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• Vladimir Sepulveda

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VERTIMILL® Grinding Mills

This submittal is to be used by the Recipient only for the purpose for which it is provided. All documents, drawings, pricing, descriptions, literature, data, etc. contained herein (whether hard copy or electronic) are Confidential Information and are to be treated as such by Recipient, to include, but not be limited to, protecting the Confidential Information from unauthorized disclosure or use.

VERTIMILL® Grinding Mill Presentation Outline

• Stirred Mills Overview • Vertimill Basics and Advantages • Test work and Selection • Circuit Considerations • Operating Parameters • Component Detail • Maintenance • Installation Considerations • The VTM-3000-WB

© Metso

CONFIDENTIAL

Stirred Milling Overview

• Stirred Mills are mills that agitate the charge with stirring mechanisms and static mill shell

• Stirred Mills are generally recognized as Cost Saving Technologies through: - Higher Energy Efficiency - Lower Installation cost - Lower Operating cost

• There are two distinct type of stirred mills: Gravity induced and Fluidized

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Stirred Milling General Presentation 2011

CONFIDENTIAL

Metso Stirred Mills We are the Industry Leader

• Metso has - The most mature stirred milling technologies - The largest installed base in terms of qty of units and installed power - An aggressive development program • Two Stirred Mill Designs, the VERTIMILL® Grinding Mill and the Stirred Media Detritor (SMD) allow us to offer the optimum equipment solution for the circuit.

• Gravity Induced Mills like the Vertimill, for grinds from 6 mm – 20 microns

• Fluidized Mills, like the SMD ,for grinds from 100 – 5 microns

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Stirred Milling General Presentation 2011

CONFIDENTIAL

Metso Stirred Mills Our Design Goals

• Energy Efficiency • Sustainability • Low Capital • Minimize Maintenance • Ease of Operation • Long mill life • Lowest Total Cost of Ownership

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© Metso

Stirred Milling General Presentation 2011

CONFIDENTIAL

Metso Stirred Mills We are the Industry Leader

• Metso has -

The most mature stirred milling technologies The largest installed base in terms of:

• Qty of Units • Installed Power • Different Application

-

An aggressive development program

• Two Stirred Mill Designs, the VERTIMILL® Grinding Mill and the Stirred Media Detritor (SMD) allow us to offer the optimum equipment solution for the circuit.

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Stirred Milling General Presentation 2011

CONFIDENTIAL

The Vertimill® Overview

• > 330 Units Worldwide • > 175,000 kW Total power • Unit Sizes from 15 to 3000 HP • Feed Size from 6 mm • Product Sizes to 15 µm • Low Intensity = Low Wear • High Density media • Media Size Matched with Grind 38 – 5 mm

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14 September 2010

Vertimill History • Developed in Japan in the 1950’s as the Tower Mill

• Licensed by Metso in 1978 • License expired in late eighties, Metso began marketing the Vertimill

• Vertimill has 80+ improvement/design changes from original Tower Mill

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August 6, 2013

INTERNAL

CONFIDENTIAL

The Vertimill® Applications

• Grinding -

Secondary - 6 mm to 75 µm Tertiary - 400 µm to 75 µm Regrind - 200 µm to 15 µm Flue Gas Desulphurization - 6 mm to 20 µm

• Lime Slaking -

Flue Gas Desulphurization Acid Neutralization Additive

Regrind

Flue Gas Desulfurization

Lime Slaking

Secondary and Tertiary

Other

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CONFIDENTIAL

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INTERNAL

Vertimill Advantages Lowest Total Cost Solution

•Higher Energy Efficiency •Lower Installation cost •Simple foundation •Quick Installation •Less Floor Space •Lower operating cost •Reduced Media Consumption •Long Wear Life •Improved Process Performance •Higher Availability •Greater Operational Safety •Improved Recovery 12

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August 6, 2013

CONFIDENTIAL

Vertimill Advantages Reported Energy Savings relative to Ball mills

• Secondary Grinding - Mexican Copper Mine : 34.2% - SW USA Copper Mine: 29 – 39% • Tertiary Grinding - Chino Mines: 35 % - Cadia: 35% • Regrinding - Red Dog : 40 % , First in large scale Vertimill Metallic Operation in 1987 - Las Encinas: 35% - La Candelaria: 44%

• VTM typically 30-50% more Energy efficient, varies by application 13

© Metso

Reference Papers for all above data available on request

14 September 2010

INTERNAL

Vertimill Advantages Why so Efficient?

•

Specifically designed to maximize the attrition grinding mechanism (shear forces)

•

Media Size -

•

Vertimill® typically 38-12 mm SMD typically < 5 mm

Charge Motion -

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Vertimill® similar to “kidney” of ball mill charge motion SMD charge is fluidized

August 6, 2013

INTERNAL

Vertimill Charge Motion

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Vertimill

CONFIDENTIAL

Vertimill Advantages Reduced Media Consumption • Less energy for grind = less media consumed • No impact grinding, less ball breakage • Vertical arrangement retains fine media

• 30 - 50% less Media consumption vs Ball Mill

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CONFIDENTIAL

Vertimill Advantages Lower Installation Cost

• Typical large ball mill takes 12 + weeks to install • Typical VTM takes 2 weeks to install - VTM-1500-WB has been installed in 5 days • Smaller Foundations

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Stirred Milling General Presentation 2011

CONFIDENTIAL

Vertimill Advantages Less Floor Space Required

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Stirred Milling General Presentation 2011

CONFIDENTIAL

Vertimill Advantages Availability and Maintenance • Fewer Parts • Less Maintenance

• Long Wear Life • Long Screw liner life ranging from 9 months to 2 years depending on application • “Permanent” shell liners

• >98% Availability

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Stirred Milling General Presentation 2011

Ball Mill

Vertimill

Motor

✔

✔

Reducer

✔

✔

Couplings

✔

✔

Hydrostatic Bearing

✔

HP/LP Bearing Lube Unit

✔

Gear and Pinion

✔

Gear Lube

✔

Trommel

✔

CONFIDENTIAL

Vertimill Advantages Improved Process Performance

• Internal, Controllable • Minimize Fines Generation • Preferentially grind coarse material

• Reduced steel contamination

100 90 80 70 Percent Passing

Classification

Vertimill Pilot Product Comparison

60 50 40 30

Rod Mill Product

20 VTM Product

10 0 10

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Stirred Milling General Presentation 2011

100 Microns

1000

CONFIDENTIAL

Vertimill Advantages Additional Advantages

• Flexibility in Feed Arrangement - Recycle and Feed Locations can affect Product size distribution • Turndown

• Less Noise – Less than 85 dB • Multiple Unit Flexibility • Greater Operating Safety - Moving parts are enclosed - Easier, Less frequent Maintenance • Operator Friendly - More forgiving - Easy to control and optimize

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Stirred Milling General Presentation 2011

CONFIDENTIAL

Secondary Grinding The big power user

• Secondary grinding or coarse grinding is still dominated by inefficient by ball mills

• Secondary Grinding is the largest user of power in a concentrator

• Applying Vertimills in this role can have the biggest impact on OPEX

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Stirred Milling General Presentation 2011

CONFIDENTIAL

Example Operational Cost Savings Calc Vertimills in Secondary Grinding

• 100,000 mtpd Copper Concentrator • Primary Grind with either SAG mill or HPGR • Secondary Mill Feed : 80% passing 1.8 mm • Flotation Feed size required: 80% passing 200 µm • Secondary Mill Requirement -

Ball Mill Power: 40,000 kW OR

-

Vertimill Power: 28,000 kW

• 12 MW power savings

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Stirred Milling General Presentation 2011

CONFIDENTIAL

Vertimills for Secondary Grinding SAG or HPGR in Primary Feeding Vertimill Required Ball Mill Operating Power Vertimill® Efficiency Factor Required Vertimill® Operating Power Assumptions Power Cost Circuit Availability Ball Mill Media consumption Vertimill Media Consumption Delivered Media cost Annual Power Cost Increase Annual Media Cost Increase Carbon Dioxide Emissions Cost of Money

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Stirred Milling General Presentation 2011

40000 kW 70% 28000 kW

0.05 $/kWh 93% 0.065 kg/kWh 0.05 kg/kWh 1000 $/mt 4% 4% 1.341 kg/kWh 8%

CONFIDENTIAL

Vertimills for Secondary Grinding SAG or HPGR in Primary Feeding Vertimill Year 1 2 3 4 5 6 7 8 9 10 NPV

Energy Savings $ 4,888,080 $ 5,083,603 $ 5,286,947 $ 5,498,425 $ 5,718,362 $ 5,947,097 $ 6,184,981 $ 6,432,380 $ 6,689,675 $ 6,957,262 $ 38,415,480

Media Savings $ 9,776,160 $ 10,167,206 $ 10,573,895 $ 10,996,850 $ 11,436,724 $ 11,894,193 $ 12,369,961 $ 12,864,760 $ 13,379,350 $ 13,914,524 $ 76,830,960

Total NPV Vertimill® Savings Over 10 Year Mine Life 25

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Stirred Milling General Presentation 2011

Carbon Savings (mt) 131,098 131,098 131,098 131,098 131,098 131,098 131,098 131,098 131,098 131,098 1,310,983

US$ 115,246,440

INTERNAL

Future Vertimill® Development • Go as big as we can economically • Portable VTM-150-WB pilot plant • Testing to determine how to modify the Vertimill to accept feed coarser than 6 mm?

• Development Partners

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INTERNAL

VERTIMILL® Selection

August 6,27 2013

VERTIMILL® Selection

INTERNAL

Methods

• Bond Power Prediction • Customer Supplied BWI or Metso BWI testing • Metso Database Estimated BWI –for preliminary sizing

• Jar Mill Test – scaled for VTM energy requirement • Pilot Testing with 3 kW unit • Lime Slakers selected based on retention time and grinding energy

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INTERNAL

VERTIMILL® Selection Bond Work Index Testing

• Customer Supplied BWI, Metso BWI testing, or Metso Database Estimated BWI –for preliminary sizing

• Utilize Bond Power formula with EF4 & EF5 • If necessary, F80 and throughput adjusted for scalped feed • If BWi value is not available for given sample, preliminary selection can be made based on Metso BWi Database

• Apply Vertimill efficiency factor derived from operating Vertimill

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COMMINUTION '10

VERTIMILL® Selection Jar Mill

• Standard, Simple, Repeatable Test • Small sample Size • Smooth-lined steel jar mill • Size analysis with Sieves and/or Malvern • Scaling Factors derived from operating Vertimill validation

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April 14, 2010

INTERNAL

VERTIMILL® Selection Lab Pilot Testing

• 3 kW Pilot Mill at Metso York Test Plant (USA)

• Closed circuit with Derrick Screen or Hydrocyclone

• Beneficial for unique applications (Iron Sands, Coke, etc.)

• Allows for product generation for downstream equipment test work

• 2–4 metric tons required for test program

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Vertimill Circuit Design

INTERNAL

Vertimill Circuit Options • Closed or Open Circuit • Pre-classified / Scalped or Fresh feed directly into the mill • Top Fed or Bottom Fed • Separating Tank and Recycle Pump

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August 6, 2013

INTERNAL

Vertimill Circuit Options • Closed or Open Circuit - Closed is the preferred choice and the most common - Open used in rare applications • Pre-classified / Scalped or Fresh feed directly into the mill

• Top Fed or Bottom Fed • Separating Tank and Recycle Pump

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INTERNAL

Vertimill Circuit Options • Closed or Open Circuit • Pre-classified / Scalped or Fresh feed directly into the mill - Scalped Feed will reduce Vertimill power - Fresh feed direct to mill if surface prep is critical • Top Fed or Bottom Fed

• Separating Tank and Recycle Pump

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August 6, 2013

INTERNAL

Vertimill Circuit Options • Closed or Open Circuit • Pre-classified / Scalped or Fresh feed directly into the mill • Top or Bottom Feed -

Both options provide advantages and disadvantages Top Fed allows for simpler gravity feed from classifier Bottom Fed ensures fresh feed is injected into ball charge Bottom Fed allows for better start-up after power outage Evidence from some sites suggest bottom feeding reduces the wear of the digging shoes

• Separating Tank and Recycle Pump

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INTERNAL

Vertimill Circuit Options • Closed or Open Circuit • Pre-classified / Scalped or Fresh feed directly into the mill • Top Fed or Bottom Fed • Separating Tank and Recycle Pump -

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Allows for control of uprising velocity in VTM Prevents over-grinding for coarser product applications Allows VTM to start-up more readily after a power outage or improper shutdown Can Bottom Feed with Recycle Pump

August 6, 2013

CONFIDENTIAL

Vertimill Flow Arrangement

15% 27%

Bottom w/ Recycle Bottom w/o Recycle Top Feed w/ Recycle Top Feed w/o Recycle 41%

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17%

INTERNAL

Vertimill Circuit - Reverse Closed Circuit Generally used for Secondary and Regrind

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INTERNAL

Vertimill Circuit - Direct Feed Generally used with Dry coarse feed and high reduction ration

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Vertimill Component Detail

Vertimill History • Developed in Japan in the 1950’s as the Tower Mill

• Licensed by Metso in 1978 • License expired in late eighties, Metso began marketing the Vertimill

• Vertimill has 80+ improvement/design changes from original Tower Mill

42

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August 6, 2013

INTERNAL

CONFIDENTIAL

Vertimill Components WRIM

• 260% Starting Torque • 1.15 Service Factor • (6) Stator Rtd’s (2 per phase) • (2) Bearing Rtd’s (1 per bearing)

• Space Heaters • Optional: Current transformers, Lightning arrestors, Surge Capacitors

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CONFIDENTIAL

Vertimill Components LRS

• Allows for reduced torque starting • Reduces in rush current and impact on plant electrical grid

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CONFIDENTIAL

Vertimill Components 3 Stage Reducer

• • • • •

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Moventas Gearbox 2.0 Minimum Safety Factor 2 Helical Stages, 1 Planetary Internal Oil Reservoir Instrumented with RTDs, flowmeters, level indication, and oil heater

CONFIDENTIAL

Vertimill Components Reducer Oil Conditioning Unit

• Includes recirculation pumps, filters, air coolers, and associated instrumentation

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CONFIDENTIAL

Vertimill Components Reducer Gauges

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CONFIDENTIAL

Vertimill Components Upper Body, Bearings, and Coupling

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CONFIDENTIAL

Vertimill Components Door and Ball Dischargers

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CONFIDENTIAL

Vertimill Components Screw and Liners

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CONFIDENTIAL

Vertimill Design Screw FEA

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CONFIDENTIAL

Vertimill Components Pedestal

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CONFIDENTIAL

Vertimill Components Recycle Pump

• Pump size depends on required flows

• Overhead or side mounting possible

• Various seal types available

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CONFIDENTIAL

Vertimill Components Lower Body

• Ships in Four parts • Assembled into 2 pieces on the ground

• Recycle inlet on lower half

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CONFIDENTIAL

Vertimill Manufacture Lower Body

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CONFIDENTIAL

Vertimill Manufacture Body and Door Manufacture

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CONFIDENTIAL

Vertimill Components Hydraulic Door Jacks

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CONFIDENTIAL

Vertimill Components Orebed

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CONFIDENTIAL

Vertimill Components Separating Tank

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CONFIDENTIAL

Vertimill Components Separating Tank

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Vertimill Maintenance

CONFIDENTIAL

Vertimill Maintenance Activities

• Grease Motor Bearings • Change Motor Brushed • Grease VTM Bearings • Change Lube oil & filters • Change Screw Liners

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April 21, 2010

CONFIDENTIAL

Vertimill Maintenance Design Considerations

• Access for greasing all bearings • Access to mill motor brushes • Access to lube skid • Crane and Fork Lift capacity and access for screw liner changes • Crane for recharging Vertimill with balls • Access for screw transport pockets • Vertimill pier height for use of ball bins

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Vertimill Maintenance Daily Activities

• Daily equipment walk-down by operators • No daily maintenance required • All maintenance and troubleshooting detailed in manual

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VERTIMILL® LIME SLAKING

VERTIMILL® LIME SLAKING

Vertimill Maintenance Schedule

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Mill System Component

Task Description

Task Duration

Interval

Mill Condition for Procedure

System

Overall Check

10 min

Daily

Operating

Mill Motor

Grease Bearings

5 min

Reducer

Change Oil

4 hrs

Yearly

Mill Stopped

Mill Bearings

Grease

5 min

Weekly

Operating or Stopped

Mill Internals

Inspect

12-16 hrs

TBD

Mill Stopped

© Metso

August 6, 2013

3000 hrs Operating or Stopped

VERTIMILL® LIME SLAKING

Vertimill Maintenance Ball Bins

• Ball Bins provide a clean and easy way to handle media

• Manual discharge port • Allows for easy loading and unloading of grinding media

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INTERNAL

Vertimill Maintenance Discharging for Screw Liner Changing

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CONFIDENTIAL

Vertimill Maintenance Screw Liner Wear

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April 21, 2010

CONFIDENTIAL

Vertimill Maintenance Door/Ball Charge Height

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April 21, 2010

CONFIDENTIAL

Liner Change Change liners in the mill, most common solution

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April 21, 2010

CONFIDENTIAL

Liner Change Option 1 – Change liners in the mill, most common solution

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April 21, 2010

CONFIDENTIAL

Liner Change Option 2 – Change Entire Screw, more common for multiple mill installation

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Vertimill Installation

14 September 2010

CONFIDENTIAL

Installation Considerations • Door Swing • Crane Capacity • Access Platforms – generally, access is only required at the upper bearing and then only rarely

• Modular design allows for components to be on any side of mill, including - Recycle Inlet - Ball/Feed Port Location - Separating Tank Location - Pedestal Access - Reducer/Motor

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CONFIDENTIAL

Vertimill Installation

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VTM Screw Installation

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CONFIDENTIAL

CONFIDENTIAL

Screw Lifting Cap 77

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CONFIDENTIAL

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Screw Transport Beams Installed 14 September 2010

CONFIDENTIAL

Screw Hydraulic Jacks 79

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14 September 2010

CONFIDENTIAL

Raising/Bolting Screw 80

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14 September 2010

Vertimill Installations Examples

CONFIDENTIAL

Cerro Verde Three (3) VTM-1500-WBs

• No structure in front of mill to allow easy crane access for screw insert and removal

• Modest pier height for easy maintenance

• Bins used for media addition as well

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CONFIDENTIAL

Cerro Verde Motor Access and Lubrication Unit Location

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CONFIDENTIAL

Cerro Verde Media addition – Same bin used for media handling

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CONFIDENTIAL

Hibbing Taconite

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CONFIDENTIAL

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CONFIDENTIAL

CVRD Sossego Copper Mine VTM-1500-WB

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CONFIDENTIAL

Cadia VTM-1250-WB • Pros - Compact - Outdoor - Good simple crane access • Cons - Structural steel in front of mill making taking the screw out difficult

-

Mill foundation too high up and ball pit in front of mill, making screw changes difficult

• Recommended changes -

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Discharge mill out the back into ball pit, so you can easily change the liners in the mill from the front

CONFIDENTIAL

Large VTM Layout

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CONFIDENTIAL

Large VTM Layout

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CONFIDENTIAL

Large VTM Layout

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CONFIDENTIAL

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The VTM-3000-WB

August 6,93 2013

CONFIDENTIAL

Creating the VTM-3000-WB Scale up Considerations

• Keep from existing Vertimill advantages: - Simplicity - Wear life - Grind Efficiency

• Challenges -

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Torque Wear

Capital Cost

CONFIDENTIAL

Creating the VTM-3000-WB From a VTM-1500-WB to a VTM-3000-WB

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Key Figures

VTM-1500-WB

VTM-3000-WB

Length (m)

4.57

6.92

Width (m)

4.37

6.36

Height (m)

14.22

17.59

Mill Mass (mt)

167

343

Charge Mass (mt)

130

260

Screw (mt)

9.3

23.6

Screw End Liner (mt)

3.5

8.4

Screw Flight Liner (mt)

2.7

4.5

6 August 2013

INTERNAL

VTM-3000-WB CAPEX Considerations

• Machine cost is the same between two (2) VTM-1500-WBs and one (1) VTM-3000-WB

• To maintain wear characteristics, we have to slow down the shaft speed, while increasing the mill power => torque triples from VTM1500 to VTM-3000

• Drive components are a higher percentage of the cost • However, Total installed cost should be less considering: -

Simpler civils, less concrete Less ancillary equipment (tanks, pumps, valves, piping, etc) Smaller foot print, structural steel Shorter installation time

• Lower labor costs • Quicker start up 96

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INTERNAL

VTM-3000-WB OPEX Considerations

• One (1) VTM-3000-WB will have lower OPEX than two (2) VTM1500-WBs

• Mechanically, the units are the same, with almost the same number of components. One VTM-3000-WB should be half the maintenance of two VTM-1500s

• Screw liners, VTM-3000-WB only has 6 liners total.

Each VTM1500-WB has 8. Once a procedure is in place to handle the large components, it should take less time to reline the VTM-3000

• Spare Parts – A set of VTM-3000-WB liners is approximately 20% less than price for two sets of VTM-1500-WB liners

• Same media motions, so media wear will be the same

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CONFIDENTIAL

The 1st VTM-3000-WB Installation Newcrest Mining Ltd. Cadia Valley Operations

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21 September 2010

CONFIDENTIAL

Newcrest Cadia High Grade Concentrator Simplified Flow Sheet

Secondary VTM-1250-WB

Tertiary VTM-3000-WB Regrind VTM-1250-WB 99

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21 September 2010

CONFIDENTIAL

Tertiary Vertimill The 1st VTM-3000-WB

• Grinding Design • • •

F80 – 150 µm P80 – 95 µm 750 mtph

• Current Performance -

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F80 – 128 microns P80 – 98 microns 780 mtph Only at 50% of Mill Power Flotation Recovery High than anticipated

CONFIDENTIAL

VTM-3000-WB Performance Summary to Date

• No Installation complications • No Mechanical complications • No Process complications • With in 3 days of the start of commissioning, the mill became an active part of plant operations

• •

Improving Recovery Increasing capacity

• Project and Installation executed with efficiency, quality, and functionality of a typical smaller VTM project

• Operational since August 2010

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CONFIDENTIAL

VTM-3000-WB Performance Internal Wear

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21 September 2010

INTERNAL

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