Risk management for Mining Industry

Transcription

1 Risk management for Mining Industry Esko Juuso Engineering University of Oulu Outline Mine processes and water Process & environment, laboratory & online Water balance weather, rainfall, snow, hydrological forecasts, 3D Automation & monitoring concept Combined measurements, trend analysis, SPC Risk management Services Conclusions 1

2 Unit processes Mining Mechanical Crushing Agglomeration Chemistry Grinding Piling Stagewise flotation Bioheap leaching Bio Drying Concentration Reactors - Stagewise metal extraction Chemistry Water Tailings Clarification Recycle Disposing Water basins Process flow sheet Machines and process equipment Water 2

3 Water handling Mine water Water supply Process water Mining & mineral processing Metallurgical extraction Wastewater (disposed) Contamination Waste à drainage, leakage Ground/Surface water Rainfall Melting of snow Treatment and recycle Remove harmful chemicals for processes for environment Explosives à nitrogen + suspended solids Settling ponds Tailing dams (=crushed stones + chemicals) & other solid materials Process flow (water, sludge & chemicals), ph, density, redox, volume, mass, temperature, level, dosage, air, pressure, gas flow, location, speed and conductivity, metal concentrations, suspended solids Environment basin levels, suspended solids, flow, temperature, metal concentrations, air quality, ph, electrical conductivity dust, particle measurements moss analysis Note! Processes are mine specific, i.e. developed for specific ores and metals. 3

4 Laboratory measurements Highly accurate in principle Time-consuming & tedious à Expensive Sampling in large areas Infrequent à hazards if leakages Even small concentrations of heavy metals can be very harmful Environmental measurements: Regular monitoring of wastewater required Measurement locations Sampling frequency: weekly, monthly, yearly Online measurements Continuous & real-time Problems Reliability & accuracy (malfunctioning periods) Applicability Speed Cost Cleaning requirements Maintenance Rough and varying operating conditions Process and weather Process measurements Condition monitoring (machines and process equipment) Environment Approval from environmental authorities? Environmental regulations 4

5 Wast areas à measurement placing? Waste rock deposits Water basins Storages of chemical substances Tailing dams Special: heap leaching piles Dynamic modelling à Forecasting? Geographical data Laser scanning à 3D data airborne, terrestrial, mobile unmanned airborne vehicles (UAV) hyperspectral lidar system Digital terrain models (DTM) Digital surface model (DSM) sensor quality imaging system atmospheric, illumination, and wind conditions during the data collection Detect environmental problems 5

6 Weather forecasts Finnish meteorological institute (FMI) provides information about air quality, wind, temperature, climate, rain, snow depth, etc. Hydrological forecasts Finland s environmental administration (SYKE) provides - Hydrological maps for water level, daily precipitation, water equivalent of snow, etc. - Warnings for flood and water level, precipitation, snow load 6

7 mmea.fi à Automation à Risk Management Risk Management Intelligent analysers Environment Weather Hydrological forecasts Mine processes 7

8 Automation à Integration Environment Risk Management Monitoring Condition Monitoring Mine processes à Intelligent analysers Signals Signal processing - Derivation & Integration - Filters - Blind source separation Process measurements Feature extraction - Norms - Histograms - Variable selection - Grouping Nonlinear scaling - Normalisation - Asymmetry - Scaling functions Intelligent indices - Indirect measurements - Stress & Condition - Trends - Quality control Process measurements Laboratory analysis Interpolation Uncertainty handling LE models - Steady-state - Dynamic - Multimodel Intelligent indices - Indirect measurements - Stress & Condition - Trends Process Cases & Faults Predictions Anomaly detection 8

9 Nonlinear scaling Meanings Expert knowledge - Linguistic levels can translated into numbers - Natural language Machines: cumulative stress = High stress à strong harmful effects à wear, fatigue Daily number index values Note: Left Vertical! Low stress à negligible effect Normal stress à moderate effect Very long smooth operation 9

10 Generalised SPC Trend analysis Change of trend index Trend index k k T 1 1 I j ( k) = å X ( k) - å X j ( k) n S j i= k -n nl + S i= k-nl 10

11 Risk management Risk analysis High-level control Diagnostics Modelling Risk identification Adaptation Performance analysis Enviromental measurements Open data Measurement technology Modelling Intelligent analyser Intelligent analyser Intelligent (Software analyser sensor) Process Decision control making Decision making Decision making Process Risk management Risk analysis High-level control Diagnostics Situation awareness Modelling Risk identification Forecasting New measurements Adaptation Performance analysis Enviromental measurements Open data Measurement technology Modelling Intelligent analyser Intelligent analyser Intelligentanalyser Decision Process control making Decision making Decision making Process New measurements Intelligent analysers: traffic lights, trends Process insight, weather, water balance Global markets 11

12 MMEA Mining Key Demonstration EE Services Concepts Monitoring and management framework for early risk management EE Management/ - Monitoring methods - Decision Support Data Management - Data Sources - Processing - Testbed Remote Sensing - Radar - Lidar - Airborne - Solution studies - High performance on-line monitoring Monitoring methods and tools Decision support systems Modelling (water, weather) Quality control & anomaly detections Weather observations & forecasting Data operator & data sources Atmospheric boundary layer sensing with radar, lidar & airborne Instruments Probabilistic regional forecasting Mining water solutions Sampling and process emission 3D modelling Smart Applications in Industrial Internet Risk analysis High-level control Diagnostics Adaptation Modelling Risk identification Performance analysis Enviromental measurements Services Store, analyse, refine, etc. Open data Measurement technology Modelling Intelligent analyser Intelligent analyser Intelligent (Software analyser sensor) Process Decision control making Decision making Decision making Process Utilise! Local processing à Efficient local use à Less data transfer GSPC & Trends IoT Thing Thing Thing Local integrated applications! I 2 os Act! Experts Things 12

13 Conclusions Process measurements à real-time Sampling à Laboratory analysis More real-time measurements Combine measurements + trend analysis + GSPC Monitoring à & Optimization Forecasting + Risk identification Situation awareness Environment Services Mine area Open data Participatory observations Mine processes 13