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EXPERT MINERALS PROCESSING SOFTWARE AND CONSULTING [email protected] www.minerality.com.au Solutions to Manage Ore Variability Effects

Presentacion Steyn

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Page 1: Presentacion Steyn

EXPERT MINERALS PROCESSING SOFTWARE AND CONSULTING

[email protected]

Solutions to Manage Ore Variability Effects

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Key Performance Indicators

IN MILLING

Maximum Throughput

Maximum Recovery

Lowest Milling Cost per Ton

123

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Variable Operation

Variable Grind

Variable Recovery

Lower Recovery

Wasted Opportunities & Wasted $$$

Performance may drop significantly as a result of mining into different part of ore domain

Variable Ore

The Challenge

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Ore Variability

Very Slow

Unrepresentative

Expensive $$$$

Size Specific

Leaves many unknowns Poor response to ore changes

The traditional approach to dealing with ore variability

send samples for ORE HARDNESS

TESTING

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Ore Variability…A story of Instability and Lost OpportunitiesFeed Ore Variability:

Plant Instability

FINAL GRIND SIZE RECIRCULATING LOADS

PRODUCT SIZE DISTRIBUTIONS MILL LOADS

- Lost recovery- Lack of grind

control

- Overgrinding- Inefficiencies

- Equipment wear - Fluctuating & Unstable

- Effects the whole plant

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Ore Variability…A story of Instability and Lost Opportunities

Feed Ore Variability

Uncertainty

Optimum Equipment

Variable Settings?

Optimum Throughput

(TPH)?

Equipment Interactions?

Liner Uncertainties –Downtime, when to

replace?

?Ore Blending Decisions?

? ? ? ?How I do to respond?

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Barriers to Peak Processing Performance

How do I know my ore is changing? Laboratory hardness tests can take months!!

How do I know what is happening with every stream in my plant?

How do I monitor recirculating loads?

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A real time, knowledge driven response to Ore Variability and Processing Problems

Plant Data SOFTWARE

Final Grind Size

Recirculating Loads

Stream Densities

Product Size Distributors

Tracks ore variabilitycontinuously

IN REAL TIME

PREDICT PREDICT

Liner Life

Optimised plant settings

Equipment variable settings

Equipment Interactions

Optimum Throughput (TPH)

Feed ore blending decisions

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Continuously Monitor Ore Hardness Changes

MONITORING PREDICTING ADVICE SIMULATING REPORTING SUPPORT

Hardness is Increasing,Throughput Decreases

• Continuously monitor and track ore hardness changes as ore enters plant – no more waiting for hardness test results

• Watch for trends in ore body

• Monitor stream or equipment properties which cannot be measured with instrumentation

Set desired parameters for each streamWarning if parameters exceeded

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Continuously Predict Stream Properties

Continuously predict the properties of every stream around the plant

Know what is happening onyour plant all the time:

• Flow Rates• Densities• Size Distributions & P80’s• Recirculating Loads• Mill Power Draws• Cyclone Pressures

What is recirculating load?Must be 250 %

What are densities?

MONITORING PREDICTING ADVICE SIMULATING REPORTING SUPPORT

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Be Advised...Make informed processing decisions

If the performance of the plant is outside the defined limits and criteria, recommendations can be made to achieve the required conditions by making changes to operating variables.

For example:If recirculating load too high, the spigot or vortex finder can be changed immediately

MONITORING PREDICTING ADVICE SIMULATING REPORTING SUPPORT

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DON’T MAKE MISTAKES...Simulate changes before you make them:

• See the downstream effects of the change.What happens to recirculating loads and product size if ball size in SAG mill changes?

• Avoid mill overloads, plant shutdowns and costly errors. Do not make changes without checking!

BE PREPARED: If a harder or softer ore is expected in a few months, simulate the performance of the plant early to prepare for the moment the new ore comes through

Avert Disasters!!

MONITORING PREDICTING ADVICE SIMULATING REPORTING SUPPORT

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Continuously Monitor Ore Hardness Changes

Calculate and report the availability of the plant, the time the plant was not performing within specifications. Report key performance indicators: TPH, Availability, Recirculating loads, P80’s, Total product produced per month.

0

50

100

Current Performance

Improvement (Process)

Improvement (Liners&Equipment)

Other

Record improvements achieved after making changes

Support: Technical support plus grinding experts available to discuss your plant.

MONITORING PREDICTING ADVICE SIMULATING REPORTING SUPPORT

Continuously record the flows, densities, P80’s of every stream. This can be reported over a user defined period.

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THANK YOU

» Boost Throughput

» Boost Recovery

» Cut Milling cost per ton

www.minerality.com.au / PO BOX 1711, New Farm QLD 4005, Australia | +61 7 3358 2288 / Suecia 15, Of.75, Providencia, Santiago, Chile | +56 9 9698 6084

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