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09.the Value of A Rigorous Method - Percy Condori

The document discusses optimization of mining operations through rigorous modelling and simulation methods. It covers sampling campaigns of mining circuits to collect operational data and characterize ore properties. This data is then used to build and calibrate models to simulate circuits and identify opportunities to reduce energy consumption, such as through alternative flowsheet designs or new technologies.

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Corazon Valiente
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114 views16 pages

09.the Value of A Rigorous Method - Percy Condori

The document discusses optimization of mining operations through rigorous modelling and simulation methods. It covers sampling campaigns of mining circuits to collect operational data and characterize ore properties. This data is then used to build and calibrate models to simulate circuits and identify opportunities to reduce energy consumption, such as through alternative flowsheet designs or new technologies.

Uploaded by

Corazon Valiente
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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The Value of a Rigorous Method in the Optimisation of a

Concentrator: Experiences in Australia, Chile and South Africa

Expositor: Percy Condori

Todays challenges in mining (IMPC 2014)


Energy consumption
Water resources

largest energy consumer in many


mine sites (30 50%)
Comminution an inefficient user of
energy (15% - 75%)

2013 Rio Tinto Technology & Innovation. Strictly confidential.

Todays challenges in mining


So, what are the drivers for reducing energy consumption?
Optimization of current operations
Modelling and simulation
Alternative flowsheet configuration/equipment selection

New technologies
High voltages (SelFrag)
Pre-weakening sorting (NuWave)

2013 Rio Tinto Technology & Innovation. Strictly confidential.

Optimization of Current Operations - Modelling and


Simulation

Sampling
campaign

Plant logged data (tph,


kw/h, m3/h, etc.)

Eq. measurements
(dimensions, speed,
etc.)

Sample collection (Feed,


intermediate, products)

Modelling
and
Simulation

Sample
characterization

% solids, density, PSD,


etc.
breakage
characteristics of ore
(Drop weight test, Bond
work index for ball and
rod mills)

Data analysis

Mass balance

Model fit

Simulation

2013 Rio Tinto Technology & Innovation. Strictly confidential.

Sampling Campaign

Circuit in usual conditions

Circuit in steady state

An intensive sampling campaign of all streams

Measurements of all units

Ore sample
Fundamental Rules for Sampling Devices

Width > 3 diameter


largest particle in stream

Length > stream width

Volume > 1 sample volume

2013 Rio Tinto Technology & Innovation. Strictly confidential.

Ball Disch
Gap = 40mm;
Contain vol ~ 10

SAG Disch
Gap = 60mm
Contain vol ~ 6

Cyc o/f
Gap = 12mm
Contain vol ~ 2

Cyc u/f
Gap = 60mm
Contain vol ~ 6

2013 Rio Tinto Technology & Innovation. Strictly confidential.

2013 Rio Tinto Technology & Innovation. Strictly confidential.

Sampling Campaign

SAG 1 and 2 discharge

Sampling Campaign

Ball 2 discharge

Sampling Campaign

Belt cut

Sampling Campaign

SAG internal measurements

SAG 2
Slurry
pooling!

Sampling Campaign

Sampling Common Mistakes

2013 Rio Tinto Technology & Innovation. Strictly confidential.

Sample Characterization
- % solids, density, particle size distribution
- Specific energy parameters in laboratory
(breakage rates, specific energy, kWh/t)

2013 Rio Tinto Technology & Innovation. Strictly confidential.

Modelling and Simulation


Data analysis, Mass balance, Model fit, Simulation
- check for inconsistencies
- seek assistance of an experienced engineer

2013 Rio Tinto Technology & Innovation. Strictly confidential.

Thank You

2013 Rio Tinto Technology & Innovation. Strictly confidential.

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