Download - Mine Based Pre-Concentration
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Mine Based Mine Based Pre-ConcentrationPre-Concentration
Ben MurphyCobar Mining Seminar - 9th August 2010
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• Introduction – Technology & Challenges• Lean Mining and Waste Elimination• Pre-concentration – Suitability and technology• The Python Concept
Overview
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Mining Sector Issues
• Few “simple mining and metallurgy” large ore bodies left• Existing ore bodies –deeper and increasing complexity• Escalating capital on large fully engineered plants • High costs around developing smaller ore bodies• Long environmental permitting• Power and water supply issues
“Economies of Scale are great but what if the ore body is simply not big enough?”
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Lean Mining Analysis
The Seven Wastes
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Lean Mining Applied
(McCarthy, 1999)
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Integrated UG Mining and Processing System Model (Bamber, 2004)
Mine Based Pre-concentration
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Pre-concentration Benefits
• Reduced transportation costs– Haul distance – smaller equipment / less energy– Haul Mass – smaller equipment /less energy
• Smaller Inventories – Smaller higher value stockpiles
• Over processing– Valuable losses to fines– Savings in power and chemicals
TO MAXIMISE BENEFIT•MINIMISE DISTANCE TO MINING•MAXIMISE WASTE REJECTION
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Pre-concentration Benefits
• Savings on mining costs of 20-50%
• Numerous studies in the literature to support this;– Bamber et al– Lane, Fountain & Brooy– Dominy, Gray & Daffern
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Pre-concentration Benefits
• In addition– May allow alternate mining methods (narrow vein)– Backfill opportunities– Permitting benefits – May allow mining of small satellite ore bodies (surface)– Increase mine life – expand reserves
“For successful application integration into mining systems is critical”
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Pre-concentration Technology
• Pre-concentration not a new thing• A rose by any other name…….. • Often applied at front end of the plant
Decreasin
g G
rade
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Pre -concentration Technology
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Suitability to Pre-concentration
• High grade into low mass – high gangue rejection• Coarse liberation• Mineralogical examination and lab test work
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Yield
Reco
very
Au Distribution
S Distribution
Ag Distribution
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Yield
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very
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Yield-Recovery Concept
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Pre-concentration Methods
• Size Scalping and screening• Density Dense Media or Gravity• Colour / Fluorescence Optical / x-ray sorter• Magnetism Magnetic Separators• Surface Chemistry Coarse Flotation• Radioactivity Radiometric Sorters
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Optical Sorting Flowsheet
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Gravity - Flotation Flowsheet
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Mine Based Case Studies
Company / Mine Metal Method Waste Rejection
Welsh Gold / Gwynfynydd* Au Gravity 98% +
INCO / McCreedy East PGM DMS 22-55%
Falconbridge / Thayer* Ni DMS 14%
Falconbridge / Fraser Cu Ore sorting 44%
Central Rand Gold / South Deeps* Au Gravity / Flash Flotation
90%+
* Operational Mine Based Pre-concentration sites
Selected Case Studies from Literature
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Python – The Concept
Design Envelope– Fit in an UG drive– Transportable– Minimal Civils– Plug’n’play– Low water– Low power
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Python – The Concept
13 Modules including MCC’s5 dry modules, 6 wet modules, 2 electrical
Designed for mobility and flexibilityPre-concentration focus
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Python - The Reality
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Mine Based Preconcentration
• Has the ability to provide step change improvements by;– Reducing mine transport costs– Reducing Inventories– Reducing Over processing
• To maximise its potential it is important to;– Minimise the distance from mine to plant– Maximise the waste rejection
• Potential savings of 20-50% of the mining costs
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“Damit,….I don’t have time for this sales man, I Have a war on my hands”
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Combined Size by Size Unit Gold
Recoveries of IPJ and Flash Flotation
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size um
% r
eco
very
flash
IPJ
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Vertical Shaft Impactor (VSI)
• Rock fed into the top of the machine.
• Feed accelerated, leaves rotor at 60 m/s.
• Rock on rock crushing
• Handle large variation in moisture content, ideally suited wet screened products
• Can handle multiple feed sizes (30:1 reduction ratio)
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Recovery from Gravity + Flotation
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Size (um)
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ove
ry (
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