Mining for Generations European Mining Academy …...Pumping Dewatering Circuit a. Thickeners and...

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

© Metso© Metso

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?

4 Metso in Mining I general I 2018

• High throughput

• High Metallurgical

performance

• Recovery

• Concentrate grade

• Optimized operation cost

Question - Key factors for profitable operation?

5 Metso in Mining I general I 2018

• 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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© Metso© Metso

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)

1

2

3

4

6

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

© Metso

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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© Metso© Metso Date Author Title

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

© Metso© Metso Date Author Title

• 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.

© Metso

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

© Metso

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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© Metso© Metso

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

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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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© Metso© Metso27 Metso in Mining I general I January 2018

© Metso© Metso28 Metso in Mining I general I January 2018

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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www.metso.com