Rikastustekniikan innovaatioilla kestävää liiketoimintaa Knuutila_Outotec.p… · Oulu Mining Summit 2016 Rikastustekniikan edistysaskelia ja kokemuksia Oulun yliopisto Kari

Rikastustekniikan innovaatioilla kestävää liiketoimintaa

Oulu Mining Summit 2016Rikastustekniikan edistysaskelia ja kokemuksia

Oulun yliopistoKari Knuutila23.-24.8.2016

© Outotec – All rights reserved

What does the industry want?

Economicalperformance

Environmentalfriendliness

Socialresponsibility

What does it mean?Ability to create wealth

sustainablyMinimal impact to

surrounding natureProvision of safe and

secure jobs

What complicates it?

• Decreasing revenues• Rising costs• Unclear investment

horizon• Undetermined business

risks• Volatile shareholder

value creation

• Outdated productionprocesses

• Inefficient equipment• Tightening regulations• Poor operation

practices• Declining raw material

grades, complex oreswith harmful impurities

• Hazardous workplace• Cyclical business• Inflexible job market• Scarcity of talent• Insufficient utilization of

human potential

23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila2


The world is not yet ready; innovations are neededto address the increasing industry challenges


Produce more

• Larger capacities• Better recovery• Less production breaks

Produce with less

• Smaller fixed costs• Smaller variable costs• Restricted investments

Consume less

• Minimal water use• Energy efficiency• Less land use

Emit less

• SO2 and CO2• Ash and other dust• Wastewater

Improve safety

• Safe workplace• Hygienic conditions• Minimal stress level

Maintain stability

• Reliable employer• Creation of jobs• Avoidance of cuts


Energy saving opportunities in comminution and betteroperation in flotationChallenges

• Optimizing comminution stages as a part of theconcentrator process

• More ore to be grinded, energy efficiency• More slurry is coming to the flotation cells

• Need for bigger units and economy of scale

• Need for better selectivity and recovery of metals

Some innovations

• Pre-concentration with grade engineering and sorting• Outotec® HIGMills

• 30-60% energy reduction

• Outotec® TankCell 630• Less energy and a simpler plant layout• Outotec FloatForce®’s slower rotation speed, lower power

consumption

• Outotec® cPlant Flotation• Containerized flotation processing plant

• Automation solutions for better selectivity andrecovery• Outotec ® Courier, PSI, Chena FrothSence, LevelSence,

CellStation, Courier, Advanced Process Control, Proscon ®

Ore Crushingand Milling Flotation De-

wateringSmelting

andconverting

Anodecasting

Electro-refining


Process chain for copper from sulfidic ore to metal


Laiva Gold mine in FinlandCustomer case, ore sorting


Study indicates that the Outotec ore sortingsolution enables reopening the mine:

“The economic assessment for the LaivaGold Mine indicated the potential forrestarting the site, which can be operated ona long-term basis at a broad range ofcommodity prices. Base-case net presentvalue of €77 million, producing 529,000 troyounces of gold over a seven-year mine life.”


HIGmill fine grinding for FQM KevitsaCustomer case, comminution

Customer benefits:• HIGmill improved overall plant performance• Copper loss to nickel circuit improved

from 12% to 8%• Overall copper recovery increased by up to 1.5%

• 1.5% increase represents around $1million increase in finalcopper value, after smelting and refining to produce LME gradecopper

• Improved concentrate grades• Less nickel in final copper concentrate• Less copper in final nickel concentrate

• Installed & commissioned without effectingproduction

• HIGmill allowed coarser primary grind and hencehigher plant throughput

• More metal out of same ton of ore < 2 year payback



Stabilizing and optimizing processes through automationand advanced process control



A modular plant design offers a fast, effective, and affordable solutionfor small mine sites, or sites requiring additional capacity


20% lowercapital

investment

30% lesslabor in

installation

Easy and costefficient totransport

enabling reuseat other mine

sites

OutoteccPlant

Flotation


The efficiency of process equipment is a critical factor inmaximizing productivity• Drivers for modernization

• Outdated technology

• Poor metallurgical performance

• Frequent mechanical failure

• Ore processing challenges

• Plant expansion

• Drive to improve energy efficiency

• Use of non-optimal equipment


http://www.outotec.com/en/Products--services/Process-equipment/Flotation-cells/Flotation-modernization-guidebook/


Treating waters requires a systematic approach and advancedprocess technology

Challenges

• Scarcity and cost of water• Increased volumes of water needed to

process larger volumes of declining ores• Large volumes of tailings are produced

• more water lost• growing size of tailings dams• Increased risk of environmental incidents

Some innovations

• Systematic mine water management, recyclingof water

• Water efficient concentrator solutions to takewater recycling up to 90%

• Paste thickening and filtration of the tailings• Paste thickening slurry for mine back filling• Dry stacking of tailings to reduce size of tailings

area

Ore Crushingand Milling Flotation De-

wateringSmelting

andconverting

Anodecasting

Electro-refining


Process chain for copper from sulfidic ore to metal


Holistic mine site water management saves operatingcosts and minimizes environmental surprises


Watersaving

andManage-

ment

Waterbalances,negative

or positive

Flow,SS,

pH, uS,mV etc

Safety issues,environ-mental

follow-up

Remotemonitoring

andassessmentcapabilities

Reporting,prediction

andoptimization

apps


Applying best practices in tailings management will bringsignificant operational cost savings and reduces safetyrisks• Paste and dry stacking technologies

combined with closed water loops arethe best available technologies forconserving water within theconcentrator environment

• The short- and long-term risks can besignificantly reduced by reducing theamount of water in the surface tailingsstorage facility


PASTEBACKFILL

DRYSTACKING

Footprint= 12%OPEX= 37%

PASTE


THICKENEDTAILINGS


WETTAILINGS

Footprint= 100%OPEX

= 100%

Documents

Rikastustekniikan innovaatioilla kestävää liiketoimintaa Knuutila_Outotec.p… · Oulu Mining Summit 2016 Rikastustekniikan edistysaskelia ja kokemuksia Oulun yliopisto Kari