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PILOT HPGR CAMPAIGN AT

THE CODELCO EL

TENIENTE COPPER MINE

F.P. van der MeerR. DickeP. Morales

H. Elgueta M.P. Negroni

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Location: Codelco El Teniente plant, near Rancagua,

89 km south of Santiago, Chile.

Plant Capacity: 137,000 tpd.

Reserves ca. 2.5 billion tons grading ca. 0.84%.Ore Type/Mineralogy: Porphyry copper & molybdenite mineralogy.

with copper- and sulphide rich breccia

(Biotite, Tourmaline, Anhydrite).

UCS 90-140 MPa

Production: approximately 430,000 t/y refined copper

Processing Scheme: SAG and conventional milling, followed by

flotation, thickening and filtration

CODELCO EL TENIENTE COPPER OPERATION

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REASONS for ON-SITE PILOT WORK

1. Variability testing of different ore types

where representative testing of smaller ore samples abroad is limited,

and costs for transport and testing for multiple ore samples is high.

Samples tested included El Teniente, Andina and Chuquicamata ores.

2. Testing for periods of extended operation

to provide an impression of the operability of a roller press,

acquaintance of the operation, and evaluating availability.

3. Test the operation in a continuous closed circuit

4. Realistic indication forwear rate on roll surface and cheek plates

5. Provide a possibility of on-site determination ofdownstream effects

(such as the reduced ball mill energy input and improved metallurgy)

6. Confirmation tests of initial small scale results (at KHD laboratories)

on a semi-production scale.

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ARRANGEMENT of PILOT HPGR at EL TENIENTE

Nominal Capacity: 40-60 t/h

Circulating load : 50-60 %

Operating gap approximately 32 mm (1)

6.0 MM

Closed circuit 6 mm dry screening

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SUMMARY of PILOT HPGR KEY DATA

Stud-Lined Rolls

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GENERALIZED PILOT HPGR SET-UP FLOW SCHEME

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PILOT HPGR SET-UP at EL TENIENTE

Feed Chute

Pilot HPGR

Discharge

Conveyor to

6 mm screen

Screen OS

recycle

conveyor

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PARAMETERS TO BE RECORDED & MEASURED(1 second interval from data logger):

Power consumption (kW) , both motors

Movable roll position; operating gap, left and right

Hydraulic pressure; left and right

Feed rate; from weigh-belt feeder or from sample weight and test duration

SAMPLES TO BE TAKEN

Fresh feed

HPGR effective feed including recycle

HPGR products. Centre and Edge.

Screen oversize (recycle)

Screen undersize

PRODUCT ANALYSES

Particle size distribution

Moisture

Density (SG)

Bulk density

Flake size, proportion and strength

PILOT HPGR TEST DATA COLLECTION

AUXILIARY MEASUREMENTS

Roll surface and lateral wall wear, desagglomeration, screen efficiency

E ll

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EXAMPLES OF HPGR TEST DATA SERIES

Codelco Andina Ore

E ll t

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EXAMPLE OF TEST RESULTS

El Teniente and Andina ores

Effect of Pressure on Specific Energy and Specific Throughput

E ll t

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EXAMPLES OF TEST RESULTS

HPGR Centre Discharge

with ca. 10 % flakes

Weak flakes;

disintegrate upon handling

Average Feed & Product Size Distributions

E ll t

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EXAMPLE OF TEST RESULTS

El Teniente and Andina ores

Effect of Pressure on Product Size

E cellent

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Projected roll surface wear life

from wear rate measurements

indicates

7,500 to 12,000 operating hours

for Stud-Plus Lining

Optimized conditions ensure

a strong autogenous roll coating

ROLL SURFACE WEAR

Excellent

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OBSERVATIONS ENCOUNTERED

Gap skew from feed segregation

and material flow hindrance in feed chute

Shallow feed chute did appear to

limit material passage

at freezing conditions

A wider chute and insulation

did achieve better flow conditions

Mass flow calculations from belt cuts

difficult to reconcile with actual throughput

Weigh belt or feeder more reliable

Sufficient spares, maintenance and

availability of support personnel essential

Excellent

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COMPARISON OF PERFORMANCEAverage Results

Excellent

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CRUSHING CIRCUIT SPECIFIC ENERGY COMPARISON

Ch 2

Ch 3

Mda.Bolas

Conventional Crushing HPGR

Mda.

Bolas

Ch 2

Ch HPGR

Courtesy of Codelco

AND: Additional savings in

reduced ball mill energyand finished product generated

in HPGR discharge

Excellent

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COMPARISON OF PERFORMANCE

average results for Andina, El Teniente and Chuquicamata

with copper ores at similar conditions

Excellent

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INDICATION OF FULL SCALE CAPACITIESof average results for Andina and El Teniente ores

for a specific pressure of 3.0-4.0 N/mm

Excellent

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CONCLUSIONS and OBSERVATIONS

Andina, El Teniente and Chuquicamata ores were amenable to HPGR

with performance parameters near average of other copper ores

Andina was slightly harder than El Teniente and Chuquicamata

with higher energy input and lower specific throughput

HPGR offers a lower energy consumption in the crushing circuitof average 18 % against SAG milling and 6-10 % against conventional crushing

No differences were observed in flotation response

Presently projected or available HPGR unit sizes

do facilitate maximum unit capacities of up to 3,000-4,000 tons per hour

Wear rates measured indicate roll surface life of 8,000 to 12,000 operating hours

Control and arrangement of a homogenous feed supply is essential

Pilot plant design needs attention equivalent to a production facility

Preparation in sampling, mass rate measurement, feed supply is critical

Excellent

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I THANK YOU FOR YOUR KIND ATTENTION.

If you have any questions, I would be happy to answer these.