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Abstract- Mineral processing is one of the most energy intensive II.HAUL TRUCKS WITH DIESEL-ELECTRIC DRIVE
industrial operations with important direct emissions given by
the Diesel fuel used in mining equipment like haul trucks for Fig.1 shows the block diagram of a diesel-electric haul truck
mineral transportation and indirect emissions generated by the drive system. For large-scale operations, the main objective is
use of electrical energy in grinding mills, slurry pumps and high- to reduce the cost per ton of material hauled. Ore and rock
current rectifiers. Therefore, there is a challenge for improving transportation from mines to stockpiles or to crushers is made
the efficiency of energy use, the abatement of carbon emissions, with haul trucks. Looking for productivity, fast run speeds
the use of water and environment care. Other challenges are uphill and downhill require the biggest haulage capacity and
given by the environment around the mining operations, with the most powerful haul trucks to transport the ore and rock
altitudes above 3000 meters above sea level, mountain conditions, from mine to stockpiles for further mineral conveying and
as well as, the growing problems stated by lower ore-grades, crushing processes. In traditional haul trucks, power is
deeper mine pits and longer tunnels, requiring systems with transferred to the rear wheels via a mechanical transmission.
higher transport and beneficiation capacity. For economy of One relative drawback of mechanical drive haulers is high
scale, high-power drives and modern technologies are needed. maintenance and repair costs associated with their
This work reviews the trend of technology and potentials for sophisticated and complex mechanical transmissions system.
carbon emission abatement and energy efficiency in mineral Elimination of the mechanical torque converter, transmission
processing. and differential is one of the major advantages of electric haul
trucks [2], [3]. AC Drives with IGBT-Inverters and vector
Keywords- Energy efficiency, Power Converters, Mineral
Processing, Industrial Applications. control offer a smooth stepless full torque operation by
motoring or braking at full operating speeds. A high starting
I. INTRODUCTION torque and high top speed allow for more ore to be transported
and at the same time giving the operator greater capacity from
III. GRINDING MILLS WITH GEARLESS DRIVES noisy, slow and with high variability, because of dependence
on mechanical components and calibration uncertainties.
About 65% of the energy demand is consumed in concentrator
plants, mainly in grinding mills. Fig. 2 depicts a gearless mil
drive (GMD). The mechanical power is transferred
electromagnetically between the stator and poles of the rotor
[4]. Due to the mass flow, materials, and power involved in
the process, SAG mills face the problem of high-energy
impacts caused by steel balls cataracting against the shell of
the mill, with loss of energy and accelerated breakage of balls
and liners. These harmful impacts result from the dynamics of
the load movement within the mill. Mill feeding, ball charge,
liner profile, load filling and speed in the mill are the main
variables [5], [6].
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For detecting harmful impacts on the shell of the mill [12] and
[13] have described a new system, the impactmeter, based on
the non-contact acoustic measurement with an array of sensors
around the mill. [14] presented a study on impacts behavior in
grinding mills. A very interesting instrumentation system
called SAG Analyzer was described by [15]. It gives an on-
line measurement of total load filling. It can deduce the filling
level of grinding media. It is based on acoustic sensor
electronics fed by rechargeable batteries, mounted in the outer
shell of the mill and information wireless communication. An
inductive sensor is employed for synchronizing the position
detection.
Some relative drawbacks of the above mentioned methods
are the dependence on mechanical variables and a certain
degree of invasive nature of the instrumentation.
Increasing industrial applications and benefits of such new Fig. 5. MONSAG for a Gearless Drive
instrumentation are discussed by [15], [9] and [16].
MONSAG system is a non-invasive method based on Additional (non-desired) input excitations are given by
digital signal processing of electrical signals of the motor the noise vector K. The noise vector represents external
drive for the on-line monitoring of load filling of a tumbling perturbations, uncertainties in parameter and measurement
mill. It allows the improvement of operational control of variables. The output vector y represents the output variables.
variables, like the speed and mill feeding for optimizing the The parameter vector T represents the system parameters. For
load movement in the mill. The method may be used for any the sake of simplicity the estimation variables will be written
type of synchronous motor, as compared in [17] where it was as X, U, 4, Y for the estimation of vectors x, u, T, y,
introduced for application with gearless drives only. respectively. The control problem may be formulated with the
Experimental results at an actual industrial installation are goal for minimizing the estimation errors given by the set of
presented. differences shown in Eq. (3)-(6), under presence of noise K:
IV. CONTROL OF GRINDING MILLS WITH GEARLESS DRIVES
dx/dt = f (x, u, K, T, t) (1)
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4
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Measured Filling, %
33
32
31
30
29
28
27
26
26 27 28 29 30 31 32 33 34 35 36
Fig.6. Improvement in Mill filling measurement. Comparison Fig. 9. Measured (inspections) v/s estimated load filling
using bearing pressures and MONSAG
VI. REDUCTION OF LINER WEAR AND BALL BREAKAGE
In order to reduce the liner wear inside the mill and to avoid
the breakage of grinding steel balls, it is need to avoid the
impacts steel-to-steel inside the mill, given by the cascading
effect shown in Fig.4. For this purpose the impactmeter
system is employed, see Fig. 10. The system has an array of
acoustical sensors around the mill. With a pattern recognition
algorithm, it is intended to detect the high energy impacts by
analyzing the behavior of the sensor signals. A too high sped
of rotation, the more harmful impacts steel-to-steel. A too low
speed of rotation, the lower the comminution inside the mill.
Operating with the optimal speed, the charge movement is
controlled for the best effective comminution. The optimal
Fig.7. Improvement in throughput employing MONSAG speed is not fixed, because it depends on multiple factors [6].
instead of bearing pressures
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VIII.REVIEW OF POTENTIALS
A. Haul trucks
Potential improvements in diesel-electric haul trucks with
better energy efficiency and emissions can be stated by the use
of new super capacitors, batteries and control of power
Fig.10 Impactmer System. Array of sensors around the mill. electronics system feeding the drives in order to enhance the
smooth operation of the diesel engine under variable operating
conditions in comparison with the conventional haul truck.
VII. HIGH-POWER RECTIFIERS Another way is the use of bio-diesel component, let’s say 20%
of the fuel, can improve further the carbon emissions in the
For electro refining or electro winning of copper, high same order of 20%.
current rectifiers are employed. Fig.11 depicts a typical
scheme of an installation for Electro-winning of copper. B. Gearless mill drives
Reliability issues of high-power converters-fed drives
employed in modern SAG circuits state the trend for using
better and modern instrumentation Energy efficiency can be
achieved by improving the instrumentation and control system
in order to stabilize and optimize the control of the charge
motion inside the mill. Use of new instrumentation for
estimating operational variables and detecting unfavorable
operating conditions like harmful impacts steel-to-steel is also
a way for avoiding downtimes and getting better efficiency, as
shown for the MONSAG- and Impactmeter system in
paragraph VII.
A saving of 0,36 kWh/Ton, for a beneficiation of
Fig.11 High-power rectifier for Electro-winning of copper
12.483.000 tons/year it represents a saving of 4494
MWh/year, with an emission factor of 0,95 Tons CO2/MWH,
the impact is a saving of ca. 4269Tons CO2 in a year.
A new technology based on grinding based on HPGR
(High Pressure Grinding Rolls) have been developed and
employed for grinding ferrous ore and it is being tested in
several hard rock mining companies. In some cases it has been
reported a value for cost reductions of 14%, [18] in
comparison with gearless mill drives for SAG mills [19].
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as well as on the avoiding of unfavourable operating [12] Pontt J., Valderrama W., Magne L., “The Impactmeter, a new instrument
for monitoring and avoiding harmful high-energy impacts on the mill
conditions like steel-to-steel impacts in the internal liners of liners in SAG mills”, Proceedings IFAC Workshop: Future trends in
the mill. The use of modern technology with new concepts Automation in Mineral and Metal Processing, MM´2000, Helsinki,
can help productivity, energy efficiency, carbon emissions and Finland, 22-24-Aug., 2000, pp.286-289.
[13] Sams C., Dreher R., Filidore A., “Smooth transitions to performance in
economy.A higher reliability means also less downtimes and
large grinding mills”, International Conference on SAG grinding,
less man-hours working in the harsh industrial environment, SAG2001, Vancouver, Canada, 2001. CD Rom.
contributing to safety. [14] Dong H, Moys MH., “Measurement of impact behaviour between balls
and walls in grinding mills”, Minerals Engineering 16 (6), Jun 2003, pp.
543-550.
ACKNOWLEDGMENT [15] Sams, C. et al, “New performance enhancements technologies for the
milling industry”, Workshop on SAG Grinding, SAG’03, Viña del Mar,
The authors want to recognize the sponsorship of the Chilean Council for Chile, 8-10 Oct. 2003. CD Rom.
Scientific and Technological Research (CONICYT) with the Proj. Fondecyt [16] Morrel S., Delbony H., “The modeling of autogenous and
1100988 and the support provided from MSI-Mideplan Proj. P07-087-F. semiautogenous mills, ”Proceedings of 2nd International Conference on
autogenous and semiautogenous grinding technology, Oct. 1996,
References SAG1996, Vancouver, B.C., Canada, Vol. 2, pp. 713-728.
[17] Pontt J., Valderrama W., Magne L., Pozo R., “MONSAG: A system for
[1] Cochilco, “ Consum of energy and greenhouse gases emission of copper the On-Line charge monitoring in semiautogenous grinding mills”,
mining, year 2008” (“Consumo de energía y emisiones de gases de efecto (MONSAG: Un sistema para el monitoreo On-Line de la carga en
invernadero de la minería del cobre, año 2008”), .July, 2009, available at Molinos SAG), Proceedings of Workshop on SAG grinding SAG’97,
www.cochilco.cl, page 14. Viña del Mar, Chile, 1997.
[2] G.M. Brown, W.G. Koellner, “A GTO Powered AC Drive System [18] K. Casteel, “Perfecting hard-rock High Pressure Grinding Performance”,
Increases the Performance of Off-Highway Haul Trucks”, Conference E&MJ, pp. 40-49.
Record of Thirty-Fourth IEEE-IAS Annual Meeting, Oct. 3-7, 1999, pp. [19] Rodríguez, J., Pontt, J., Newman, P., Musalem R.,Morán, L., “Technical
222 –233. Evaluation and Practical Experience of High Power Grinding Mill Drives
[3] W.G. Koellner, G.M. Brown, J. Rodríguez, J. Pontt, J. Cortés, H. Miranda. in Mining Applications”, Proceedings 38th IEEE Ind. Appl. Soc. Annual
“Recent Advances in Mining Haul Trucos”, IEEE Transactions on Meeting IAS 2003, USA. 12-16 Oct. 2003, Vol. 3, pp. 1629 – 1636.
Industrial Electronics, Vol. 51, Issue 2, pp. 321-329, April 2004.
[4] Errath, R., Riezinger F., Knecht J, “Exploring today’s limits of SAG and
ball mills technology”, Workshop on Semiautogenous Grinding, SAG’03,
Viña del Mar, Chile, 8-10 Oct. 2003.
[5] Valderrama, W., Magne, L., Pontt, J., “Semiautogenous grinding based on
the mill load movement”, (Molienda semiautógena basada en el
movimiento de la carga en el molino”), Proceedings of Workshop of
Semiautogenous Grinding, SAG’99, Viña del Mar, Chile, May, 12-14, Jorge O. Pontt (M’00–SM’04) received the
1999. CD Rom. Engineer's and M.S. degrees in electrical engineering
[6] J. Pontt, G. Sepúlveda, W. Valderrama, P. Espinoza, “New Methods and from the Universidad Técnica Federico Santa Maria
plant experience for detection of harmful impacts on shell liners in high- (UTFSM), Valparaíso, Chile, both in 1977. Since
power semiautogenous grinding mills”, Proceedings of IEEE-IMTC’04, 1977, he has been a Professor in the Department of
May, 2004. Electrical Engineering and Department of
[7] Rajamani R., Mishra B.K., “Three-dimensional simulation of charge Electronics Engineering, UTFSM with R&D and
motion in plant size SAG mills”, Proceedings of International Conference graduate program of Power Electronics. He is
on autogenous and semiautogenous grinding technology, SAG2001, Vol. coauthor of the software Harmonix that is used in
IV, Vancouver, B.C., Canada, pp. 48-57. harmonic studies in electrical systems. He has more
[8] Hlungwani O, Rikhotso J, Dong H, Moys MH, Further validation of DEM than 100 refereed journal and conference papers. He is a consultant in the
modeling of milling: effects of liner profile and mill speed, MINERALS mining industry, particularly in the design and application of power
ENGINEERING 16 (10), pp. 993-998, Oct. 2003. electronics, drives, instrumentation systems, and power quality issues, with
[9] Apelt T.A., Asprey S.P., Thornhill N.F., “Inferential measurement of SAG management of more than 80 consulting and R&D projects. He has had
mills parameters, Minerals Engineering 14 (6), pp. 575-591, June 2001. scientific stays at the Technische Hochschule Darmstadt, Darmstadt, Germany
[10] Pax, R.A., “Non-Contact acoustic measurement of in-mill variables of (1979/1980), the University of Wuppertal, Wuppertal, Germany (1990), and
SAG mills”, International Conference on SAG grinding, SAG2001, the University of Karlsruhe, Karlsruhe, Germany (2000/2001). He is co-
Vancouver, Canada, 2001. CD Rom. pp. II 386-II 393. founder of the spin-off company ETT Ltda. (Chile) and Valtec related with
[11] Campbell J., Spencer D., Sutherland S., Rowlands T., Weeller K., Cleary instrumentation and monitoring systems for large grinding mills. He leads the
P., Hinde A., “SAG mill monitoring using surface vibrations, Proceedings Laboratory for Reliability and Power Quality, UTFSM (LACSE) and currently
of International Conference on autogenous and semiautogenous grinding he is Director of Millennium Nucleus on Industrial Electronics, Mechatronics
technology, SAG2001, Vol. II, Vancouver, B.C., Canada, pp.373-385. and Process Control (NEIM), UTFSM.
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