normally HPGR is located after the primary/secondary crushing
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Can replace tertiary crushing with SAG mill, where a ball mill is still
required
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Can replace secondary/tertiary/quaternary crushing
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Not suitable for all ore types
−
−
−
High fines/clays lead to impaired comminution
High ore competency and abrasiveness will lead to increased wear rates
High moisture (>10%) will cause washout of the autogenous layer
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HPGR vs. SAG Mill Design
1. Original circuit design SAG/AG mills
and ball mills (Huckleberry SABC
circuit), however very energy
intensive and also energy inefficient
accounting for ~80% of the overall
process plant energy (depending on
the overall process)
2. Changes to design lead to HPGR
and ball mill circuits, thus lowering
the energy consumption costs
slightly
3. Further examination, HPGR and
stirred mills circuits demonstrated it
is technically feasible and showed
promising benefits over traditional
options
1
2
3
Source: E&MJ News (2013)
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Why Choose HPGR? What are the
Drivers?
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Benefits to downstream processing – magnetic separation, flotation,
leaching
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Better energy efficiency – lowering costs
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Replacement of equipment to increase grinding efficiency
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Willing to investigate with testwork to see if ore is amenable
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Testwork
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Prior to selection of HPGR testwork is required
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Testwork involves:
−
−
−
Pressure tests
Roll speed tests
Roll gap tests
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Testwork reveals if the ore is amenable to HPGR
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HPGR settings influence throughput, product size distribution and
micro-cracking
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References
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•
•
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Karara Mining Ltd (2013) Energy Efficiency Opportunities KML Expansion Project
TNG Limited (2012) Executive Summary Mount Peake Project Pre-Feasibility Study
Moore, P (2011) Samarco – An Iron Ore Pioneer, International Mining, Dec 2011
Burchardt, E (2013) HPGRs in Hard Rock Mining, Mining Magazine
Wang, C., Nadolski, S., Mejia, O., Drozdiak, J., Klein, B (2013) Energy and Cost Comparisons of HPGR-Based
Circuits, E&MJ News
Morley, C (2010) HPGR-FAQ, Journal of the Southern African Institute of Mining and Metallurgy
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THANK YOU
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