geomet for process design 8 8 2012 kv

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  • Geometallurgical capability at Ausenco and

    how it might support Process Design

    Presented by Simon Michaux | 8 August 2012

  • Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 2

    Geometallurgy is about cross-

    discipline integration..

    a team-based approach to support a rock-based manufacturing process

    Everyone has to change their perception and their language describing

    the mining process to create a new discipline

  • Economic justification of geomet

    More intelligent full scale test (DWT) sampling to produce

    a result that works well as opposed to works OK

    Fit for purpose quantification of variability in a processing

    context

    Used as a design tool to determine the most efficient style

    of circuit

    Risk management of process performance of designed

    plant

    More sophisticated modeling of economic net position

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 3

  • Geomet can be used to turn a Type 4 into a Type1 operation

    NPV makes the first few years critical to successful operation

    Plant design

    capacity

    Fast run up to

    full capacity

    Slow run up to

    partial capacity

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 4

  • The efficiency in which capital, labour, materials,

    services, and energy are utilised to generate a

    unit of product

    Multifactor productivity

    Australian Bureau of Statistics 2011, Experimental Estimates of Industry Multifactor Productivity, 2010-11, ABS, Cat no:

    5625.0.55.002, Canberra.

    50

    60

    70

    80

    90

    100

    110

    Ind

    exe

    d 2

    00

    0-0

    1 =

    10

    0

    Topp et al. (2008) ABS (2011)

    It now takes 40% more inputs to generate a single unit of

    mineral product

    Australian Bureau of Statistics 2011, Experimental Estimates of Industry Multifactor Productivity, 2010-11, ABS, Cat no: 5625.0.55.002, Canberra.

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 5

  • About 2-3% grade was the operational threshold

    Bingham Kennecott

    (Grade=0.2-0.57%)

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 6

  • Economic goal posts are shifting for future deposits (compared to 30 years ago)

    Huge low grade deposits

    Operating on an economy of scale never been seen

    before (4MT blasted rock a day, 60% of which is

    ore!)

    Energy & water shortages

    Penalty minerals present in deposit that prevent

    efficient processing

    Ever decreasing grind sizes

    Economic penalties for carbon footprint

    Challenging site locations with social issues are

    influencing decision making of final outcome

    Geomet in the short term is about risk mitigation, reducing costs and extracting more profit.

    In the long term it could be used for mine sites to start at all and to stay in business.

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 7

  • The pickle and the rub for our clients

    NPV

    Capital Cost

    If this ratio is too low, then the project doesnt start

    Projects are paid for by net profit from high grade parts of

    the deposit processed in the short term. There seems to

    be no Plan B if there are no high grade parts!

    So what is the

    real NPV?

    What is the real

    needed plant

    size?

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 8

  • Geometallurgy is about cross-

    discipline integration..

    The rock is the Rosetta Stone for the mining process. All stages of

    mining measure it and design from those measurements.

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 9

    Rename Geometallurgy: Leveraging Rock Properties

    (LRP)

  • The geologists view of rocks

    Geologists have a predisposition to describe rocks in terms of their genesis.

    The language is interpretative, often influenced by exploration and at times

    poetic..

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 10

  • The mineral processing view of rocks

    A bulk feed material for a manufacturing process that should be described in

    terms of its processing characteristics and variability relative to specification.

    Tell me what my feed is relative to size not what the rock used to be

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 11

  • Challenge of scale-dependent views W

    ha

    t th

    e g

    eo

    log

    ists

    se

    e a

    t co

    re s

    ca

    le

    Wha

    t the

    grin

    din

    g a

    nd

    flota

    tion

    circ

    uits

    se

    e

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 12

  • Geometallurgy is process defined data relationships

    The Holy Grail:

    the multi-shell geomet

    block model as

    a stand alone complex

    Everyone has a definition

    Geomet is ore response behaviour

    data interrelationships

    Rename Geometallurgy: Leveraging Rock Properties

    (LRP)

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 13

  • Trends Rankings Calibrations Behaviors

    Assays

    Rock type

    Alteration

    Hardness

    Mineralogy

    Texture..

    Ci Index

    A*b values

    Grind Index

    Recovery

    Texture-based

    finite element

    modelling

    Turning data into processing attributes

    Geometallurgical dataset building

    Indirect

    proxies

    Direct

    Proxies Direct

    Measures

    Linking

    Models

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 14

  • For a given job, where are you in the mining cycle?

    Very different approaches

    & methodologies

    Resource Model

    Geomet passed into block models

    Issues of additivity and intrinsic vs.

    derived attributes

    Process Mill Design

    Key output built on long term models

    Crucial decisions usually driven by

    engineering

    Deposit Valuation

    Understanding economic implications

    of geomet changes to resource

    model and operational outcomes

    Linking geomet variability with

    conditional simulation

    Risk mitigation

    Life of Mine Simulation

    Total site footprint

    Mine closure and environmental

    rehabilitation

    Geomet for long term variability

    Conceptual Study

    Pre-feasibility

    Feasibility

    Process Design

    Life of Mine Footprint Simulation

    Geomet for scheduling

    Scheduling & Life of Mine Planning

    Geomet for operations

    Detailed Study Process Design

    Commissioning start up

    Operation and production

    Expansion

    Life of Mine Simulation

    Total site footprint

    Mine closure and environmental

    rehabilitation

    Process Operation

    Show stoppers & penalties in feed

    stream (clay, Cl, Fl, As, etc)

    Predicted variability in ore hardness

    Metal reconciliation

    Maintenance schedule

    Environmental site impact & rehabilitation

    Dust generation

    Acid Mine Drainage

    Tailings management

    Geomet for Enviro Impact

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 15

  • Support Mine Design

    Sup

    po

    rt M

    ine

    Sch

    ed

    ulin

    g

    Economic Scenario Assessment

    Blo

    ck M

    od

    el

    Ge

    ne

    rati

    on

    Process Design

    Envi

    ron

    men

    tal

    Imp

    act

    The geomet plan..

    Conceptual Study

    Pre-Feasibility Study

    Feasibility Study

    Detailed Study

    Geomet Study

    Economic Scenario Study

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 16

  • Geomet test scope 1500-2000m of half drill core

    siteDiscontinuous destructive tests

    Develop process defined efficiency ranking

    1000s of data points for a single study

    Each sample has multiple

    tests/signatures from the same spatial

    point (2m interval of core)

    Data collected by client and assay lab

    (ALS Chemex)

    Each comminution Ci test is of the

    order of $50

    Data analysis is a couple of weeks

    once data collected

    Geometallurgical capability at Ausenco and how it might support Process Design | 8 August | 17

  • 0

    20

    40

    60

    80

    100

    120

    140

    160

    180

    6.00 8.00 10.00 12.00 14.00

    Axb

    BMWi @212 mm cls

    Ernest Henry

    18

    A*b as a function of BMWi Ernest Henry

    KSpar dominant

    324

    Carbonate-magnetite

    236

    246

    377

    428

    211 481

    290

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