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CODELCO EL TENIENTE COPPER OPERATION Location: Plant Capacity: Ore Type/Mineralogy: Codelco El Teniente plant, near Rancagua, 89 km south of Santiago, Chile. 137,000 tpd. Reserves ca. 2.5 billion tons grading ca. 0.84%. Porphyry copper & molybdenite mineralogy. with copper- and sulphide rich breccia (Biotite, Tourmaline, Anhydrite). UCS 90-140 MPa approximately 430,000 t/y refined copper SAG and conventional milling, followed by flotation, thickening and filtration
Production:
Processing Scheme:
6. Confirmation tests of initial small scale results (at KHD laboratories) on a semi-production scale.
6.0 MM
Stud-Lined Rolls
Feed Chute
Pilot HPGR
Discharge Conveyor to 6 mm screen Screen OS recycle conveyor
AUXILIARY MEASUREMENTS Roll surface and lateral wall wear, desagglomeration, screen efficiency
EXAMPLE OF TEST RESULTS El Teniente and Andina ores Effect of Pressure on Specific Energy and Specific Throughput
HPGR Centre Discharge with ca. 10 % flakes Weak flakes; disintegrate upon handling
EXAMPLE OF TEST RESULTS El Teniente and Andina ores Effect of Pressure on Product Size
OBSERVATIONS ENCOUNTERED
Gap skew from feed segregation and material flow hindrance in feed chute Shallow feed chute did appear to limit material passage at freezing conditions A wider chute and insulation did achieve better flow conditions
Mass flow calculations from belt cuts difficult to reconcile with actual throughput Weigh belt or feeder more reliable
Sufficient spares, maintenance and availability of support personnel essential
Ch 2
Ch 2
Courtesy of Codelco
Ch HPGR
AND:
Ch 3
Additional savings in reduced ball mill energy and finished product generated in HPGR discharge
Mda. Bolas
Mda. Bolas
Conventional Crushing
HPGR
COMPARISON OF PERFORMANCE average results for Andina, El Teniente and Chuquicamata with copper ores at similar conditions
INDICATION OF FULL SCALE CAPACITIES of average results for Andina and El Teniente ores for a specific pressure of 3.0-4.0 N/mm
Presently projected or available HPGR unit sizes do facilitate maximum unit capacities of up to 3,000-4,000 tons per hour
Wear rates measured indicate roll surface life of 8,000 to 12,000 operating hours Control and arrangement of a homogenous feed supply is essential Pilot plant design needs attention equivalent to a production facility Preparation in sampling, mass rate measurement, feed supply is critical
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