Essentials of Investments, 8th Edition Bodie, Kane, Marcus
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Est sta abl blis ishi hing ng th the e Li Link nks s Be Betw twe een Ore Cha hara racte cteris ristics tics and Crus rushin hing g& Grinding Performa rformance nce W Valery & K Runge Mets tso o Minerals Minerals Process Tech Technol nology ogy,, Aus Austr tra ali lia a and Asi A sia aPacific
A R Butcher, T Helms, & P Gottlieb Intell ntelle ecti ction on Pty Pty Ltd, Lt d, Br Bris isbane bane,, Aus Austr tra ali lia a
Wha hatt is i s Pro Proce cess ss Integr Integra ati tion on and Opt Optim imis isa ati tion on? ?
The development of integrated operating and control strategies from the mine to the plant that min minimis imise es the overa ove rallll cost pe perr tonne t onne and and ma m aximi ximise ses s profit pr ofita abil bility ity . Opt pt((bl bla ast stin ing+. g+...+ co comm mmin inut utio ion n + fl flot ota ati tion on...) = Max($ x($$ $$)
How profitability can be increased with Process Integration and Optimisation?
increasing throughput
reducing costs
improving process efficiency (from mine to mill)
increasing mineral recovery
increasing availability of equipment
Traditional Process Optimisation Blasting
Grinding
Separation Grade & tonnes
Grind size & throughput
Grade & recovery
Integrated Process Optimisation •
Measurement of ore characteristics across different ore types
-
Blastability – Rock structure, rock strength Grindability – Rock strength (breakage properties) Separability – Mineral composition, grain size & texture, degree of alteration
•
Recognition that the operation of all processes impacts on the optimum performance of its upstream and downstream processes
•
Development of relationships between ore characteristics and performance across all operations Objective
Maximise profitability
Process Integration and Optimisation Rock Structure Rock Strength Mineralogy
Ore Characterisation
RF ID Tags
Mineralogical Properties
Process Integration and Optimisation Process modelling and simulation
RF ID Tags
Process Integration and Optimisation On-Line Instrumentation and Measurement
OreMarkers VisioRock
VisioRock
RF ID Tags
OreMarkers
VisioFroth
VisioRock
OreMarkers
CCM
Establishment of Ore Specific Size Reduction Targets Unbroken Ore
Blasting
Crushing & Grinding
Liberation
Ore mineral
Particle size progressively reduced
Optimum Blast Fragmentation • • •
Blasting should be recognised as the first comminution process Maximise throughput through subsequent grinding process Optimise cost distribution between blasting and grinding
Drill and Blast Primary Crushing Milling (SABC)
Cost ($/t) 0.15 0.75 3.75
Energy (kWh/t) 0.2 2.0 20.0
Example of a gold operation, open pit, relatively hard ore
Optimum Grind Size • •
Maximise recovery and grade achieved in the subsequent separation processes Balanced by the need to minimise costs of size reduction and maximise throughput Average GrainGrain Sizes R ou Feed gher Feed Average SizeininAB Rougher 180 ) 160 s n 140 o r c i 120 m ( e 100 z i S n 80 i a r G 60 e g 40 a r e v 20 A
All_Material Pentlandite Chalcopyrite Pyrrhotite
0 0
20
40 60 80 100 120 140 160 180
Ave r age Par tic le Size (m icr o n s)
Methodology Definition of Ore Domains
Strength
100%
Structure
80%
g n i s 60% s a p %40% m u C 20%
0%
Mineralogical Properties
Ag/Sag Mill Product In-Situ Blocks
Crusher Product
ROM
0.1
1
10 100 Size mm
1000
10000
Establishment of Operating Targets
Measuring Structure: Scan line mapping and Image analysis
Results of structure characterisation: in situ block size distribution 1.6
1.4
1.2 ) 1 m ( e z i S k 0.8 c o l B u t i s 0.6 n I
3
X50 X80
0.4
0.2
0 OYGMD1
OYGMD2
OYGMD3
OYGMD4 Structural Domain
OYPB
STGMD1
STGMD2
Measuring Strength: Point Load Tests
Point Load Strength Results
30
25
20 y c n e u 15 q e r F
Norte Brecha Sul Diorita
10
5
0 1
2
3
4
5
6 Is50
7
8
9
10
Measurement of Mineralogical Properties – QEMSCAN Analysis Rims
Interstitial
Exsolved
Ore Characterisation
Inclusions
Disseminated
Laminated
Case Study: Polymetallic Ore
Galena Bearing Particles
Galena Grain Size Distribution
- 2 0
- 2 7 / +
2
- 3 8 / + 0
- 4 5 2
7
/ +
- 5 3 3
/ +
8 G
a
l e
- 7 5 4
/ +
5 n
a
B
i -
S
- 1 0 5
6
3
i z
e
D
i s
t
- 2 1 / +
r
7 5 i b
u
t i o
n
2
- 3 0 / +
1 0
6
0
- 4 5 / +
2 1
2
0 / +
- 6 0 3 0
0
+ 0 / +
4 5
0
6
0 0
Sphalerite Grain Size Distribution
- 2 0
- 3 8
/ +
- 5 3 2
0
/ +
3
- 7 5 / + 8
- 1 0 5
3
6
- 2 1 / +
7 5
2
- 3 0 / +
1 0
6
0 / +
- 4 5 2 1
2
0
- 6 0 / +
3 0
0
+ 0
/ +
4 5
0
6
0 0
CaseStudy: Blast Fragmentation Modelling Powder Factor versus Size Distribution and Costs Powder Factor vs Particles Size (P80, P50, & P20) and Cost Coronado - Square Pattern 20
$0.40
18
$0.36
16
$0.32
14
$0.28
) 12 s e h c n 10 i ( e z i S
$0.24
8
$0.16
6
$0.12
4
$0.08
2
$0.04
0 0.30
$0.20
0.40
0.50
0.60
0.70
0.80
0.90
1.00
Powder Factor (lb/tn)
1.10
1.20
1.30
1.40
1.50
$0.00 1.60
) n t / $ ( t s o C
P20 P50 P80 Cost Linear (Cost) Power (P80) Power (P50) Power (P20)
Case Study: ROM and Primary Crusher Product 100
Case Study 3 Pow der factor (kg/t) Throughput (t/h) Product s ize ( m )
90
80
Normal 0.44 353 93
Improved 0.63 370 93
Normal Blast ROM
70 g n i s 60 s a p % e 50 v i t a l u m 40 u C
Normal Blast Crusher Product Improved Blast ROM Improved Blast Crusher Product
30
20
10
0 1
10
100
size (mm)
1000
Summary
•
New technologies have been developed to characterise the blastability, grindability & separability of ore domains.
•
Online and offline measurement systems are allowing the understanding of ore types in terms of their lithology, mineralogy, breakage properties & recovery characteristics.
•
Modelling, simulation, integration and optimisation of all processes (blasting, crushing, grinding and separation) within the production environment are providing the industry with rapid and cost effective means of increasing profitability.
