Flotation machine RCS

Transcription

1 Technology at work for you Andrew Wilkinson Metso TR Seminar 27 April 2012

2 Features and capabilities Designed for increased capacity, reduced maintenance, and increased reliability

3 Contents Metso introduction Product application Features and benefits Needed to size Reference applications Service business line Conclusion 3

4 Product role Flotation is a mineral separation process, which takes place in a watermineral slurry. The surfaces of selected minerals are made hydrophobic (water-repellent) by conditioning with selective reagents. The hydrophobic particles become attached to air bubbles that are introduced into the pulp and are carried to a froth layer above the slurry thereby being separated from the hydrophilic (wetted) particles. Hydrophobic reagents Particle surface Air bubble Particle 4

5 Benefits Create bulk slurry flow patterns - Solids suspension - Particle bubble contact - Solids resuspension Effective air dispersion and distribution Extended wearlife Minimise absorbed power 5

6 Features Enhanced performance Ideal hydraulic flow zones to maximise recovery of all sizes Minimised slurry short circuiting Improved access Cell top walkway improves maintenance access to mechanism drive Reduced installation costs Cell top walkway reduces building floor area Single side froth discharge simplifies froth handling Modular tank design simplifies installation 6

7 Complete flotation machine Mechanism assembly Feed box Motor Air supply Level control Main support frame Cross flow froth launder Flotation cell tank Intermediate and discharge box 7

8 Mechanism assembly Air swivel Spindle bearing V-belt drive Motor Motor sub frame Mechanism sub frame Stand pipe Diffuser Impeller 8

9 Feedbox, intermediate and discharge box Level and flow function 9

10 Mechanism drive V-belt drive < RCS 130 > Gear box 10

11 Froth launders Take out of flotated mineral 11

12 TM Patented mechanism design Enhanced flotation performance - Maximum particle bubble contact - Effective solids suspension - Controllable aeration Reduced operating costs - Cast polyurethane wear parts - Minimised absorbed power Improved maintenance - One piece fully suspended mechanism - Wear parts replaceable in-situ 12

13 Mechanism design Top recirculation Aerated radial flow Aerated radial flow Primary return flow 13

14 Mechanism design Hollow shaft Controlled air addition Standpipe Impeller Diffusor vane 14 14

15 Mechanism design 15

16 Mechanism design 16

17 Mechanism design 17

18 Level control system Ultrasonic transmitter / detector Pneumatic actuator Target plate Float Valve stem Down flow dart valves 18

19 Aeration control Flexible air hose Air swivel Pneumatic air control valve Air flow meter 19

20 Mechanical cell type RSC 20

21 CFD Simulation Predicted bubble rise velocity in a vertical plane 21

22 Bank design 22

23 Bank design 23

24 Bank design 24

25 Bank design 25

26 Bank design 26

27 Bank design 27

28 Bank design 28

29 Bank design 29

30 Tank design Cell top walkway Single side froth discharge 30

31 Bank design 31

32 A Platinum Plant 32

33 Size range 33

34 Applications Iron flotation, Non-ferrous metals, Industrial minerals 34

35 Installations Suncor Millenium Agnico Eagle Boliden Imerys Zinkgruvan LKAB Boliden Endomines Nordkalk Poltava Gaiski Varvariuskoye Navoi Mining Ruby Creek Stillwater Platinum Asarco Mission BHP Tintaya Volcan Colquisiri Shougang Hiero Atacocha Copper Casapalca Tintaya Lead/Zinc SIMSA Platinum Other El Teniente Rudna Polkowice K&S Almagrera Youssofi Khouribua Gradir Buenaventura Luiswishi Sungun Rotem Sar Chesmeh Carrolindo Miduk Crown Mining Ivan Lonmin Karee Sylvania Mining Lonmin Karee Bendigo Mortimer Waterval Kilken Platinum Amandelbult Pasminco Elura Impala Rustenburg SASA Kaltun Eti Bakir Rapu Rapu Toms Gully 35

36 Flotation machines RCS 15 and 40 European Pb/Zn concentrator modernization Benefits - increased flotation volume - reduced maintenance/operating costs - improved metallurgical performance Phase 1 modernization program: cell RCS 15 bulk cleaner 4 - cell RCS 15 lead cleaner cell RCS 15 separation rougher 2 - cell RCS bulk cleaner 6 - cell RCS 40 bulk rougher Phase 2 Cu circuit cell RCS 15 Cu rougher 4 - cell RCS 15 Cu cleaner 2,700 TPD Lead Zinc Ore 10-11% Zn 4% Pb 1 3 Before JELE OK After PF 1-2 PF 3-4 SR 1-2 BLYRÅ- SCAVENGER KRETS BLYREPETERINGS KRETS SAMREPETERINGS KRETS SAMRÅ-SCAVENGER KRETS Flot at ionshall Flot at ionsdel plan SF Flotationshall 1-2 Flotationsdel plan +189 ZINKGRUVAN MINING AB svenh FLOTATIONSHALL PLAN +189 rev C D E F G H J C D E F G H J 36

37 Flotation machines RCS 15 and 40 Benefits 1% increase in Zn concentrate grade maintained Pb concentrate grade more stable production Reduced flotation power draw from 2.2 kw/m 3 to 1.1 kw/m 3 Reduced rotating equipment for maintenance:flotation mechanisms from 156 to 28 pumps from 32 to19 Increased spare floor area for further plant improvements Typical Concentrate Grades: Zn concentrate 56% Pb concentrate 74% 1% Pb 6% Zn 37

38 Flotation machines RCS Copper rougher Benefits Additional plant recovery with RCS % Cu concentrate grade 25-28% Cu RCS Cell Cu recovery average 37% range 16-77% RCS Cell Cu concentrate grade average 28% range 17-33% RCS fully integrated into plant operation with concentrate directed according to feed mineralogy. RCS Mechanism power draw 0.70 kw/m 3 18,000-20,000 TPD Chalcopyrite Copper Ore Ore grade and mineralization vary widely % Cu Non sulfide Copper 7-20% of total Cu 38

39 RCS Cell bank copper rougher Benefits Improved fines recovery resulting in an additional 1% overall plant recovery 39

40 6-cell South American iron ore concentrator Benefits 25% reduction in energy costs Improved recovery from 95% to 97-98% 40

41 RCS 50 41

42 RCS TM 5 Flotation machine test cell 42

43 43 Thank you