Mining on Top - Stockholm

Stirred Grinding Mill Development and Application Expansion

Graham Davey

Process Manager

Contents

Current offering

Efficiency and application range development

Machine development and where we are going

Key project updates

© Metso

Metso Stirred Milling Goals

• What we know and what we

don’t know

• We rely on operations and

projects to give us feedback

• Learn more together

• Ask the right questions

• Circuit Design, Optimization

and Modelling

• Maintenance Best Practices

and Strategies

• Update on the technology and

future developments

3

Contents

4

Current offering

Efficiency and application range development

Machine development and where we are going

Key project updates

© Metso

Stirred milling Design goals

5

Lowest total cost of ownership

Energy efficiency

Grinding media consumption

Sustainability

Minimal maintenance

CAPEX

Ease of operation

© Metso

VERTIMILL® grinding mill Overview

• Over 420 units worldwide

• Over 270,000 kW total power

• Unit sizes from 15 to 4500 hp

• Feed size from 6 mm

• Product sizes to <15 µm

• Low intensity = low wear

• High density media

• Media size matched with grind

38 – 5 mm

6

© Metso

VERTIMILL® grinding mill Components and features

7

Gear reducer

Motor

Ball port

Feed chute

Dart valve operator

Recycle hose

Separating tank

Thrust bearing

Reducer pedestal

Recycle pump

Drain

Low speed coupling

Driver shaft

Screw with liners

Upper body

Product elbow

Lower body

Access door

Magnetic lining

© Metso

VERTIMILL® grinding mill Lowest total cost solution

8

• Low operating cost

- Energy efficient

- Reduced media consumption

- Long wear life

• Low installation cost

- Simple foundation

- Quick installation

- Less floor space

• Improved process performance

• Higher recovery

• Higher availability

• Greater operational safety

© Metso

Stirred Media Detritor Overview

• Primarily for fine and

ultra fine grinding

• Low density media:

sand or ceramic

• Optimum grinding

intensity for optimum

wear life

• >170 units by Metso

9

SMD-185-E SMD-355-E SMD-1100-E

Contents

10

Current offering

Efficiency and application range development

Machine development and where we are going

Key project updates

© Metso

Stirred milling Design goals

11

Lowest total cost of ownership

Energy efficiency

Grinding media consumption

Sustainability

Minimal maintenance

CAPEX

Ease of operation

© Metso

Vertimill Energy Efficiency Primary Reasons

• High Shear Energy

- Generally accepted to be more

efficient

• Minimal Impact

- Wasted ball mill energy with balls

impacting balls and balls impacting

liner

- Also contributes to higher ball wear

• Retention of Fine Media

- Vertical arrangement keeps the fines in

the mill

- Fine media will float out of a ball mill

(will wear out pumps and screens fast

too)

12

© Metso

Striving to full understanding of the VERTIMILL and ball mill power relationship

13

10 100 1000

Sp

ecif

ic E

nerg

y (

kW

h/m

t)

P80 (microns)

Bond Ball mIll Power VTM Power

“30-50% more efficient than a

Bond Ball Mill”

• True in most cases

• Over simplification

•Function of the feed size, product

size, and material grindability

• How far coarse and how fine can

we go?

• Efficiently

• Practically

• How do we determine this

relationships for all ore types?

Contents

14

Current offering

Efficiency and application range development

Machine development and where we are going

Key project updates

© Metso

Stirred milling Design goals

15

Lowest total cost of ownership

Energy efficiency

Grinding media consumption

Sustainability

Minimal maintenance

CAPEX

Ease of operation

© Metso

Current/Planned Development Activities •Bigger mills at economical prices

•Enable secondary grinding VTM-6000 (or larger!)

•Create multiple VTM Pilot units to be distributed into third party facilities

•Looking for WA partner to take a unit VTM-10 Pilot Unit

•New Test in development with the JKMRC

•Jar mill continued development

Stirred Milling Bench Scale Equipment

•Fill in our product offering for improved project economic

•VTM-2250-WB and VTM-3750-C Intermediate VTM Sizes

•Available for Extensive field trials VTM-75-WB Portable Pilot Plant

• Integral device for faster liner handling

• Included features to remove grinding media VTM Liner Handler

•Hydraulic Actuated valve

• Integrate water flush lines Automated Media Discharge

•Condition Monitoring and advanced process control

•Standard unit supervisory control to reduce installation cost and time SMART Equipment

•Faster media addition during operation and after mill relining Automated Media Reloading

•Reduce project engineering cost

• Incorporates beset practices in maintenance and operation Standard Layouts

16

© Metso

Creating the VTM-3000-WB from the VTM-1500-WB

Previous Scale up Considerations

• Wanted to Keep existing

Vertimill advantages:

- Machine Simplicity

- Long Wear Life

- Grind Efficiency

• Challenges

- Torque and Availability of Drive

Components

- Wear

- Minimize Capital Cost

- Maintainability

17

The VTM-3000-WB was the most successful development and

new machine for Metso in recent memory

© Metso

VTM-6000-C And beyond

• What we want to provide

- Lower CAPEX, enable use of large machines

- VTM-4500 equal or better OPEX

- Shorter mill deliveries

- Smaller wear components

• Will use innovative and new to metallic mineral processing drive

concepts

• Will be shorter overall height than VTM-4500-C

• Ready to offer by Dec 2013, target delivery of 1Q15

18

© Metso

Current/Planned Development Activities Stirred Media Detritor

• Completion of the E Series Product Line

• E series improves wear life, maintainability and reduces cost SMD-E

• Next Larger size SMD

• Ready for the market in 1Q 2014 SMD-3300-E

• DEM and PEPT Work to further optimize the SMD operation

• Continued co-development with Imerys

Simulation and Modeling

• Extensive field program jointly with Anglo Platinum to put the SMD-1100-E through its paces

SMD-1100- E Field Trials and Validation

• Continued development on impeller material for specific applications

• Bench scale impeller wear test rig

• Advantage of pin is new machines immediately test various materials

SMD Impeller Arm wear materials

19

© Metso

Stirred milling testing capabilities

20

APA

CIS

EMEA

SAF SAM

NAM

Jar Mill

SMD-0.75

USMT

KW-3

SMD-P

© Metso

VERTIMILL® grinding mill Standard Layouts

21

• Takes the full experience of the

Metso team

• Incorporates different strategies

for maintenance

• Saves times and cost

© Metso

VERTIMILL® development activities Not ready to show

• Integral device for faster liner handling

• Included features to remove grinding media

VTM Liner Handler

• Hydraulic Actuated valve

• Integrate water flush lines

Automated Media

Discharge

• Faster media addition during operation and after mill relining

Automated Media

Reloading

22

Contents

23

Current offering

Efficiency and application range development

Machine development and where we are going

Key project updates

Northlands’ Resources Kaunisvaara Project

Five (5) VTM-3000-WB

One (1) VTM-4500-R

© Metso

Vertimill Multi Unit Arrangement Kaunisvaara Advantage

• Trend is for single stage ball mill to save CAPEX, but this limits

flexibility

• Additional space has been left for a 5th Vertimill in the Sahavaara

Line

• Only the Mills that are required will be run, saving:

- Energy – each mill operated at optimum efficiency

- Wear and Parts

• Vertimills Enabled a change in Mining Schedule

- Original Plan was to have line 1 with Tapuli Ore, line 2 with Sahavaara Ore

- All ore now planned to be tapuli, delayed delivery of one mill

- Conversion of one unit to VTM-4500-R to have greater capacity than plan

• Design = F80 300 microns to a P80 of 34 microns.

• Schedule for Review by JKMRC

25

© Metso

Northlands Screw 15 months expected wear life

26

© Metso

VERTIMILL® & Stirred Media Detritor Barrick Lake Cowal

Gold sulphide concentrate

• Design grinding duty:

- F80: 150 microns

- P80: 15 microns

- Bimodal size distribution

- Reduction ratio: 10

• Customer requested single stage

VERTIMILL®

• Metso provided an optimal media

size and reduction ratio solution

of two stage grinding

27

Mills are exceeding grinding

performance targets

© Metso

Grind water

Mill discharge

Circuit feed

Dilution

water

Metso VERTIMILL®

Dilution water

Scalping cyclone overflow

Cyclone overflow

Underflow

Cyclone feed

SMD product

SMD feed

Final

product

Scalping cyclone feed

Metso Stirred Media Detritors

VERTIMILL® & Stirred Media Detritor Barrick Lake Cowal (cont.)

Alternative two stage grinding

• First stage

- One VTM-1000-WB

- F80: 150 microns

- P80: 40 microns

- 12 mm steel media

• Second stage

- Two SMD-355 in series

- F80: 40 microns

- P80: 15 microns

- 3 mm ceramic or sand media

• Overall specific energy reduced through:

- Optimum technology

- Efficient media

28

Mining on Top - Stockholm

Stirred Grinding Mill Development and Application Expansion

Graham Davey

Process Manager