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September 3-5, 2008.

Santiago, Chile

The
The Use of Composite Materials
to Improve the Wear Life in SAG
Mill Feed End Liners

Craig Faulkner
Bradken, Australia

Contents





Introduction
SAG Mill - FE Liner Optimisation and Design
Summary
Conclusion

September 3-5, 2008. Santiago, Chile

Introduction
 Cadia Valley Operations (CVO) consists of two
distinct processing plants
Cadia Hill - Low Grade Plant
Ridgeway - High Grade Plant
 Underground
 16,300 tpd @ 2.4g/t Au and 0.8% Cu
 Annual Production:
 35,000 t Cu
 290,000 oz Au

September 3-5, 2008. Santiago, Chile

Ridgeway Operation
 Semi-Augeounous Grinding













32ft Dia. x 16ft Long SAG Mill


700 t/h new feed
6500 kW
14.5 EGL
8.6 10.7 rpm
62.6 78.6% critical
28% Mill volume
13% Ball charge
125mm Dia. Balls
50mm grate aperture
15mm trommel aperture
Steel liners ( 417 tonne)
September 3-5, 2008. Santiago, Chile

FE Liner Optimisation & Design


 The Drivers





Liner life
Combat excessive wear
Reduce reline times per annum
Improve profitability

September 3-5, 2008. Santiago, Chile

Feed End Liner Design


 Original Design
 Typical lifter liner (OEM) design
 Three row setup (throat, middle & outer)
*Note Throat liner missing from image

September 3-5, 2008. Santiago, Chile

Feed End Liner Design


 Original Design






High wear through joint


Both parts changed-out together
Liner life 120 days (avg.)
2.0 Mt processed
3 relines per year

September 3-5, 2008. Santiago, Chile

Feed End Liner Design


 Intermediate Design change





Reduce the length of middle liner


Extend outer to cover full charge volume
Increase lifter thickness (40mm) to improve wear life
Reduction in liner bolts from 160 to 128 per reline (20%)

September 3-5, 2008. Santiago, Chile

Feed End Liner Design


 Intermediate Design change






Liner life - 4.4 months & 2,122,801 tonnes


Extra thickness to lifter bar (25mm)
Change in CTR bolt position
Extra liner mass
Short of desired overall life of 6 months

September 3-5, 2008. Santiago, Chile

Composite Liner Design


 Design Criteria








CAD Modeling incorporating DEM output


Achieve 6 month liner life
Review alternative wear materials
Safe and Easy to install
No additional liner mass
Survive SAG milling environment
Manufacturability

September 3-5, 2008. Santiago, Chile

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Composite Liner Design


 White-iron insert Chrome Moly liner

September 3-5, 2008. Santiago, Chile

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Composite Liner Design


 Implementation
 Risk
 Trial installation 13-03-07
 Inspection & Wear monitoring

September 3-5, 2008. Santiago, Chile

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Composite Liner Design


 Liner Inspection
 Wear monitoring 31-05-07
 Liner predictions

September 3-5, 2008. Santiago, Chile

13

Composite Liner Design


 Trial Results
 Trial liners removed 24-07-07
 Liner Performance

Processing Details
Tonnes
@
Installation

Tonnes
@
Removal

Period
Tonnes

Date
Installed

Date
Removed

Days
in
Service

Tonnes
p/day

27,061,534

29,184,335

2,122,801

13/03/2007

24/07/2007

133

15,961

Liner Wear Details


Position
Forward
Material
CrMo
Measureing Point ID @ 475mm
MID @ 1030mm
Original Thickness
395
395
Removed Thickness
120
80
Material Loss
275
315
mm per day
2.068
2.368
mm per m/t
130
148

Trial
Composite
ID @ 475mm
MID @ 1030mm
395
395
260
265
135
130
1.015
0.977
64
61

September 3-5, 2008. Santiago, Chile

Behind
CrMo
ID @ 475mm
MID @ 1030mm
395
395
140
95
255
300
1.917
2.256
120
141

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Composite Liner Design


 Full Implementation
 Set installed 13-11-07
 White-iron performance
 Liner results

September 3-5, 2008. Santiago, Chile

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Composite Liner Design


 Full Implementation
 Liner Inspections

18-02-08 (3.0 months)

September 3-5, 2008. Santiago, Chile

30-04-08 (5.5 months)

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Composite Liner Design


 Full Implementation
 Liners removed 20-05-08
 6.2 months life (189 days)
 2,985,348 tonnes milled

September 3-5, 2008. Santiago, Chile

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Composite Liner Analysis


 Wear Analysis Chrome-moly liner
 Laser scanning
 Mass reduction
 Rate of wear

Part No.
BK53212A

Material
Chrome-moly

Installed

Life
Life
Removed (Days) (Months)

24/07/2007 13/11/2007

112

3.7

Installed
Tonnes

Removed
Tonnes

Period
Tonnes

Tonnes
per Day

29,184,335

30,973,378

1,789,043

15,974

September 3-5, 2008. Santiago, Chile

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Composite Liner Analysis


 Wear Analysis Chrome-moly liner
Mass
Mass Reduction
Installed Height
Removed Height
Material Worn
mm per MT
mm per Days Milled

New
Worn
Kg's
%
mm
mm
mm

1974
1420
554
28%
395
150
245
136.94
2.19

September 3-5, 2008. Santiago, Chile

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Composite Liner Analysis


 Wear Analysis WI Composite liner
 Laser scanning
 Mass reduction
 Rate of wear

Part No.
BK53212B

Material

Installed

Life
Life
Removed (Days) (Months)

WI Composite 13/11/2007 20/05/2008

189

6.2

Installed
Tonnes

Removed
Tonnes

Period
Tonnes

Tonnes
per Day

30,973,378

33,958,726

2,985,348

15,795

September 3-5, 2008. Santiago, Chile

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Composite Liner Analysis


 Wear Analysis WI Composite Liner
Mass
Mass Reduction
Installed Height
Removed Height
Material Worn
mm per MT
mm per Days Milled

New
Worn
Kg's
%
mm
mm
mm

1940
1361
579
30%
395
226
169
56.61
0.89

September 3-5, 2008. Santiago, Chile

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Composite Liner Analysis


 Wear Analysis
Feed End Liner Analysis
450

3500000

400

3000000
2500000

300
250

2000000

200

1500000

150

Tonnes Milled

Liner Thickness

350

1000000

100
500000

50
0
0

0
189

112
Days in Service
CrMo

WI Composite

CrMo - Tonnes

WI Composite - Tonnes

September 3-5, 2008. Santiago, Chile

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Summary
 Results





Achieved 6 month relines


Reduction in one reline per year
Reduced overall annualised reline times by 24 hours
Increased wear life by 68.75%

ORIGINAL OEM DESIGN


Liner Description
Feed End
Middle Liner
Outer Liner

REVISION 2
Liner Description
Feed End
Middle Liner
Composite Outer Liner

Quantity
Per Set

Liner Mass
Per Set (kg's)

Change-out Time
Per Set (Hours)

Wear Life
(Months)

Annualised
Change-out Time (Hours)

16
32

24,000
44,880
68,880

4.53
9.07

3.8
3.8

14.3
28.6
43

Quantity
Per Set

Liner Mass
Per Set (kg's)

Change-out Time
Per Set (Hours)

Wear Life
(Months)

Annualised
Change-out Time (Hours)

16
32

10,816
62,080
72,896

4.53
9.07

42.7
6

1.3
18.1
19

September 3-5, 2008. Santiago, Chile

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Conclusion

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Conclusion
 The use of the composite materials on the feed end outer liners in the
Ridgeway SAG mill has provided a viable solution to reduce the overall
relines per annum and increase mill availability.
 This fully integrated approach offers significant opportunity for
improvements in milling environments with the flexibility in solving
operational / scheduling issues beyond the usual option of increasing
liner mass.

The
The Use of Composite Materials to
Improve the Wear Life in SAG Mill
Feed End Liners

September 3-5, 2008. Santiago, Chile

25

Acknowledgements
 Bradken
 Newcrest Mining Cadia Valley Operations

THANK YOU
Notice:
The Design and Technical information as detailed in this document is the exclusive property of the Bradken Pty. Ltd. and its related
entities. It is issued on the strict condition that except with our written permission it must not be reproduced, copied or communicated to
any third party nor be used for any purpose other than that stated in the particular enquiry or contract with which it is issued.

September 3-5, 2008. Santiago, Chile

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