Professional Documents
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Vale S/A
Mina do Sossego s/n, Garoy
Cana dos Carajs, PA, 68537-000
(*Corresponding author:Luis.machado@vale.com)
Sossego Mine was the first Vale SAG mill operation to process copper-gold ore. It is located in
the state of Para, in the south-eastern Amazon region of Brazil. In the first six years of continuous
operation, Vale investigated different alternatives for improving circuit performance by investigating
operating conditions, mainly focusing on the SAG mill.
Today, after a steady increase over five years the annual production rate seems to have stabilized.
It is hoped this work will show how the SAG operating practice have been perfected with time and as new
data are collected. Historical data of mill grind-outs and crash stops helped create operation curves
depending on the ball charge volume and total charge volume. Also noted were impacts on throughput due
to the effect of reducing liner weight and the ore type characteristics.
KEYWORDS
Sossego, SAG, grate, ore, circulating load.
INTRODUCTION
Sossego is the first Vale project in the copper business. It is based on a copper-gold resource
discovered in early 1997 comprising of the Sequeirinho and Sossego adjacent orebodies. The mine is
situated approximately 70 km south-west of the Carajs area, near the town of Cana dos Carajs, in the
south of Para state, Brazil. The concentrator was designed to process 41,000 metric tons per day which is
equivalent to 15 million metric tons per year from an open pit mine. The proven reserve is 255 Mt with an
average grade of 1.0% Cu and 0.3 g/t Au. The ore is granite with significant incidence of magnetite, with
typical Bond ball mill work indices (WI) of 17 to 20 kWh/t and very high abrasiveness indices.
Operation of the Sossego mine and processing plant started in April 2004 targeting an average
concentrate production of 540,000 metric tons per year at 30% Cu and 8 g/t Au.
Industrial Circuit
The Sossego industrial plant comprises a typical high-tonnage primary crushing-SABC-flotation circuit
based on large capacity equipment in each unit operation. A brief description of the Sossego circuit
follows.
Primary Crushing
Run-of-Mine ore is delivered to a 60x89 gyratory crusher by 240 ton rear dump trucks. The primary
crusher operates with a nominal closed side setting of 140 mm which results in a P80 of 125-150 mm.
Crushed ore is conveyed to a conical pile adjacent to the concentrator by a 4 km conveyor belt operating at
a nominal rate of 2,300 t/h.
Crushed Ore Stockpile
The conical ore stockpile has a live capacity of 41 kt, equivalent to 24 hours of plant operation. Three
tandem apron feeders are located underneath the stockpile feeding a single conveyor belt that supplies the
SAG mill.
Grinding
The grinding circuit consists of a single line configured as SABC with a nominal capacity of 1.841 t/h. A
11.58 meters diameter by 7.01 meters (EGL) SAG mill is driven by a 20 MW gearless motor. The SAG
mill discharges onto two 3.65 x 7,31 m horizontal vibrating screens whose oversize is conveyed to the
recycle crushing building where two MP800 cone crushers reduce the pebbles to a nominal P80 of 12 mm.
The crushed product is sent to the SAG mill feed closing the circuit. The screen undersize is pumped to two
separate nests of 838.2 mm hydrocyclones. Each nest underflow is sent to one of two 6.70 x 9.75 m ball
mills, equipped with 8.5 MW motor single pinion fixed speed drives. The targeted P80 of the hydrocyclone
overflow is 0.21 mm at 40% solids.
Flotation and Regrinding
The hydrocyclone overflow from each ball mill circuit feeds the rougher stage consisting of seven 160 m
cells. Rougher tailings from both lines reports to the regrind circuit consisting of two Vertimills (1,500 HP
motor each) operating in a reverse mode with 380 mm hydrocyclones. The regrind circuit product, with a
nominal P80 of 0.044 mm is pumped to six cleaner flotation columns (4.27 x 10 m). The column tails feeds
one row of seven 70 m cleaner/scavenger cells. The cleaner-scavenger concentrate is combined with the
rougher concentrate, thus forming the circulating load of the flotation circuit. The cleaner-scavenger tails
are pumped to the tailing dam, whereas the cleaner concentrate is pumped to a thickener.
Thickening and Filtering
Final concentrate flows by gravity to a 20 m diameter thickener. The thickener overflow is recycled to the
flotation feed and the underflow is pumped at 60% solids to the filter plant tanks. From the filter feed tank
concentrate is pumped to two filters. The filtrate returns to the thickener and the cake with 9% moisture is
stocked in a 5250 t capacity conical pile, located in a moisture controlled building. The concentrate is
reclaimed by front end loaders to 35 t haul trucks which dump it in a storage building in the city of
Parauapebas and then transport it by an 800 km railway to the port of Itaqui, in Maranho state. Figure
1shows a summary of the Sossego flowsheet.
Circulating Load
The circulating load is greatly influenced by the grate discharge slot opening. The Sossego SAG
mill has no pebbles ports, and after extensive testing (37generations of grates) the initial slot opening is
currently 76.2 mm, with double grates and a total open area of 8.9 m2. There are 16 grates and each month
(after processing ~ 1,000,000 t), 4 new grates are exchanged. At the end of 4 months there is a regime of
stable total open area. From the time that it took this exchange cycle, the circulating load of SAG acquired
another pattern. Previously, all the grates were exchanged simultaneously after 4 months of operation. With
this procedure, the circulating load was low in the first month and increased considerably as it approached
the end of grate life. With the alternating exchange cycle, this problem disappeared. The main influence on
the circulating load currently is wear of the cylinder body lining. Figure 2 illustrates this for the last two
lifters exchanges in 2010/2011.
There is an increased circulating load current depending on lifter wear and lower grinding media
launch from the lifter face angle in the SAG mill.
Circulanting Load
70
60
Circ. Load - %
50
40
30
20
10
0
Time - hours
jan/11-Mai/11
out/10-jan/11
2100
throughput - t/h
1900
1700
1500
1300
1100
900
700
500
24,0
26,0
28,0
30,0
32,0
34,0
36,0
38,0
Mar
Abr
2100
1900
throughput- t/h
1700
1500
1300
1100
900
700
500
24,0
26,0
28,0
30,0
32,0
34,0
36,0
38,0
14,85%
13,79%
12,77%
Ball Charge
Figure 4. SAG mill throughput as a function of ball charge and total charge from actual plant operating.
Target Weight
Normally, the total charge of mill is 30%. This is controlled by the measurement following crash
stops which determine the load cell weight that corresponds to the charge filling. With the range of data
collected from the crash stops, it was possible to construct a theoretical curve of weight reduction. Target
weight is reducing as more mass is processed in the mill and the lifters are being consumed (Figure 5).
Thus weight control of the SAG became more constant and ensures higher levels of mill throughput most
of the time.
Weight target - t
1100
1000
900
800
700
600
500
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
Figure 5. SAG mill weight target for total charge of 30% as a function of feed run of pile for campaigns of
lifters.
Feed Size Distribution
The SAG mill throughput profile in relation to feed F80 is shown in Figure 6 (monthly sampling).
Note that the highest throughput is achieved for an F80 between 4 and 5 inches. For higher and lower sizes
the throughput is smaller.
Histograme F80 X Sag Mill Throughput
2000
40,0
1950
35,0
Freqency - %
1850
25,0
1800
20,0
1750
1700
15,0
1650
10,0
1900
30,0
1600
5,0
1550
0,0
1500
3
Freqency
Sag throughput
35,0
2100
30,0
2000
25,0
1900
20,0
1800
15,0
1700
10,0
Frequency - %
1600
5,0
0,0
1500
20
25
30
35
40
Sag throughput
Figure 7. SAG mill throughput a function of retained of critical fraction of feed and frequency distributions
(monthly sampling).
Ore Characteristics
It is not possible to disregard the influence of ore characteristics. In correlation with the Bond
Work Index (WI), the historical record of monthly average throughput occurred when the plant was fed an
ore with a WI below historical average, providing a value of 1,900t/h (see Figure 8). The typical WI is 17
kWh/t.
Sag Mill Throughput x WI
19,0
18,0
17,0
WI - kW/t
16,0
15,0
14,0
13,0
12,0
11,0
10,0
1500
1550
1600
1650
1700
1750
1800
1850
1900
1950
Porcentagem - %
16
14
12
10
8
6
4
2
pl
us
43
41
39
37
35
33
31
29
27
25
23
21
19
17
15
11
,0
13
,0
9,
0
5,
0
7,
0
Normal WI (jan/11)
Figure 9. SAG mill circulating load with bimodal distribution as a function of ore with smaller Bond Work
Index
Energy Consumption
There is a relationship of SAG motor specific power and mill throughput (see Figure 10).
However, note that this type of data allows Sossego to evaluate problems of energy consumption at the
plant, since for the same SAG mill throughput there is a distinct energy consumption. Reduced rates due to
pebble cone crusher problems are easily detected by these relationships.
1950,0
1900,0
1850,0
1800,0
1750,0
1700,0
1650,0
8,00
9,00
10,00
11,00
12,00
13,00
Figure 10. SAG throughput as a function of monthly SAG mill specific motor power)
14,00
CONCLUSIONS
There are plenty of data stored in six years of operation and there are still much to analyze and correlate.
Only as mall part are presented here. For example, information of quality results in knowledge and fine
control of the SAG mill operation and this is sought continuously and systematically at Sossego.
ACKNOWLEDGEMENTS
The authors wish to thank Vale S/A for permission to publish this paper.
REFERENCES
Delboni, H., Rosa, M. A. N., Bergerman, M. G. and Nardi, R. P. (2006) Optimisation of the Sossego SAG
mill, SAG 2006, University of British Columbia, Vancouver, B. C., Canada.
Starkey, J. & Scinto, P. (2010) SAG Mill Grinding design versus geometallurgy Getting it right for
competent ores, , XXV International Mineral Processing Congress (IMPC) Proceedings,/ 6 - 10
September, Brisbane, Qld., Australia.