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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. Overview. Metso PTI. SmartTag™ SmartEar™ SmartSAG™
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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
Metso PTI SmartTag™ SmartEar™ SmartSAG™ SmartRIP™ Whole of system Approach PIO Crushing Grinding Flotation Ore characterisation Development of an Eco-Efficient Mining Process The vision of this team is to provide a technical resource of the highest quality to both industry and Metso's related business lines.
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 Maximum return on the invested capital New solution and profit increase Process Integration and Optimisation
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 • Production rate • Final P80 size Mineral Recovery Flotation Model (PTI) 5
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 6 Effect of Blast and Plant Changes on Throughput
Benefits of PIOCase Study - Antamina 23% reduction in grinding energy For more information refer to SAG 2011 PAPER: OPTIMISATION AND CONTINUOUS IMPROVEMENT OF ANTAMINA COMMINUTION CIRCUIT
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.
Increase and better distribute energy of blasting to reduce energy in downstream comminution stages. Project Areas A potentially a cheaper and more eco-efficient method of transporting material. Especially for large volumes and large distances. High Intensity Selective Blasting Discarding barren waste to significantly reduce energy consumption of downstream processes Pre-Concentration In-Pit Crushing and Conveying Comminution of ore (crushing and grinding) is the most energy intensive stage of mineral production. Energy Efficient Dry Comminution Energy Efficient Comminution Circuits The mining industry typically consumes 0.6 to 1.0m3 of water for each ton of ore processed by flotation If coarser particles could be recovered by flotation, less power would be required for the previous comminution stages. Coarse Particle Flotation Water Recovery Optimisation
An Eco-Efficient Mining Process High Intensity Selective Blasting • May incorporate any combination of these possibilities • Requires tailored solutions based on detailed understanding of the process and ore. Pre-Concentration In-Pit Crushing and Conveying Energy Efficient Dry Comminution Energy Efficient Comminution Circuits Coarse Particle Flotation Water Recovery Optimisation
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