Resource Efficient Mining Processes of Tomorrow

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1 Metso Process Technology & Innovation (PTI) Resource Efficient Mining Processes of Tomorrow R&D Project Authors: K Duffy W Valery A Jankovic P Holtham General PTI presentation

2 A Resource and Eco-Efficient Mining Process Introduction In the face of - Increasing energy costs - Limited water resources - More stringent legislative requirements - Lower grade and more difficult to extract deposits the mining industry is searching for more sustainable technologies and practices METSO PTI is conducting an R&D Project : Development of a Resource and Eco-Efficient Mining Process 2

3 A Resource and Eco-Efficient Mining Process Overview Focus: Focus Improving resource efficiency creating more value with less impact, and consequently a better economic return from the available resource. Mining operations need to operate more efficiently to meet environmental targets, but also to remain economically viable. Improving the resource efficiency can make the difference between a project being viable or not. 3

4 A Resource and Eco-Efficient Mining Process Objective and Target Objective: Investigate alternative technologies and practices in mining and minerals processing that reduce the usage of energy, water and carbon emissions, while minimising waste and maximising value. Target: Target Propose eco-efficient mining services and flowsheet(s) to trial in collaboration with a major mining company target to reduce energy usage by 30% and greenhouse gas emissions by 50%. Looking for solutions that are technically and economically viable to be implemented in a reasonably short timeframe. 4

5 Today A Conventional Mining Process 5

6 Future A Resource and Eco-Efficient Mining Process Tailings Filtration 6

7 Inter-related Project Areas High Intensity Selective Blasting To enable alternative technologies downstream and improve efficiency of downstream processes In-Pit Crushing and Conveying Potentially a cheaper and more efficient method of transporting material Pre-Concentration Discarding barren waste prior to downstream processing Efficient Comminution Circuits Increased capacity with reduced cost and energy consumption Efficient Dry Comminution Coarse Particle Flotation Reduced cost and energy consumption in preceding comminution stages 7 Water Recovery Optimisation

8 Inter-related Project Areas High Intensity Selective Blasting To enable alternative technologies downstream and improve efficiency of downstream processes In-Pit Crushing and Conveying Potentially a cheaper and more efficient method of transporting material Pre-Concentration Discarding barren waste prior to downstream processing Efficient Comminution Circuits Increased capacity with reduced cost and energy consumption Efficient Dry Comminution Coarse Particle Flotation Reduced cost and energy consumption in preceding comminution stages 8 Water Recovery Optimisation

9 High Intensity Selective Blasting (HISB) Background Blasting is the most energy efficient and cheapest comminution stage Higher intensity selective blasting is expected to result in another step change in energy efficiency Specific Energy kwh/t Cost $/t Drill and Blast Crushing Grinding Involves increasing and better distributing energy using advanced initiation systems to: - Improve blast fragmentation - Control the movement of the ore and minimize dilution 9

10 High Intensity Selective Blasting (HISB) Benefits Controlled top size & more fines Top size ~350mm compared to ~1m Reduce downstream comminution energy Overall system optimisation (costs/energy) Reduce overall greenhouse gas emissions Improved load and haul productivity Improved forecast modelling and blending Better overall process stabilisation Improved viability of pre-concentration and alternative load/haul technologies Industrial Scale Trials To demonstrate finer fragmentation can be achieved while controlling the blast to 10 prevent unfavourable results. Cumulative Percent Passing (%) Effect of High Intensity Blasting on ROM Fragmentation top size ~350 mm top size ~1000 mm Size (mm) Conventional Blast PF = 0.9 kg/m3 High Intensity Blast PF = 3.1 kg/m3

11 Inter-related Project Areas High Intensity Selective Blasting To enable alternative technologies downstream and improve efficiency of downstream processes In-Pit Crushing and Conveying Potentially a cheaper and more efficient method of transporting material Pre-Concentration Discarding barren waste prior to downstream processing Efficient Comminution Circuits Increased capacity with reduced cost and energy consumption Efficient Dry Comminution Coarse Particle Flotation Reduced cost and energy consumption in preceding comminution stages 11 Water Recovery Optimisation

12 In-Pit Crushing and Conveying (IPCC) Background Loading and hauling ore accounts for about 50 % of the total operating cost of a mine, and is where most accidents occur In-Pit Crushing and Conveying is the use of fully mobile, semi-mobile or fixed in-pit crushers with a conveyor system to remove material from the pit. It can eliminate the use of diesel and is more efficient than conventional truck and shovel operation. Interest in IPCC is growing due to: Declining mineral deposit quality Increasing price differential between diesel fuel and electricity Skilled labour shortages Tighter environmental restrictions 12

13 In-Pit Crushing and Conveying (IPCC) Benefits Requires careful evaluation of geological, technical and economic factors specific to the operation. Can significantly reduce operating costs, manning requirements, and emissions for many applications. Improves safety (most mining accidents occur during load & haul). The greatest benefits would be achieved in operations that require the movement of large volumes of material over long distances % LOWER OPERATING COSTS ~ 80% LESS ENERGY CONSUMPTION 100, ,000 t CO 2 / y LESS GREENHOUSE GAS EMISSIONS 13

14 Inter-related Project Areas High Intensity Selective Blasting To enable alternative technologies downstream and improve efficiency of downstream processes In-Pit Crushing and Conveying Potentially a cheaper and more efficient method of transporting material Pre-Concentration Discarding barren waste prior to downstream processing Efficient Comminution Circuits Increased capacity with reduced cost and energy consumption Efficient Dry Comminution Coarse Particle Flotation Reduced cost and energy consumption in preceding comminution stages 14 Water Recovery Optimisation

15 Pre-Concentration Background Removal of barren material at as coarse a particle size as possible Comminution is the largest energy consumer in mineral processing (up to 70%) Removing barren material prior to comminution can significantly reduce the energy and water consumption and operating cost per tonne of product 15 Technologies: Pre-screening Bulk Ore Sorting Gravity Separation Magnetic Separation

16 16 Pre-Concentration Pre-screening Valuable minerals are often softer or more friable than gangue minerals Concentration of valuable in fine size fractions after initial breakage stages Examples for various commodities: - uranium - platinum - gold - base metals Cumulative Mass and Uranium Recovery (%) Recovery, grade and size relationship for a Uranium Ore 85% Uranium in 60% Mass Size Fraction (mm) Mass Recovery Uranium Recovery Grade Bougainville copper Pre-screening plant Screened 6000 tph at 32 mm Increased production and resource utilisation by lowering the cut-off grade and increasing concentrator throughput Cumulative Uranium Grade (%)

17 Pre-Concentration Bulk Ore Sorting 1. Sensor(s) - to measure (or infer) the grade of bulk quantities of ore, such as on a fully loaded conveyor belt. Requires penetrative and fast sensors. 2. Control system to make accept / reject decision 3. Diverter system - to separate the valuable batches of ore from waste Metso has developed conceptual designs for mechanical diversion systems (in-pit and fixed)

18 Pre-Concentration Applications and Benefits of Bulk Ore Sorting Improve resource utilisation By rejecting barren gangue, the cut-off grade in the mine can be decreased, and mineral reserves increased. Recover marginal material upgrade low grade or waste stockpiles making them economic to treat Produce dry coarse waste dry coarse waste from the sorter may be useful as aggregate or other fill purposes Bulk Ore Sorter Reduce mining costs Using selection of ore by bulk ore sorter may require less selective mining processes reducing costs. Improve grade control Sorter measurement decreases misclassification of ore and waste, reducing dilution and ore losses. Reduce ore transport requirements reject barren waste and transport less tonnes to the process plant Reduce comminution energy Gangue minerals are usually hard. Removing these can reduce the hardness of ore to be treated, increasing the capacity and reducing the energy consumption of comminution circuits Power Water Reduce environmental footprint Less tonnes of ore are treated per tonne of product reducing the energy consumption, 18 greenhouse gas emissions, water losses and fine wet tailings per tonne of product. Process A Process B Tailings Storage Facility Product Optimise process route Different ore types can be separated and processed differently Increase plant feed grade By upgrading the plant feed, less tonnes are treated per tonne of product. Thus: Reduce costs Lower operating costs Lower capital costs in new plants Improve Recovery Higher feed grade improves graderecovery performance of some processes Increase production More product per tonne of ore treated

19 Inter-related Project Areas High Intensity Selective Blasting To enable alternative technologies downstream and improve efficiency of downstream processes In-Pit Crushing and Conveying Potentially a cheaper and more efficient method of transporting material Pre-Concentration Discarding barren waste prior to downstream processing Efficient Comminution Circuits Increased capacity with reduced cost and energy consumption Efficient Dry Comminution Coarse Particle Flotation Reduced cost and energy consumption in preceding comminution stages 19 Water Recovery Optimisation

20 Efficient Comminution Circuits Comminution is the largest energy consumer in minerals processing Novel application of efficient comminution and classification technologies could reduce energy consumption by more than 50 % Air classification for dry circuits Feed HPGR or VRM Air Classification Fine Screens Fine screens improve classification efficiency and capacity of closed grinding circuits Product Technologies such as HPGR, VRM and stirred mills are more efficient than conventional technologies Stirred Mill 20

21 Inter-related Project Areas High Intensity Selective Blasting To enable alternative technologies downstream and improve efficiency of downstream processes In-Pit Crushing and Conveying Potentially a cheaper and more efficient method of transporting material Pre-Concentration Discarding barren waste prior to downstream processing Efficient Comminution Circuits Increased capacity with reduced cost and energy consumption Efficient Dry Comminution Coarse Particle Flotation Reduced cost and energy consumption in preceding comminution stages 21 Water Recovery Optimisation

22 Efficient Dry Comminution Technologies VRM and HPGR are dry processes, eliminating water losses Can be operated in closed circuit with air classification for dry circuit Also use no steel grinding media, reducing embodied energy and costs Airflow VRM 25 40% more energy efficient than ball milling for similar comminution HPGR in closed circuit with air classifier 20 30% more efficient than ball mill to final grind size 22

23 Inter-related Project Areas High Intensity Selective Blasting To enable alternative technologies downstream and improve efficiency of downstream processes In-Pit Crushing and Conveying Potentially a cheaper and more efficient method of transporting material Pre-Concentration Discarding barren waste prior to downstream processing Efficient Comminution Circuits Increased capacity with reduced cost and energy consumption Efficient Dry Comminution Coarse Particle Flotation Reduced cost and energy consumption in preceding comminution stages 23 Water Recovery Optimisation

24 Coarse Particle Flotation Background Flotation is not energy intensive, but flotation at coarser size could significantly reduce comminution energy Flotation at 0.3 mm rather than 0.1 mm could reduce comminution energy by 30 to 50 %. Preliminary coarse flotation followed by regrinding and cleaning of a much smaller quantity Circuit Recovery (%) CS5 Flotation Recovery drops significantly for coarse particles CS5 CS4 CS3 CS2 CS1 +38 um +53 um Size Fraction +75 um +106 um +150 um +212 um +300 um +425 um 24

25 Coarse Particle Flotation Strategies to Improve Coarse Particle Flotation 1. Improving coarse flotation in existing cells Collaboration Test program with Metso s 3m 3 test rig investigating: - Factors affecting suspension of coarse particles - Turbulence (cell aspect ratio, impeller speed, impeller size, feed density) - Bubble size, froth stability and residence times - Split conditioning / flotation - Aerosol reagent addition for improved coating on coarse particles 25

26 Coarse Particle Flotation Strategies to Improve Coarse Particle Flotation 2. Evaluation of Alternative Technologies Fluidised bed froth flotation is the most promising for coarse particle flotation Uses continuous injection of aerated fluidisation water 3. Optimisation of Grind/Float Interaction Understanding the effect of grinding technologies (breakage mechanisms) on flotation performance - Size distribution shape - Preferential breakage 100 Mass Percent Passing Hammer Mill Piston & Die Size (microns)

27 Inter-related Project Areas High Intensity Selective Blasting To enable alternative technologies downstream and improve efficiency of downstream processes In-Pit Crushing and Conveying Potentially a cheaper and more efficient method of transporting material Pre-Concentration Discarding barren waste prior to downstream processing Efficient Comminution Circuits Increased capacity with reduced cost and energy consumption Efficient Dry Comminution Coarse Particle Flotation Reduced cost and energy consumption in preceding comminution stages 27 Water Recovery Optimisation

28 Water Recovery Optimisation Filtration and Dry Stacking of Tailings Most of the water consumed in mining is lost in tailings dams in evaporation, entrapment and seepage. Dry stacking of filtered tailings is becoming an increasingly common consideration, particularly in areas with high seismic activity or limited water supply Reclamation and closure costs are significantly reduced - Reduced footprint - Easier construction - Progressive rehabilitation The dry tailings management system at Gindalbie's Karara iron ore mine is the first of its kind in Australia. It represents a significant investment in water recycling capacity, allowing the project to reduce its water consumption by about one third. 28

29 Inter-related Project Areas High Intensity Selective Blasting To enable alternative technologies downstream and improve efficiency of downstream processes In-Pit Crushing and Conveying Potentially a cheaper and more efficient method of transporting material Pre-Concentration Discarding barren waste prior to downstream processing Efficient BENEFITS Comminution Circuits Increased capacity with reduced cost and energy consumption Efficient Dry Comminution Coarse Particle Flotation Reduced cost and energy consumption in preceding comminution stages 29 Water Recovery Optimisation

30 Benefits Reduction of Energy, GHG, Water, and Tailings 35 % LESS ENERGY 35 % LESS GHG EMISSIONS 40 % LESS WATER 80 % SMALLER TAILINGS FOOTPRINT Conservative estimates In metal production, the quantity of GHG produced closely follows the energy consumption The greatest water savings are possible through the application of filtration and dry stacking of tailings 30

31 Benefits Resource Efficiency Resource Efficiency Maximising the recovery of value from an ore deposit, while reducing impact Inherently, improving the efficiency of the overall operation will reduce costs, energy and water consumption, and reduce emissions per tonne of product Thus, improving the economic returns of the operation while reducing environmental impact Mining operations need to operate more efficiently to meet environmental targets, but also to remain economically viable Improving the resource efficiency can make the difference between a project being viable or not 31

32 Next Steps and Challenges Research has shown very promising results in a number of areas Starting industrial trials in some areas Seeking mining partners - To develop concepts further - Conduct trials at operating sites - Pioneer new processes in Greenfield projects - To validate practicality and economic viability of concepts - Quantify eco-efficiency benefits 32 Unlocking Energy Efficiency in the Mining Process

33 General PTI presentation 2014

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