From sand to ceramics - celebrating successful innovation
Demand for technologies delivering renewable energy and improved energy efficiencies continues to increase, with a worldwide movement towards low-carbon economies.
The IsaMillTM Ceramic Media project is a key example of Mount Isa Mines’ innovation in the industry. The project included the design and installation of an improved quick charging system, the new IsaChargerTM, together with new media recovery and slurry feed distribution systems.
Travis Whebell, Regional Lead – Value Realisation said continuously improving our business is a key priority for Queensland Metals to remain sustainable.
“Our renewed approach through improved project management is helping achieve tangible results across the business from the mine through to the port.
The recently commissioned IsaMillTM Ceramic Media project undertaken by the Zinc Lead Concentrator team has converted our IsaMillsTM from sand to ceramic media with the ceramic material properties offering far better efficiency,” says Travis.
IsaMillTM Ceramic Media project team L-R: Fourie Boje - Operations Superintendent, Bert Knopjes - Maintenance Superintendent, Sandeep Yeolekar - Project Metallurgist, Farhan Rajiwate - Superintendent Metallurgy Projects (Project Owner), Georgie Athanasiou - Senior Electrical Engineer, Callum Jones - Concentrator Projects Engineering Superintendent, Nick Donker - Manager Engineering.
The previous sand feeder system was not compatible with ceramic media, requiring a new process. Peter Woodall, Principal Engineer, led the inhouse design work for the system in collaboration with the Zinc Lead Concentrator Operations, Zinc Lead Maintenance, Technical Services, Concentrator Engineering Projects teams, combining their skill and expertise to devise a more efficient, streamlined charging and recovery system.
This is the world’s first 100% media recovery system and ensures that the plant is easy to operate, has low ongoing maintenance requirements and lasts for the life of mine.
The new IsaChargerTM model now takes a speedy 15 minutes to load the ceramic media and charge all M3000 IsaMillsTM to meet power setpoint, as opposed to the six hours used by the sand system. This has greatly assisted in promoting early start-up following shutdowns.
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New IsaChargerTM model which provides a more efficient fast charge.
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IsaMillsTM installed at the Mount Isa Mines Zinc Lead Concentrator (also known as GFM Concentrator).
The improved charging (filling) and recovery (emptying) systems ensure there is no media spillage which avoids wastage and prevents safety hazards. A new feed slurry splitter also allows for equal flow distribution to the IsaMillsTM.
Glencore Technology’s IsaMillTM was pioneered at Mount Isa Mines about 30 years ago and continues to be used and installed in operations around the world.
It is the world’s only commercial-scale horizontal fine grinding technology and was jointly developed by Mount Isa Mines and Netzsch Feinmahltechnik GmbH in the early 1990s to unlock finer ores for processing.
Today, the IsaMillTM forms part of Glencore Technology, with more than 150 sold and installed in over 23 countries, including eight at our Mount Isa operations.
Our people bring these innovations to life and the successful results are testament to their hard work. Congratulations to everyone involved in the successful commissioning of the IsaMillTM Ceramic Media project.