mining for generations european mining academy …...pumping dewatering circuit a. thickeners and...
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Process design & implementation for increased recoveries & decreased OPEX
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Mining for Generations–
European Mining Academy
Beldrade, June 18 2019
© Metso© Metso2
Metso – a world leading industrial company
Metso in Mining I general I 2018
We deliver solutions for
• Leading technology and services provider for
end-to-end minerals processing
• Leading flow control provider with offerings for
oil and gas, mining, and process industries
MINING AGGREGATES
Sales
EUR 2.7
billion
in 2017
12,000 employees worldwide
65%of revenue from service business
RECYCLING VALVES FOR
PROCESS
INDUSTRIES
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Extensive global presence close to our customers
3 Metso general presentation | 2018
180Locations
>50Countries with
Metso operations
12,000 Industry experts
>80 Service centers
Operating locations
~20Global network of
R&D centers
Question - Key factors for profitable operation?
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• High throughput
• High Metallurgical
performance
• Recovery
• Concentrate grade
• Optimized operation cost
Question - Key factors for profitable operation?
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• Correct process design
• Correct plant design
• Advanced plant control
• Service and maintenance,
process monitoring
continuous improvement
• High throughput
• High Metallurgical
performance
• Recovery,
• Concentrate grade
• Optimized operation cost
Correct process design
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Process design – Identification of ore and metallurgical performance
MiningDrilling, Blasting and Earthmoving (upstream)
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2
3
4
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5Comminution Circuita. Primary, Secondary &
Tertiary Crushingb. Screeningc. Primary, Secondary &
Tertiary Grinding
Separation Circuit – either of or combinationa. Gravity Separationb. Hydro Cyclonesc. Ultra Fine Screensd. Flotatione. Magnetic Separationf. Leachingg. Pumping
Dewatering Circuit a. Thickeners and
Clarifiersb. Filtersc. Filters for Tailings
Filtration (under development)
Pyro ProcessingPelletizing
Unloading & Loadinga. Rotary Car Dumpers
and associated Equipment
Clarifier
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Project target Test work Determination of process parameters
Metso in Mining I general I 2018
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Question – What should be determined for each process stage?
MiningDrilling, Blasting and Earthmoving (upstream)
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2
3
4
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5Comminution Circuita. Primary, Secondary &
Tertiary Crushingb. Screeningc. Primary, Secondary &
Tertiary Grinding
Separation Circuit – either of or combinationa. Gravity Separationb. Hydro Cyclonesc. Ultra Fine Screensd. Flotatione. Magnetic Separationf. Leachingg. Pumping
Dewatering Circuit a. Thickeners and
Clarifiersb. Filtersc. Filters for Tailings
Filtration (under development)
Pyro ProcessingPelletizing
Unloading & Loadinga. Rotary Car Dumpers
and associated Equipment
Clarifier
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Project target Test work Determination of process parameters
Metso in Mining I general I 2018
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Comminution
Barren MiddlingLocked Liberated
Scale: particle images are from +53 or +75um size fractions
• Liberation size
• Grindability
• Abrasiveness
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Grade and recovery in a flotation circuit
RougherScavenger
Regrind
Cleaner 1
Cleaner 2
Cleaner
Scavenger
Tails
Tails
Concentrate
Separation - flotation
• Retention time and regrind
• Flotation plant configuration to balance recovery and grade
Correct plant design
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Question - Factors Affecting Plant Design?
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• Plant Capacity
• Ore Characteristics
• Metallurgical performance
• Life of Mine
• Project Specifics
Factors Affecting Plant Design
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Factors Affecting Plant DesignLife of Mine
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• Short Mine Life
- Capital cost is the major concern due to high cost per ton
of throughput
- Often sacrifice operating costs to reduce capital costs
• Long Mine Life
- High throughput allows economy of scales, larger
equipment
- Operating cost very important over longer term
• Relationship between CAPEX and OPEX varies
based on project specific circumstances0
50
100
0 5 10 15 20 25 30
Mine Life (Years)
CAPEX Dominates
OPEX Dominates
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• Existing equipment available
• Historical Use
• Client Preference
• Climate / Location
• Operator Skill Level
• Energy / Media / Labor Costs
• Water Availability
• Commonality of Equipment
• Shipping Limitations
• Available Space
• Etc.
Factors Affecting Plant DesignProject Specifics
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Comminution EquipmentAvailable communution equipment
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How can we develop flow sheet?
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Circuit configurations
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How can we develop flow sheet?
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Circuit configurations
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Advances plant control
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© Metso
VisioFroth image analyser
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An advanced froth-imaging system which continually monitors a wide
variety of froth characteristics and can be linked to a plant monitoring
system, VisioFroth gives real-time velocity information that can be used
to either adjust cell level or cell aeration rate to ensure maximum
recovery of valuable minerals from each flotation cell.
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Plant Control System
Combined with expert OCS expert system.
OCS is is reading current date and control
automatically flotation machines
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Advanced automation systemControlled by based on fuzzy logic rules programmed in OCS-4D© - self controlling system
• Air measurement (flotation machines)
• Level measurement (flotation machines)
• X-ray analyser – measurement of grade in the feed, raugher/final concentrate, cleaner/final tailings,
• pH analyser
• Density measurement
• Flow measurement
• Air flow (flotation machines)
• Level control (flotation machines)
• pH
• Density
• Reagent dosing station
Basic Mesurement
• VisioFroth –advanced froth-imaging system Advanced Mesurement
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VisioFroth ™ Implementation - Results for Customers
PTFI, Indonesia
186 VisioFroth™ cameras
Advanced flotation control
+1,3% copper recovery
increase
-25% frother consumption
Escondida Laguna Seca, Chile
102 VisioFroth™
cameras
Advanced flotation control
+1,5% copper recovery
Veliki Krivelj, Serbia
18 VisioFroth™ cameras
with advanced flotation control
+3% copper recovery increase
thanks to OCS©
+10% throughput thanks to Metso
RCS
Metso RCS™ flotation machines
Service and maintenance, continuous improvement
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Wear solutions Spare partsField service
and repairs
Engineered
spares,
refurbishments
and upgrades
Life cycle
services
Services for the mining industry
Expert services to optimize
performance of operations
Production essentials to ensure availability
and quality of operations
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Metso Team is Here to Serve Our Customer Needs
2525
Today’s Presence
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Direct Presence Balkans Region
Serbia – Metso Belgrade
- 6 Sales engineers
- 2 Service engineers
Macedonia – Metso Skopje
- 4 Sales engineers
- 5 Service engineers
Romania – Metso Bucharest
- 5 Sales engineers
- 4 Service engineers
Bulgaria – Metso Sofia
- 4 Sales engineers
- 3 Service engineers
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Spare partsField service
and repairs
Engineered
spares,
refurbishments
and upgrades
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Question – Benefit of process monitoring Metso Metrics
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Question – Benefit of process monitoring Metso Metrics
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Three project stages – Metso as a partner for each step
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Project target definition:Capacity, recovery, concentrate quality
Basic test work:Laboratory ore analysis: mineralogy, liberation size; Flotaton test (lab&pilot)
Flow sheet and mass balance development
Equipment selection:Test work for equipment sizing; Equipment sizing
Basic engineering
Detailed engineering
Plant erection
Plant start-up and commissioning
Service and maintanance
Continuous plant optimization
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