Improvements in Service Life and Cost reduction for ... · Improvements in Service Life and Cost...

Improvements in Service Life and Cost reduction for Gyratory Primary Crushers through Mantle and

Concaves optimizationIgor Elias – Steve Chaffer – Efrain Moya

[email protected]@outotec.com

© Outotec – All rights reserved

Moving from Production towards Productivity

7/20/2015 | Outotec company presentation2

Outotec FocusChange Enabling

Technologies


+100 years of experience in Comminution

7/20/2015 External | Outotec company presentation3


CASE STUDY

Traylor Gyratory Crusher 60x110

7/20/2015 Internal | Presentation name, Author4


Traylor Gyratory Crusher 60x110



Customer Specs

Large Copper Mine in South America2012 Net Sales: 3,5 Billion US$ 2006-2012 Average Production: 354.000 metric tonnes of copper per year 2013 Production: 405,300 tones of Copper + 9.000 tonnes of Molybdenum MillMapper used in all their Mills CrusherMapper used in all their Crushers


Minecrush Conference 2013 – Chile (Presented by the customer)


Customer Scenario

• There are two operating Primary Crushers FFE Traylor 60”x110” TC type, identified as PC1 and PC2

• Both Crushers have been “mapped” with CrusherMapper Technologies, being the first South American user of this service since 2011, been so far 7 liner life's for PC 1 and 7 liner life's for PC2.

• Due to the different nature of their operations, and the wear in their concaves, the following strategies have been put in place to optimize the operation in both crushers:

1.Liner Analysis (Concaves and Mantle profile analysis) 2.TPD & TPH analysis 3.Mantle reutilization. 4.Detection and control of loosen concaves. 5.Detection and control of uneven wear and Hot Spots.



Detection and control of loosen concaves

• During an inspection (6/Feb./2013) it’s observed a thickness increment on the first (or upper) row of concave liners (#4)



Detection and control of loosen concaves

• As this is a major issue, a deeper analysis is conducted between actual and previous survey



Detection and control of uneven wear and Hot Spots • For previous Liner Life's, the critical wearing zone has been detected

or both crushers.



Detection and control of uneven wear and Hot Spots • Flat Wall Analysis



Improvements Opportunities Detected

• Action Plan 1.New concave design, (Based on OEM) 2.Mantle Standardization, (Based on OEM):

•Ø 110” / Ø 113” / Ø 115” 3.Controls on installation surfaces between:

•Shaft - Mantles •Concaves – Crusher Frame •Concaves - Pins

4.Laser Surveys before and after liner installation 5.Monthly CrusherMapper Inspection 6.OSS/CSS Control and Simulation for Mantles at reline time 7.Wear Forecasts and Installation Size forecasts accordingly to tonnage



OSS/CSS Control and Simulation for Mantles at reline time












Need to change



CrusherMapper OSS/CSS









Mantle Recycling, PC 1



Relation between Crushing & Grinding





• Control of primary crusher product is particularly critical in a SAG circuit.



• 2.2% reduction in SAG throughput for 25mm (1 inch) increase in primary crusher OSS.

• Example:• 100,000tpd concentrator.• Cu Grade 1.0%• 90% recovery.• 2.2% reduction in throughput = 6648tonne Cu/Year.• Revenue decrease of US$35.5m / Year.











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Achievements



Achievements

• TPH increment • Product Size under Control (large impact on SAG Mills performance and

Energy Consumption) • Concave Liner Life Tonnage increment • Massive Liner Savings (Concaves and Recycled Mantles)



Take Away Message

Comminution needs to be “Managed as a system, not

process islands”

NOTE: Some sites have introduced the roles of Comminution Manager (Crusher to Mill), being accountable for: • Circuit TPD • Recirculating Load • Size Reduction Total ratio • Total Energy Consumption (Crusher + Mills)


Date post:	06-May-2018
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