Metso Process Technology

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Metso Process Technology Innovation (PTI)
Unlocking Energy Efficiency in the Mining
ProcessEnergy Efficiency Opportunities (EEO)
Workshop   Kristy-Ann DuffyMetso (PTI)
Perth - 6 September 2012
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Overview
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Metso PTI

• 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
Whole of system Approach PIO
Crushing Grinding Flotation Ore
characterisation
Development of an Eco-Efficient Mining
Process
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Process Integration and Optimisation (PIO)
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
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The PIO Approach
Blast Design
Ore Characterisation Lithology zones Rock
Strength - Point Load Index - SMC Tests -
Drop Weight Test results - Work Indices Rock
Structure - Rock Quality, FF, Mapping
PTI Blast Fragmentation Model
Blasting
ROM Ore size Distribution
Grinding Circuit Model (JKSimMet and PTI models)
Primary Crusher Model (JKSimMet and PTI models)
SAG Feed Size Distribution
Throughput Final Grind Size
Mineral Recovery
Flotation Model (PTI)
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Benefits of PIOCase Study - Antamina
OBJECTIVE To increase throughput when treating
harder ores.
SAG Feed Size F80 vs. Throughput Antamina
Increased throughput with the same installed
power, reduces the energy consumption per
ton Unlocking energy savings
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Effect of Blast and Plant Changes on Throughput
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Benefits of PIOCase Study - Antamina
For more information refer to SAG 2011
PAPER OPTIMISATION AND CONTINUOUS IMPROVEMENT OF
ANTAMINA COMMINUTION CIRCUIT
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RD 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.

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Project Areas
Increase and better distribute energy of blasting
to reduce energy in downstream comminution stages.
High Intensity Selective Blasting
Discarding barren waste to significantly reduce
energy consumption of downstream processes
Pre-Concentration
In-Pit Crushing and Conveying
Energy Efficient Dry Comminution
Energy Efficient Comminution Circuits
Coarse Particle Flotation
Water Recovery Optimisation
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An Eco-Efficient Mining Process

• May incorporate any combination of these
  possibilities
• Requires tailored solutions based on detailed
  understanding of the process and ore.

High Intensity Selective Blasting
Pre-Concentration
In-Pit Crushing and Conveying
Energy Efficient Dry Comminution
Energy Efficient Comminution Circuits
Coarse Particle Flotation
Water Recovery Optimisation
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Summary
Continuous improvement
Detailed understanding of the process and ore
Unlocks energy savings while improving business
profitability
Optimising the process as a whole
R D Looking for the next step
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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.

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