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Mining and Milling Process Integration

and Optimisation
Walter Valery
Metso Minerals Process Technology Asia-Pacific

SME 2004
Denver, CO
25 February 2004

What is Process Integration and Optimisation?

The development of integrated operating and control


strategies from the mine to the plant that minimises the
overall cost per tonne and maximises profitability.
Opt(blasting+..+ milling+ flotation..) = Max($$$)

Metso Minerals, Inc. 2004

What is Process Integration and Optimisation?

It is not
Increasing powder factor to increase throughput
Opt(blasting) ++ Opt(milling) + Opt(flotation) Max($$$)

Metso Minerals, Inc. 2004

How profitability can be increased with Process


Integration and Optimisation?

increasing throughput

improving process efficiency (from mine to the plant)

increasing metal recovery

reducing energy consumption and green house gas


emissions

increasing availability of equipment

Metso Minerals, Inc. 2004

What is required?

Appropriate methodology and systems

Management commitment

Planning and close cooperation between all phases of


the operating cycle - geology, mining and processing

Metso Minerals, Inc. 2004

Objectives and Importance of Drill and Blast


Traditionally:
Obtain suitable fragmentation for muck pile excavation and
transportation to primary crusher at minimum cost
In an integrated process:
Drill and Blast are the first steps of comminution
Blasting process has to be adjusted for different types of ore
Energy in the blast can be manipulated
Wall stability, damage, grade control/dilution are the
constraints

Metso Minerals, Inc. 2004

Breakdown of Costs and Energy


Example of a gold operation, open pit, relatively hard ore

Drill and Blast


Primary Crushing
Milling (SABC)

Metso Minerals, Inc. 2004

Cost
($/t)
0.15
0.75
3.75

Energy
(kWh/t)
0.2
2.0
20.0

What is optimum fragmentation?

Coarse

Metso Minerals, Inc. 2004

Fine

What is the Optimum Circuit Feed Size?


Top Size
100

Intermediate
or Critical Size

90

% Cumulative Passing

80
70
60
50

Fines

40
30
20
10
0
1

10

100
Size (mm)

Metso Minerals, Inc. 2004

1000

What is the Optimum Circuit Feed Size?


Top Size
100
90

Intermediate
or Critical Size

% Cumulative Passing

80
70
60
50
40

Fines

30
20
10
0
1

10

100
Size (mm)

Metso Minerals, Inc. 2004

1000

What is the Optimum Feed Size?


Fully Autogenous Mill
100
90

% Cumulative Passing

80
70
60
50
40
30
20
10
0
1

10

100
Size (mm)

Metso Minerals, Inc. 2004

1000

What is the Optimum Feed Size?


Semi-Autogenous Mill
100
90

% Cumulative Passing

80
70
60
50
40
30
20
10
0
1

10

100
Size (mm)

Metso Minerals, Inc. 2004

1000

What is the Optimum Feed Size?


3 Stage Crushing
100
90

% Cumulative Passing

80
70
60
50
40
30
20
10
0
1

10

100
Size (mm)

Metso Minerals, Inc. 2004

1000

Drill and Blast Process Variables

Type of explosive (density, VOD)


Quantity of explosive
Hole diameter
Blast pattern
Energy containment
Timing (initiation systems)

Metso Minerals, Inc. 2004

Throughput Dependence

Ore competence (strength)


Feed size distribution
(strength and structure)

Type of explosives
Quantity of explosives
Blast hole diameter
Blast pattern
Contain energy
Initiation systems

Process Flowsheet
Product size distribution

Metso Minerals, Inc. 2004

Type, size and power of


comminution machines

Mill Operation

Crusher size and gap


Mill grate/pulp lifter design
Shell lifter/liner design
Mill speed
Ball charge and size
Total charge level
Water addition
Classification

Control Strategy

Successful Process Integration and Optimisation


Methodology
Characterise Ore Domains (Strength and Structure)
Benchmarking, Modelling and Simulation
Potential Impact on Wall Damage/Control and Dilution
Implement Blast Design in the Field
Measure Fragmentation
Evaluate Effect of Blast Design on Fragmentation
Implement Crushing and Milling Strategies and Systems
Quantify the Effect of Fragmentation on Mill Performance

Characterisation - Structure and Strength

Metso Minerals, Inc. 2004

Example of Ore Domains based on Strength and Structure


West

East

ST BFB

OY GMD4
OY PB
OY GMD3
OY GMD2

OY GMD1

Metso Minerals, Inc. 2004

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

Case Study 1: Measured Size Distributions


ROM Envelope

Crusher Product Envelope


100

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)

Metso Minerals, Inc. 2004

1000

10000

10

100
Size (mm)

1000

10000

Metso Minerals VisioRock System

Metso Minerals, Inc. 2004

Limitation of all on-line image analysis systems

Metso Minerals, Inc. 2004

Sampling Crusher Product and AG/SAG Mill Feed

Metso Minerals, Inc. 2004

Case Study 1: ROM Sizes


% retained

% cumulative passing
Normal Blast ROM
100

45

90

40

80
35

Normal Blast - ROM


Improved Blast - ROM

30

60

% retained

Cumulative % passing

70

50

25

20

40
15

30

Improved Blast ROM

20
10

10

10

100
size (mm)

Metso Minerals, Inc. 2004

1000

10000

1000

500

125

63

31

size (mm)

16

Case Study 1: Crusher Product Sizes


% retained

% cumulative passing

100

40

90

Improved Blast Crusher Product

80
70

Improved Blast - Crusher Product

30
25

60

% retained

Cumulative % passing

Normal Blast - Crusher product

35

50
40

20
15

30

Normal Blast Crusher Product

20

10
5

10

0
1

10

100
size (mm)

Metso Minerals, Inc. 2004

1000

10000

400

250

125

63

31
Size (mm)

16

Case Study 1: ROM and Crusher Product


100

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

Normal Blast ROM

60
50

Improved Blast ROM

40
30

Normal Blast Crusher Product

20

Improved Blast Crusher Product

10
0
1

10

100
size (mm)

Metso Minerals, Inc. 2004

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

Case Study 2: Measured Size Distributions


ROM Envelope

Crusher Product Envelope

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)

Metso Minerals, Inc. 2004

1000

10000

10

100

Size(mm)

1000

10000

Case Study 2: ROM Sizes


% retained

% cumulative passing
Normal Blast ROM
40

100
90

35

80

Normal Blast - ROM


Improved Blast - ROM

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)

Improved Blast ROM

Metso Minerals, Inc. 2004

10000

Case Study 2: Crusher Product Sizes


% retained

% cumulative passing

40

90

35

80 Blast Improved
Crusher70Product

30

Normal Blast - Crusher Product


Improved Blast - Crusher Product

25

60

% retained

cumulative % passing

100

50
40

20
15

30

Normal Blast Crusher Product

20

10
5

10

0
1

10

100
size (mm)

Metso Minerals, Inc. 2004

1000

10000

200

100

50

16
size (mm)

Case Study 2: ROM and Crusher Product


100

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

Normal Blast ROM

60

Improved Blast ROM

50
40

Normal Blast Crusher Product

30
20

Improved Blast Crusher Product

10
0
1

10

100
size (mm)

Metso Minerals, Inc. 2004

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

Primary ball mill


17x28 , 5400 HP

Case Study 3: ROM Sizes


% retained

% cumulative passing
Normal Blast ROM
100

30

90

25

80

Normal Blast - ROM


Improved Blast - ROM
20

60

% retained

Cumulative % passing

70

50

15

40

10
30
20

10

0
1

10

100

size (mm)

Metso Minerals, Inc. 2004

Improved Blast ROM

1000

400

250

125

44
size (mm)

16

Case Study 3: Primary Crusher Product Sizes


% retained

% cumulative passing

100

Improved Blast Crusher Product

30

90

Improved Blast - Crusher Product

70

20

60

% retained

Cumulative % passing

Normal Blast - Crusher Product

25

80

50
40

15

10
30
20

10

0
1

10

100

250

125

88

44
size (mm)

size (mm)

Normal Blast Crusher Product

Metso Minerals, Inc. 2004

1000

16

Case Study 3: ROM and Primary Crusher Product


100

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

Normal Blast ROM

Cumulative % passing

70
60

Normal Blast Crusher Product

50

Improved Blast ROM

40

Improved Blast Crusher Product

30
20
10
0
1

10

100
size (mm)

Metso Minerals, Inc. 2004

1000

Metso Services and Systems

Equipment Know-how

Process
Know How

Metso Minerals, Inc. 2004

Automation and
Information Management
Know-how

Process Integration and Optimisation


Equipment and Process Design Drill Rigs

RF ID Tags

VertiMills and
SMD

Crushers
Screens
Ball Mills

Flotation
Cells

SAG Mills
Pumps

Metso Minerals, Inc. 2004

Process Integration and Optimisation


Increase equipment availability

RF ID Tags

Metso Minerals, Inc. 2004

Process Integration and Optimisation


Process modelling and simulation

RF ID Tags

Metso Minerals, Inc. 2004

Process Integration and Optimisation


Instrumentation and Measurement

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

Metso Minerals, Inc. 2004

Process Integration and Optimisation


Basic Control

RF ID Tags
PLCs
DCS
SCADA

Metso Minerals, Inc. 2004

Process Integration and Optimisation


Advanced Control

OCS
PLCs
DCS
SCADA

Metso Minerals, Inc. 2004

RF ID Tags

Process Integration and Optimisation


Information Management

Information
Management

OCS
PLCs
DCS
SCADA

Metso Minerals, Inc. 2004

RF ID Tags

Information Management System Overview

Metso Minerals, Inc. 2004

Process Integration and Optimisation


Increase Operations Profitability
Collaboration/Partnership
Gain-Sharing / Risk-Reward

Metso Minerals, Inc. 2004

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