Copper Concentrator - SAG & Ball Mill Case Study of Biokem

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Copper Concentrator - SAG Ball Mill Case Study
of Biokem
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1. SAG Mill Fixed Bearing Circuit Tank 6000L

• Starting ISO 21/21/17 (out
  of spec)
• After Purification ISO 16/15/12
• Water Content Not tested at start
• Water Content after lt50ppm
• VDOPS Purifying Time 26.9 Hrs

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• Comment Client had sensibly drained the
  contaminated oil and deployed a small centrifuge
  that helped. VDOPS further reduced the moisture
  and significant larger debris was captured as
  shown.

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2. SAG Mill Floating Bearing Circuit Tank 4500L

• Comment Filtration was commenced on this oil
  however the oil did not respond normally. It had
  a very dark appearance and smelled burnt. A
  sample was taken and this oil displayed a cake
  of fines.

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• Action Client was advised to go offline drain
  this tank as this contamination will cause
  significant wear.
• A cake of fines is a very high concentration of
  silt size particles and/or additive pack
  ingredients that build up on the patch membrane
  obscuring all other contaminants.

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• If the additive package breaks down in this way
  and drops out of solution it is no longer
  performing its intended function. The oil that
  was removed was dehydrated and left to be
  filtered over the next two weeks with depth
  filter media to remove these sub-micron
  contaminants. Afterwards an additive pack will
  be needed to restore this oil.

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3. Outside Bulk Tank 5000L

• Operating outside and beyond ISO 4406 spec
• Starting ISO 23/22/17 (out
  of spec)
• After Purification ISO 21/17/15
• Water Content 5000ppm (out of
  spec!)
• Water Content after 100ppm
• VDOPS Purifying Time 20.3 Hrs

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• Comments A huge 25L of water was removed and
  lubricant could then be returned to service. The
  image shows the VDOPS collection chamber
  extracting water from the emulsified oil. No free
  water was present.

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Summary

• In total 24,500L of oil was purified to better
  than target specification in 114.2 Hrs.
• The outcome was returning the plant to operation
  with a minimum of downtime and without discarding
  any lubricant resources and associated costs.

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• The client was so impressed with our response
  service and professionalism they have requested
  a regular 90 day service agreement to manage the
  oil cleanliness.

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Job Vol ISO 4406 Start ISO 4406 Finish Hrs Note
1 SAG Mill Fixed 6,000L 20.19.16 16.15.12 26.9 Excellent improvement in ISO4406
2 SAG Mill Floating 4,500L - - 33.5 Clean, however sub-micron cake of fines still present
3 Bulk Tank 5,000L 23.22.17 20.19.16 20.3 Highly emulsified oil, 25L of water removed
4 SAG Mill Floating Polish 4,500L 20.19.16 - 12.3 Low level fines residue visually OK
5 Ball Mill Floating 4,500L 23.22.17 Await result 21.2 Oil was dry, however anticipate significant improvement in cleanliness.
TOTAL 24,500L - - 114.2  
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http//www.biokem.com.au/