Maximising Productivity for Iron Ore

Transcription

1 Maximising Productivity for Iron Ore IMP has been providing complete solutions from sampling to analysis for the mining and metallurgical industries since 1987

2 Challenging conventional sample processing techniques to maximise productivity At IMP we think differently, we challenge conventional sample processing techniques, and we work with like-minded customers to engineer ground breaking innovative solutions. Using cutting edge technology, the best equipment available in the world, and collaboration with our customers, IMP consistently delivers products and systems that improve health and safety for laboratory personnel, improve precision and accuracy of results produced, improve laboratory efficiency and maximise productivity. This passion for technology, innovation and change, together with forward thinking customers has made IMP world leaders in our field. We work in close cooperation with all major manufacturers of analytical equipment and system components for logistical interfacing. This ensures that systems are customised to optimally meet the specific needs and preferences of each customer. If you are looking for an automation partner, please contact us. 1

3 We have successfully designed, installed and commissioned many automated laboratories and we would like to share our expertise to provide you with the best solutions for your business needs. Advantages of IMP s automation systems include: l Improved health and safety for employees with lower exposure to noise, heat, and dust and reduced manual handling l Improvement in accuracy and precision of results l Low risk of sample mix up l Reduced cross contamination l Quick sample turnaround times l Reduction in costs Notable IMP milestones and achievements l The largest laboratory automation project in the world to Anglo Platinum in South Africa (the facility is the size of a football pitch and uses 14 robots) l The largest robotic sample preparation and wet chemistry system in the world for FMI (previously Phelps Dodge) in the USA l The largest fully automated iron ore laboratory in the world for BHP BIO in Western Australia l The largest fully automated robotic port laboratory in the world for Rio Tinto in Western Australia 2

4 IMP Automation has been at the forefront of the development of semi and fully automated sampling plants and analytical laboratories in the Iron Ore industry. These world leading producers have embraced our automated analytical technology in their operations. Port Laboratories Rio Tinto Cape Lambert Australia Scope of supply: This world first state of the art facility is the largest fully automated iron ore port laboratory in the world. The automated system consists of four large robots operating on two 20 metre long tracks servicing machines for sample dividing, rapid sample drying, natural or dry lump sieving, dry fines sieving, moisture determination, splitting, archiving, weighing, sample preparation, automated XRF and four point TGA analysis. The entire process from the sample stations to final analysis is fully automated. FMG Port Laboratory 2 Australia Scope of supply: Representative samples taken during ship loading are automatically transported to the automated robotic laboratory by conveyor or IMP s monorail sample transport system. The automated laboratory has two robot cells in a figure eight configuration - one robot cell for each sample station. The two robot cells are able to share the workload evenly by passing buckets to one another via a buffer turntable. The figure eight configuration with turn table also allows dual redundancy between the cells. Each cell has been designed to split samples as required, carry out particle size and sample moisture content analysis automatically. An aliquot from each sub lot is dried using IMP s rapid dryer, then crushed and pulverised for chemical, TGA, and other analysis. 3

5 Roy Hill Port Australia Scope of supply: Representative samples taken during ship loading are automatically transported to the robotic laboratory by conveyor or monorail. The automated robotic laboratory houses a large robot on a linear track that services automated sample dividing equipment, automated sieving, splitting, archiving, sample preparation and chemical analysis equipment. The entire process from sampling to analysis is fully automated. Up to four 500kg composite samples can be accumulated for distribution to client or additional testing. The laboratory has been designed such that a mirror of the facility can be produced in the future lining up the two facilities together via the rotating magazine. All analytical and process data is stored and managed by the IMP ControlTrack LIMS. FMG Port Lab Australia Scope of supply: This robotic laboratory automatically receives up to 36kg representative samples taken during ship loading. The automated robotic laboratory automatically divides samples, building sub lot composites for particle size and moisture analysis. Moisture determination and particle size determination is fully automated. The robotic facility also dries, crushes, pulverises and splits milled aliquots for subsequent chemical and TGA analysis. Composite samples up to 500kg can be produced as part of the process. Results obtained from the laboratory are used to certify the cargo. 4

6 Kumba Resources Saldanha Port Lab South Africa Scope of supply: IMP designed the world s first sampling and robotic facility to straddle the ship loading conveyors. As real estate around the ship loading area is often limited, this economical use of space has proven to be a success. The entire process from automatically producing representative samples during ship loading to final analysis and certification of the cargo is fully automated. The robotic laboratory is designed in a figure eight configuration with a unique turn table that joins the two cells together. Each robotic cell serves a single sample station but the novel design allows samples to be passed from one cell to the other as required. This allows backup redundancy between the cells. Based at Saldanha Port, the automated robotic system splits the samples in order to build composites for each sub lot. Crushing, milling, splitting, sizing, moisture determination, TGA analysis and chemical analysis by XRF using fused beads is all fully automated. This facility is used for ship loading certification. BHP Billiton Nelson Point Australia Scope of supply: IMP has provided two fully automated robotic sample weighing systems and two fully automated fusion systems. These systems were specifically designed for maximum redundancy to ensure the Nelson Point system has no single point of failure. This means that the BHP port laboratory will never be in the situation where analytical samples cannot be prepared for analysis. Mine Laboratories Kumba Resources Sishen South Africa Scope of supply: This end to end fully automated robotic laboratory was designed to receive 2kg samples from the plant and to automatically prepare and analyse these samples reporting the results directly to the plant. The automated pressed powder and fusion laboratory consists of two automated mills, sample press, fully automated fusion apparatus, magazine rack for approximately 120 sample bottles, an automated sample weighing and splitting station, an industrial robot, 2 XRF spectrometers and software to control and monitor the process. 5

7 BHP Billiton Iron Ore Area C Australia Scope of supply: This innovative satellite robotic iron ore sample preparation laboratory was designed to prepare samples ready for chemical analysis at the Newman central laboratory. The facility receives samples of up to 15kg from the mine. The robotic laboratory automatically dries the samples, determines the moisture content and then crushes and pulverises the samples. Once pulverised, an aliquot is automatically placed into barcoded vials in a 100 position tray. A duplicate tray is filled and retained in the laboratory while the original tray is transported to the Newman facility for automated analysis. BHP Billiton Iron Ore Newman Australia Scope of supply: The Newman automated laboratory is the largest fully automated robotic iron ore laboratory in the world. The end to end automated facility receives up to 15kg samples from the plant. These samples are registered and manually entered into one of two automated sample prep lines. The samples are automatically dried and, where required weighed, to determine the moisture content. The samples are subsequently crushed, split, pulverised and dosed into barcoded vials. The vials are then automatically transported to one of four automated robotic fusion and TGA machines. These machines weigh samples for TGA and fusion for subsequent XRF analysis. The entire process from the 15kg wet sample to XRF and TGA analysis is fully automated. The facility also accepts sample trays from satellite laboratories that are automatically processed. Rio Tinto Tom Price Australia Scope of supply: The automated robotic sample preparation facility is located in Tom Price Western Australia. The robotic laboratory was designed to receive up to 15 kg of dried iron ore for automated sample preparation. The system includes two automated crushers that crush the samples to less than 2.8mm and split the samples into smaller aliquots for pulverising. The robot transports the samples between the crushers, mills and dosing device. Aliquots of around 50g are placed in vials or cups and transported out of the preparation area for manual chemical and TGA analysis. The system is designed to process 700 samples per day. 6

8 FMG Christmas Creek Mine Australia Scope of supply: IMP provided the complete fully automated robotic laboratory on a turnkey basis. The automated laboratory is used to process mine pit and plant samples. Plant samples requiring rapid turnaround of results are dried using IMP s novel IR dryers prior to entering the automated system. Pit samples are dried using IMP s conventional dryers. Dry samples up to 15 kg can be placed into the robotic automated laboratory. The entire comminution process including crushing, splitting and pulverising is fully automated. The subsequent fusion process, XRF and four point TGA analysis is also integrated and automated. Archived samples are stored in easy to access sample trays in uniquely identified vials. Kumba Resources Sishen Expansion Project South Africa Scope of supply: IMP provided a state of the art automated sample station, fully integrated into two separate automated robotic sample preparation and analysis cell on a turnkey basis. The sample station receives different samples up to one ton in mass from the plant. These samples are dried in IMP s novel IR Vibro dryers before being hoisted automatically into the sample station. The sample station is equipped with crushers, IMP VICO RSD s and IMP VICO splitters, to produce a range of samples for the integrated robotic laboratories. One automated laboratory, processes the samples for moisture and particle size determination. The second integrated robot cell crushes, mills and presses samples into rings for XRF analysis. IMP also provided integrated pycnometers to determine the density of the ore. The entire process through the sample towers and including analysis is fully automated. Samples for manual jigging and other metallurgical tests are automatically produced in the process. Kumba Resources Sishen Upgrade South Africa Scope of supply: This end to end fully automated robotic laboratory was designed to receive 2kg samples from the plant and to automatically prepare and analyse these samples, reporting the results directly to the plant. The automated robotic pressed powder laboratory consists of a sample splitter, three automated mills, two automated sample presses and a magazine rack for approximately 120 sample bottles, an automated sample weighing and splitting station, an industrial robot, 2 XRF spectrometers and software to control and monitor the process. The laboratory ensures rapid turnaround times of analytical results to the plant metallurgists. 7

9 Assmang South Africa Scope of supply: This world class laboratory was designed and supplied by IMP to Assmang in the Northern Cape, South Africa on a turnkey basis. The laboratory services the plant and mine with rapid accurate and precise sample analysis. The facility includes automated sample preparation, including crushing, splitting, milling, production of pressed pellets for XRF analysis, automated density measurement, and preparation of aliquots for wet chemical analysis. The entire process after sample entry including comminution and XRF analysis is fully automated. FMG Cloud Break Mine Australia Scope of supply: IMP designed and supplied this fully automated sample preparation and analysis facility on a turnkey basis. The automated laboratory is used to process mine pit and plant samples. Plant samples requiring rapid turnaround of results are dried using IMP s novel IR dryers prior to entering the automated system. Pit samples are dried using IMP s conventional dryers. Up to 15kg of dry samples are entered into the automated system, after which all processes including crushing, splitting, milling, fused bead making, XRF analysis and 4 point LOI is fully automated. The facility runs with minimal staff and produces 800 fusions per day. Having the automated laboratory based on the Cloud Break mine site provides FMG with the advantage of very quick turnaround times on chemical analysis. Access to quick accurate chemical analysis on site, enables FMG s management to make timely informed decisions on product grade for its mining, production and beneficiation processes, ensuring that the highest quality products are economically produced. Assmang Khumani Expansion Project South Africa Scope of supply: IMP designed and supplied the fully automated sample preparation and analysis facility on a turnkey basis. This facility includes three robot cells. Samples are automatically crushed, split and milled in the first cell. Aliquots for XRF pressed powder method are then milled down to less than 45 microns and pressed into pellets in the second integrated robotic cell. Aliquots for wet chemistry and density determination are also automatically prepared. Density is determined in the third robotic cell. The entire process from sample entry to XRF analysis and density determination is fully automated. 8

10 Roy Hill Mine Australia Scope of supply: IMP designed and supplied this state of the art fully automated sample preparation and analysis facility on a turnkey basis. The laboratory consists of three robot cells. One cell is interfaced to the plant sample stations. Representative samples up to 36kg are automatically transported from the sample stations to the laboratory using IMP s novel monorail system. The samples are then sub divided and prepared for moisture and particle size analysis. An aliquot is sent to the second robot cell for further processing. The second robot cell not only processes the plant samples, but can also accommodate up to 600 pre dried 15kg pit samples per day. Samples are crushed, split, pulverised and dosed into vials in this cell. The third cell, which is also integrated, fuses the samples for XRF analysis and four point TGA analysis. The entire process including sampling, transport of samples to the lab, drying, particle size, moisture analysis, comminution and chemical analysis is fully automated. This integrated end to end automation assures the best possible efficiency and fastest possible turnaround times of analytical results to the plant. All process and analytical data is captured in IMP s ControlTrack LIMS. BHP Billiton Newman Line 4 Australia Scope of supply: BHP Newman, the largest automated iron ore mine laboratory in the world, required more capacity. To meet the demand IMP installed a fourth HAG 6 automated robotic fusion line, allowing BHP to cope with the increased fusion, XRF and TGA capacity required. The total fusion capacity of the facility was increased close to 3000 fused beads a day. Atlas Iron Mt. Webber Australia Scope of supply: Fully automated sample preparation and analysis facility, initially for 800 samples per day, with the capability to increase the processing capacity to 1000 samples per day. The automated system will process a mix of geochemical mining and pit control samples, metallurgical control samples and a dedicated line to process near mine geochemical exploration samples. 15 kg samples are dried in the IMP drying ovens before they are entered into the system via a bar coded sample input. These are then crushed to nominally 2.5mm, and then split to ~800g, before being pulverising to 90% passing 106μm. Pulverised samples are dosed into a vial. Analysis, which includes 4 point LOI and the fusion of glass beads for XRF elemental determination is automatic. The entire process is fully automated. IMP provided the facility on a turnkey basis. 9

11 BHP Billiton Jimblebar Australia Scope of supply: This turnkey project consists of an automated robotic iron ore sample preparation facility, that includes drying, ISO moisture analysis, crushing, splitting, pulverising and dosing into vials. These vials are automatically stored in trays that are tagged with RFID's. These trays are transported to a laboratory in Newman, where the same RFID technology can recognise the tags and process the samples automatically in the facility. Intertek Fusion Automation Australia Scope of supply: An automated fusion and TGA system. The system incorporates the latest in fusion and TGA technology for XRF analysis. The system incorporates a 200 positions sample magazine, free automated weighing stations, six induction heating systems, automated platinum cleaning station and interface to an XRF. The system is capable of weighing, fusing and analyzing (XRF and 3 point TGA) close to 1000 samples per day. This system compliments a second system installed a few years prior. Scope of supply: An automated fusion and TGA system. This system was implemented using three sequential XRF's as opposed to one simultaneous XRF. With the implementation of customisable recipes in the Prepmaster control system, many ore types could be prepared for XRF analysis with iron ore being the predominant product. Kalassay Fusion Australia 10

12 FMG Solomon Australia Scope of supply: This is the third similar fully automated robotic mine site laboratory that IMP has provided to FMG on a turnkey basis. The automated laboratory is used to process mine pit and plant samples. Plant samples requiring rapid turnaround of results are dried using IMP s novel IR dryers prior to entering the automated system. Pit samples are dried using IMP s conventional dryers. Up to 15kg of dry samples are entered into the automated system after which all processes including crushing, splitting, milling, fused bead making, XRF analysis and 4 point LOI is fully automated. The facility runs with minimal staff and produces 800 fusions per day. All process and analytical data is managed by IMP s ControlTrack LIMS. Intertek Genalysis Australia Scope of supply: Intertek has been an early adopter of IMP s automation technology and has purchased two robotic automated sample preparation systems and three automated robotic fusion and TGA systems. One automated robotic prep cell consists of two automated crushers with five automated milling machines, a bagging machine and a sample cup output belt magazine. A second robotic prep system has six automated mills. LKAB Sweden Scope of supply: The supply of two automated robot laboratories with an air tube system to transport samples to the laboratory, automated IR dryers to dry slurry samples (including slurry samplers) mills presses and XRF systems. (This project was supplied by Herzog GmbH). 11

13 Citic Pacific Laboratory Australia Scope of supply: The latest in fusion and TGA technology. This fully automated fusion and TGA system is connected into three XRF's. With the six induction furnaces for fusion and the unique TGA automation, this system is able to produce just under 600 samples per day Minanalytical Perth Australia Scope of supply: IMP provided Minanalytical with an End to End fully automated robotic laboratory on a turnkey basis. The facility is designed specifically to handle exploration samples where there is a requirement to retain crusher and pulp residue samples. The system includes four crusher splitters, six mills and two spear dosing machines with vial magazines. The system is capable of preparing more than 1000 samples per day. Also included is an automated fusion system with automated TGA and XRF. By integrating all of these processes, maximum efficiency is achieved with reduced health and safety risks, improved precision and accuracy and faster turnaround times for analytical results. ALS Perth Australia Scope of supply: In expanding their operations, ALS required a capacity of 10,000 fusions per day. To help them achieve this goal, a HAG 8 fusion system has been supplied with a further three HAG 8's to come. The automated fusion system will allow a capacity of 800 samples per day. This robotic automation includes a 300 position vial magazine, automated sample weighing, fusion and XRF analysis and automated four point TGA. The ALS system also includes the latest IMP TGA s and Parcher type moisture TGA. Tata Steel Canada Scope of supply: IMP provided the facility as a turnkey project. The laboratory is set in Northern Canada where the equipment ancillary services had to be designed to be conducive to extreme cold conditions. The laboratory includes sample drying (both conventional and IMP s novel infrared rapid sample dryers), comminution equipment such as crushers, semi-automated pulverisers with sample magazines, fully automated fusion TGA and XRF equipment. 12

14 SGS Perth Australia Scope of supply: IMP provided SGS with semi-automated sample preparation equipment which included four semiautomated HP-M 1500 mills and magazines for iron ore samples. IMP also provided a fully automated robotic fusion and TGA system (HAG 8). This automation allows automated weighing and fusion of in excess of 800 samples per day. Samples are automatically analysed on the XRF. Moisture and three point LOI are measured on the integrated TGA system. Sishen South Physical Testing South Africa Scope of supply: IMP provided an automated robotic laboratory on a turnkey basis that includes automated moisture determination to ISO standards for iron ore as well as automated particle size analysis. Included in the robotic cell are two automated drying ovens, two automated sieve shakers and an automated splitting device (RSD). FMG Christmas Creek Temporary Laboratory Australia Scope of supply: Prior to the automated robotic laboratory being available, IMP was requested to provide a temporary laboratory. The temporary laboratory included transportable buildings, sample drying equipment, crushing, semi-automated pulverising equipment, sample dividing and splitting equipment. Sample analysis equipment such as particle size analysers, TGA instruments and XRF instruments were included. 13

15 Sishen South Sample Tower and Chemical Laboratory Scope of supply - Chemical Lab: The scope of supply includes fully automated crushing and splitting, pulverizing, fine pulverizing (-45 micron), automated density determination and automated XRF analysis. Aliquots for wet chemical analysis are presented to the operator on an output magazine. The entire process is fully automated. Sample Tower: This system is capable of automatically processing 40 kg to 160 kg samples. The system begins with the manual loading of moist iron ore samples, of +/-25 kg, into an infrared dryer conveyor hopper. Once the hopper registers the correct mass the sample is automatically fed from the hopper through the drier. The dried sample is then automatically collected, weighed and lifted to the top of the tower where it is gravity fed through a system of crushers and splitters to produce a representative sample of 0.6 kg to 1 kg, ready for presentation to the IMP robotically automated laboratory for further sample preparation and chemical analysis. FMG Solomon NITA S & Online Moisture Analysis Scope of supply: 4 x NITA II (Neutron Inelastic scatter and Thermal capture Analysis) online elemental analysers for the rapid and reliable measurements of the elemental composition of bulk materials directly on-belt. Online microwave moisture measurement systems compliment the elemental analysers with fast and accurate moisture analysis of the stream in real time. FMG Christmas Creek NITA S & Online Moisture Analysis Scope of supply: 3 x NITA II (Neutron Inelastic scatter and Thermal capture Analysis) online elemental analysers for the rapid and reliable measurements of the elemental composition of bulk materials directly on-belt. Online microwave moisture measurement systems compliment the elemental analysers with fast and accurate moisture analysis of the stream in real time. 14

16 IMP Group Australia 34 Hasler Road, Osborne Park, WA 6017 PO Box 1183 Osborne Park WA 6916 Australia Tel: +61 (8) Fax: +61 (8) IMP Africa Cnr Commissioner & Christopher Street, Boksburg East, 1459 PO Box 1110 Boksburg, 1460, South Africa Tel: +27 (11) Fax: +27 (11) IMP Brazil R. Fernandes Tourinho, 147 Sala Savassi Belo Horizonte-MG Brazil Tel: +55 (31) Fax: +55 (31) IMP Canada Suite 103 / 2902 Sth. Sheridan Way Oakville, ON, L6J7L6 Tel: Fax: Cell: info@impautomation.ca