Marcelo Perrucci, Global Product Manager, Jornadas Tecnicas Peru, 23 April 2015 ABB variable speed solutions Grinding applications

Marcelo Perrucci, Global Product Manager, Jornadas Tecnicas Peru, 23 April 2015 ABB variable speed solutions Grinding applications

Agenda ABB drive systems for grinding Gearless Mill Drives Ring-geared Mill Drives Mill application control features High Pressure Grinding Rolls References

ABB drive systems for grinding A comprehensive portfolio for optimal results

ABB in mining and mineral processing Drive solutions for all grinding applications Gearless Mill Drive Ring-geared Mill Drive High Pressure Grinding Rolls Ring-motor own manufacturing E-House w/ Cycloconverter and auxiliaries Transformers Service Grinding functions E-House with MV Drive and auxiliaries Transformers Motors Service Grinding functions MV Drive Transformers Motors Service Application functions on development CONFIDENTIAL - We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. Copyright ABB Switzerland Ltd.

ABB drive systems Product integration into mining solutions Interface engineering Documentation Project management Plant environment Service and maintenance Packing and transport Design and development Supply network Mechanical interface Installation Feasibility studies Process control system Commissioning Consulting Training Ring motors manufacturing

Mill drive solutions Power/speed positioning Total installed drive nominal power [MW] 30 Gearless 25 20 Ring-geared low speed without gearbox 17.5 15 Ring-geared high speed with gearbox 12.5 10 7.5 5 2.5 8 16 150 200 1000 1800 Motor nominal speed [rpm]

Gearless Mill Drives GMD

Gearless Mill Drives Concept Motor poles installed directly on the mill Highest mill drive availability Highest mill drive achievable power Highest mill drive energy efficiency Highest availability through No coupling, no gearbox, no pinion and no ring gear No time-consuming alignments of mechanical transmission No need to re-align mechanical transmission when operating at different mill loads Variable speed, bi-directional, positioning without additional motor Flexible power and size according mill manufacturer s requirements

Gearless Mill Drives Overview - ABB Scope of Supply HF & PFC Equipment MV Switches Harmonic Filter & Power Factor Compensation Study Converter Transformers Application Design & Engineering f1 S T2 T1 T1 T1 E-house & Auxiliaires Cycloconverter & Excitation n2 n1 B i- i+ A u+ u- Ringmotor ir is it AC800 PEC Ctrl ie ur us SM 3 ut f2

Gearless Mill Drives E-House MCC s Video Monitoring System Excitation Converter Cycloconverter & Thyristor Stack Power Part & Cooling PEC Controller & PLC Front Panel

Gearless Mill Drives Pedestal versus foot mounted PEDESTAL MOUNTED BALL MILL GMD Available for Ball Mills 26 diameter FOOT MOUNTED BALL MILL GMD Available for Ball Mills 26 diameter

Gearless Mill Drives Ringmotor Stator of the Synchronous Machine Typically spilt in 4 Stator quarters Stator quarters divisions are at 12, 3, 6 and 9 o clock Stator quarters assembled one to each other on site

Gearless Mill Drives Manufacturing

Gearless Mill Drives Finite Element Analysis ABB has performed the Overall System Study with Finite Element Analysis for several GMDs, taken into consideration: Soil characteristics Foundations Mill bearings Mill with rotor poles Magnetic pull Stator Therefore ABB gained the required know-how of the complete system for the design of large GMDs

Gearless Mill Drives Power Factor Correction & Harmonic Study Study of the Power Factor Correction & Harmonic for the overall Plant at the Point of Common Coupling Complete the Study to bring the Plant Consumption in regards of Power Factor and Harmonics at the Level required by the Local Electrical Authorities. Specify the Equipment - Power Factor Capacitor Bank & Harmonic Filters Sets.

Gearless Mill Drives Visualization System

Ring-geared Mill Drives RMD

Ring geared mill drives Single Pinion Low speed solution High speed solution No gear box Low rated motor speed (~180 rpm) Typical power 3 9 MW With gear box High rated motor speed (~1000 rpm) Typical power 3 9 MW

Ring geared mill drives Dual pinion Low speed solution High speed solution No gear box Low rated motor speed (~180 rpm) Typical power 7 18 MW With gear box High rated motor speed (~1000 rpm) Typical power 7 18 MW

The basic equipment Transformer Transformer Dry or oil type Surge arresters With our without terminal boxes

The basic equipment MV drive Converter With integrated mill controller Multidrive solution for dual pinion RMD > 8MW Active rectifier solution for leading power factor requirements Drive Monitor with touch screen Pre-magnetisation unit available as option Off load disconnect switches as option

The basic equipment Motors General air or water cooled different standards High speed solution asynchronous motor Low speed solution synchronous motor with brush excitation or brushless excitation as option Motor hollow shaft for air clutch solution

The basic equipment Compact low speed synchronous motors While DOL motors require high number of poles (>30) to achieve low speeds results in bulky design high shaft height VSD driven synch. motors only need low number of poles (8-12) Compact design with low shaft height: (800-1250 mm) Smaller footprint Less maintenance

Standard option MLCP

Standard option Local isolator switch

Standard option Mill auxiliaries controller

Standard option MCC

Solution standard option Cooling systems

Standard option E-house: everything included

Mill application control features For GMD and RMD

ABB variable speed solutions for mills Current functionalities * For RMD solution only Starting torque and current limitation Automatic positioning Creeping speed Frozen charge detection Frozen charge remover Controlled roll back Over-duty cycle mode * Coupling supervision * Mill power ride through Load sharing (for dual pinion) * Empty mill detection Special solution for weak networks * Variable Speed

Mill application features Starting sequence

Starting sequence Electrical soft starting Mill starting, network side: low power, nominal voltage, low current (e.g. 15% of rated current) Low speed Mill starting, motor side: High torque (e.g. 130% T n ), low power High current (e.g. 130% I n ), low voltage No air-clutch required High speed

Mill drives Electric soft starting RMD example Starting torque 107% MOTOR SPEED MASTER [rpm] MOTOR SPEED FOLLOWER [rpm] MOTOR TORQUE MASTER [%] MOTOR TORQUE FOLLOWER [%] NETWORK CURRENT [%] Network current draw: only 10% No high inrush current Very smooth for the electrical supply network Not a true constant torque application => speed influences torque Use of variable speed reduces start torque and related stresses

Operation remarks: Mechanical smoothness required Trend: higher power and torque transfer per pinion Pinion & ring gear teeth getting wider. Teeth width for 2 x 6340 kw: SAG mill 1 016 mm Ball mill 1 050 mm More challenging to have a perfect alignment If no perfect alignment, torque transfer not over complete teeth surfaces, but over hot spots Beneficial to avoid rough starts and torque spikes during all operation conditions >1meter

Mill application features Controlled rollback

Mill drives Controlled roll back RMD example MOTOR SPEED MASTER [rpm] MOTOR SPEED FOLLOWER [rpm] MOTOR TORQUE MASTER [%] MOTOR TORQUE FOLLOWER [%] NETWORK CURRENT [%] Mill slowing down Controlled roll back: Low negative speed Still positive torque Mill stopped with charge in unbalanced position

Mill drives Controlled roll back RMD example MOTOR SPEED MASTER [rpm] MOTOR SPEED FOLLOWER [rpm] MOTOR TORQUE MASTER [%] MOTOR TORQUE FOLLOWER [%] TORQUE DIFFERENCE [%] No mill rocking Mill rolls back controlled with low speed (1 rpm motor speed, 0.1 rpm mill speed) Takes about 62 seconds to stop mill in balanced position Negative speed, but always positive torque à No backlash

Mill drives Controlled roll back vs coast stop RMD example 62s to stop mill in balanced position, no backlash 217s to stop mill in balanced position, with backlash

Mill drives Stopping sequence without backlash MOTOR SPEED [rpm] MILL ANGLE [Deg] MOTOR SPEED [rpm] Such backlash does not occur with controlled roll back

Mill application features Automatic positioning

Automatic positioning Measurement 1. Required angle set by operator at MLCP: 180 2. Mill starts, cascading measured at 27

Automatic positioning Measurement 1. Example: Required angle set by operator at MLCP: 180 2. Cascading measured at 27 3. Mill turns totally 27 + 180 = 207 and stops in unbalanced position

Automatic positioning Measurement 1. Example: Required angle set by operator at MLCP: 180 2. Cascading measured at 27 3. Mill turns totally 27 + 180 = 207 and stops in unbalanced position 4. Control roll back, mill stops in balanced position at 179.2

Mill application features Creeping

Creeping Measurement Cascading mill charge (frozen charge protection) Start with 10% rated speed (mill speed ~1 rpm) Motor speed 3.293 rpm (mill speed ~0.2 rpm) Controlled roll back (mill speed ~0.1 rpm)

Mill application features Frozen charge protection

Mill drives Frozen charge protection Under normal conditions, the charge in a mill starts to cascade as soon as a certain mill angle is reached. In rare cases, for instance after long suspended mill operation, the charge can settle in a large lump and sticks to the mill liners. Frozen charge protection is a system that prevents that lump of ore to be lifted and then dropped, that could cause damage to mill liners, bearings and even mill shell.

Mill application features Frozen charge remover

Mill features Measurement frozen charge remover Impact of torque steps on mill speed Torque steps superimposed on actual motor torque Both torque and speed are always positive à contact between pinion and ring-gear is always maintained, hence no backlash!

High Pressure Grinding Rolls HPGR

ABB variable speed drive solutions for HPGRs State-of-the-art system Speed reference Identical load sharing between rolls with speed match Single point of contact & solution ownership Dedicated application expertise to ensure smooth startup More than 45 running systems, with largest installed base for high power solutions ( > 2 MW)

Electrical system layout for HPGRs MV breaker Converter Transformer Rectifier Unit DC-Link Capacitor Inverter Unit Sine Filter ACS 1000 Commonly used for MV,1 to 3 MW Motor

ABB variable speed drive solutions for HPGRs State-of-the-art control concept - start up snapshot Motor 1 speed Motor 2 speed % Torque RPM Motor 1 torque Motor 2 torque CONFIDENTIAL - We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure TIme to third parties without express authority is strictly forbidden. Copyright ABB Switzerland Ltd.

Intelligent drive systems for HPGRs Maximize system availability and roller life

Intelligent drive system for HPGRs Advanced functionalities Launch RollXtend - Load share control Improve roller lifetime by equalizing roller wear Roller maintenance without auxiliary drive Improve productivity and safety In Pilot Roller wear measurement Wear reduction Predictive maintenance and remote monitoring Prevent unscheduled stoppage

Roller maintenance mode To improve productivity and safety

Intelligent drive system for HPGRs Maintenance Mode Chain Position rollers individually with main drive for carrying out inspections and repairs. Reduce manual operations and time to engage auxiliary drive K$ 330* additional copper concentrate produced / year Increased Safety Eliminates additional auxiliary drive unit K$ 25 ~30 saved on additional CAPEX * 2.8 MW, 0.4% grade, 6637 USD / Ton

ABB grinding solutions References

ABB Gearless Mill Drives worldwide 123 total units installed and recently ordered 12 units in USA & Canada Sweden 2 units Romania 5 units 12 units in Europe Canada 2 units Belgium 1 unit USA 10 units France 1 unit 7 units in the Middle East South Korea 6 units Kazachstan 6 units Dom. Republic 1 unit Panama 6 units Peru 21 units Chile 25 units 60 units in the Americas Italy 3 units Mauretania 3 units Brazil 7 unit Algeria 2 units 7 units in Africa S. Arabia 6 units South Africa 2 units Iran 1 units Indonesia 7 units India 1 unit Taiwan 1 unit Australia 4 units 25 units in Asia & Oceania

Go gearless for best-in-class up time Recent project highlights One of world s most powerful GMD at highest altitude (4600 masl) running at Toromocho mine in Peru (Minera Chinalco): 28MW, 40. 6 x GMD systems (22MW, 27 ) for Cerro Verde copper mine expansion, Peru (Freeport-McMoRan Copper & Gold). 3 GMD systems for the Yanacocha Minas Conga (4200 masl) copper gold mine in Peru (Newmont Mining Corporation): 1x 28MW 42 + 2x 15,6MW 26.

ABB ring-geared mill drives worldwide 80 total units installed and recently ordered Canada 21 units Norway 3 units Sweden 8 units Finland 4 units 20 units in Europe USA 8 units Mexico 4 units Dom. Republic 2 units Suriname 2 units 39 units in the Americas Portugal 1 unit Ireland 1 unit Spain 1 unit Argentina 2 units Mali 2 units Liberia 3 units Namibia 2 units 12 units in Africa Ghana 1 unit DRC 1 unit South Africa 3 unit Ukraine 1 unit Armenia 2 units 6 units in the Middle East India 4 units Russia 1 unit Australia 3 units 3 units in Oceania

Smooth operations for ring-geared mills Recent project highlights Order for the world s biggest dual pinion RMD: 5 x 18MW for Hycroft gold mine, USA (Allied Nevada Gold). Recently commissioned the world s biggest single pinion RMD: 1x9MW for Opinaca Eleonore, Canada (Gold Corp). 3 x 7,4MW single pinion high-speed RMD systems for the Western Range iron ore greenfield project in Liberia, West Africa (ArcelorMittal).

ABB High Pressure Grinding Rolls worldwide 45 total units installed and recently ordered Canada 1 unit 2 Units in Europe 31 Units in the Americas Croatia 1 unit Bulgaria 1 unit Mexico 1 unit Peru 14 units 12 Units in Oceania Chile 5 unit Brazil 10 units Australia 12 units

Your best deal for reliable high pressure grinding Recent project highlights 4 HPGR systems 2,8MW for Boddington gold mine, Australia Upgrade of 1x fixed-speed HPGR system to variable-speed at Mogalakwena North open-pit mine, South Africa (Anglo American Platinum). 8 x 2,8MW twin-drive systems for HPGRs for Cerro Verde copper mine expansion, Peru (Freeport-McMoRan Copper & Gold)

ABB Group April 30, 2015 Slide 66