Presented by:
Paul Wilson
Technology Manager
Calibre Automation, Communications & Technology Group
The mills
Porgera Mine, PNG
4.5 Megawatt, variable speed drive
About 500 tonnes per hour per mill
Highly variable lithology with grinding factors from
6 to 18 kilowatt hours per tonne
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The mills
Unstable behaviour
The mills were often unstable, seen as oscillations
in the feedrate trend graphs
Loss of production
As much as 15% on bad days
Up to 380 ounces of gold per day on bad
days
At $425 US per ounce = $160,000 per day
You could hire a very good plant operator
for that kind of money
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Natural instability
Poor tuning causes natural instability
Operator-caused instability
Poor operator skills also forces instability
Performance comparison
Expert system control is far better than poor operator control
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PATIENT
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The result
In 2004 / 2005 mill production rose from
850,000 ounces to 1,000,000 ounces
At $425 US per ounce that was
$63.75 million US increase per year
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Additional development
The decision to secondary crush the harder
ores.
A secondary crusher was installed. With a bit of clever
mathematics we were able to estimate SAG mill
grinding factor at the primary crusher. We used this
to feed some of the hard ore (GF > 10 kWhr per
tonne) through the secondary crusher thus
increasing SAG mill throughput on the harder ore.
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Questions
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