Continuous Improvements in Mineral

Processing Mining on Top – Stockholm

Minerals Engineering 2013 – Lucy England

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

2

3

130 years of experience and leadership in cement

100 years of rich experience in minerals

Essentially “invented” the cement industry and fuelled major developments within minerals

Unsurpassed expertise and know-how in both industries

Delivering results for more than a century

3 FLSmidth corporate

presentation 2013

4

One Source

One Source Supplier

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Sustainable Mining

6

New Product Investment

• HPGR – Finished and tested

• Semi Mobile Crushers

• SX Reverse Mixer/Settler

• Large Gyratory Design

• Vertical Stirred Mill

• Deswick Fine Grinding Mill

7

Product Optimization Investments

• Expand Gyratory Top Service Design

• Mill Gear Optimization and Standardization

• Larger Flotation Cells

• Flotation Optimizations – coarse particle recovery and froth vision

• Expand Cone Crusher Sizes

• Larger AFP and other Pressure filter improvements

• Sedimentation Optimization

8

RESOURCE EFFICIENCY

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Global Technology Center - Salt Lake City Integrated Solutions & Capabilities

World Class Ore Characterization / Metallurgical Lab

Full-disciplined Engineering

• Process Optimization

• PFS/FS/DE

• Flow Sheets, P&IDs, Layout Optimization

• Civil/Structural

• Mechanical/Piping

• Electrical / Automation and Controls

• 3D Models

Experienced Project Management Staff

• Cost Controls, Reporting

• Procurement Specialists

In-House Equipment Products Specialists

• Comminution

• Flotation

• Dewatering / Filtration

• ADR

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SAFETY AND ECONOMY

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Fourth Generation (Mk IV)

Traylor Type TS

Gyratory Crusher (2005 – Present)

Third Generation (Mk III)

Traylor Type NT

Gyratory Crusher (1990 – Present)

First Generation (Mk I)

Traylor Type C (Bulldog)

Gyratory Crusher (1905 - 1950)

Second Generation (Mk II)

Traylor Type TC

Gyratory Crusher (1950 – 1990)

13 28 November 2013 Primary Gyratory Crushers

Primary Gyratory - History

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Gyratory - Added Value in Design

14 28 November

2013

Primary Gyratory Crushers

1. Fuller-Traylor Bar-Type Spider

• 4-Bolt Attachment

• Simple Geometry

• Fast to Install, Fast to Remove

• Compact Lay-Down Areaxxxxx

• Saves 10 Hours of Down Time per Main

Shaft Change-out

• Annually this equals 10 hrs x 4 persons x 3

changes per year = 120 man hours or 30

hours of additional annual production.

15

Gyratory - Added Value in Design

15 28 November

2013

Primary Gyratory Crushers

2. Fuller-Traylor Specialty Maintenance Tools

• Concave Replacement Platforms

• Eccentric Maintenance Carts

• Provide Safe Work Area

• Pre-Assemble Concaves While Plant is Operating

• Reduces Crusher Down-time for Concave

Replacement from 48 hours to 36 Hours.

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Latest Developments

16 28 November

2013

Primary Gyratory Crushers

Top Service “TS” Design Gyratory

• Designed for Safe Maintenance

• NO Eccentric Cart Required

• NO Large Discharge Bin Doors

• Replacement Times:

4 Hours Main Shaft Assembly

6 Hours Eccentric Assembly

10 Hours Outer Eccentric Bushing xxx

• Safety Value….Less Exposure

125 Man-hours less for unscheduled

Eccentric Bushing replacement.

• Plant Design Savings +$ 400,000

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Fuller-Traylor®

Primary Gyratory Crushers

World’s Largest Gyratory

1600 x 3000 (63” x 118”), 1200 kW

Hudbay Minerals – Constancia Copper

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New Concepts:

• 100+ Years of Experience

• Benefit of Finite Element Analysis

• Benefit of Solid Works 3D Modeling

• Modern Control Techniques

• Willingness for “Out of the box Thinking”

• Desire to “Break away from Traditional Ideas”

Constraints:

• Modern Day Foundry Capacities

• Modern Day Machine Shop Capacities

• Transportation Limitations

• Industry Reluctance to Accept New Ideas

Desires:

• Increased Capacity (Not at Expense of OSS Setting)

• Increased Power (More efficiently utilized)

• More Maintenance Friendly

• New Materials for Increased Wear Life

• Improved Safety Features

Primary Gyratory Cruhers

Gyratory – Future Developments…?

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RESOURCE EFFICIENCY AND ECONOMY

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FLSmidth Research and Development: Our Investment Improves your Recovery

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

FLSmidth Flotation Technologies

28 November 2013

21 technologies

WEMCO 300 & 600

Dorr-Oliver 300 & 600

XCELL 350

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600 Series SuperCell™

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Final 600 Series Supercell Result: 600 series SuperCell™

Design Summary

Tank Summary:

Nominal Tank Volume: 600m3

Active Tank Volume: 660m3

Diameter: 10870mm

Overall Tank Height: 8415mm

Wetted Height: 7720mm

Aspect Ratio: 0.71

Drop height: 1200mm

Manway Dimensions: 2400mm x 2400mm

Tank Drain Size: (2) @ 18”

Launder Width: 575mm (22.6”)

Froth Surface Summary: Tank Surface Area: 92.8m2

Peripheral Launder Lip Length: 34.1m

Number of Radial Launders: 16

Radial Launder Width: 300mm

Total Radial Launder Lip Length: 68.8m

Total Radial Launder Area: 9.6m2

Total Lip Length: 93.7m

Effective Area: 59.5m2

Motor: Installed Motor HP: 1000 test

Operation 450-900 HP

VFD included

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Effect of Bubble and Particle Size

2

b

p

cD

DAP

elephant curve

Collision probability • Sutherland, 1948; Reay and Ratcliff, 1973; Flint and Howarth, 1971; Weber and Paddock,

1983; Ahmed and Jameson, 1989; Luttrell and Yoon, 1989

Gaudin, 1931

R

UtUr

r

Rb

R

UtUr

r

Rb

25

Energy Barrier (E1)

HDET VVVV

Extended DLVO theory

k

AE

EP 1exp

H

H

H

E

ee

e

rr

rrV

2

2

2

2

1

21

21

2

2

2

1210

1ln1

1ln

2

Hbc

bl

rrH

rrAVD

1

211

6 21

21132

Hrr

KrrVH

21

13221

6

26

2 We U 2

1/ 2

1

Fr23

1

Wes

ln

h0

hcr

Tres Trup

Tres Trup

Transition from bouncing to penetrating particle is predicted by:

27 28 November 2013 27

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Predicted Attachment Rate

- DO Rotor 300m3 Machine

10 microns 150 microns 300 microns

Standard Stator

New Slotted Stator

Attach Inside Stator Attach Outside Stator

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Hybrid Energy Flotation™

Standard energy (standard mechanism) Easy floating material. Recovery is froth phase controlled

High energy (standard mechanism, high RPM) Fine material

Low energy (larger rotor, low RPM) Coarse material

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Mixed Row Flotation

Hybrid Mechanism Flotation™

Standard mechanism Easy floating material Recovery is froth phase controlled

New mechanism More blades Fine material

New mechanism Holes in stator Coarse material

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

28 November 2013 30

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

28 November 2013

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