IV-45

IV-46 The currently delineated reserve is 1.4 billion tons at 0.49% Cu. Although the head grade is relatively low by current standards, the waste to ore ratio is approximately 0.6:1 for the life of the sulfide project thanks to the leaching operations which strongly and positively influence project economics. However, the relatively low head grade encouraged the project team to pursue innovative solutions to improve project economics. The large ore reserve and +30 year operating life led to a strong focus on minimizing both operating and capital costs. Many items were considered along these lines such as: Development of a compact plant layout that took advantage of gravity flow as much as possible. Completion of ore characterization studies to quantify the variation in processing parameters to allow design factors to reflect anticipated process variation. Utilizing an open air plant design suited to the local climate. Focus on life cycle cost rather than first cost. Minimizing risk to plant operational performance and project schedule. A significant item considered was a re-evaluation of the use of the standard SABC comminution technology that most concentrators constructed in the past 15 years have utilized. COMMINUTION CIRCUIT ENERGY REQUIREMENTS A prefeasibility study of the potential to construct a large concentrator at Cerro Verde was conducted in 2001 and 2002. During the prefeasibility study a total of 135 paired SAG Performance Indicator (SPI) and Bond Work Index (BWI) tests were performed on samples collected in a structured manner based upon lithology and alteration type. This data formed the basis for determining SABC circuit energy requirements, and provided insight into the variation in ore hardness that would be expected when processing the Cerro Verde ore body. Phelps Dodge had previously utilized the SPI technology at its Chino and Candelaria concentrators, both of which utilized SABC circuits, and felt comfortable with the SPI prediction methodology as developed by Minnovex. This was especially true in the case of Candelaria which possessed a very similar ore hardness distribution as Cerro Verde. The average SPI value for the sample data base was 136 minutes and the average Bond work index was 15.3 kWh/mt. Based upon Minnovex CEET analysis, the required operating SAG and ball mill comminution energies were 38,000 kW each. This translated into an overall 15.5 kWh/mt grinding circuit specific energy split evenly between the SAG and ball mills. Grind-recovery flotation testing identified 125 microns as the optimum flotation feed size. No pilot SAG testing was performed.

SAG
2006
DEPARTMENT OF MINING ENGINEERING
UNIVERSITY OF BRITISH COLUMBIA Vancouver, B. C., Canada

HPGR IMPLEMENTATION AT CERRO VERDE By J. L. Vanderbeek,1 T. B. Linde2 , W. S. Brack3 , and J. O. Marsden4 Concentrator Manager, Sociedad Minera Cerro Verde SA, Arequipa, Peru; 2Primary Sulfide Project Manager, Phelps Dodge Mining Company, Arequipa, Peru; 3V. P. Engineering, Phelps Dodge Mining Company, Phoenix, Arizona, USA; 4Sr. V. P. Technology & Product Development, Phelps Dodge Mining Company, Phoenix, Arizona, USA ABSTRACT Phelps Dodge is constructing a 108,000 mtpd copper-molybdenum concentrator near Arequipa, Peru. Plant start up is projected in the last quarter of 2006. Comminution will be accomplished by primary crushing, secondary crushing and tertiary crushing followed by ball milling. The tertiary crushing stage utilizes four 2.4 m diameter x 1.6 m high pressure grinding rolls (HPGRs). This represents the first application of HPGRs in hard rock base metal ore processing. This paper discusses the rationale behind the selection of HPGR technology and discusses comminution circuit design details. BACKGROUND Organized mining has taken place at Cerro Verde since 1977 when Minera Peru commissioned a leaching and solvent extraction/electrowinning facility that processed oxide and secondary sulfide mineralization. Cerro Verde currently processes 40,000 tpd of crushed leach material. The combined production from crush for leach and run of mine leaching is 200 million pounds of cathode copper per year. Underlying the current leach mining operation is a large primary sulfide ore body consisting primarily of chalcopyrite mineralization.
1

IV-47 Based upon this, two 40 ft x 22 ft SAGs with 22 MW gearless drives and four 24 ft x 35 ft ball mills each with 12 MW gearless drives were specified. Pebble crushing requirements were satisfied by three MP1000 crushers. Prior to advancing to the feasibility study phase in 2003, six inch diameter core drilling was performed to obtain ore samples to support a large scale flotation pilot plant program study. In addition to the ore for the flotation testing, a total of 14 tons of ore were obtained for HPGR testing. Three composite samples were constructed representing harder than average ore, softer than average ore and the most common ore type. The criteria used to quantify the samples ore hardness were the SPI distributions determined during the pre-feasibility study. These samples were distributed to three HPGR manufacturers for testing. The objectives of the HPGR testing were to achieve the following: Determine HPGR energy requirements. Determine the effect of HPGR operating parameters on performance Develop data required for full scale HPGR equipment sizing Evaluate potential HPGR effects on ball mill operation Develop data to allow HPGR liner wear life estimation. A total of 31 open circuit and locked cycle tests were performed on pilot scale HPGRs ranging between 0.60 and 0.80 meters in roll diameter. Two of the pilot HPGRs used studded rolls and one test HPGR unit used Hexadur rolls. The testing established relationships between HPGR specific press force (N/mm2), specific throughput (t-s/m3-hr), specific energy (kWh/t) and product size distribution. Relationships between feed moisture, specific throughput and specific energy were also determined. The relationship between roll speed and specific throughput was investigated. Test results between vendors were quite consistent. The scalable parameter specific throughput, exhibited a slight reduction with increasing press force. This is because the crushing zone thickness decreases slightly as press force increases. HPGR specific energy increased linearly with increasing press force. HPGR product fineness was strongly influenced by press force with increased fines produced with the higher pressing forces. As the pressing force was increased over 3.5 N/mm2 to 4.0 N/mm2 a point of diminishing returns was achieved with product fineness. The higher press forces produced minimal additional fines while HPGR specific energy and required power inputs continued to increase. Increasing feed moisture from 2% to 4% resulted in a 5% reduction in specific throughput and a 20% increase in specific energy. Increasing roll speeds from 0.4 m/s to 1.4 m/s resulted

IV-48 in a slight reduction in specific throughput (increased slip) and also produced a slightly coarser product size distribution. The harder ore sample composite exhibited a slight reduction in specific throughput and generated a coarser product than the softer ore sample at equivalent press force conditions. Specific throughput increased around 10% under locked cycle testing because the composite feed sizing to the HPGR became finer as a consequence of recycling discharge screen oversize material. Also the locked cycle specific energy decreased open circuit values by 10%. Flakes or agglomerates are formed as a natural consequence of the HPGR process. The intense HPGR crushing action presses finer material into sheets. The durability of the flakes is a strong function of mineralogy with softer material and materials containing clay and/or clay-forming minerals being more prone to the formation of durable flakes. The major problem durable flakes pose to the proposed Cerro Verde circuit is reduced screening efficiencies. The hard and soft ore samples exhibited no indication of flake de-agglomeration issues. Modest flake de-agglomeration problems were experienced during the locked cycle testing of the most predominate (softer material) ore type sample. The flakes produced broke relatively when dropped on the floor, dissolved readily in water, and could also be broken easily by hand. Based upon this, features that promote flake de-agglomeration were built into the HPGR circuit design and layout. Abrasion (wear) testing was also performed to allow estimation of roll (tire) wear lives. The Cerro Verde ores were judged to be moderately abrasive compared to other ores processed via HPGR. Tire wear lives of 6,000 hours were projected based upon these wear tests. Based upon these test results the following HPGR design criteria were adopted: Specific throughputs ranging between 230 and 250 t-s/m3-hr. Specific energy (total feed basis) between 1.7 kWh/t and 2.0 kWh/t. Press forces between 3.5 N/mm2 and 4.0 N/mm2. Four 2.2 x 1.6 m (D x L) HPGRs with 2 x 2,500 kW drives each were specified based upon the above. The roll diameter was subsequently increased to 2.4 m for risk mitigation purposes as discussed below. Due to uncertainties associated with HPGR circuit operation, chiefly related to HPGR circuit circulating loads, a conservative approach was

IV-49 taken to ball mill sizing. Simulation analysis was conducted on the entire crushing and grinding circuit to aid in developing conditions for mill sizing. Although the expected tertiary screen (ball mill feed) opening is 56 mm the ball mill was sized to accommodate screen openings of +10 mm under worst case ore conditions. Mill sizing was confirmed via conventional analysis. The result was the same size ball mill (24 x 35 foot diameter ball mill with 12 MW gearless drive) as specified for the SAG option. This approach allows a high level of flexibility in balancing secondary crushing, tertiary crushing and ball mill loading. No allowance was taken in the HPGR-ball mill sizing process for potential reductions in Bond work index from micro-fracturing that may be induced by the HPGR crushing process. COMMINUTION CIRCUIT SELECTION PROCESS The initial focus of the feasibility study was the optimization of the design and layout of the SABC circuit identified during the pre-feasibility study. A scoping evaluation was performed midway through the feasibility study that evaluated the relative benefits of replacing the SABC comminution circuit with an HPGR-based comminution circuit. The results of this scoping evaluation implied that the installation of an HPGR-based comminution circuit had a high potential to enhance project economics. A full feasibility level evaluation proceeded for the HPGR circuit based upon these conclusions. The evaluation of the SABC and HPGR circuits was driven by economics (i.e. discounted cash flow analysis, capital and operating costs) and the relative risks associated with each option (operability, maintainability, flexibility, schedule, safety). These aspects are discussed below. CIRCUIT EQUIPMENT DETAILS Simplified flow sheets of the SABC and HPGR comminution circuits are presented in Figures 1 and 2 (see next page) and illustrate the major components associated with each option. The SABC option is representative of SABC circuits as implemented in recent large concentrator installations. The 60 in. x 113 in. primary crusher is installed in a conventional fixed structure with a 500 tonne capacity dump pocket. Crushed ore is reclaimed from the primary crusher product surge pocket by an apron feeder onto a coarse ore transfer conveyor and hence to the coarse ore conveyor. The coarse ore conveyor discharges to a coarse ore stockpile with 60,000 tonne live capacity, 250,000 tonne dead capacity and 400,000 tonne ultimate capacity (pushed via dozer). Ore is reclaimed from the coarse ore stockpile by three apron feeders (per conveyor) onto two parallel SAG

IV-50

Figure 1: SABC Circuit Flowsheet

Figure 2: HPGR Circuit Flowsheet feed conveyors. The apron feeders and SAG feed conveyors are located in separate concrete tunnels installed below the coarse ore stockpile. Each of the two parallel SAG feed conveyors feeds a 40 x 22 foot EGL SAG mill powered by a 22 MW gearless drive. Each SAG mill

IV-51 discharges ore onto a single 3.0 x 7.3 m double deck, low head, banana type screen. SAG screen undersize material is combined with the discharge from two ball mills in a common sump and is pumped with two operating 28 x 26 inch variable speed pumps to separate ball mill cyclone clusters. Cyclone underflow from each cyclone cluster reports by gravity to a 24 x 35 ball mill powered by a 12 MW gearless drive. Each SAG mill feeds two ball mills. Cyclone overflow reports to rougher flotation. SAG screen oversize is conveyed to the pebble crushing stockpile with 5,000 tonnes live capacity (approximately four hours) and 46,000 tonnes total capacity. Pebbles are reclaimed from beneath the pebble stockpile by three parallel conveyors installed in separate tunnels. The reclaimed pebbles feed three MP-1000 cone crushers. Pebble crusher product is conveyed back to the SAG feed conveyors with a common conveyor and proportioned to each SAG mill as desired. The HPGR comminution option utilizes the same primary crushing, coarse ore conveying and coarse ore stockpile arrangement as outlined above for the SABC option. Ore is reclaimed from the coarse ore stockpile by four apron feeders installed in a single reclaim tunnel beneath the stockpile. These feeders feed the coarse ore reclaim conveyor system that consists of two conveyors in series. This arrangement allows for metal detection and removal without shutting down the entire secondary crushing plant. The coarse ore conveyor distributes ore to a 3,200 tonne secondary crusher surge bin via two shuttle conveyors. Ore is reclaimed from the secondary crusher surge bin with four belt feeders, each of which feeds a 3.6 m x 7.9 m double deck secondary crusher screen (four screens are installed). Oversize from each screen feeds one MP-1000 secondary cone crusher (four secondary crushers are installed). Crusher discharge is recycled back to the secondary crusher surge bin. Coarse ore screen underflow is conveyed to the 4,800 tonne tertiary crushing surge bin and is distributed to the bin using a tripper system. Ore is reclaimed from the tertiary crushing surge bin with four belt feeders each of which feeds a 2.4 x 1.6 m HPGR with twin 2,500 kW variable speed drives (5,000 kW total per HPGR). There are four HPGRs installed. HPGR product is conveyed to a 20,000 tonne concrete ball mill surge bin and distributed into the bin with a tripper system. Ore is reclaimed from the ball mill surge bin via eight belt feeders. Each belt feeder feeds a single 3.0 x 7.3 m double deck vibrating screen (eight screens are installed, two per ball mill). Wet screening is utilized at this point in the flowsheet to improve screening efficiency, reduce dust emissions and to facilitate the breakdown of any agglomerated flakes which may be present. Ball mill screen oversize is conveyed back the HGPR surge bin. Ball screen underflow from the two screens falls into a common ball mill cyclone feed sump (four sumps are installed). A 28 in. x 26 in. cyclone feed pump with a 1,120 kW variable speed drive feeds each ball mill cyclone cluster. Ball mill cyclone

IV-52 underflow reports to the ball mill feed. Ball mill cyclone overflow reports to rougher flotation. Each of the four ball mills is 24 x 35 feet long and is powered by a 12 MW gearless drive. CAPITAL COST COMPARISON Estimated capital costs for the SABC and HPGR options are tabulated in Table 1. Capital costs are presented for the entire comminution circuit from primary crushing through ball milling by process area. Table 1: Comminution Circuit Capital Cost Summary Comminution Circuit Capital Costs ($ x 106) Process Area SABC HPGR HPGRSABC Primary Crushing to SAG Feed $35.1 $33.4 ($1.8) or 2nd Crusher Bin Fine Crushing Secondary Crushing $0 $37.5 Tertiary Crushing $0 $55.4 Pebble Crushing $23.1 $0 Ball mill bin feed system $0 $39.6 Total Fine Crushing $23.1 $132.5 $109.4 Grinding SAG $67.7 $0 Ball Mill $58.5 $61.9 Total Grinding $126.2 $61.8 ($64.4) Total Comminution Direct Cost Relative Indirect Cost Total Comminution Capital Cost $184.4 $0 $184.4 $227.7 $9.8 $237.5 $43.3 $53.1

On a comminution circuit basis, HPGR capital costs exceed SABC direct costs by approximately $43 million on a direct cost basis (+23.5% versus SABC direct cost) and $53 million on a total capital cost basis. HPGR capital costs are higher than SABC capital costs chiefly because of the increased complexity of the material handling aspects of the multi-stage HPGR crushing circuit. The HPGR circuit requires more pieces of equipment than the SABC circuit. The three HPGR circuit inter-stage storage bins also are a significant contributor to the higher HPGR capital costs. A further exacerbating factor is the high seismic design criteria associated with Cerro Verde which resulted in moreextensive steel supporting structures for the elevated secondary and tertiary crusher surge bins and structures.

IV-53 Table 2: SABC and HPGR Circuit Operating Cost Comparison

Power Requirements SAG Mills Coarse Ore Conveying Grinding Ancillary Equipment Pebble Crushers Pebble Crushing Ancillary Equipment Ball Mills Secondary Crushing Tertiary Crushing (HPGR) nd rd 2 and 3 Stage Crushing Ancillary Equipment nd rd 2 and 3 Stage Conveyors Dust Collection Total Operating Power (kW, kWh/t) Power Cost ($/t) SAG Balls Ball Mill Balls SAG/HPGR Liners Ball Mill Liners Pebble/Secondary Crusher Liners Total Balls and Liners ($/t) Operating and Repair Supply costs Pebble Crushing/Secondary Crushing SAG Milling/Tertiary Crushing (HPGR) Ball Mills Total Operating & Repair Supply Costs ($/t) Operating + Maintenance Labor Costs Pebble Crushing/Secondary Crushing SAG Milling/Tertiary Crushing (HPGR) Ball Mills ($/t)Total Operating + Mntce Labor Costs Comminution Operating Costs Compared 0.189 0.195 0.053 0.045 Specific Energy, kWh/t SABC HPGR 8.71 0.50 1.56 0.37 0.27 8.71 0.00 0.00 0.00 0.00 0.50 1.66 0.00 0.00 8.03 0.49 3.25 0.22 Power, kW SABC 38,181 3,000 6,852 1,790 1,316 38,200 0 0 0 HPGR 0 2,976 7,292 0 0 35,236 2,387 15,043 1,083 SABCHPGR

IV-54 OPERATING COST COMPARISON SABC and HPGR comminution circuit estimated operating costs are tabulated in Table 2 (see previous page). The basis for these estimated operating costs are outlined below. SAG and ball mill operating powers were determined by Minnovex CEET analysis which accounts for expected ore hardness variation and load shifting between the SAG and ball mills as ore conditions vary. HPGR circuit ball mill operating power is based on a Bond work index of 15.3 kWh/mt (deposit average), a 22% split of fresh ball mill feed (tertiary screen underflow) to flotation, a 10% reduction in Bond work index due to HPGR induced micro-fracturing (from independent laboratory testing of HPGR product material) and a 4,950 micron F80. The SABC and HPGR options both produce a ball mill P80 of 125 microns. Energy consumption associated with comminution circuit ancillary equipment was included in the operating cost analysis. SABC and HPGR grinding circuit ancillary equipment includes reclaim feeders, conveyors, lube systems and screens. Pebble crushing ancillary equipment includes conveyors, magnets and lube units. Secondary/tertiary crushing ancillary equipment includes feeders, screens and lube units. Secondary/tertiary crushing conveying and dust collection energy requirements are detailed separately. SAG mill and ball mill liner wear rates were based upon actual Candelaria liner wear rates converted to a g/kWh basis. Pebble crusher and secondary crusher liner wear rates were based upon observed Candelaria (pebble) and El Abra (secondary) crusher liner wear performance. Grinding media wear rates were based upon actual Candelaria wear rates on a g/kWh basis. The Candelaria and El Abra operations are located in Chile and are majority-owned and operated by Phelps Dodge. Operating and repair supply costs were based upon observed Candelaria (SABC) and El Abra (secondary/tertiary crushing) costs as appropriate. Operating and repair labor costs were estimated in a similar manner. The data in Table 2 shows that the HPGR based comminution circuit offers a significant operating cost benefit ($0.368/mt reduction) when compared to the SABC based comminution circuit. The following operating cost elements, extracted from Table 2, illustrates that the HPGR circuit offers major operating cost savings versus SABC in the areas of power and grinding media.

0.00 0.00 20.11

1.27 0.49 15.91

0 0 89,339 0.704 0.203 0.176 0.132 0.042 0.012 0.565

6,220 2,250 72,487 0.557 0.000 0.164 0.141 0.040 0.015 0.359 0.206 16,852 0.147

Grinding Media and Liner Costs

0.138 0.046 0.237

0.124 0.046 0.215 0.022

0.000 0.000 0.189 1.695

0.000 0.000 0.195 1.326 (0.006) 0.369

IV-55 Operating Cost Element SABC-HPGR Operating Cost Differences ($/mt) 0.144 0.215 (0.009) 0.022 (0.006) 0.368

IV-56 Several formal and informal sessions were conducted throughout the course of the feasibility study that served to define risks and characteristics of the two options. The composite results of these sessions appear below. Safety The activity with the highest potential for injury for plant maintenance personnel is the replacement of SAG mill liners. Implementing the HPGR circuit will eliminate over 30 years of SAG liner replacements. The hazards associated with SAG liner replacements that must be managed include falling muck, exploding balls, flying shrapnel from hammering out bolts and liners, climbing in and out of large diameter mills, walking on uneven mill charge surfaces, rigging and handling heavy liner pieces and disposing of worn liners. Replacement of HPGR liners involves the rigging and heavy lifting of the worn and new roll components in the plant environment. Actual HPGR liner replacement takes place off line in the controlled environment of a maintenance/repair shop. Less people are involved in the HPGR roll exchange process than with SAG liner replacement. Operability High wear rates experienced (and associated downtime) on the HPGR roll surface, the sides of the roll, and the cheek plates have been the major factor impeding the successful evolution of the HPGR into hard rock mining. The HPGR vendors have made great strides in liner technology since the initial full scale test of HPGR technology in hard rock mining at Sierrita in 1996. Studded tires, as opposed to segments, are now the standard for abrasive applications. Variations in stud chemistry and hardness have resulted in significant improvements in wear life. It is now standard to vary the hardness of the studs across the face of the roll in order to maintain a flat wear surface across the roll. Softer studs are placed on the edges (to compensate for lower pressing forces on the edge) while harder studs are placed in the middle of the roll face (to compensate for higher pressing forces). In addition to wear of the roll face, wear on the edges and sides of the rolls have been a significant issue in the past. Extensive welding (and downtime) has historically been required to maintain the wear surfaces on the edges and sides of the machines. The HPGR venders have also worked to solve this problem. Current HPGR edge liner designs are available that completely eliminate roll edge and side welding requirements.

Power Grinding Media Mill and crusher liners Operating and repair supplies Operating and repair labor Total Operating Cost Delta

Power savings are achieved due to the inherently more efficient size reduction process possible with HPGR. Ancillary equipment power requirements are included in these operating costs. The distribution between direct size reduction and ancillary equipment power requirements are shown below. Comminution Circuit Specific Energy (kWh/mt) Category SABC HPGR Size Reduction Equipment 17.8 11.8 Ancillary Equipment 2.3 4.1 Total Comminution Circuit 20.1 15.9

Significant grinding media savings are possible with the HPGR circuit due to the elimination of expensive SAG mill grinding media. RISK ANALYSIS Analysis identified that installation of the HPGR comminution circuit rather than the SABC option would allow a significant reduction in long term operating costs at the expense of a higher initial capital cost. These economic criteria were only one facet or input to the process of selecting the comminution circuit technology. In addition, an in-depth analysis of the relative advantages, disadvantages and risks associated with each option was performed, including a detailed review of many HPGR operations worldwide. Producing a cost effective design was a major goal of the feasibility study and the detailed engineering efforts. It was expected, however, that the final design product would offer no compromises to safety and would be readily operable and maintainable. Minimization of the construction schedule and the amount of time required for production rates to ramp up to design levels were also key areas of focus.

IV-57 HPGR liner lives of 6,500 hours are being achieved in abrasive diamond crushing applications. At Cerro Verde HPGR tire wear life is projected conservatively as 6,000 hours is equivalent to SAG mill shell liner lives. Based on this, it was felt that HPGR liner wear does not represent a significant technical risk to the implementation of HPGR technology. The SABC circuit operation is sensitive to the size distribution of the material fed to it and performance is improved as the size distribution from the primary crusher product is reduced (tighter closed side setting). Primary crushing equipment to be installed at Cerro Verde is constrained as to the amount of size reduction possible to properly support the SABC circuit while satisfying crusher throughput requirements. The HPGR circuit is relatively insensitive to wider primary crusher closed side settings eliminating primary crusher operational constraints. As a consequence of site layout constraints, the coarse ore conveyor discharges onto the coarse ore stockpile at approximately a right angle to the reclaim conveyors under the stockpile. This will result in size segregation of material from one side of the pile to the other. This means that the SAG mills, fed by separate reclaim conveyors, will always receive different size distributions. This creates on-going operational and process control issues. The single reclaim system for the HPGR circuit eliminates this issue. Pebble crushing circuits associated with SABC operation are difficult to control and expensive to operate, and are sensitive to tramp steel (e.g. grinding ball pieces). No pebble crushing circuit is required for HPGR circuit operation. The single 3.05 x 7.32 m SAG discharge screen approaches capacity limitations under higher throughput conditions. The design solution is a dual screen system which injects a complicated feed distribution system. SAG circuits are inherently sensitive to changes in ore hardness and ore feed size distribution. The crushing-based HPGR circuit is much less sensitive to changes in ore characteristics than the SABC circuit. The SABC circuit has limited optimization potential compared to the HPGR circuit. The 40 ft x 22 ft SAG mills represent the bleeding edge of technology. There is limited upside potential to improve SAG throughput except for finer blasting practice. On the other hand HPGR circuit offers extensive flexibility to balance loading, and to improve performance via changes to secondary crusher closed side settings and secondary and tertiary crusher screen openings. The 2.4 m diameter HPGR rolls selected (versus the 2.2 m roll size identified from testing) also provide additional flexibility to react to unknown ore conditions.

IV-58 Schedule SABC circuit installation time is estimated to be three months longer than the HPGR circuit installation time. This is a consequence of longer equipment lead times and longer installation times. The SABC construction site would be very congested. The timely installation of the six gearless mill drives required for the SABC circuit is a daunting challenge. There is significant schedule risk associated with the SABC option due to the number of large mill castings required. There are only a limited number of suppliers capable of manufacturing these castings remaining in the world and their shop loadings are high. Quality issues with these large castings are a major concern. Serious casting problems or a failed casting (even from another project) would completely upset the project schedule. The HPGR circuit should have a quicker ramp up time to full production than the SABC circuit. The learning curve for the operational staff will be longer for the SABC circuit. Although the HPGR circuit has more pieces of equipment than the SABC circuit, the HPGR circuit equipment is conceptually simpler to properly operate, control and maintain. COMMINUTION CIRCUIT SELECTION Although the HPGR circuit had higher initial capital cost than the SABC circuit, the reduced operating costs achievable with the HPGR circuit allowed an approximate 1.5% higher internal rate of return to be achieved for the project as a whole when compared to the SABC circuit. The HPGR circuit also exhibited a lower risk profile than the SABC circuit. The longer SABC installation schedule, mill casting quality and delivery issues and a variety of other SABC related operational issues drove this conclusion. Since the HPGR circuit exhibited better economics and a better risk profile than the SABC circuit the decision was made to proceed with the HPGR circuit. HPGR CIRCUIT DESIGN FEATURES Significant aspects of the HPGR circuit design are outlined below. These items combine to reduce the operational risk associated with the circuit. The HPGR testing described above determined that that four HPGRs with 2.2 x 1.6 m rolls each with a drive capacity of 5,000 kW would be able to handle the expected crushing duty. Based upon uncertainty with implementation of the HPGR process and the amount of test data

IV-59 available, the decision was made to increase the HPGR roll diameter to 2.4 m while maintaining the 5,000 kW drive system. The 2.4 x 1.6 m HPGR has 1.09 times the capacity of the 2.2 x 1.6 m HPGR. Initially, variable speed drives were specified for only two of the four HPGRs. The dynamic simulation analysis described below predicted a 350,000 t improvement in annual throughput by installing variable speed capability on all four HPGR units. The variable speed drives allow the HPGRs to operate at lower rates (reduced wear) but also takes advantage of the catch up capacity exhibited by the 2.4 m diameter rolls to reduce elevated HPGR feed bin levels and prevent reductions in secondary crushing circuit throughput. Oversize material must be prevented from entering the rolls. Stud breakage may occur if material larger than the HPGR operating gap (5065 mm) enters the rolls. The application of closed circuit secondary crushing process in the Cerro Verde circuit eliminates this as a concern. Effective tramp metal detection and removal is critical to prevent stud breakage. The Cerro Verde design, borrowed from the designs observed during HPGR benchmarking activities, automatically bypasses metal around the HPGRs based upon metal detector sensing. In addition two self-cleaning magnets are installed for tramp steel removal from the circuit. Segregation of material in the HPGR feed bin should be avoided. An uneven split of coarser and finer material across the face of the HPGR roll may lead to roll skewing causing uneven wear and inefficient crushing. The Cerro Verde design feeds material to the bin in-line with the crushers so this is not expected to be an issue. Potential flake generation issues were noted during HPGR pilot testing. The flake mitigation strategies employed in the Cerro Verde design include: The installation of static breaker bars under the HPGRs to break down large sheets of flake material. Taking advantage of conveyor transfer points to help break down flakes. There are a total of 10 transfer points between the HPGR discharge and the return of recycled material to the HPGR feed that will serve to break down flakes. The ball mill screen feed material will be completely slurried prior to screening. HPGR testing revealed that flakes, if formed, will break down readily in water. The use of high pressure water sprays on the ball mill screen decks will help break down surviving flakes.

IV-60 A dynamic simulation analysis was conducted of the combined coarse ore feed, secondary crushing, tertiary crushing and ball milling circuits. The effects of ore conditions (proportion of hard/soft ore), processing conditions, planned maintenance schedules and unscheduled downtime (driven by mean time between failure information from Phelps Dodge operations and other similar concentrator operations) on overall circuit throughput on an annual basis were analyzed. The initial focus of the dynamic simulation analysis was to investigate the effects of inter-stage surge bin capacities. The analysis revealed that a significant reduction in the storage capacity of the fine ore bins could be made without sacrificing annual production rates. This resulted in a significant capital cost reduction in bin sizing and bin feed conveyor drive capacity. Results of the surge bin sizing analysis appear below. Another significant finding was that the coordination of planned maintenance activities between secondary crushing, tertiary crushing and grinding was essential to maintaining required production rates. Surge Bin Bin Capacity (t) by Processing Line Initial Final 800 800 1,200 1,000 9,000 5,000

Coarse Ore HPGR Fine Ore

The control of dust emissions from the HPGR crushing process was a major concern during the HPGR evaluation process. The intense crushing action imparted by the HPGR creates significant amounts of dust. Benchmarking of other HPGR facilities showed that properly operated dust collection systems would mitigate dust emissions. All conveyor transfer stations have atomizing type sprays installed. All surge bins have dry dust collection systems. A wet scrubbing system is installed to collect dust generated by the HPGR circuit. CONCLUSIONS SAG milling technology has evolved to its realistic limit with the advent of 40 foot diameter mills and is a mature technology whose risks and challenges are well known. Just because these risks and challenges are known does not make them less daunting. SAG technology was originally applied to ores with mixed hardness, often containing clays and other fine material that could interfere with crushing and material handling operations. This took advantage of wet slurry handling to remove clays and fines while utilizing coarse grinding media to break more competent material. It is well known that relatively uniform, competent ores can be treated efficiently (and with low operating costs)

IV-61 at a large scale using three-stage crushing, for example as applied at Phelps Dodges Sierrita operation, Arizona. However, SAG milling has evolved to its current state because of lower capital costs (compared with three-stage crushing), inertia (due to its widespread use), combined with the fact that no viable alternative to the technology has emerged. The recent advances in HPGR studded lining technology have changed this situation. HPGR has become a viable alternative to SAG milling given the application to the appropriate ore type(s). This applies in the case of the Cerro Verde primary sulfide reserve with its relatively uniform, hard ore and only limited clay content. Since SAG milling is a mature technology limited gains or improvements are expected in the future. HPGR, being a relatively new technology, is expected to offer excellent opportunities in for operational and maintenance improvements in the future. ACKNOWLEDGEMENTS Many people and organizations contributed to the activities described above. In particular the authors would like to thank the following: The senior management of Phelps Dodge for their willingness to support to new ideas and to make the timely decision to proceed with something a bit different when its backed up by the facts. Personnel from HPGR suppliers Krupp-Polysius, KHD and Koppern for their open and frank discussions of the pros and cons of HPGR technology in general and their equipment in particular. The staff of Fluor Vancouver for producing a high quality feasibility study under intense time pressure. In particular, Brad Mathews and Ken Wood were instrumental in advancing the cause of selecting the proper comminution circuit for Cerro Verde. The many HPGR operations and operators who opened their doors to us and provided helpful information.