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Metso Process Technology & Innovation (PTI) Unlocking Energy Efficiency in the Mining Process Energy Efficiency Opportunities (EEO) Workshop Kristy-Ann.

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Presentation on theme: "Metso Process Technology & Innovation (PTI) Unlocking Energy Efficiency in the Mining Process Energy Efficiency Opportunities (EEO) Workshop Kristy-Ann."— Presentation transcript:

1 Metso Process Technology & Innovation (PTI) Unlocking Energy Efficiency in the Mining Process Energy Efficiency Opportunities (EEO) Workshop Kristy-Ann Duffy Metso (PTI) Perth - 6 September 2012

2 © Metso Overview Unlocking Energy Efficiency in the Mining Process 2 Introduction to Metso Process Technology and Innovation (PTI) Unlocking energy savings using Process Integration and Optimisation (PIO) Case Study: Antamina Research and Development “Development of an Eco-Efficient Mining Process”

3 © Metso Metso PTI Unlocking Energy Efficiency in the Mining Process 3 The vision of this team is to provide a technical resource of the highest quality to both industry and Metso's related business lines. SmartTag™ SmartEar™ SmartSAG™ SmartRIP™ Development of an Eco-Efficient Mining Process Whole of system Approach PIO Crushing Grinding Flotation Ore characterisation

4 © Metso Process Integration and Optimisation (PIO) 4 The development of integrated operating and control strategies from the mine to the plant that maximise throughput, minimise the overall cost and energy consumption per tonne and maximise profitability Unlocking energy savings Process Integration and Optimisation Maximum return on the invested capital New solution and profit increase

5 © Metso The PIO Approach Ore Characterisation Lithology zones Rock Strength - Point Load Index - SMC Tests - Drop Weight Test results - Work Indices Rock Structure - Rock Quality, FF, Mapping Ore Characterisation Lithology zones Rock Strength - Point Load Index - SMC Tests - Drop Weight Test results - Work Indices Rock Structure - Rock Quality, FF, Mapping Blast Design PTI Blast Fragmentation Model ROM Ore size Distribution Primary Crusher Model (JKSimMet and PTI models) SAG Feed Size Distribution Grinding Circuit Model (JKSimMet and PTI models) Throughput Final Grind Size Mineral Recovery Flotation Model (PTI) Blasting Production rate Final P80 size 5

6 © Metso Benefits of PIO Case Study - Antamina OBJECTIVE: To increase throughput when treating harder ores. SAG Feed Size F80 vs. Throughput – Antamina Effect of Blast and Plant Changes on Throughput Increased throughput with the same installed power, reduces the energy consumption per ton Unlocking energy savings 6

7 © Metso Benefits of PIO Case Study - Antamina For more information refer to SAG 2011 PAPER: OPTIMISATION AND CONTINUOUS IMPROVEMENT OF ANTAMINA COMMINUTION CIRCUIT 23% reduction in grinding energy

8 © Metso R&D Project: Development of an Eco-Efficient Mining Process Objective Investigate alternative technologies and practices in mining and minerals processing that reduce the usage of energy, water and carbon emissions. Target Propose eco-efficient mining services and flowsheet(s) to trial in collaboration with a major mining company target to reduce - energy usage by 30% and - greenhouse gas emissions by 50%. Solutions that are technically and economically viable to be implemented in a reasonably short timeframe. Unlocking Energy Efficiency in the Mining Process 8

9 © Metso Project Areas Unlocking Energy Efficiency in the Mining Process 9 High Intensity Selective Blasting In-Pit Crushing and Conveying Pre- Concentration Energy Efficient Comminution Circuits Energy Efficient Dry Comminution Coarse Particle Flotation Water Recovery Optimisation Increase and better distribute energy of blasting to reduce energy in downstream comminution stages. Discarding barren waste to significantly reduce energy consumption of downstream processes A potentially a cheaper and more eco-efficient method of transporting material. Especially for large volumes and large distances. Comminution of ore (crushing and grinding) is the most energy intensive stage of mineral production. If coarser particles could be recovered by flotation, less power would be required for the previous comminution stages. The mining industry typically consumes 0.6 to 1.0m 3 of water for each ton of ore processed by flotation

10 © Metso An Eco-Efficient Mining Process Unlocking Energy Efficiency in the Mining Process 10 High Intensity Selective Blasting In-Pit Crushing and Conveying Pre- Concentration Energy Efficient Comminution Circuits Energy Efficient Dry Comminution Coarse Particle Flotation Water Recovery Optimisation May incorporate any combination of these possibilities Requires tailored solutions based on detailed understanding of the process and ore.

11 © Metso Summary Unlocking Energy Efficiency in the Mining Process 11 Detailed understanding of the process and ore Optimising the process as a whole R & D Looking for the next step Unlocks energy savings while improving business profitability Continuous improvement

12 © Metso Date Author Title 12

13 © Metso Optimisation of Blast Fragmentation Definition of Fragmentation domains - Defined by in-situ block size distribution (structure) and rock strength properties. - PTI use blast fragmentation models and systems to optimise the blast for each fragmentation domain. - Produces consistent blast fragmentation. 4/19/2015Date Author Title Example of Blast Domain Mapping (16 Domains) The aim is to produce ROM fragmentation that will maximise throughput and the efficiency of subsequent crushing and grinding operations.

14 © Metso Vale, Sossego - CU KinRoss, RPM - Au Anglo, Los Bronces - Cu Freeport,Candelaria - Cu Anglogold, Iduapriem - Au Anglo, Morila Au Eldorado Gold Corp, Kisladag - Au NewMont Batu Hijau - Cu NewCrest,Telfer – Cu/Au BHP - Fe NewMont, Bodington - Au Kalgoorlie, Fimiston - Au WMC - Ni Goldfields,St Ives - Au Goldfields,St. Ives - Au BHO, Cannington – Pb/Ag Barrick, Cowal – Ouro/ Cu Oz, Minerals - Zn Xstrata, Ernest Henry - Au Vale, Salobo - Cobre Codelco, Andina - Cu Antamina – Cu/Zn Los Pelambres - Cu Codelco, Mansa MIna - Cu BHP, Escondida Cu Anglo, Sadiola - Au Impala, Zimplats - Pt Kansanshi - Cu Fosfértil, Catalão/Tapira, PM - P BHP, Cerro Colorado Cu CSN, Casa de Pedra - Fe Gold Mine Co, Lihir - Au Barrick,Cortez - Au Freeport, Cerro Verde- Cu New Mont, Phoenix- Au New Mont, Carlin- Au Rio Tinto, Kennecott - Cu BHP, Olympic Dam–U/Cu/Au Anglo, Mantos Blancos - Cu Anglo, Geita- Au NewMont, Ahafo - Au Major Projects BHPB, Newman - Fe Phosagro, Apatit – PO Polymetal, Varvarinskoye – Au/Cu Peñoles, Franciso I. Madero – Zn


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