Thesis ESTUDIO DE AUMENTO DEL TONELAJE EN PLANTA DE CHANCADO-MINERA ALTOS DE PUNITAQUI (MAP)
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Date
2017
Authors
SALAS TELLO, DIEGO ALONSO
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Abstract
La memoria de titulación presentada en este estudio tiene el objetivo de analizar el proyecto de aumento de tonelaje en la etapa de chancado de Minera Altos de Punitaqui (MAP).Se investigó la viabilidad técnica – económica de aumentar el tonelaje desde 3000 TPD hasta un tonelaje deseado (i.e., 4200 – 4500 TPD) sin modificar la infraestructura y con el mismo rendimiento metalúrgico (i.e., hipótesis planteada). También, se realizó un plan de acción para solucionar los problemas y alcanzar el tonelaje deseado.La logística del proyecto se centró en evaluar el desempeño de la planta de chancado para corroborar o refutar la hipótesis. Para esto se realizó una revisión de la literatura, donde se abarcaron proyectos de aumento de tonelaje con el fin de obtener los principales parámetros a tomar en cuenta. Luego fueron recopilados los datos en la planta de chancado antes del aumento del tonelaje. Este paso tuvo el objetivo de establecer la línea de referencia base. En la tercera etapa se actualizó la información de la planta de chancado para el tonelaje procesado durante el estudio. Finalmente, se evaluó el proyecto de aumento de tonelaje para un tonelaje deseado.Los resultados obtenidos indicaron que en la etapa de aumento de tonelaje se aumentó la disponibilidad de la planta de un 62% hasta un 71%. Esto fue posible debido a las nuevas propiedades de mineral que se procesa (Blending de menor dureza) y una mayor confiabilidad de los equipos. Por otra parte, la evaluación metalúrgica reveló que la tolva terciaria presenta un importante grado de segregación hacia el circuito terciario, provocando problemas de sobrecargas y mala distribución de tamaños hacia los equipos de clasificación. Este problema hace inviable aumentar el tonelaje deseado manteniendo la misma infraestructura.El plan de acción para solucionar los problemas y aumentar el tonelaje fue el cambio del chancador secundario (1), rediseño de la tolva terciaria (2), y la disposición de un supervisor en terreno (3) junto a un operador del cargador frontal (4). Con esto sería posible llegar a 4500 TPD de forma eficiente.La evaluación económica de todos los cambios realizados debido al aumento de tonelaje dio una inversión de USD$528.000. En las condiciones menos favorables para el proyecto se obtuvo un VAN de USD$195.294, considerando una tasa de 20% a 2 años. El TIR del proyecto es de un 50% y el plazo de recuperación es de 13 meses.Las conclusiones de este estudio son que la hipótesis es refutada, debido a que en la planta es necesario realizar cambios para aumentar el tonelaje (viabilidad técnica). Sin embargo, el estudio económico nos indica que realizando las mejoras del plan de acción planteadas, es posible alcanzar el tonelaje deseado con un flujo de caja favorable bajo restricciones pertinentes.Se recomienda realizar un muestreo donde se pueda analizar la segregación de los finos luego de realizada la mejora en la tolva terciaria. También, si es requerido seguir aumentando el tonelaje, deben ser analizado las potencias de las correas transportadoras N°5 y N°3 que se encuentran dentro del límite aceptable, pudiendo ser cuellos de botellas ante una nueva optimización. En tal caso, un tonelaje recomendable seria 5400 TPD como máximo, ya que los chancadores terciarios se encontrarían en su máxima capacidad. Finalmente, es también recomendado remover la presencia de finos de la correa transportadora N°2. Para esto, la fracción de finos pasaría directamente hacia el producto final evitando el circuito terciario.
This final year project (i.e., thesis) had as a main objective to evaluate the tonnage increase on the crushing stage at the “Minera Altos de Punitaqui” (MAP).The thesis investigated the technical-economic feasibility of increasing the crushing plant throughput from 3000 TPD up to 4500 TPD. The idea behind was to keep the same infrastructure conditions. Nonetheless, some potential negative consequences were expected to happen, and mitigation strategies were considered to overcome them. The hypothesis of this project stated that the tonnage increase does not have implications on process performance.The project logistic was based on validate or disprove to the hypothesis. First, a critical review of the literature was carried out. This review allowed the identification of other projects that considered increasing tonnage, and their relevant operating parameters to be taken into account. Second, an assessment of plant performance was conducted to determine the process baseline. Third, having completed the baseline work, changes were introduced to increase tonnage and quantify the impact on performance. Finally, an evaluation of baseline and increased tonnage situation was performed and reported.The results show that by increasing throughput, the plant availability increases from 62% up to 71%. This situation appears to be unusual because a much softer ore was processed during the testing time, and a better reliability of equipment was obtained. The metallurgical analysis revealed that the tertiary hopper underwent a significant level of segregation. This in turn caused overloading and a biased size distribution towards the classification equipment. This problem makes difficult to increase tonnage keeping the same operating conditions.The strategies identified to increase tonnage consisted of: (1) replacing the secondary crusher; (2) re-design the tertiary hopper, and (3) creating new positions for a supervisor in the field and (4) a operator for a frontal loader. These strategies would make possible the tonnage increase up to 4500 TPD. The economic evaluation of the proposed changes for the tonnage increase resulted in USD$528,000.00 investment. Assuming a 50% increase for the operating cost, the NPV estimated was USD$195,294.00, this was calculated out considering a 20% interest rate over 2 years. The IRR for the project was estimated to be 50%, and the paid back period was determined to be 13 months.The conclusions drawn of this thesis work are as follows: The proposed hypothesis was refuted due to the number of changes required to effectively increase tonnage. The technical-economic feasibility study revealed that it would be possible to achieve a tonnage increase as long as mitigation strategies are in place.In terms of the recommendations, a survey is recommended to be carried out, so that fines segregation can be accounted for in the tertiary hopper. Also, if a further increase of tonnage is required in the future, power requirement considerations need to be performed, especially for conveyor belt No3 and No5. For instance, if target increase were 5,400 TPD, tertiary crushers would be performing to their maximum capacity which is risky. Finally, it is also recommended to remove the presence of fines of the conveyor belt No2. This will allow the fraction of fines to be sent directly to the final product section avoiding the tertiary stage.
This final year project (i.e., thesis) had as a main objective to evaluate the tonnage increase on the crushing stage at the “Minera Altos de Punitaqui” (MAP).The thesis investigated the technical-economic feasibility of increasing the crushing plant throughput from 3000 TPD up to 4500 TPD. The idea behind was to keep the same infrastructure conditions. Nonetheless, some potential negative consequences were expected to happen, and mitigation strategies were considered to overcome them. The hypothesis of this project stated that the tonnage increase does not have implications on process performance.The project logistic was based on validate or disprove to the hypothesis. First, a critical review of the literature was carried out. This review allowed the identification of other projects that considered increasing tonnage, and their relevant operating parameters to be taken into account. Second, an assessment of plant performance was conducted to determine the process baseline. Third, having completed the baseline work, changes were introduced to increase tonnage and quantify the impact on performance. Finally, an evaluation of baseline and increased tonnage situation was performed and reported.The results show that by increasing throughput, the plant availability increases from 62% up to 71%. This situation appears to be unusual because a much softer ore was processed during the testing time, and a better reliability of equipment was obtained. The metallurgical analysis revealed that the tertiary hopper underwent a significant level of segregation. This in turn caused overloading and a biased size distribution towards the classification equipment. This problem makes difficult to increase tonnage keeping the same operating conditions.The strategies identified to increase tonnage consisted of: (1) replacing the secondary crusher; (2) re-design the tertiary hopper, and (3) creating new positions for a supervisor in the field and (4) a operator for a frontal loader. These strategies would make possible the tonnage increase up to 4500 TPD. The economic evaluation of the proposed changes for the tonnage increase resulted in USD$528,000.00 investment. Assuming a 50% increase for the operating cost, the NPV estimated was USD$195,294.00, this was calculated out considering a 20% interest rate over 2 years. The IRR for the project was estimated to be 50%, and the paid back period was determined to be 13 months.The conclusions drawn of this thesis work are as follows: The proposed hypothesis was refuted due to the number of changes required to effectively increase tonnage. The technical-economic feasibility study revealed that it would be possible to achieve a tonnage increase as long as mitigation strategies are in place.In terms of the recommendations, a survey is recommended to be carried out, so that fines segregation can be accounted for in the tertiary hopper. Also, if a further increase of tonnage is required in the future, power requirement considerations need to be performed, especially for conveyor belt No3 and No5. For instance, if target increase were 5,400 TPD, tertiary crushers would be performing to their maximum capacity which is risky. Finally, it is also recommended to remove the presence of fines of the conveyor belt No2. This will allow the fraction of fines to be sent directly to the final product section avoiding the tertiary stage.
Description
Catalogado desde la version PDF de la tesis.
Keywords
ESTUDIO DE TONELAJE , MINERA ALTOS DE PUNITAQUI (MAP) , PLANTA DE CHANCADO