ENERGY EFFICIENCIES FROM CONCENTRATE REGRIND in an ISAMILL

Procemin Mineral Processing Conference October 2008 Cecilia Arru and Leonardo Soto

Anglo Base Metals

Las Trtolas Cu and Mo Concentrator

Part of the Los Bronces Division and wholly owned by Anglo American Chile During 2007, the entire Los Bronces Division produced 231,216 tons of Cu, 182,894 ton as concentrates, 46,420 ton as cathodes and 1,903 ton as sulphates plus 2,582 ton fine Mo.

Anglo Base Metals

Flowsheet
Rougher and Scavenger Concentrate Regrind

Anglo Base Metals

Test Objectives
Evaluate the energy savings and enhanced flotation characteristics from regrinding in an IsaMill. Of particular interest was regrinding the concentrate when the plant was treating a higher amount of a harder ore called Donoso Este.
Chalcopyrite finely dissimilated. Increased liberation is needed. This ore is expected to constitute a greater portion of the plants feed in the near future. Extra grinding capacity is required.

Earlier studies: Donoso Este ore, the concentrate would need to be ground to a P80 of 30 m at a minimum energy requirement of 42.9 kWh/t.

Anglo Base Metals

IsaMill
GRINDING MECHANISM & MEDIA RETENTION
Shaft rotating at high speeds generating disc tip speeds ~ 20 m/s Multiple stages of grinding Impeller pumps liquid back into chamber to retain media

Grinding Disks

Displacement Body

Product exit

Shaft

Grinding Chamber PATENTED PRODUCT SEPARATOR

Recirculating grinding patterns of media occur between disks due to variation in velocity profile across disks

Rotor Media centrifuged to outside of grinding chamber by high centrifugal force generated inside mill CLASSIFICATION ZONE

Anglo Base Metals

Methodology
The tests were conducted using a M20 IsaMill pilot unit in accordance with Xstrata Technologys standard signature plot procedures. These proven procedures allow for direct scale up data for large scale installations. Signature plot tests are essentially a batch type test where slurry is passed through the mill in 4 to 5 successive stages. Used 3.5 mm MT1 ceramic media. Fine media key to IsaMills energy efficiency.

Anglo Base Metals

Results
Gross Specific Energy vs Product Size 100
Upper Range Limit

Ball Mill (Minimum) = 42.9 kWh/t

Gross Specific Energy (kWh/t)

29 kWh/t Lower Range Limit

10 Test 5
17 kWh/t

Test 8 Test 12 Test 9 Test 10 Ball Mill - minimum

1 10
30

100

Product Size (m)

Anglo Base Metals

Effect on Flotation

40,0 35,0 30,0

Cu Grade, %

25,0 20,0 15,0 10,0 5,0 0,0 0% 10% 20% 30% 40% 50% 60% 70% 80% Standard Isamill - T8 Isamill - T9

Cu Rec, %

Samples were floated several weeks after grinding and therefore the particle surface may have been oxidized
Anglo Base Metals

Operating Cost Estimates

Operating Expenses for Forecasted Energy Prices

Anglo Base Metals

Conclusions
Testwork results demonstrate that the IsaMill can process the rougher-scavenger concentrate achieving the desired P80. The IsaMill was found to offer advantages in energy efficiency even when:
Assuming the higher energy requirements found in the measured range. Preliminary estimates for the alternatives is significantly underestimated.

When using the IsaMill to regrind down to a P80 of 25 m, an increase in final concentrate grade was observed (from 18% to 31% Cu) in the preliminary flotation tests, with no major impact on Cu or Mo recovery.
Anglo Base Metals

Conclusions
An IsaMill at Las Trtolas would be operated in open circuit thus eliminating the recirculating load and simplify the flowsheet. Pre-cyclones or thickeners would be considered only to increase the IsaMill feed density. Despite the higher purchase price for ceramic media than that of steel, IsaMills offer reduced total operating costs because of more efficient milling and lower media consumption. Not the complete picture more work should be carried out to further demonstrate the benefits of regrinding in an IsaMill.

Anglo Base Metals

Advancements in the field of Concentrate Regrind in an IsaMill Continuous operation.

- Confirm grinding media consumption and/or optimal type and size. - Test different ore types (to have a complete idea of energy savings)

Analysis of energy requirements for different plant feed. Further analysis of a narrow size distribution and inert grinding media on cleaner flotation. A more detailed comparison of the IsaMill performance to other technology types.
High confidence head-to-head tests?

Anglo Base Metals

ISAMILL

Anglo Base Metals