1

OUTOTEC CUSTOMER eNEWSLETTER 3/2018

Editor: Laura White, laura.white@outotec.com

SOUTH EAST ASIA PACIFIC

CONTENTS• 5 critical steps in your mill installation, page 1

• Flotation launder design, does it matter? page 5

• Benefits of equipment inspections, page 8

• Business news and festive closure, page 10

3/2018

5 CRITICAL STEPS IN YOUR MILL INSTALLATION

The milling/grinding area is traditionally known as “the heart of the plant”. So, when it comes to preparing the installation of a plant’s “heart”, your installer needs a great deal of forward planning. Here are five steps in this planning process.

Step 1 - method statementAll safety aspects, especially how to handle the large components, must be the primary consideration when planning your mill installation.

Your mill OEM will provide the method statement which, apart from installation procedure, generally also includes site preparation, equipment and tools. As all mills are bespoke, all method statements are different. The main thing is to ensure your mill OEM is available to work closely with your installer and support them on whatever queries they have. Most reputable mill OEMs are also available to provide onsite technical or supervisory expertise during the installation, whether it be for a portion or for all of the installation. Ideally your mill installer will have extensive experience on your new mill and intimately know the procedure to predict what’s required.

The resulting method statement, in turn, helps with organising the special equipment required for various possible configurations of custom-built grinding mills.

Step 2 - scheduleOnce the method statement is formed, preparation of the task schedule is advisable to sort different disciplines into their work groups.

One method is to group tasks according to how the various mill sections are assembled. This provides an overview of issues like timeline, resources, personnel and tools. Planning and preparation ensures full efficiency during the installation.

Lifting attachments at the centre of gravity for level landing.

Outotec SEAP Customer eNewsletter 3/2018 2

Outotec installation experts controlling the lift on 40ft dia, 28 MW GMD (Gearless Mill Drive).

Another benefit of a well-prepared activity schedule from your installer is that it then doubles as a progress report during your actual installation.

Step 3 - crewIn today’s marketplace with acute shortages in qualified technical staff, finding the right crew for the job has never been more difficult. Tradespeople must have heavy fitting experience and be trained in all relevant technical equip-ment. For example, both the use of laser alignment for the drive train and ultrasonic bolt micro-meters for measuring the elongation of critical fasteners are Outotec mandatory standards today.

Outotec handling and rigging crew must also have heavy lifting experience in a similar industry for minimum 10 years. 100 tonne section lifts are commonplace these days as processing plants become larger. So there are pitfalls awaiting the inexperienced - graphically documented on some websites.

Step 4 - toolsSelecting the right tools sounds easy enough – but this can be a minefield to the inexperienced! The list can be mind-boggling – an experienced provider’s ‘toolkit’ can cost AU$400-500,000 and more depending on special lifting requirements.

Items in a tool container could include temporary power generator, customised lifting equipment, computerised laser alignment equipment, a hydraulic torque multiplier (for the large critical fasteners) and temporary oil lube systems (for floating the mill during construction as site is often without mains power). One of the largest costs nowadays are lifting attachments and rigging as mills become larger.

Purpose-built tools on lift.

3 Outotec SEAP Customer eNewsletter 3/2018

Purpose-built cradles fixed to shell flange on an Outotec 40ft SAG mill.

The lifting attachments for large critical lifts need to be designed and certified by the OEM, with the centre of gravity clearly found on the OEM’s installation drawings for installers to follow.

The correct clamping force on critical fasteners is vital as these bolts are designed to last the lifetime of a mill. An ultrasonic bolt micro-meter, for example, measures the elongation of a bolt much more accurately than the ‘old ‘(and, unfortunately, still used) method via a hydraulic multiplier which can be plus or minus 25% accuracy.

A suitable grouting machine must also be sourced as the bearing housings now will take up to five tonnes of grout and at depth. This means adequate formwork needs to be specifically designed to prevent grout blow outs.

Apart from your installer having an adequate toolkit, there are other tooling issues to consider. All rigging equip-ment and attachments, for example, must be certified for use, with all certification up-to-date in a log book and presented at site. Items such as slings must be checked and registered before dispatch.

Step 5 - delivery timeline and flexibilityFor smooth installations, component delivery to site must be such that it arrives to compliment the progress of the installation. This avoids congestions and double handling. The weights and size of components means crane reach and working space adjacent to the mill installation are usually at a premium.

The installer must also have a contingency plan for delays. Continuity of installation activities is most impor-tant, so task planning must include flexibility to accom-modate emergency responses and remove any potential lost time.

Some final pointersEnvironmentDepending on a project’s location - be it the tropics or a dusty desert - a lot of large tarpaulins are needed to protect the machined items from rust corrosion or contamination while the machine is being erected. Some large mills take up to 12 – 14 weeks to build and rust/dust prevention is an ongoing task during mill erection.

Mill arrangementsMills such as large wrap around Gearless Mill Drives (GMDs) take a lot longer to assemble, with mill instal-lation done in two distinct sections. Mill shell, heads, trunnions and brake come first. Once this is completed, the motor (which is in several sections) is placed together with all its poles first and then the stator.

Site ops and maintenanceDuring the main mechanical erection, it makes good sense to involve the operational and maintenance staff as much as possible. Usually the various components are already exposed, thus enabling ‘hands on’ visual expla-nations. This is important not only for smooth day-to-day operation but also when it comes to choosing long term critical maintenance spares (other than commissioning and first 12 month run spares). Site operators and maintenance crews will feel more comfortable with the machine if they are involved during the mill erection. It is human nature for people to look after a machine better when the machine’s features and intended operational aspects are understood.

Commissioning Commissioning is very important for compiling all elec-trical and mechanical settings ensuring the integrity of design is fulfilled.

Outotec SEAP Customer eNewsletter 3/2018 4

The mill charge is normally increased gradually to full load over some days. The drive train sometimes has to be reset to suit the hot alignment and dynamic condi-tions as load is gradually increased. Your site mill staff should keep handy and retain copies of all the final full load starting data settings for reference against the new ‘as built’ data readings.

Housekeeping and watch that hose!“Housekeeping” on mills cannot be overlooked. This is especially the case for a wet area and, in the case of SAG mills, usually a messy area. When housekeeping has been well maintained, there are far less instrument and mechanical problems. Care, however, should be taken when hosing down around any bearings. Operators should be made aware of what can and cannot be hosed down. With GMD mills, for example, operators should be careful with water around the large motor as well as bearings.

ConclusionThere are so many hundreds of different things to look out for when planning and building large heavy machinery. These range from the day scabbling of latent surface concrete , through to final paint and punch lists, so this is just a ‘taster’ of some considerations. The best advice, when it comes to planning the erection of a large mill, is to get advice from your mill OEM first. An experienced professional can either assist in the project planning or manage the mill erection completely – either on a stage-by-stage basis, or from start to finish.

After all, the “heart” is key to optimum performance in a plant. And if poor planning or lack of experience results in poor performance, time wasting or, worse still, regular breakdowns, an experienced provider also makes very sound economic sense.

FOR FURTHER INFORMATION PLEASE CONTACT:

PETER.NILSSON@OUTOTEC.COM

“Heart of the plant”.

About the authorPeter Nilsson is currently responsible for global comminution installations for Outotec and is based in our Perth office. Apart from the supervision of mill installations around the globe, Peter is also responsible for the international training of personnel on safe and correct mill installation practices. Since joining Outotec in 1989, Peter has been responsible for more than 200 mill installations across the world.

Outotec SEAP Customer eNewsletter 3/2018 5

FLOTATION LAUNDER DESIGN, DOES IT MATTER? There are two key factors at play when deciding the flo-tation equipment selection for your circuit viz. residence time and froth transport parameters. Both are highly dependent on the specific ore characteristics such as mineral grade, liberation, flotation kinetics and specific gravity.

The first factor, residence time, dictates the circuits’ re-quired volume and is determined from lab scale testwork with design scale up factors applied.

The second factor, froth transport parameters, is used to select the launder arrangement for froth removal. It is more difficult to quantify as the laboratory scraping tech-nique does not mimic the natural behaviour of a full-scale plant. Thus, industry “rules of thumb” were developed some 15 years ago based on experience and metallurgical survey data.

This article will discuss how these industry rules of thumb for launder arrangements compare against plant data at various sites. We also discuss how to adjust these parameters for operating float cells.

Launder design and froth transport There are three froth transport parameters which are used to calculate the optimal launder design. Two of these parameters, froth carry rate (FCR) and lip loading (LL), are governed by these industry ‘rules of thumb’. With the third parameter, froth transport distance (FTD), Outotec is not aware of any industry rules of thumb.

So let’s discuss these two parameters which are actually governed by rules of thumb and how they compare to actual plant data.

1. Froth Carry Rate (FCR)Is defined as the amount of dry concentrate (tonne) trans-ported by the froth over a specific surface area (m2) in a given time frame (hours), giving us the units (t/m2h). In the table below, you can see the “rules-of-thumb” for froth carry rates of different flotation duties i.e. the rougher, scavenger and cleaner. The values given refer to whole banks of flotation cells. Individual cells in the bank may have higher or lower values. Particle size and mineral type will also affect these design values. The values given are generally representative of base metal sulfide operations with a feed particle size P80 >80 microns. For non-sulfide minerals, such as iron or coal, much higher froth carry rates have been observed.

Rules of thumb for froth carry rates. - note: values for whole banks of cells. Individual cell values may vary.

Outotec SEAP Customer eNewsletter 3/2018 6

2. Lip Loading (LL)The second parameter to consider is lip loading. This is defined as the amount of dry concentrate passing over the launder lip per hour per unit length, and is expressed in units of t/m/h.

Once, the FCR is considered suitable, the lip loading should be calculated. Different launder configurations will have different lip lengths. The rule-of-thumb is to keep this value <1.5 t/m/h.

Froth transport parameters vs industry “rules of thumb”We compared froth transport parameters calculated from measured plant data to the industry “rules of thumb”. The measured data was taken from the JKTech database, which is one of the most comprehensive databases of metallurgical and plant operating data.

The data has been analysed in different ways and the key findings were:• The froth parameters (FCR and LL) were generally

below the industry “rules of thumb”. This implies that in most circuits we don’t have sufficient crowding in our cells.

• Of all the commodities investigated, copper opera-tions best followed the industry “rules of thumb”.

• There was no correlation between cell size or type and the froth transport parameters. Instead, emphasis was placed on cell duty (i.e. rougher, scav-enger or cleaner).

• Operations with finer grinds had less crowding. This follows the industry practice of allowing more froth surface area for finer sized particles.

• Lastly, and most importantly, it was observed that the froth transport parameters were significantly different

for cells down the bank i.e. the first cell’s FCR and LL were significantly higher than the last cell’s values. This confirmed that having one type of launder arrangement for all the cells down the bank is not the best approach.

The key question “Do we need to worry about launder design?” considering there are so many operations with froth transport parameters outside the industry “rules of thumb”. Well, our answer is an emphatic yes. In the past, most circuits were designed with sufficient flotation redundancy that efficient froth removal was not critical. This approach can still be adopted, however ore types are also becoming more difficult to treat. It would be risky to ignore froth transport parameters and adopt one launder design for all ore characteristics and flotation duties.

Launder design - 5 warning signsFor those existing operations, where you feel the launder design may be affecting your circuit’s metallurgical performance, below are the top five indicators… 1. A change in ore feed conditions i.e. grade or mineral

when compared to the initial circuit design2. Variable metal grade/recoveries when compared to

laboratory float testwork3. Difficulty maintaining consistent concentrate mass

recovery, periods with no mass pull and/or high mass pull

4. Metal visually present on the float cell froth surface due to poor froth mobility i.e. sticky froth properties

5. High reagent consumption e.g. frother to maintain stable froth conditions

Review of operating data - down-the-bank.

7 Outotec SEAP Customer eNewsletter 3/2018

FOR MORE DETAILED RESULTS PLEASE CONTACT:

SHERWIN.MORGAN@OUTOTEC.COM

Froth crowder.

If this is your plant situation, Outotec can modify your launder arrangement. Below are three most common scenarios:

Scenario 1 – FCR is too low and/or FTD too long (for e.g. in the scavengers)• Cell crowding can be physically modified• Easy to increase booster cone size if perimeter

launders installed, reduces FTD• Radial froth crowders can also be installed for

perimeter and central launders• Increasing superficial gas velocity profile down-the-

bank to balance FCR

Scenario 2 – LL is too high and/or FTD too long• Install radial launders to provide additional lip length

and reduce transport distance

Scenario 3 – FCR is too high• Split feeding – feed to first cell is split to first two

cells. Averages out FCR over both cells

For new circuits, Outotec can also provide customised launder arrangements depending on the specific ore characteristics. For example, if the ore type has very fast floating kinetics, we would recommend a combination of launder arrangements. For the first few cells, where the mass pull is expected to be high, external launders and for the last cells, where low mass pulls are likely, donut launders with radial crowders.

ConclusionsBy optimising the FCR, LL and FTD, we may get to a stage where we can reduce the residence time scale-up factor between laboratory and full-scale, building smaller plants and having savings in both capital and operating expenses.

Radial froth crowder.

Some of the launder designs available. From left to right - external launder, internal launder and donut launder.

Outotec SEAP Customer eNewsletter 3/2018 8

REGULAR, SYSTEMATIC EQUIPMENT INSPECTIONS DELIVERES USEFUL SITE TOOL AND GREATER RELIABILITY

Optimise equipment performance and safetyRegularly and proactively scheduled inspections are critical for ensuring the longevity and peak performance of equipment and processes at sites. As we all know, unplanned equipment downtime can cause severe finan-cial losses. Equipment failures, multiple calls to a service centre, degrading process efficiency – these are all poten-tial outcomes from equipment that has not been regularly inspected (and, as a result, maintained)

Regular, systematic inspections provide a clear under-standing of the current condition and maintenance needs

of site equipment, including future spare parts require-ments. With this information, customers can maximize equipment uptime and better plan long-term resource and production schedules.

The Outotec Equipment Inspection service provides clear data and expert recommendations that help to improve decision-making, and help keep site operations running like clockwork.

CHALLENGES• Unplanned downtime,

reduced availability• Premature wear

SOLUTION • Regular, proactive Outotec

maintenance inspections

RESULTS• Provides consistent, clear

data and expert recommen-dations

• Maximizes equipment uptime• Increases equipment relia-

bility and life• Improves safety and mainte-

nance planning

Outotec SEAP Customer eNewsletter 3/2018 9

FOR FURTHER INFORMATION PLEASE CONTACT:

MELINDA.ADDISON@OUTOTEC.COM

What does an inspection include?An Outotec Equipment Inspection comprises data anal-ysis and preparation, on-site equipment evaluation, and a full inspection report with follow up as agreed. Many customers choose to include inspection services as part of a long-term maintenance agreement.

Faster and more convenient reporting with digital toolsOutotec technicians use a cloud-based mobile app to make the inspection and reporting process faster. This means customers get the results more quickly and in a clear, accessible format that’s easy to share with colleagues. The app guides technicians through the inspection process, and even allows them to capture thermal images to support more accurate deci-sion-making.

Comments Charlie Romano, Maintenance Superintendent at KCGM, Kalgoorlie, Australia “It’s a useful report with a good overview. Outotec’s service is very professional”.

As soon as the inspection is complete, customers receive a preliminary report via email, ready for sharing with colleagues. A full report follows after our experts have performed in-depth analysis of all the equipment data gathered during the inspection.

Explains one Production Metallurgist in Australia “The report looks good and is easy to follow. The summary table is particularly handy. Turnaround time from inspec-tion to initial report is also impressive, so it’s a useful site tool for us”

Benefits of digital inspection tools• Faster, easier inspections mean quicker results • Reports are clear and easy to share with

colleagues• Identify trends based on historical data gathered in

previous inspections• Benchmark equipment based on available data and

history• Comprehensive data gathering improves

decision-making

Greater reliability and optimised future planningA clear understanding of the condition of the equipment and the service needs, including the anticipated need for spare parts in the future, is critical. With the equip-ment inspection, operational capacity can be maxim-ised by reducing unscheduled downtime. Operating expenses over the long term can also be more easily planned. A key benefit of regular, systematic inspec-tions is greater equipment reliability.

Explains KCGM’s Charlie Romano “since restarting with the Outotec flotation inspections, (we used Outotec previously many years ago) we have seen an improve-ment in equipment reliability”.

“It’s a useful report with a good overview. Outotec’s service is very professional” - Charlie Romano, Maintenance Superintendent at KCGM

10 Outotec SEAP Customer eNewsletter 3/2018

COPPER SMELTER IN INDONESIAOutotec has signed a contract for the Front-End Engineering Design (FEED) of a new copper smelter to be located at Benete Bay in Sumbawa, Indonesia. The contract partner is PT Amman Mineral Industri, a subsidiary of copper and gold producer PT Amman Mineral Nusa Tenggara.

Outotec’s scope of engineering covers the design of the entire copper smelter. The engineering will be based on Outotec® Flash Smelting and Flash Converting technology, and include an electrolytic refinery, slag concentrator, precious metals refinery, wet gas cleaning and Lurec® sulfuric acid plant as well as effluent treatment plant and its associated infrastructure.

Outotec’s design work will take place in the following nine months and is a continuation of the feasibility study conducted in 2017. Once completed, the new smelter is planned to primarily process Indonesian copper concentrate.

“PT Amman Mineral Industri set the overriding design criteria to be proven technology that fulfills the strict international environmental standards. We are happy to help them to meet their sustainability goals by designing a copper smelter based on the most advanced technology in the world”, says Kalle Härkki, Head of Outotec’s Metals, Energy & Water business.

More information is available here....

MINERALS PROCESSING TECHNOLOGY TO SOUTH AMERICAOutotec has been awarded an order for the delivery of minerals processing technology to a new copper concentrator to be built in South America. Outotec’s scope includes engineering and the delivery of flotation cells and filters. The deliveries will take place by the end of 2019. More information is available here....

OUTOTEC AWARDED ECOVADIS GOLD RECOGNITION IN SUPPLIER CSR ASSESSMENTOutotec has been awarded a Gold level recognition for its corporate responsibility practices and ranked in the top 5% of suppliers evaluated by Ecovadis. EcoVadis operates an international platform to assess the corporate social responsibility (CSR) of suppliers in respect to environment, labor prac-tices, ethics and sustainable procurement.

Outotec reports its corporate responsibility using the Global Reporting Initiative (GRI) Standards, is committed to the UN Global Compact initiative and the most relevant UN Sustainable Development Goals as defined by the company. For several years, Outotec has been included in the Global 100 index of the world’s most sustainable companies, ranking 5th in 2018.

“We are proud to be ranked amongst the top CSR performers in this comprehensive and independent assessment made by EcoVadis. Their platform serves our global customers very well, as the supply chain management and suppliers’ commit-ment to corporate responsibility is extremely important in large projects”, says Outotec CEO Markku Teräsvasara.

EcoVadis (www.ecovadis.com) has assessed over 30,000 companies from 150 sectors and 110 coun-tries. Its methodology and criteria used are in line with international CSR standards including the GRI, UN Global Compact, and ISO 26000.

More information is www.outotec.com/sustaina-bility-report/2017.

Outotec SEAP Customer eNewsletter 3/2018 11

HOLIDAY CLOSURE INFORMATIONIn preparation for this year’s holiday period, Outotec’s Australian offices will be closed from Friday December 21, 2018 and re-open Wednesday January 2, 2019.

We at Outotec would like to encourage you to review critical maintenance and spare parts holdings to ensure your required parts are delivered on site in time to support your requirements.

During our holiday closure period, please use the following numbers to reach our Services teams.

Field and site services team +61 8 9211 2574/+61 429 621 086seap_field_services@outotec.com

Spares team +61 8 9211 2521 or +61 8 9211 2418 spares.australia@outotec.com

Services sales team +61 8 9211 2567services.proposals.seap@outotec.com