Page 13 - 2 BK SP MKT Globaleyes Edition 10 July 2013_English

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BULLNOSE
INNER DISCHARGE LINER
MIDDLE GRATE
MIDDLE PULP
LIFTER
(BEHIND)
OUTER VORTEX GRATE
OUTER VORTEX
PULP LIFTER
(BEHIND)
SUPER BULLNOSE
SUPER VORTEX
PULP LIFTER
(BEHIND)
SUPER VORTEX
GRATE
INNER PULP
LIFTER
(BEHIND)
To understand the full design
scope, the current Vortex
®
Discharge End design together
with the previous straight radial
design was reviewed using single
2D trajectory modelling. This gave
the team an understanding and
comparison between modelling
and actual performance that was
seen at site. From this a draft
concept was prepared to test
the limit that could possibly be
achieved while still ensuring
it could be secured in the mill.
The software modelling showed
considerable throughput
improvements using like for
like parameters, so the team
was confident to proceed with
full CAD modelling allowing
them to view the design in 3D.
The result of this was a
SuperVortex Discharge End
curved Mill End Liner design
developed to maximise mill
throughput, and further reduce
mill downtime during relines.
The design consisted of single
length Discharge End Liners
(excluding the Discharge Cone),
that the Bradken team is
confident is a world first.
To further understand the
manufacturing issues, scale
models were produced to help
communicate with the foundry
technical team. These also helped
when marketing the product and
maximised sales potential.
To complete the enhanced
system, a further improvement
was made to the Bullnose
®
, which
resulted in the development of
a complementary SuperBullnose
Discharge Cone.
Following a successful
consultation with the customer,
production on the SuperVortex
and SuperBullnose commenced,
with the extra-large castings
produced at Bradken's Adelaide
foundry. This facility has excelled
in producing large complex
castings. The liner mass for the
Super parts were 2,914kg for the
SuperGrate and 3,409kg for the
SuperVortex Pulp Lifter.
The SuperVortex Discharge End
design was successfully installed
into the Cadia 40ft SAG Mill at
the end of October 2012. The
large castings were installed
in record time, which led to a
considerable reduction in reline
downtime and costs, adding
value to the mine’s operation.
The total reduction in liner
castings for the discharge end
of the 40ft SAG Mill was 314
to 234 respectively, a 25%
reduction. Production figures
will be collected during the
coming months to see the true
overall benefit, but at this stage
the anticipated benefits are
expected to be achieved.
Bullnose configuration.
Super bullnose configuration.
13
globaleyes / edition 10
13
product story