FLSmidth Filtration For Tailings Management

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FLSmidth Filtration for Tailings ManagementTodd Wisdom 1-801-230-8409The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Wet Tailings SolutionsLisheen mine tailings pond (Vedanta) in IrelandThe L-L embankment of the Valley impoundmentThe Highland Valley Copper Mine is located just outside thetown of Kamloops in British Columbia, Canada. The mineproduces copper (435,000 tones in 2003) and molybdenum(6405 tones in 2003) concentrates. The tailings pumped to theValley Impoundment in 2003 were 48.5 million tons.River and sea disposal Submarine Tailings Disposal (STD)is perhaps the most common offshore disposal technique andinvolves the deep water discharge of tailings to the seaThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.2

Facts about Tailings and the handling processes Depending on the type of mineral the tailings can representanywhere from 30% to 99% of the solids mined Most minerals tailings currently are handled with wet tailingsprocess and stored in tailings impoundments These need careful construction, maintenance and monitoring, andalso suffer from high evaporation/loss ratesThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Facts about Tailings and the handling processes Depending on the type of mineral the tailings canrepresent anywhere from 30% to 99% of the solids mined Most minerals tailings currently are handled with wettailings process and stored in tailings impoundments These need careful construction, maintenance andmonitoring, and also suffer from high evaporation/lossrates Several drivers towards dry tailings, including:olack and cost of wateroSuitable tailing pond lands,oreclamation responsibilities,oenvironmental legislation and,owet tailings storage risksThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Dry Stacking DriversThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.5

Tailings Solutions OptionsDry stacking-La Coipa Mine (Anglo American, Chile)Surface paste disposal at Myra Falls Mine,Vancouver Island, Canada Surface thickenedThickened discharge at Kidd Creek, ON, Canada (left)and at Mt Keith, Western Australia (right)Fresh paste depositing over a desiccated layer (left) andone of the risers at the Bulyanhulu Mine (Barrick), Tanzania(Courtesy Golder Associates)The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.6

Wet or Dry Tailings?The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.7

Water ratio’s for typical granular tailingsSlurry % solidsH2O vol. / mt Tailings(m3/mt)204.0Ore processing302.3Plant tailings501.0Thickened slurry600.67High Density slurry750.33Thickened to paste820.21Vacuum filter880.13Pressure filterDescriptionCOURTESY MINE PASTE ENGINEERING LTD.The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Slurry Material ContinuumCOURTESY MINE PASTE ENGINEERING LTD.The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Facts about Tailings and the handling processes The dry tailings process will increase with new operations,especially those situated in deserts environments andareas where tailings land availability is a constrainingfactor Solids content in thickened tailings is between 40% and70%. Dry cake tailings solutions can increase the solids contentto as high as 85%, which represents substantial watersavings for the mine Dry tailings are also easier to reclaim and have lowerenvironmental impact risks during operation and after theclosure Dry Tailings provide the lowest risk profile with respect tofailures and the costs associated with cleaning up thosefailures.The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Tailings accidentsThe majority of historical tailings related incidents have been influenced by poor day to day management.Cerro Negro near Santiago Chile 2003Wet tailingsAccident in Stava Trento Italy, 1985Cycloned sand tailingsAlong its path, the mud killed 268 peopleand completely destroyed 3 hotels, 53homes, and six industrial buildings; 8bridges were demolished and 9 buildingswere seriously damaged. A thick layer ofmud measuring between 20 and 40 cm inthickness covered an overall 435,000square m over 4.2 km. According to thesubsequent inquiries, the collapse wascaused by the chronic instability of thedams, especially in the upper one, whichwere below the minimum factor of safetyrequired to avoid collapses.Marriespruit South Africa 1994Wet tailingsThe TVA Kingston Fossil Plant coalin the USA fly ash slurry spilloccurred just before 1 a.m. onMonday December 22, 2008, whenan ash dike ruptured at an 84-acre(0.34 km2) solid waste containmentarea at the Tennessee ValleyAuthority's Kingston Fossil Plant inRoane County, Tennessee, USA.1.1 billion gallons (4.2 million m³) ofcoal fly ash slurry was released.The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.11

Tailings accidentsThe Ajka Timfoldgyar Alumina Plant Tailings Dam Accident October 4th 2010 in Hungary. Hungary'sgovernment estimated that it would cost more than US 51 million and take at least a year to clean up thedamage. Hungarian state news service MTI estimated at the time of the accident that Hungary stores about50 million tons of the red tailings with about 800,000 tons generated annually.The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Title12

World Market for Dry TailingsExpected high global growthFLSmidth’s Tailings StrategyDry Tailings GlobalMarket Outlook&FLSmidth Strategy2011 One of the leading suppliers of tailingsequipment and bundled products.Near Future The leading supplier of dry tailings islandssolutions.Long Term The Leading supplier of dry tailingsmanagement solutionsDry TailingsVery ColdDry TailingsOpportunities&FLSmidthLocationsTargeted markets#1 Copper, Gold, Coal#2 All base metals andPMsVery Warm,Very Dry Dry, desert areas,lack of water.SouthernHemisphere inspecific Water issues andTSF type guided bystrongenvironmentallegislation Very cold climates,freezingtemperatures,permafrostThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.13

FLS Dry Tailings SolutionsThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Title14

FLS Values for Tailings SolutionsThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Title15

FLSmidth FiltrationKey filter linesVacuum Filters Horizontal Belt Filters and Pan Filters up to 250m2 High Performance and Flexible Vertical Drum Filters and Disc Filters up to 310m2 Simple, Robust and ReliablePressure Filters Horizontal Filter Press up to 24m2 volume, 960m2 area Simple, Robust and Reliable Vertical Pheumapress up to 100m2 area High Performance and FlexibleGlobal ClientsThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.16

Lab and Pilot TestingBench-Scale and/or Pilot Testing are used todetermine material filtration characteristicsFor equipment proper selection and sizing.The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Rev 1.0, Jan 14, 200917

AFP Pilot UnitThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Title18

FLSmidth Pilot Filter Press500mm Membrane Mixed-Pack Plate StackThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.19

Tailings Dewatering Options TestedThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Title20

Options for Tailings DewateringFine Tails – Cyclone Overflow26% CakeP80 - 30.5Total Tails18 % CakeP80 – 204The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.21

Most Effective Solution – Filter CakeFilter Press Technology Produce Consistent Dry Cake w/othe Need for Expensive PolymersRefuse BeltCoal Refuse Filter CakeThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Titel22

Full Range of Filter Press ProductsLow CostStandardProducts Filter Presses from small tolarge / Fully and FullyAutomatic to Fully Manual Worlds Largest Minerals Filter Press 10% capital cost saving 120 Chambers – twice the size of Competitors 2x2 lower feed eye filter platesHighPerformanceAdvancedProductsThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.23

Key Elements for Cost Effective FilterDesign TCO must be competitive with traditional solutions High Initial Costs 100,000,000 USD Low Operating Costs 0.75 USD/ton Minimize Filtration Capital Costs Minimize Cycle time Maximum Filter Size Minimize Filtration Operational Costs Minimize energy usage Eliminate wasted energy Minimize Cloth Consumption Use cost effective designThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

For High-Volume ProductionLarge-Scale Filters with 2M x 2M PlatesFilter Specifications: 2 x 2 Plates 16 bar rated Overhead Type 100 Bar Cloth WasherThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Title25

Single Plate Indexing – Discharge 10 min.Shriver Filter PressThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Titel26

Air flow rate m3/MINCake Filtration STAGES ‐ DewateringThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Typical Tailings Cycle TimeThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Minimize Cycle TimeEliminate MembranesBottom Feed Recessed ChamberTop Feed MembraneThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Titel29

AFP IVTM FILTERFiltration Pressure Slurry Pumps Are Used ToCreate The Filtration Flowand PressureVFD control ensurespumps operate torequired filtration curve.Liquid Core Allows Pressure tobe Applied Uniformly OverEntire Forming CakeTurbulenceMaintainedUniformFillingCakeForms inLayersHomogenousCakeThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.30

CompetitionUpper Feed Eye Chambers fill in series, not inparallelLow density Cakes are more consolidated atthe bottom of the plate than atthe top of the plate Membranes are required toconsolidate into even cakesHigh densityThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.31

PLATE DESIGNMembrane Plate SectionThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.32

Filter Plates ComparisonTop Feed Membranes requiredPlate removal not required forcloth changePlate life limitedCost up to US 20,000 eachMembrane accessories needed –higher OpexLonger cycles for membranesqueeze means less productionper cycle and more filter pressarea requiredBottom Feed – FLS TechnologyNo membranes requiredRemove plate for cloth change –Not significantPlate life extendedCost US 2,000 each The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Titel33

Minimize Cycle TimeDischarges In 1 Min.AFP IV Automatic Filter PressThe information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.Titel34

Cross Head SystemDischarges 120 Chambers in 1 Min.Cross head system lock pins

Filter Press up to 24m2 volume, 960m2 area Simple, Robust and Reliable Vertical Pheumapress up to 100m2 area High Performance and Flexible Global Clients. The