The client contacted NCPI after a severely cracked trunnion journal was reported. Recognizing the urgency of the situation, NCPI immediately dispatched our engineering manager who travelled to the remote site to assess the trunnion journal. A detailed technical evaluation revealed that the trunnion was damaged beyond repair, but that the mill could continue operating while awaiting a replacement. The mill head was originally designed and supplied as an Integral head by another Mill OEM prior to 1980. NCPI reverse engineered the mill head and trunnion taking all critical dimensions from a detailed site evaluation, and then engineering the journal & spigot dimensions from first principles.

The mill head was re-designed as a split 180deg Head with a bolt on trunnion to allow the quickest possible manufacturing time and allow dimensions for Air freighting to site. This design also facilitated use of the overhead crane during the proposed future mill head changeout.

NCPI initially estimated 22 Weeks for manufacture based on expedited delivery due to the critical nature of the trunnion condition.

The mill head was designed and drafted by NCPI and the order for the manufacturing was placed immediately. Utilzing NCPI’s long-standing relationship with an Established foundry and machine shops, NCPI was able to deliver the Mill head and trunnion within 18 weeks, 4 weeks ahead of schedule.

The mill head and trunnion were loaded into an Atlas Air cargo plane and flown to the mine site in Alaska. The parts are delivered to site and awaiting the planned shut to allow changeout. The client’s risk has been mitigated by a proactive approach, and world class performance by NCPI, once again living up to our reputation for exceptional service and reliability. We take pride in our ability to meet and exceed client expectations, once again confirming our status as a World-Class Grinding Mill Supplier.

Contact NCPI for any Mill Component replacement items for whatever Mill you have installed at your plant.

The year 2022 was a year which saw a boom in commodity markets post-Covid. The need for new grinding mills for projects being developed worldwide was high, with foundries and fabrication workshops filled with new orders. Lead times for components were being increased dramatically based on full order books.

Early 2022, NCP International was approached by Hummingbird Resources plc to supply an 18x31ft, 4500kW SAG Mill for their Kouroussa Gold Mine (KGM) in Guinea. NCP International discussed the needs and expectations of the customer to understand their specific project requirements clearly.

Delivery ex-manufacturing works had to be achieved within a timeframe to meet the installation schedule. The project also had to be within the budget and quality requirements.

Based on well-developed relationships with key suppliers, NCP International planned the manufacture of the grinding mill components to meet the delivery schedule.

The SAG mill required the manufacture of all new components: mill shell in halves, integral cast mill heads, single-stage gearbox with barring drive, girth gear and pinion gear, main motor with VVVF variable speed drive, lubrication systems, composite mill liners and a mill control panel.

NCP International was commissioned to manage the delivery of the mill components to Guinea in conjunction with the Hummingbird Resources plc team. This involved the packing and delivery of 500 tonnes of equipment from various manufacturing points worldwide.

Several challenges were met along the way, including Covid lockdowns in China, port shutdowns in South Africa, and backlogs in European ports. Despite all the challenges, the mill components were delivered in line with the mill installation requirements.

Further, NCP International will assist Hummingbird Resources plc with a team of instrumentation, mechanical, and automation technicians to ensure that the SAG mill commissioning is completed efficiently and successfully.

Some graphic details below highlighting the SAG Mill transportation and installation.

This project is the second project NCPI has been awarded over the past 5 years by Hummingbird Resources plc. In 2018 NCP supplied a 12 x 18ft, 1250 kW Ball Mill for the Yanfolila project in Mali. NCP is excited to have been awarded the opportunity to build the relationship with the client and we believe that it will continue to grow through continued after market and sales support. We look forward to what the future holds.

NCP successfully completed the supply of 32ft dual drive SAG mill for TIETTO’s ABUJAR GOLD project in Côte d’Ivoire, West Africa. NCP was awarded this contract by Australian exploration company Tietto Minerals and has delivered on all the contractual commitments made at sales stage for an accelerated delivery.

The contract allowed for the supply of a Ø32 x 20ft, 11.5MW Dual Drive Bi-directional Semi-autogenous (SAG) mill, supported off hydrostatic trunnion bearings.

The dual pinion drive train consists of two existing 5750kW, 6 pole slipring electric motors converted to operate as a squirrel cage induction motors allowing operation through a MVW3000 VVVF Variable Speed Drive.

The specified duty of the mill is to process Run of Mine (ROM) material fed at a rate of 500TPH from the primary crushing circuit at a F80 material size of 159mm, delivering a product of P80-115µm. The mill size selected offers slightly more capacity providing upside potential in terms of throughput.

The mill was delivered within 28 Weeks ex works from raw components arriving in South Africa, once again highlighting NCP’s world leading ability to meet tight project deadlines.

NCP’s scope of work included the supply of the mill, installation and commissioning. NCP will supply the client full aftermarket sales service, on-site assistance and technical support.

“Abujar first gold pour achieved within 12 months of breaking ground and the start of construction.”

NCP supplied and completed the installation of the 32ft SAG Mill on-time and is proud to have met the client’s expectations in this regard.

NCP is looking forward to supporting Tietto Minerals into the future and ensuring that this mill continues to deliver what it is designed to do.

As you may have read in our last blog, NCP recently supplied a 17’ diameter Ball mill into Burkina Faso for the Bombore Gold Project, allowing us to not only cement our position in Burkina Faso, but also to increase our footprint throughout Africa.

NCP designed, manufactured, supplied, and commissioned a new 12’ x 18’, 1250kW Ball mill over the same period for a brownfields project in Gwanda District in Zimbabwe, including supply of critical and operational spares. This brings the total number of NCP milling projects supplied into Africa to 220 with several African projects in production at present.

NCP provided technical support and guidance to the client and included a PLC for the control & monitoring of this milling station.

For this project, lead time was significantly critical, and NCP did achieve an amazing delivery time of 24 Weeks EXW for a new mill, living up to all our commitments made during the sales stage of the project.

When all is said and done, one of the biggest compliments we can receive is an email after commissioning the mill, from our client, that reads:

“It was a pleasure working with you guys – including Manie, Barry, Craig and Stef – and all the people we never met. You made it easier for us by your high standards and consistency to accuracy. You brought to us sophistication in milling, and while it is a challenge, it is an exciting piece of equipment that will we are very confident will help us achieve our targets.” – Cavin Magwenzi
(Engineering Manager Caledonia Mine)

Embedded in the culture of day to day running at NCP and Illustrated in the picture below – “Through teamwork, Everything Is Possible”.