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CURRENT SITUATION
SAG
2006
DEPARTMENT OF MINING ENGINEERING
UNIVERSITY OF BRITISH COLUMBIA
Vancouver, B.C., Canada
ABSTRACT
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So when considering the impact of feed size, what is the typical
situation? Normally, the mine (or supplier) delivers material of sufficient
quality to satisfy their own needs does it dig well? Will the truck loading
be good? Will it fit in the crusher? Beyond that, there is typically little
consideration of how to improve the quality of the ROM material further.
On the other hand, the customer (or concentrator) understands the
impact of feed size on their process but normally only the negative
effects and at the extreme levels: If the feed is too big, we have
problems and if it is too small we also have problems. Quite often the
effect of feed size on mill performance is not well understood and results
in the customer not being clear in their requirements: Just dont give us
the same stuff as last week.
Rather than focussing on the negative effects, the concentrator needs to
understand how quality parameters can positively affect performance. In
addition, understanding should be based on measurements that can be
reproduced: We need more of the 25mm material in the feed than what
we measured this morning.
Understanding which quality parameters are important to each
concentrator is the first step. The next one is to measure them
continuously if possible and then develop methods to control them so
that the quality of mill feed is as high as possible.
By communicating with the mine how the quality of their product (or the
concentrator feed) can affect downstream performance leads to ways to
improve the value of mill feed. That is, ore can now be judged on its
overall quality parameters and not just grade. Despite the grade, if
certain material will not process well due to low production or higher
costs that lowers its value. In addition, it eliminates the opportunity to
process material of higher value by using up concentrator capacity.
Understanding and measuring important parameters that affect mill feed
quality can lead to the identification and elimination of poor performing
ores that should not be sent to the concentrator without being blended.
The reason that most operations do not follow this path to enlightenment
is a lack of resources and a definite plan with clear objectives. Metso
Minerals Process Technology Asia-Pacific (MMPT-AP), have been
working with customers to develop such plans and to reveal the
inefficiencies hidden in the way they currently operate. The work is
rewarding in that often the improvements in efficiency are very
significant. In the case of throughput, MMPT-AP projects typically result
in increases of 5 to 20%.
MMPT-AP provide an integrated approach or methodology that
eliminates costly (both in time and resources) plant trials, from which the
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benefits can be difficult to quantify. Also, MMPT-AP can provide the
guidance and support to make the significant step changes that are
sometimes required.
In the case studies discussed below, the quality parameter of interest is
material size and the objective is increased production. There is no
reason the same approach cannot be used for cost reduction, recovery
increases or final product grade by characterising the material using
other quality parameters.
METHODOLOGY
The methodology that MMPT-AP uses is called Process Integration and
Optimisation (PIO) and has been developed over the past ten years at a
number of operations worldwide. It represents a wider application of
optimisation than Mine-to-Mill, as it can focus on any quality parameter
of interest and not just feed size. That being said, most of our
customers are interested in understanding how their material properties
affect mill production and how to increase mill throughput.
The methodology involves a number of steps: benchmarking, rock
characterisation, measurements, modelling/simulation and where
required, material tracking. A PIO project is normally comprised of a
number of site visits spaced over a few months. The first site visit is to
establish current operating practice, initiate rock characterisation and
collect measurements of blast fragmentation and mill performance. This
is followed by modelling and simulation studies to determine how to
best exploit hidden inefficiencies. These recommendations are then
followed by further site visits to implement the changes, monitor the
results and ensure the improvements are maintained over time.
We have made long-term agreements with some customers so that they
have access to our services without the delay of setting up individual
projects.
Benchmarking
The first step of a PIO project is to benchmark the current practices by
auditing the operation and control of the blasting, crushing, grinding and
flotation processes.
The quality of blast pattern implementation is assessed and the
resulting ROM fragmentation measured using image analysis. The
crushing, grinding and flotation circuits are surveyed and process
control strategies reviewed. All of these measurements allow
mathematical models to be developed for the complete process chain.
These models are later used to simulate the impact of operational
changes in the mine or concentrator on the entire process.
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Rock Characterisation
Once the current operating performance has been measured under one
set of conditions, the effect of changing rock properties can be
quantified. This involves rock characterisation.
The MMPT-AP methodology for rock characterisation utilises simple and
inexpensive measurements that can be performed by trained site
personnel. Quite often, the measurements are already being collected by
the operation. The advantage of simple measurements is the amount of
data that can be collected in a very short timeframe, as the samples do
not require shipping to an outside laboratory. When attempting to
characterise an entire orebody, the density of data is very important.
For rock characterisation, MMPT-AP use measurements of rock strength
(Point Load Index, PLI and/or UCS) and rock structure (Rock Quality
Designation, RQD and/or fracture frequency). Both PLI and RQD
measurements can be taken on drillcore and Point Load tests can also
be performed on irregular shaped samples of material.
The PLI value can be correlated to Unconfined Compressive Strength
(UCS) as well as the JKMRC Drop Weight test parameters A and b. The
Drop Weight parameters are necessary in order to model the crushing
and grinding circuits. Therefore, the use of the Point Load Index allows
sites to characterise their rock properties quickly and easily while still
making use of the sophisticated grinding models that are available.
The rock structure is represented by the RQD value that indicates the
fracture frequency present in the drillcore. This measurement is routinely
taken at operations for geotechnical purposes but has been shown to be
very useful in blast fragmentation modelling in the absence of detailed
rock mass structure mapping.
Once the PLI and RQD data are available, the range of rock properties
are mapped out and domains are defined (see Figure 1). Within each
domain, the material will behave similarly in the blasting, crushing and
grinding processes while all of the domains cover the complete range of
rock properties that are present.
Soft
Ore Type 1
Ore Type 2
Fine
Medium
Coarse
Fine
Medium
Coarse
Medium
Hard
1
3
4
7
9
2
5
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(When flotation is involved, material domains are defined based on
different characterisation measurements, but the method is the same.)
The domain structure shown in Figure 1 follows the existing ore type
characterisation used by the site but expands further into areas of
structure (coarse, medium and fine) and strength (soft, medium and
hard). The ranges of strength and structure used are based on the
variability of the orebody. The more variable the PLI and RQD values
measured in the orebody, the greater definition required for domains.
In the example shown in Figure 1, there are three levels of strength and
three levels of structure for each ore type: or a possible total of nine
domains per type. If a domain does not occur significantly in the
orebody, it may be combined with a nearby domain so that the overall
number of domains is less. In Figure 1, there are a total of ten domains
defined for the two ore types shown.
Once the domains have been defined, different blasting practices,
crushing and milling operational strategies are established. Through
modelling and simulation studies, the impact of blending different
domains can be reviewed. Most importantly, as the rock properties have
now been well characterised and the processes modelled, the variable
nature of the material can now be compensated for.
For example, consider Domain 6 in Figure 1. This material is of Ore
Type 1 and both hard and coarse in structure. This indicates that it
would require higher energy blasting to overcome the difficult rock
properties. Otherwise, the resulting ROM fragmentation will be difficult
to crush and mill. On the other hand, Domain 1 is soft and fine in
structure (highly jointed). This material can be blasted will less energy
and achieve an adequate fragmentation size. In most cases, operations
use the same blast pattern (and hence powder factor or energy level)
for all material in one ore type (or even all ore types). The rock
characterisation method details how and where energy should be
usefully applied and not wasted.
In the example discussed, the quality parameter of interest is mill feed
size and the objective is to maximise mill production. By developing
customised blasting practices for each domain, the resulting ROM
fragmentation can be controlled much better. The result is more
consistent mill throughput by compensating for the different rock
properties.
Measurements
10
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There are currently two methods to track material movements from the
mine to the concentrator: model-based and sacrificial instruments.
These are illustrated in Figures 2 and 3.
100
Stockpile
Ore Block #2
until shift change
Ore Block #1
Ore Block #2
80
Ore Block #1 for 4 hours
at start of shift
% of Mill Feed
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60
night shift shows large
swings between
Block #2 and Stockpile
Stockpile being
added as required
40
intermittent feed
20
0
03-Apr
07:00
03-Apr
09:00
03-Apr
11:00
03-Apr
13:00
03-Apr
15:00
03-Apr
17:00
03-Apr
19:00
03-Apr
21:00
04-Apr
01:00
04-Apr
03:00
04-Apr
05:00
04-Apr
07:00
POST BLAST
[ID,x,y,z]
POST CRUSHER
All of these questions can be evaluated using the model of all the stages
of comminution (blasting, crushing and grinding).
DETECTOR
Material Tracking
RECEPTOR
[ID, time]
03-Apr
23:00
DETECTOR
[ID, time)
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The first method of tracking material involves the development of a
software program to record the movements of material from the open pit
or underground to the intermediate or long-term stockpiles, through the
crusher and coarse ore piles and into the concentrator. Each stockpile
can be represented by simple perfect mixing models or if necessary,
more sophisticated three-dimensional models. The models allow the
effect of material mixing and delays to be incorporated and provide a
reasonably accurate estimate of mill feed. In the trend shown in Figure 2,
the material transactions were updated every fifteen minutes combining
the different ore sources into packets that were tracked through the
inventories and into the concentrator. Such a system provides much
greater definition or detail on changes in concentrator feed. In Figure 2,
the twenty-four hour period shows episodes of stockpile versus muckpile
feed, intermittent feed when the primary crusher was not operating as
well as changes in the blend of different blocks of ore. A daily summary
will not provide such a degree of detail.
Another method for tracking material movements being employed by
MMPT-AP are Ore Block Markers or OBMs. MMPT-AP have developed
passive radio frequency (RF) transponders for use in blasted material
monitoring. These RF tags are small, robust and inexpensive and can be
dropped into the blasthole stemming column or placed on the muckpile
surface post-blast (see Figure 3).
The tags are not powered but are detected by antennas placed over
conveyor belts (see Figure 4). Each tag has a unique identifying number
that the antenna transmits to a remote computer for recording along with
the date/time. By noting the initial position of each tag (i.e. blasthole ID),
an estimate of the origin of the material being processed can be made.
By tracking the actual material itself, concerns about estimating stockpile
volumes, mixing and retention times can be avoided.
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APPLICATIONS OF PROCESS INTEGRATION
In this section, a number of case studies will be summarised illustrating
the MMPT-AP methodology in a variety of applications. All of these
cases are actual projects conducted by MMPT-AP in the past few years.
Case Study 1: Conventional Crushing Circuit
This site was operating three crushing circuits ahead of SAG and ball
mill circuits and was interested in ways to reduce operating costs and
increase crusher and mill throughput. Two of the crushing plants were
owned while a third plant was contracted out to provide additional
capacity.
MMPT-AP conducted a Process Integration and Optimisation program
in order to recommend changes in operating practices.
The initial phase of the PIO study was dedicated to benchmarking the
blasting performance in the pit. A typical production blast was chosen
for auditing and the implementation and performance of a blast was
monitored. Hole depth variance, drilling accuracy, explosive usage and
blast performance (with particular attention to fragmentation), were all
measured during the site visit.
Blast fragmentation modelling was then undertaken to determine new
blast designs that would decrease the ROM particle size and rehandle
costs. These blast designs were adopted by site and represented a
3.5% increase in total blasting costs. The results of the finer
fragmentation were quite dramatic with an increase in crushing plant
productivity of 21 to 32% and the cessation of the contract crushing
plant operation. In addition, excavator productivity increased and
primary crusher rock breaker usage decreased significantly. Overall, the
improvements in productivity more than accounted for the increase in
drill and blasting costs.
Case Study 2: SAG/Ball Mill Circuit
This operation was experiencing lower SAG mill throughput due to a
higher proportion of harder material. MMPT-AP deployed their PIO
methodology to characterise the range of rock properties expected to be
processed to the end of mine life and estimate their impact on mill
production.
As always, the PIO project commenced with an audit of the sites
current drill and blast, crushing and grinding practices. This included an
audit of a typical production blast along with the use of Ore Block
Markers to directly measure the concentrator performance on the
audited material.
The drillcore results indicated that with depth, both the PLI and RQD
values would increase and then plateau (see Figure 5).
120
12
RQD
Is50
100
10
80
60
40
20
0
0
100
200
300
400
500
Mine Elevation (m)
600
700
800
Rock characterisation based on PLI and RQD values showed that the
blast domains were relatively simple: all ore types showed strength
variations but were not significantly different. At the time of the site visit,
the operation was using the same blast pattern for all ore types.
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RQD(%)
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0
900
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600
140
UCS
Wi*10
Ore Type
100
400
80
300
60
200
40
100
20
0
2000
500
min p.f.
120
2005
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2010
2015
2020
2025
0
2030
PLI 0 - 3
RQD 0 - 30
RQD 30 - 60
RQD >60
Volcanic
Diorite
Intermediate
Tonalite
Young
Tonalite
RQD 0 - 30
RQD 30 - 60
RQD >60
RQD 0 - 30
RQD 30 - 60
RQD >60
RQD 0 - 30
RQD 30 - 60
RQD >60
PLI 3 - 6
PLI >6
V-MM
V-CM
V-CS
Hardness
(Point Load Index)
V-FH
V-FS
V-MH
V-CH
D-FM
D-FS
D-CS
D-CM
IT-MM
D-CH
IT-MH
IT-CH
YT-CH
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The predicted mill throughput then represents what is achievable by the
operation with good blast implementation as well as consistent crusher
and grinding circuit operation.
Blast Design
Ore Characterisation
Lithology zones
Rock Strength
- PLI
- DWi, A x b, ta
Rock Structure
- RQD, Mapping
MMPT Blast
Fragmentation
Model
TPH
Final Product
Size Distribution
8,000
Metso Minerals Process Technology Asia-Pacific has over the past ten
years developed a proven methodology for optimising the mineconcentrator interface. This method involves characterisation of the rock
strength and structure using simple and effective measurements. These
measurements can be done by site personnel at little or no expense
and are calibrated to more comprehensive measurements like the
JKMRC Drop Weight test. The end result is a mapping of rock
characteristics into domains of similar properties.
7,000
CONCLUSIONS
Grinding Circuit
Model
(MMPT/JKSimMet)
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6,000
REFERENCES
5,000
4,000
3,000
Renner D., et. al., 2006, AngloGold Ashanti Iduapriem Mining and
Milling Process Integration and Optimisation, proceedings SAG 2006,
Sept 23 Sept 27, Vancouver, Canada.
Actual tph
Model tph
2,000
Dec-03
Feb-04
Apr-04
Jun-04
Aug-04
Oct-04
Dec-04
Feb-05
Apr-05
Jun-05
Tondo L.A., et. al., 2006, Kinross Rio Paracatu Minerao (RPM)
Mining and Milling Optimisation of the Existing and New SAG Mill
Circuit, proceedings SAG 2006, Sept 23 Sept 27, Vancouver,
Canada.