COMMINUTION & CRUSHING
operators of the Kamoa-Kakula copper operation in the Democratic Republic of the Congo ( DRC ). Kamoa-Kakula , owned 39.6 % by Ivanhoe Mines , 39.6 % by Zijin Mining 39.6 %, 20 % by the DRC Government 20 % and 0.8 % by Crystal River , has become a major copper producer over the last few years , moving from hitting commercial production on the Phase 1 mine in 2021 to producing 393,551 t of copper concentrate in 2023 under Phase 2 .
The Phase 3 concentrator project is targeted for ramp up in June 2024 , which , following commissioning , will have a total design processing capacity of 14.2 Mt / y and could increase annualised copper production to an average of approximately 620,000 t / y over the next decade .
This move to become one of the world ’ s leading copper mines has been supported by CITIC HIC , which , for Phases 1 & 2 , supplied four sets of Φ6.1 × 9.75 m ball mills to bring processing capacity up to 7.6 Mt / y .
The debottlenecking program for Kamoa- Kakula ’ s Phase 1 and Phase 2 concentrators , meanwhile , has been designed to increase the nameplate ore processing capacity by 22 % from 7.6 Mt / y to 9.2 Mt / y of ore .
For Phase 3 , CITIC HIC has upped the ante , providing two sets of Φ7 × 10.36 m ball mills , each with 5 MW of installed power , as part of a 5 Mt / y circuit to bring overall capacity to 14.2 Mt / y .
Kamoa-Kakula , its contractors and the CITIC HIC team brought the concentrator commissioning in ahead of schedule and on budget on both Phases 1 and 2 .
In Sierra Leone , meanwhile , CITIC HIC has supplied a PXZ50-65 gyratory crusher , a Φ7.6 × 7 m single stage SAG mill and a CSM-1600 vertical stirred mill to the Marampa iron ore mine . These units were acquired as part of an expansion looking to more than double output from 3.25 Mt / y to 7 Mt / y . that directly lead to improved performance , the company said .
All technical aspects of MagoSense , such as wireless data transmission , power supply and overall system robustness , have been proven and widely adopted by industry leaders in the cement industry , yet the tool is designed specifically for the mining industry , according to Magotteaux .
The company previously conducted a trial installation on the primary ball mill at a platinum concentrator in South Africa . This device was measuring the total filling degree of the mill , as well as the level of direct impact of balls on liners . The latter can help minimise liner damage and wear by helping reduce the occurrence of ball impacts on liners .
With this trial concluded , the company has now deployed the solution on a commercial basis to other PGM mines in South Africa , in addition to operations in Australia and Brazil , Marius Kruger , Regional Sales and Technical Manager – Mining NAM at Magotteaux , confirmed to IM earlier this year .
He said some of these mines are integrating the data feeds into existing SCADA systems to ensure the information reaches the right people within the operation .
The initial results from these early deployments in mining are yet to become publicly available , but two of the core unique aspects that come with MagoSense are : n All measuring devices are installed directly to
MagoSense uses vibration and shell-bending sensors , as well as digital signal processing technology , to provide information about what is happening at each of the 360 degrees of the mill , Magotteaux says
the outside of the mill shell . MagoSense does not suffer from sound interference like other off-mill sensors do ; and n The energy required to power all the electronics is supplied by a pendulum-driven electrical generator , meaning no batteries are required .
Molycop process optimisation solutions in action
Molycop ’ s expanded suite of digital tools means it can complement its traditional grinding media business with additional optimisation services and support .
Technologies now available , such as MillSlicer VIP and MillROC ( Milling Remote Optimisation Consulting & Coaching ), provide real-time data and insights into comminution circuit performance , enabling advanced process control on mills so they can maximise throughput ,
Magotteaux ’ s MagoSense catching on
Gaining insights into what is happening inside the tumbling mill has always been sought after , and the introduction of more accurate and robust sensor technology , plus complementary analysis platforms , is now allowing this to happen .
Magotteaux has adopted a technology from its Germany-based partner , KIMA Process Control , to offer this to the mining sector , with the MagoSense solution the result .
MagoSense uses vibration and shell-bending sensors , as well as digital signal processing technology , to provide information about what is happening at each of the 360 degrees of the mill , Magotteaux claims . Providing the total volumetric filling and ball impact information , it allows the operators to closely follow mill operation and seek optimal working conditions
Molycop digital tools are enabling mining operations to maximise throughput , increase power efficiency , reduce wear and promote longer liner life
48 International Mining | APRIL 2024