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P R O C E S S I N G S O LU T I O N S Metso Delivering Largest HPGR Unit for Morenci Copper, Bulk Handling System for Brazilian Phosphate Metso is set to provide an HRC-3000 high pressure grinding roll (HPGR) for Freeport-McMoRan Copper & Gold's Morenci copper mine in Arizona, USA, which will be the largest machine of its kind, according to the company. "Operating costs are increasing throughout the industry, with power being a key component, and our customers are looking for more efficient technology to achieve the best returns in these circumstances," said Andy Lingenfelter, Metso's global key account manager for Freeport-McMoRan Copper & Gold. The HRC-3000 will perform tertiary crushing for the Morenci plant's comminution circuit, which includes crushers and ball mills also supplied by Metso. Metso said the HRC-3000's ability to meet the demands of this application is a result of its innovative design, which surpasses throughput and efficiency performance of existing HPGR technology. Over 8,000 hours of testing—including 4,000 hours in a pilot plant operating at New design elements boost throughput and efficiency of the new HRC-3000 HPGR, according to Metso. 88 E&MJ; • DECEMBER 2012 Grupo Galvani's industrial complex in Paulina, Brazil. Morenci—have proven the design and efficiency of the HRC, according to Metso. Design features include a new arch frame to eliminate downtime, and flanges to maintain wear and increase throughput. Metso said the machine's patented arch frame design creates an even gap setting across the width of the tires, limiting skewing that results in downtime for mining operations. This anti-skewing arch frame also prevents damage to the roller bearings (caused by misalignment) that often occurs with traditional HPGR designs. Flanges—used in place of springloaded cheek plates—help maintain even pressure while crushing ore, according to the company. This even pressure minimizes the amount of material that bypasses the crushing zone, enabling greater circuit capacity and increasing overall crushing efficiency. The flanges also distribute wear on the surface of the tires evenly, providing an increased life for the machine's most significant wear part. These design changes, said Metso, were implemented precisely for the type of application in which the HRC-3000— scheduled to be online by early 2014— will be operating: high-tonnage tertiary crushing of hard rock. The incentive for operators, thanks to improvements in efficiency at increased throughput, is cost savings. "One of the reasons [our customers] are looking at HRC technology is because they see how our design can provide long-term benefits in operating costs," said Lingenfelter. Metso also recently announced it was selected to supply grinding and bulk materials handling equipment for Galvani Group, a Brazilian family-owned company active in mining, fertilizers and construction businesses. Two separate contracts signed with Galvani Group include the supply of a travelling stacker, a bridge reclaimer and two yard conveyors, two rod and two ball mills, as well as field services for assembly, startup and commissioning. Equipment will be delivered to the company's new phosphate processing plant in Serra do Salitre, Minas Gerais—a greenfield project with projected production of 1.2 million metric tons per year (mt/y). The supply agreement includes a 1,920-mt/h-capacity, bridge-type bucketwheel reclaimer; a 2,880-mt/h stacker; an 830-m belt conveyor which will feed the stacker; and another conveyor for receiving material from the reclaimer at 1,920 mt/h. In addition, the agreement calls for delivery of two Metso 14 x 20-ft rod mills and two 18 x 33-ft ball mills. www.e-mj.com