flotation 150113
TRANSCRIPT
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Electraulic™ Actuation
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• Minerals – Copper, Molybdenum, Platinum, Gold, Coal, and Phosphate– Separates sulfide ores– Reduces total material movement– Trend is larger cell size
• Locations– Dart Valves – Modulating
• Tank Froth Level Control– Consistent froth layer
» too thick – collapse» too foamy – poor transfer to
launder – Level consistency– Increase recovery % & grade
• REXA Eliminates “bath tub drain effect”
• Reduce energy consumption– Air Flow Control Froth
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• Rexa Advantages– Stiffness
– Reliability
– 100% Duty Cycle
– Low Energy Consumption
Dart Valves
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• Velocity increases as slurry exits. When plug is <20% open the decrease in pressure will cause valve to close with a pneumatic actuator
• Bath Tub Stopper Effect Impacts Process Stability and Pulp Level!!!
Pneumatic Actuator Position %
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REXA REDUCED PV Range 43%! Note: 12 months
pneumatic and 4 Months REXA production data
Process Variable Variation
REXA Actuators
Pneumatic Actuators
• Four X2L10000 Actuators• 10,000 lbs. Force• Accumulator Fail Safe• Successful Retrofit
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Total Return on Investment
Actuator Cost
-
Compressor Depreciation
-
Maintenance
-Energy
-Down Time
-
Improved Recovery
+
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• Rexa Maintains Low Scavenger Tails Cu Grade During Upsets
Dart Valves
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Assumptions:• 76k tons per day ore feed• 5% feed to tails• 3% process disruption time (43 min/day)• $3.25 Cu price per lb
• REXA Maintains Process Set Point• Less Copper is lost to Final
Tailings• Impact is 31,000 Cu Lbs/YR
returned to Rougher!
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• High Electrical Costs• High Maintenance
Costs• Risk of Multiple
Actuator Fails with Loss of Air
Source: US DOE
• Electrical Cost Assumptions– 100 HP Motor for 10
Pneumatic Actuators– $.05 per kWh– 10 years– Compressor 80% loaded– 8400 hrs. per year
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• Dallas Stadium– ~$60,000 each Sunday*
• 4 Pneumatic Actuators– $60K in 3.2 years
– $0.05/kWh
• 4 REXA Actuators– $4.8K in 3.2 Years!– REXA only 7.5%!
Dallas Stadium*EE Times 8/18/2009
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• Slow to position during slurry flow surges often result in tank overflow and product loss
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• Copper Mine• Cu Scavenger Cells • Fast Reaction to Set
Point Changes• Stiffness of Hydraulics• Low Maintenance
2000 lbf Thrust6 Inch (6mm) StrokeFail in Place
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• Gold Mine
• Fast Reaction to Set Point Changes
• Stiffness of Hydraulics
• Low Maintenance
Model L2,000-6-B-P2000 lbf (8896N) Thrust6 inch (100mm) stroke6 seconds per inch
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• Penasquito Gold Mine
• Actuator strokes closed until calibrated delta Pressure (dP) is reached– motor is turned off
– relay tells DCS the actuator has reached full “closed” pressure.
• Extended maintenance interval achieved– actuator adjusts for plug erosion
as compared to set position
20,000 lbf (88976 N) thrust22 inch (733mm) stroke10 seconds per inch
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• Coal Mine • Coal Washing • Tank Liquid Level
Control• 2,000 lbf thrust
linear actuators• Over 100 Actuators
used in OEM Application
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• Step Changes in decreasing air flow rate
• Production (Platinum)
Relative GradeA)1.0
B) 0.59
C) 0.38
Source: M. Kistner, L Auret, C. Aldrich
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• Flotation Cells• Air Flow Control • 12 units installed
at Copper mine
• REXA R2500• Rotary Actuator• 2500 lbf•in (282
N•m) torque