Beruflich Dokumente
Kultur Dokumente
and Optimisation
Walter Valery
Metso Minerals Process Technology Asia-Pacific
SME 2004
Denver, CO
25 February 2004
It is not
Increasing powder factor to increase throughput
Opt(blasting) ++ Opt(milling) + Opt(flotation) Max($$$)
increasing throughput
What is required?
Management commitment
Cost
($/t)
0.15
0.75
3.75
Energy
(kWh/t)
0.2
2.0
20.0
Coarse
Fine
Intermediate
or Critical Size
90
% Cumulative Passing
80
70
60
50
Fines
40
30
20
10
0
1
10
100
Size (mm)
1000
Intermediate
or Critical Size
% Cumulative Passing
80
70
60
50
40
Fines
30
20
10
0
1
10
100
Size (mm)
1000
% Cumulative Passing
80
70
60
50
40
30
20
10
0
1
10
100
Size (mm)
1000
% Cumulative Passing
80
70
60
50
40
30
20
10
0
1
10
100
Size (mm)
1000
% Cumulative Passing
80
70
60
50
40
30
20
10
0
1
10
100
Size (mm)
1000
Throughput Dependence
Type of explosives
Quantity of explosives
Blast hole diameter
Blast pattern
Contain energy
Initiation systems
Process Flowsheet
Product size distribution
Mill Operation
Control Strategy
East
ST BFB
OY GMD4
OY PB
OY GMD3
OY GMD2
OY GMD1
ST GMD4
ST GMD2
ST GMD1
ST GMD3
OY GMD4
Case Study 1
ROM
Product P80 = 210 m
Primary
crusher
Spiral
classifier
To pebble bin
Stockpile
Case study
Ore
Rock type
UCS (Mpa)
Axb
Bond Wi (kWh/t)
Metso Minerals, Inc. 2004
1
Copper
Biotite schists
75
80-90
10 12
AG mill
22x40
7000 HP
Pebble mill
17x21
2500 HP
100
90
90
80
80
70
% Cumulative Passing
% Cumulative Passing
70
60
50
40
60
50
40
30
30
20
20
10
10
0
0
1
10
100
Size (mm)
1000
10000
10
100
Size (mm)
1000
10000
% cumulative passing
Normal Blast ROM
100
45
90
40
80
35
30
60
% retained
Cumulative % passing
70
50
25
20
40
15
30
20
10
10
10
100
size (mm)
1000
10000
1000
500
125
63
31
size (mm)
16
% cumulative passing
100
40
90
80
70
30
25
60
% retained
Cumulative % passing
35
50
40
20
15
30
20
10
5
10
0
1
10
100
size (mm)
1000
10000
400
250
125
63
31
Size (mm)
16
Case Study 1
Powder factor (kg/t)
Throughput (t/h)
80
Product size (m)
Normal
0.86
615
190
90
Improved
1.17
700
204
Cumulative % passing
70
60
50
40
30
20
10
0
1
10
100
size (mm)
1000
10000
Case Study 2
Pebble
crusher
Primary
crusher
Ball mill
14x24
3000 HP
Ball mill
14x24
3500 HP
Stockpile
P80=120m
P80=120m
SAG mills
28x12
7000 HP
Ball mill
18x28
6500 HP
Case study
2
Ore
Gold
Rock type
Hornblend Diorite
UCS (Mpa)
138
Axb
40-45
Bond Wi (kWh/t)
18-20
Metso Minerals, Inc. 2004
P80=120m
100
100
90
90
80
% Cumulative Passing
% Cumulative Passing
80
70
60
50
40
70
60
50
40
30
30
20
20
10
10
0
1
0
1
10
100
Size (mm)
1000
10000
10
100
Size(mm)
1000
10000
% cumulative passing
Normal Blast ROM
40
100
90
35
80
30
25
60
% retained
cumulative % passing
70
50
40
20
15
30
10
20
10
0
1
10
100
1000
1000
500
200
70
20
size (mm)
size (mm)
10000
% cumulative passing
40
90
35
80 Blast Improved
Crusher70Product
30
25
60
% retained
cumulative % passing
100
50
40
20
15
30
20
10
5
10
0
1
10
100
size (mm)
1000
10000
200
100
50
16
size (mm)
Case Study 2
Powder factor (kg/t)
Throughput (t/h)
Product size (m)
90
80
Normal
0.22
673
115
Improved
0.38
775
131
cumulative % passing
70
60
50
40
30
20
10
0
1
10
100
size (mm)
1000
10000
Case Study 3
Oversize
stockpile
ROM
Grizzly
Two tertiary
crushers
HP500
Two secondary
ball mills
14x21 , 2500 HP
Secondary
crusher
HP500
Primary
jaw crusher
C140
Fine ore
stockpile
Case study
Ore
Rock type
P80=93m
3
Gold
Vulcanoclastics
/ porphyry
UCS (Mpa)
120
Axb
36-40
Bond
WiInc.(kWh/t)
17-19
Metso Minerals,
2004
% cumulative passing
Normal Blast ROM
100
30
90
25
80
60
% retained
Cumulative % passing
70
50
15
40
10
30
20
10
0
1
10
100
size (mm)
1000
400
250
125
44
size (mm)
16
% cumulative passing
100
30
90
70
20
60
% retained
Cumulative % passing
25
80
50
40
15
10
30
20
10
0
1
10
100
250
125
88
44
size (mm)
size (mm)
1000
16
Case Study 3
Powder factor (kg/t)
Throughput (t/h)
Product size (m)
90
80
Normal
0.44
353
93
Improved
0.63
370
93
Cumulative % passing
70
60
50
40
30
20
10
0
1
10
100
size (mm)
1000
Equipment Know-how
Process
Know How
Automation and
Information Management
Know-how
RF ID Tags
VertiMills and
SMD
Crushers
Screens
Ball Mills
Flotation
Cells
SAG Mills
Pumps
RF ID Tags
RF ID Tags
OreMarkers
VisioRock
VisioRock
RF ID Tags
OreMarkers
VisioFroth
VisioRock
OreMarkers
CCM
Metso Minerals, Inc. 2004
Ore Markers
POST
BLAST
[ID,x,y,z]
POST
CRUSHER
DETECTOR
RECEPTOR
Dispatch
Database
Spatial
Database
Temporal
Database
[ID,t]
DETECTOR
MILL FEED
RF ID Tags
PLCs
DCS
SCADA
OCS
PLCs
DCS
SCADA
RF ID Tags
Information
Management
OCS
PLCs
DCS
SCADA
RF ID Tags