XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 3855
Figure 11. Mill output power and subsequent recovery during a network transient event
For the motors this includes real-time online tem-
perature and vibration monitoring of the stator, rotor, and
bearings inspection, cleaning, and testing of bearings and
auxiliary lubrication and cooling systems twice per year
inspection, cleaning, and testing of the rotor and excita-
tion coils twice per year and Lifetime Expectancy Analysis
Program (LEAP) testing of the stator coil once every two
years.
For the drives this includes real-time online monitor-
ing of the drive cooling system upload and backup drive
parameters, event logs and datalogger, visual inspection,
cleaning, replace air and water filters, check and tighten
cable, wire, and bus connections, and cooling system
checks once per year fiber optics cleaning and testing every
two years replace cooling fans and pumps every five to six
years upgrade drive control, interface, and measurement
controller hardware and software as needed, and replace
CT’s, capacitors, power supplies, and IGCT gate control
boards after 10 years (in process).
Additionally, an independent Data Acquisition System
(DAS) has been installed on each drive which monitors
and records 16 high speed and high frequency voltage,
current, and speed data points to aid maintenance tech-
nicians with monitoring drive performance. Development
and implementation of detailed testing, troubleshooting
and maintenance procedures has also improved the onsite
maintenance teams’ ability to quickly resolve issues during
breakdown events, thus minimizing downtime and lost
production. Detour Lake Mine is also working with ABB
to procure and install an on-line spare drive, which will be
used as a test bench for testing new or rebuilt drive com-
ponents, particularly IGCT modules, as well as for training
on site personnel in operation, maintenance, testing and
troubleshooting.
Throughput Improvements over the Years
Since 2013 monthly average plant throughput has increased
from 2,200 Tonnes Per Operating Hour (TPOH) to 3,400
TPOH (Figure 13). This represents a 43% increase over
original grinding plant design throughput. Throughput
increases have been achieved through many non-grinding
related debottlenecking and optimization projects includ-
ing ultra fine blasting, primary crusher choke feeding,
secondary crusher pre-screening, addition of post-crush-
ing refeed system, various leaching and recovery system
throughput improvements, and improved maintenance
practices. Additionally, milling optimization has been
achieved most notably by operating consistently at nearly
100% of the mill drive system rated power and up to 112%
of the mill drive system rated speed. Utilizing the vari-
able speed and torque control capability of the drives has
allowed especially the SAG mills to operate at significantly
increased throughput while maintaining efficient grind size
output and optimal mill impact zone control. The grinding
system has yet to present as a bottleneck limiting further
throughput increases.
Figure 11. Mill output power and subsequent recovery during a network transient event
For the motors this includes real-time online tem-
perature and vibration monitoring of the stator, rotor, and
bearings inspection, cleaning, and testing of bearings and
auxiliary lubrication and cooling systems twice per year
inspection, cleaning, and testing of the rotor and excita-
tion coils twice per year and Lifetime Expectancy Analysis
Program (LEAP) testing of the stator coil once every two
years.
For the drives this includes real-time online monitor-
ing of the drive cooling system upload and backup drive
parameters, event logs and datalogger, visual inspection,
cleaning, replace air and water filters, check and tighten
cable, wire, and bus connections, and cooling system
checks once per year fiber optics cleaning and testing every
two years replace cooling fans and pumps every five to six
years upgrade drive control, interface, and measurement
controller hardware and software as needed, and replace
CT’s, capacitors, power supplies, and IGCT gate control
boards after 10 years (in process).
Additionally, an independent Data Acquisition System
(DAS) has been installed on each drive which monitors
and records 16 high speed and high frequency voltage,
current, and speed data points to aid maintenance tech-
nicians with monitoring drive performance. Development
and implementation of detailed testing, troubleshooting
and maintenance procedures has also improved the onsite
maintenance teams’ ability to quickly resolve issues during
breakdown events, thus minimizing downtime and lost
production. Detour Lake Mine is also working with ABB
to procure and install an on-line spare drive, which will be
used as a test bench for testing new or rebuilt drive com-
ponents, particularly IGCT modules, as well as for training
on site personnel in operation, maintenance, testing and
troubleshooting.
Throughput Improvements over the Years
Since 2013 monthly average plant throughput has increased
from 2,200 Tonnes Per Operating Hour (TPOH) to 3,400
TPOH (Figure 13). This represents a 43% increase over
original grinding plant design throughput. Throughput
increases have been achieved through many non-grinding
related debottlenecking and optimization projects includ-
ing ultra fine blasting, primary crusher choke feeding,
secondary crusher pre-screening, addition of post-crush-
ing refeed system, various leaching and recovery system
throughput improvements, and improved maintenance
practices. Additionally, milling optimization has been
achieved most notably by operating consistently at nearly
100% of the mill drive system rated power and up to 112%
of the mill drive system rated speed. Utilizing the vari-
able speed and torque control capability of the drives has
allowed especially the SAG mills to operate at significantly
increased throughput while maintaining efficient grind size
output and optimal mill impact zone control. The grinding
system has yet to present as a bottleneck limiting further
throughput increases.