OPERATING AND MAINTENANCE TENIENTE SAG MILL N 1.

October 2004
1

PLANT MANAGEMENT

Octubre 2004

SAG UNIT

Octubre 2004

MINE SEWELL
TTE.5 TTE.5 COARSE ORE CRUSHING TTE.8

CURRENT BUSINESS MINE CONCENTRATOR

ORE BINS

MILLING

SECONDARY CRUSHINGO

PRIMARY CRUSHING

COLON
MILLING SAG

MILLING

FLOTATION

FLOTATION

FLOTATION SAG

TAILINGS PLANT RETREATMENT (COLUMNS)

MOLYPLANT

TAILINGS TO CAREN Cu CONCENTRATE MOLY CONCENTRATE

Octubre 2004

TENIENTE GRINDING SAG PLANT.

FLOW CHART
TO FLOTATION
18 % +100M

Octubre 2004

OPERATING EXPERIENCES

Octubre 2004

CODELCO

SAG MODULE, PROCESING RATE

EL TENIENTE

TP
where :

P x U x 24 / E

TP = Processing rate (tmsd) P = Power Draw (Kw)

U = Utilization SAG mill (%/1) E = Energy specific consumption (Kwh/tms)

Octubre 2004

ALTERNATIVES EVALUATION
(AUGUST 15 TO DECEMBER 30, 91)

FULLY AUTOGENOUS SEMI AUTOGENOUS 4% BALLS TO FLOTATION

18 % +100M

SEMI AUTOGENOUS 10.5 % BALLS

Octubre 2004

RESULTS

POWER (KW) LEVEL

FULL AUTOG. SEMI AUT. 4% SEMI AUT.10.5% SEMI AUT.12,3%

KWH/TMS BALLS M. TMS/HR F 80 SAG

SAG M.

BALLS M. SAG M.

7095 8474 10621 10998

3810 4204 4232

19,0 12,3 8,9 11,3

10,3 6,0 7,4 8,0

381 700 1193 976

81283 53065 87871 108540

Octubre 2004 Octubre 2004

10 10

RATE (TMS/HR)
INCREASE OF COARSE ORE FALLA MOTOR MOBO 411 FED TO THE SAG MILL (DEL 3 A 23 DE MARZO) CAMBIO CHANGE DEL OF PESOMETRO GRID POR OPENING UNO FROM DE 4 ESTACIONES 2 1/2 TO 2
(OCT 98)

1200 10861060 1099 1000

1116 1123 1058

1105 977

MOBO 412 2 MONTHS OFF PER DISCHARGE BEARING. SCRATCHED

MAY 97 A MULTIDISCIPLINARY EQUIPMENT IS CREATED

921 926

965 977 940

800
92 93 94 95 96 97 98 99 00 01 02 (S EP 03 T) 04

YEAR
Octubre 2004 11

SAG F-80 VARIATION

175000 150000 125000 100000 75000 50000 96 98 2000 2002 2003 2004 YEAR 70000 110000 140000 124700 123650 108540

Octubre 2004

12

OPERATING PARAMETERS
% OF + 100 MESHES BALLS CONSUMPTION
SAG MILL BALLS MILL

POWER CONSUMPTION

Octubre 2004

13

+ 100 MESHES (%)

25 24 23 22 21 20 19 18 17 16 15 14

17,5

18,5

17,7

16,5

16,9

16,2

16,4 14,7

17,6

17,3 16,2

20 00

94

95

96

97

98

99

01

02

03 (S

YEAR

Octubre 2004

ep t)

04

14

BALLS CONSUMPTION GR/TON

400 300 200 100 353 332 345 348

320 303 300 289 290297

320 307

274 263 254 209 200 210 185

290 304
251

305
244

LL BA

SM

ILL

235 235

SAG

10 FEB, START 6 BALLS RECHARGE TO SAG MILL

YEAR

Octubre 2004

(S ep 0 3 t) 04

92

93

94

96

97

95

98

99

00

01

02

15

POWER CONSUMPTION (KWH/TMS)

14,0 11,4 11,0 11,4 11,2 11,3 9,6 8,4 7,0

92 93 94 95 96 97 98 99 00 01 02 0 pt 3 .) 04 (S

9,1

9,4

9,1

9,6

9,8

11,0

YEAR

Octubre 2004

16

PLANTA POWER CONSUMPTION (KWH/TMS)

26,6 25 20,5 20 17,2 15

92 93 94 96 95 97 98 99 00 01 02 0 ep 3 t) 04 (S

19,8 19,5 19,4 19,6 18,6

20,7

22,2 22,4 21,5

23,6

YEAR

Octubre 2004

17

Wi

(kWh/Tcs)

20,0 18,2 17,4 17,5 17,1 16,6 17,3 17,7 17,8 17,0 17,2 17,2 17,4

18,2

15,0
92 93 94 95 96 97 98 99 00 01 02 0 pt 3 .) 04 (S

YEAR

Octubre 2004

18

OPERATION MANAGEMENT MAIN INDICATORS

UTILIZATION PERCENTAGE COSTS ACCIDENTS FREQUENCY RATE PRODUCTIVITY

Octubre 2004

19

UTILIZATION (%)
DELAY IN PROGRAMMED EVENTO CLIMATICO MAINTENANCE (JUNIO 97: 88 HR) (JUL. 97: 55 HR) SAGMILL STATOR DISPLACEMENT (MAY. 00: 170 HR)

100 95 90 85 80
92 93 94 95 96 97 98 99 00 01 02 0 (S ep 3 t) 04

93,9 92,3 87,5 84,2 85,3 91,3

95,2

93,7 93,0

93,6

94,7 92,6 90,0

116 HR CH 1 ACB Total= 94.2 % 70HR DELAYED IN ACT-T8 51 HR DUE TO LACK OF WATER

YEAR
Octubre 2004

20

UTILIZACION IMPROVEMENT CAUSES

MODIFICATION OF TRANSFER CHUTES DUE TO NON SUITABLE DESIGN (Discharge area is increased) MODIFICATION OF SAG FEEDING CHUTE (Transfer area is increased) MODIFICATION OF TRANSFER BELTS DESIGN(Grater power motors and higher capacity belt conveyors) DESIGN MODIFICATION OF EMERGENCY CABLE STOP SYSTEM (Defenses over cable are installed, to avoid the stop action of falling stones)

Octubre 2004

21

PLANT SHUT DOWN HOURS DUE TO TRANSFER CHUTES AND BELTS OBSTRUCTIONS

150 100
54 66

128

53

58

52 13 19 11 13

50
6 10 6

92

93

94

95

96

97

98

99

00

01

02

YEAR

Octubre 2004

(S ep 03 t) 04

22

PLANT SHUT DOWN HOURS DUE TO SAFETY CABLES OPERATION

40,0

37,0

43,7

20,0

14,6 8,6 4,7 4,1 1,2 3,8 2,2 1,5 1,1 1,9 2,4

0,0

YEAR

Octubre 2004

(S

ep 03 t) 04

95

92

93

94

96

97

98

99

00

01

02

23

SAG PLANT COSTS

(US$/MTS MILLED)

4 3 2
1,3 1,7 2,0 1,9 2,0 3,0 2,5 2,2 2,0 2,3 2,6 2,3 2,7

1
96 97 98 99 00 01 02 03 (S
YEAR
Octubre 2004 24

92

93

94

95

ep t

04

ACCIDENTS PER YEAR

3 92 93 94 95 96 97 98 99 2000

2
2

22

FROM MARCH 95 NO ACCIDENTS WITH LOST TIME

1
1

11 1 1

2001 2002 2003 2004

00

0 00
STP

000

00000000 0
CTP

Octubre 2004

25

PRODUCTIVITY
(MTSHR/H REGISTERED)

45 40 35 30 25
92 93 94 95 96 97 98 99 00 01 02 ep 03 t) 04 (S
26

39

38 39

40

40

38

39 35 35

36

37

38

36

YEAR
Octubre 2004

PRODUCTIVITY
(MTS DAY/H REGISTERED)

1000 900 800 700 600 500

94 95

844

885

906 839

905 785 791 805

847

911

852

96

97

98

99

00

01

02

03 (S

YEAR

Octubre 2004

ep t

04
27 28

OPERATION STRATEGY
MAXIMUM TONNAGE TREATMENT
MILL OPERATION FILLING LEVEL (26 TO 30% FILLING) MAXIMUM SPEED (10.3 RPM) WITH FEED SOLIDS % AS LOW AS ALLOWED BY RECIRCULATION USING THE SUPERSAG EXPERT CONTROL SYSTEM

IMPROVED FINAL PRODUCT

P 80 147 MICRONS

Octubre 2004

EFFICIENCY V/S FILLING LEVEL

WET TM /HR
(SEP. 98 TO APRIL 99)

1060 1050 1040 1030 1020 1010 1000 990

1051 1032 1016

<29,5

29,5 a 30,4

30,5 a 31,5
29

Octubre 2004

EFFICIENCY V/S FILLING LEVEL

(JANUARY TO OCTOBER 2000)

1000 954 923 902 900 859

800

< 26 %
Octubre 2004

26 A 27,9 %

28 A 29,9 %

> 30 %
30

EFFICIENCY V/S COARSE %

(JANUARY TO OCTOBER 2000)

1000

957 926
<5,1 A 6 %

900

858

6,1 A 8 % >8%

800
Octubre 2004 31

HOW TO REVERT A LOW EFFICIENCY SITUATION?

CHANGING THE BALL DIAMETER

RECHARGING 6 BALLS
IMPLEMENTATION DATES YEAR 2.004

FEED

SIZE DISTRIBUTION MODIFICATION

PRE-CRUSHING PROCESS
IMPLEMENTATION DATES YEAR 2.006

Octubre 2004

32

FINE % EFFECT ON SAG PLANT PROCESSING ANALYSIS

30.000 28.000 26.000 24.000 22.000 20.000 18.000 16.000 0

Tpd (24 hrs)

26.600 24.150 23.508 21950

21350
7% adicional

22900
3% adicional

10

20

30 40 50 % - 1 inch

60

70

80

Octubre 2004

33

MINE SECTORS STUDIED IN SAG GRINDING PILOT TESTS

SECTOR QUEBRADA TENIENTE SUB-6 ESMERALDA ISLA MARTILLO

LITHOLOGY SECONDARTY ANDESITE PRIMARY ANDESIT PRIMARY ANDESITES-BREACHES PRIMARY DIORITE

C.E.E
(KWH/TMS)

5,63 12,97 11,03 12,50

Octubre 2004

34

RELATION S.E.C. SAG V/S BOND BALL Wi

18

17

Wi (Kwh/tcs)

16

15

14

13 5 6 7 8 9 10 11 12 13 14 15

E (Kwh/tms)

Octubre 2004

35

SAG S.E.C. (C.E.E) VARIATION RELATED TO PRIMARY CRUSHER SETTING

14,00

13,50

C.E.E. (Kwh/tms)

13,00

12,50

12,00

11,50

11,00 7
Octubre 2004

4
36

Setting (")

SAG S.E.C. (C.E.E) VARIATION RELATED TO FINES ADDITION

12,00

11,50

11,00

C.E.E. (Kwh/tms)

10,50

10,00

9,50

9,00 0,00

Octubre 2004

10,00

20,00
37

Finos (%)

SAG S.E.C. (C.E.E.) VARIATION RELATED TO CRUSHED INTERMEDIATE FRACTION

12

11

10

C.E.E. (Kwh/tms)

6 Original
Octubre 2004

-5 " +3"

-5 " +2"

-5 " +1"
38

Fractions

SAG S.E.C. (C.E.E.) VARIATION RELATED TO GRANULOMETRIC PROFILE AND TYPE OF ORE MIX
13,00

12,00

C.E.E. (Kwh/tms)

11,00
Lithology : 100% Primary Andesite

Lithology: 55% Secondary Andesite and 45% Primary Andesite

10,00

9,00

8,00

Lithology: 100% Primary Andesite

7,00 0,00

10,00
Octubre 2004

20,00

30,00

40,00

50,00

60,00
39

% -1"

CIRCUIT CRUSHINGCRUSHING-SABCSABC-A

+6
TO

-6/+1

FLOTATION

-1

-1

-1
TO FLOTATION

FINES

COARSES SAG

Octubre 2004

40

CIRCUIT CRUSHINGCRUSHING-SACSAC-A

+6 -6/+1 TO FLOTATION

-1

-1

-1

FINES

COARSES

SAG

Octubre 2004

41

SPECIFIC POWER CONSUMPTION IN ALTERNATIVE CIRCUITS FOR A PRODUCT OF 20%+100M

22

20

18

kwh/tms
16 14 12 SABC-A SABC-B SABCAF(10%) SABCAF(20%) SABC-ACG PCH-SABCA(-5"/+3") PCH-SABCA(-5"/+2") PCH-SABC- PCH-SAC-A(A(-5"/+1") 5"/+1")

circuito
Octubre 2004 42

70

DECREASE RATIO OF E (%) V/S TONNAGE INCREASE (%)

60

50

Aumento tmsd (%)

40

30

20

10

0 0 5 10 15 20 25 30 35 40 45

Reduction Kwh/tms (%)

Octubre 2004 43

POWER CONSUMPTION MILLING AND CRUSHING

24,0 23,0 22,0 21,0 20,0 19,0 18,0 17,0 16,0 15,0 14,0 13,0 12,0
93 Sewell Coln SAG 15 17 94 95 96 97 98 99 00 01 02 03

KWH/T

04 Sep

15,3 16,7 17,5 17,5 17,5 16,8 17,4 17,6 17,8 19,4 19,0 16,3 16,3 16,4 16,2 16,8 16,6 16,1 15,9 16 16,6 16,4

20,5 19,8 19,5 19,4 19,6 18,6 20,7 22,2 22,4 21,5 23,6 26,6
44

Octubre 2004

SAG MILL LININGS RATIONALIZATION

324 252

350 300 250 200 150 100 50 0 180

127 81

144 108 81 108

TAPA ALIMENTACION CILINDRO TAPA DE DESCARGA

1995

1997-1998

2004

Octubre 2004

45

ELEMENTS QUANTITY REDUCTION

TOTAL 800 600 400 200 0 1995 1997-1998 2004 631 441 333

Octubre 2004

46

CONCLUSIONS
THE SAG MILL FEED SIZE DISTRIBUTION IS THE MOST IMPORTANT VARIABLE ON THE ENERGETIC AND METALLURGIC PROCESS EFFICIENCY. THE PERCENTUAL INCREASE OF FINE MATERIAL (FRACTION -1) ON THE FEED SIZE DISTRIBUTION, CONSIDERABLY REDUCES THE SAG MILL SPECIFIC ENERGY CONSUMPTION, AND SIGNIFICANTLY INCREASING ITS PROCESSING RATE. DEPENDING ON THE CRITERION USED TO INCREASE THE PRESENCE OF FINES IN THE SAG FEED SIZE DISTRIBUTION FOR A LITHOLOGIC MIX, IT IS POSSIBLE TO DECREASE THE SPECIFIC POWER CONSUMPTION BETWEEN 11% AND 35%. FROM ALL THE CRITERIA ANALYZED FOR THE MODIFICATION OF THE ORIGINAL FEED SIZE DISTRIBUTION, THE MOST ATTRACTIVE IS THE ONE THAT CONSIDERS A PRE CRUSHING STAGE OF THE INTERMEDIATE FRACTION -6 / +1.

Octubre 2004

47

CONCLUSIONS
FOR LITHOLOGIC MIXES OF DIFFERENT SAG GRINDING COMPETENCIES, IT IS POSSIBLE TO EQUALIZE THE SPECIFIC ENERGY CONSUMPTIONS, AND CONSEQUENTLY THEIR PROCESSING RATES, WHEN PROCESSING IDENTICAL SAG FEED GRANULOMETRIC DISTRIBUTIONS. IN THIS SPECIFC CASE, THE BOND BALL Wi, USUALLY USED IN THE SAG STAGE TO ESTABLISH GREATER OR LOWER HARDENESS OF THE PROCESSED ORES, NO MEANS ANY CORRELATION WITH DE SPECIFIC POWER CONSUMPTION IN THIS GRINDING STAGE. FOR THIS REASON ITS UTILIZACION MUST NOT BE CONSIDERED WITH DIMENSIONING PURPOSES AND CALCULATION OF PROCESSING RATES. IN RELATION WITH THE RESULTS OBTAINED IN THE CURRENT STUDY, WHEN DESIGNING THE SAG MILLING PILOT TESTS, IT IS IMPERATIVE TO CONSIDER THE REVISION OF THE EFFECT OF THE GRANULOMETRIC PROFILE VARIATION, BESIDES THE TRADITIONALLY STUDIED VARIABLES AS THEY ARE: CRITICAL SPEED OF THE MILL, TROMEL OPENING, NUMBER OF ROCK-PORTS OPEN, CIRCUTS CONFIGURATION, BALLS FILLING LEVEL, ETC.

Octubre 2004

48

SUMMARY
THE CHANCES FOR OPTIMIZING THE USE OF THE POTENCIES INSTALLED AND, THEREFORE THE TONNAGES PROCESSED ARE:

IN THE EVENT THAT CONVENTIONAL AND SAG MILLING CIRCUITS EXISTS AT A PLANT , IF LACK OF ORE OCCURS, THE SAG PLANTS PROCESS MUST BE MAXIMIZED AS PRIORITY, BY STOPPING, IF
NECESSARY, PROCESSING STEPS IN CONVENTIONAL CIRCUITS.

SPECIFIC POWER CONSUMPTION OF THE ORE MIX CAN BE VARIED BY CHANGING THE FEEDING GRANULOMETRY TO THE PLANTS, EITHER ADDING FINES OR BY PRE-CRUSHING THE COARSE
MATERIAL LESS COMPETENT WITH THE SAG MILLING.

OPTIMIZING THE UTILIZACION OF THE PLANT. BY IMPROVING THE MATERIALS QUALITY, ADVANCED DESIGN OF PARTS AND PIECES AND BY REDUCING THE NUMBER OF LINING PIECES, LIFTERS AND
PULP LIFTERS, SO AS TO MINIMIZE THE MAINTENANCE HOURS.

OPTIMUM OPERATION PARAMETERS MUST BE DETERMINED, SUCH AS FILLING LEVEL, BALLS LEVEL, MILL SPEED, PERCENTAJES OF SOLIDS, ETC., WICH MUST BE INCORPORATED TO EXPERT
SYSTEMS.

TP (tmsd)

P (Kw) x U (%/1) x 24 / E (Kw/tms)

Octubre 2004

49

END OF PRESENTATION

Octubre 2004

50