Case Studies

Exploring Case Studies
With Steady Insights

Business Case Study and Report - 1

Project Name: Copper Mine in South America

Challenges (faced by customer)
  • Improvement in recovery and concentrate specifications
  • Reduction in Grinding Media Wear Rate
  • Reduction in Flotation Reagent consumption
Mitigation

Implementation of MillART technology through

  • Tailor made hichrome grinding media
  • Optimised reagent scheme for enhanced hichrome performance
Benefits Achieved
  • Reduction in Grinding Media wear rate by 41% in comparison to forged steel
  • Improvement in Cu recovery by 2.34%
  • Improvement in concentrate grade by 0.84%
  • Elimination of lime consumption in flotation
Project Snapshot
6 MTPA
Plant capacity
Iron oxide copper-gold
Type of ore
Financial realisation
(Annualised) in Million USD
~ 8.75
Business Case Study and Report – 2

Project Name: Iron ore mine in Asia

Challenges (faced by customer)
  • Reduction in specific power consumption
  • Target for production increase
Mitigation

Conversion of Overflow Ball Mill to Grate discharge Ball Mill

  • Introduction of energy efficient pulp lifter
  • Redesign of shell liners
  • Optimization of ball charge and ball size
Benefits Achieved
  • Increase in mill throughput by 24%
  • Reduction in grinding specific power consumption by whopping 46%
  • Fulfilling business requirement with lesser number of mills in operation (from 4 to 3 mills)
  • Optimisation in ball size and ball charge
Project Snapshot
1.03 MTPA
Plant capacity
Iron
Type of ore
Opportunity realisation (Annualised) in Million USD
~ 9.46+
financial benefit due to reduced number of mills in operation
Business Case Study and Report – 3

Project Name: A Gold Mine in Africa

Challenges (faced by customer)
  • Targeting for a production increase
  • Improvement in wear life of mill internals
  • Elimination of SAG Liner Breakage
  • Reduction in installation time
Mitigation
  • Design conversion for increased production: Energy-efficient pulp lifters
  • Design modification of liners
  • Modification in metallurgy of liners
Benefits Achieved
  • Consistency in throughput despite significant increase in ore hardnessm—Which could have resulted into decrease in throughput by 18% if customer design was continued)
  • Increase in liner life by 50% to 80%
  • Elimination of shell liners breakage
Project Snapshot
14 MTPA
Plant capacity
Gold
Type of ore
Opportunity realisation (Annualised) in Million USD
~ 160.83
Business Case Study and Report - 4

Project Name: Lead Zinc Mine in Asia

Challenges (faced by customer)
  • Reduction in specific power consumption
Mitigation

Conversion of Overflow Ball Mill to Grate discharge Ball Mill

  • Introduction of energy efficient pulp lifter
  • Redesign of shell liners
  • Optimisation of ball charge and ball size
Benefits Achieved
  • Reduction in specific power consumption by 25%
Project Snapshot
1.6 MTPA
Plant capacity
Lead Zinc Sulphide
Type of ore
Opportunity realisation (Annualised) in Million USD
~ 0.47
Business Case Study and Report - 5

Project Name: A Gold Mine in Africa

Challenges (faced by customer)
  • Reduction in specific power consumption
  • Target for production increase
Mitigation

Conversion of Grate Discharge Ball Mill with Radial Pulp Lifter to Grate Discharge Ball Mill with Energy Efficient Pulp Lifter

  • Introduction of energy efficient pulp lifter
  • Redesign of shell liners
  • Optimisation of ball charge and ball size
Benefits Achieved
  • Reduction in specific power consumption by 22.45 %
  • Increase in mill throughput by 2.1 % (Opportunity for mill throughput increase upto 5%)
Project Snapshot
3.8 MTPA
Plant capacity
Gold
Type of ore
Opportunity realisation (Annualised) in Million USD
~ 8.96