1. Metso Process Technology & Innovation (PTI) Unlocking Energy Efficiency in the Mining Process Energy Efficiency Opportunities (EEO) Workshop   Kristy-Ann Duffy Metso (PTI)
Perth - 6 September 2012

2. Overview Unlocking energy savings using Research and Development
Introduction to
Metso Process Technology and Innovation (PTI)
Unlocking energy savings using
Process Integration and Optimisation (PIO)
Case Study: Antamina
Research and Development
“Development of an Eco-Efficient Mining Process”
Firstly, I’ll start with a brief introduction to Metso PTI (who we are, what we do)
Then I’ll describe the PIO methodology and how we can use this to unlock energy savings, using the Antamina case study to demonstrate.
And finally I will give a short overview of our R&D project “D of an EEMP”
Unlocking Energy Efficiency in the Mining Process

3. Metso PTI
The vision of this team is to provide a technical resource of the highest quality to both industry and Metso's related business lines.
Whole of system
Approach
PIO
SmartTag™
SmartEar™
SmartSAG™
SmartRIP™
A division of Metso which offers a global consulting service for the mining and construction industries.
FOCUS: providing Total Process Integration and Optimization (PIO) services.
Optimization of the mining (drill and blast), comminution, flotation and dewatering processes for both Greenfield and existing operations.
Whole of system approach – to maximise resource efficiency
also offer laboratory and pilot plant services
- important components of the PIO projects
- can also be offered directly to clients.
A range of products (including SmartTag ore tracking)
- designed to enhance the operation of mineral processes
- used in consulting projects and supplied directly to clients.
In addition to improving resource efficiency in consulting projects
Metso PTI conducts R&D projects to look for the next opportunities
One of our current projects “D of EEMP”
SmartTag™ – Ore Tracking from Mine to Mill.
SmartEar™ – Acoustic Mill Monitoring.
SmartSAG™ – SAG Mill Dynamic Model.
SmartRIP™ – Conveyor Belt Monitoring (commercial prototype).
Crushing
Grinding
Flotation
Ore characterisation
Development of an Eco-Efficient Mining Process
Unlocking Energy Efficiency in the Mining Process

4. Process Integration and Optimisation (PIO)
The development of integrated operating and control strategies from the mine to the plant that maximise throughput, minimise the overall cost and energy consumption per tonne and maximise profitability
Unlocking energy savings
Process Integration and Optimisation
Maximum return on the invested capital
New solution and profit increase
The PIO methodology is a whole of system approach to improve resource efficiency
It is… the development…
Our team has been able to deliver considerable increases in the profitability of our customers operations: significant increases in throughput (5 to 30%) and metal recovery, cost and energy reduction, as well as overall process efficiency increases (from the mine to the plant) have been achieved at a number of operations worldwide.
This methodology unlocks energy savings while improving business profitability

5. SAG Feed Size Distribution
The PIO Approach
Blast Design
Ore Characterisation
Lithology zones
Rock Strength - Point Load Index
- SMC Tests
- Drop Weight Test results
- Work Indices
Rock Structure - Rock Quality, FF, Mapping
PTI Blast Fragmentation Model
Blasting
ROM Ore size Distribution
Primary Crusher Model (JKSimMet and PTI models)
SAG Feed Size Distribution
Grinding Circuit Model (JKSimMet and PTI models)
Production rate
Final P80 size
The mine is essentially a series of operations that are inter-connected and therefore inter-related with the performance of one operation affecting the performance of another.
The PIO Approach analyses each process in the context of the whole operation
Starting with understanding the ore
- ore characterisation
- Definition of domains (based on ore strength and structure)
Feeds into the models of each of the stages / processes
Smart tag used to track the ore through the process
Measurement, modelling and optimisation of each stage (blasting, crushing, grinding, flotation) of process is conducted in the context of the whole.
This allows operating parameters and control strategies in the mine and processing plant to be adjusted and optimised for different ore types, thereby reducing costs, minimising energy and increasing profitability.
Throughput
Final Grind Size
Mineral Recovery
Flotation Model (PTI) 5

6. Benefits of PIO Case Study - Antamina
OBJECTIVE:
To increase throughput when treating harder ores.
SAG Feed Size F80 vs. Throughput – Antamina
Increased throughput with the same installed power, reduces the energy consumption per ton
Unlocking energy savings
Antamina is a polymetallic mining complex that produces copper and zinc concentrates as primary products
situated in the central Peruvian Andes around 4,300 meters above sea level
The advent of harder ores presented a problem for the operation (cutting plant throughput in half)
Objective of the PIO project…
Followed PIO methodology – review existing operations (mine to plant), ore characterisation, definition of ore domains, measurement, modelling and simulation of the entire process.
Different conditions simulated
different blast designs,
primary crusher setting,
SAG mill grate design,
SAG mill ball charge level,
ball mill operating conditions,
changes in classification with hydrocyclones,
use and operation of recycle/pebble crushers
establish optimum operating strategies – implemented at Antamina in several stages
These included:
changes to blasting design and energy, to produce a finer ROM (graph)
And a number of changes and adjustments were made to the crusher, SAG and ball mill circuits
to best performance of downstream processes with the finer ROM 6
Effect of Blast and Plant Changes on Throughput

7. Benefits of PIO Case Study - Antamina
23% reduction in grinding energy
During a base case survey of the operation at the beginning of the initial PIO project, a throughput of 2,600 tph was achieved with a specific energy consumption of 14 kWh/t (using two ball mills 10.75MW each).  At the end of the project, a sustained throughput of 4,400 tph was achieved with a specific energy of 10.7 kWh/t (using three ball mills). This represents a significant increase in resource efficiency by reducing the total environmental impact of metal concentrate production with an energy saving of 23% for Antamina.
 Alternatively...
This accounts for 25% reduction in grinding kWh/t for Antamina.
For more information refer to SAG 2011 PAPER:
OPTIMISATION AND CONTINUOUS IMPROVEMENT OF ANTAMINA COMMINUTION CIRCUIT

8. R&D Project: Development of an Eco-Efficient Mining Process
Objective
Investigate alternative technologies and practices in mining and minerals processing that reduce the usage of energy, water and carbon emissions.
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%.
Solutions that are technically and economically viable to be implemented in a reasonably short timeframe.
Unlocking Energy Efficiency in the Mining Process

9. Project Areas High Intensity Selective Blasting
Increase and better distribute energy of blasting to reduce energy in downstream comminution stages.
Project Areas
A potentially a cheaper and more eco-efficient method of transporting material.
Especially for large volumes and large distances.
High Intensity Selective Blasting
Discarding barren waste to significantly reduce energy consumption of downstream processes
In-Pit Crushing and Conveying
Pre-Concentration
Comminution of ore (crushing and grinding) is the most energy intensive stage of mineral production.
Energy Efficient
Comminution Circuits
Energy Efficient Dry Comminution
The mining industry typically consumes
0.6 to 1.0m3
of water
for each ton of ore processed by flotation
If coarser particles could be recovered by flotation, less power would be required for the previous comminution stages.
Novel application of existing technologies and tailored solutions based on detailed understanding of the process and ore.
Typical Energy of blasting (powder factors) has increased over the past 15years
Taking to the next level - Using Advanced initiation systems (tie-up using electronic detonators) it is possible to
Increase and better distribute energy
Without increasing dilution or causing wall damage
Allows selective blasting (ore moves towards ore, and waste away from ore)
Cost of hauling ore makes up 50% of the total operating cost of a mine.
Diesel powered trucks generate most of the dust and GHG emissions of a mining site.
Most mining accidents occur during load & haul
main advantages - are low operating costs, reduced manning requirements, high capacity, low emissions,
improved safety
Comminution is the largest energy consumer in mineral processing (up to 70%).
Removing barren material prior to comminution can significantly reduce the energy consumption per tonne of concentrate produced.
This section investigates how, with some refinement, existing eco-efficient comminution technology can be applied
in novel flowsheet arrangements to provide energy savings.
Optimised operation and novel flowsheets incorporating efficient technologies such as HPGR, Vertimills, pebble mills and autogenous mills could significantly reduce energy
Coarse Particle Flotation
Water Recovery Optimisation
Unlocking Energy Efficiency in the Mining Process

10. An Eco-Efficient Mining Process
May incorporate any combination of these possibilities
Requires tailored solutions based on detailed understanding of the process and ore.
High Intensity Selective Blasting
In-Pit Crushing and Conveying
Pre-Concentration
Energy Efficient
Comminution Circuits
Energy Efficient Dry Comminution
Novel application of existing technologies and tailored solutions based on detailed understanding of the process and ore.
Typical Energy of blasting (powder factors) has increased over the past 15years
Taking to the next level - Using Advanced initiation systems (tie-up using electronic detonators) it is possible to
Increase and better distribute energy
Without increasing dilution or causing wall damage
Allows selective blasting (ore moves towards ore, and waste away from ore)
Cost of hauling ore makes up 50% of the total operating cost of a mine.
Diesel powered trucks generate most of the dust and GHG emissions of a mining site.
Most mining accidents occur during load & haul
main advantages - are low operating costs, reduced manning requirements, high capacity, low emissions,
improved safety
Comminution is the largest energy consumer in mineral processing (up to 70%).
Removing barren material prior to comminution can significantly reduce the energy consumption per tonne of concentrate produced.
This section investigates how, with some refinement, existing eco-efficient comminution technology can be applied
in novel flowsheet arrangements to provide energy savings.
Optimised operation and novel flowsheets incorporating efficient technologies such as HPGR, Vertimills, pebble mills and autogenous mills could significantly reduce energy
Coarse Particle Flotation
Water Recovery Optimisation
Unlocking Energy Efficiency in the Mining Process

11. Summary Detailed understanding of the process and ore
Continuous improvement
Detailed understanding of the process and ore
Unlocks energy savings while improving business profitability
Optimising the process as a whole
Data collection, benchmarking, modelling, simulation
Optimising the process as a whole
Developing integrated solutions
unlocks energy savings while improving business profitability
Of course, as with any improvement process, it is an iterative process to provide sustained benefits and continuous improvement
R & D
Looking for the next step
Unlocking Energy Efficiency in the Mining Process

12. Date Author Title

13. Optimisation of Blast Fragmentation
Example of Blast Domain Mapping (16 Domains)
Definition of Fragmentation domains
Defined by in-situ block size distribution (structure) and rock strength properties.
PTI use blast fragmentation models and systems to optimise the blast for each fragmentation domain.
Produces consistent blast fragmentation.
The aim is to produce ROM fragmentation that will maximise throughput and the efficiency of subsequent crushing and grinding operations.
4/12/2017Date Author Title

14. Major Projects CSN, Casa de Pedra - Fe
Polymetal, Varvarinskoye – Au/Cu
Phosagro, Apatit – PO
Eldorado Gold Corp, Kisladag - Au
Barrick ,Cortez - Au
New Mont, Phoenix- Au
New Mont, Carlin- Au
Rio Tinto, Kennecott - Cu
Anglo, Sadiola - Au
Anglogold, Iduapriem - Au
Peñoles, Franciso I. Madero – Zn
NewMont, Ahafo - Au
Anglo, Morila Au
Anglo, Geita- Au
Antamina – Cu/Zn
Vale, Sossego - CU
BHPB, Newman - Fe
NewMont Batu Hijau - Cu
Freeport, Cerro Verde- Cu
Vale, Salobo - Cobre
BHP, Cerro Colorado Cu
Gold Mine Co, Lihir - Au
CSN, Casa de Pedra - Fe
Los Pelambres - Cu
NewCrest,Telfer – Cu/Au
KinRoss, RPM - Au
Anglo, Los Bronces - Cu
Fosfértil, Catalão/Tapira, PM - P
BHP, Olympic Dam–U/Cu/Au
NewMont, Bodington - Au
BHP, Escondida Cu
BHP - Fe
Freeport,Candelaria - Cu
Kalgoorlie, Fimiston - Au
Codelco, Andina - Cu
Anglo, Mantos Blancos - Cu
Codelco, Mansa MIna - Cu
Goldfields,St Ives - Au
Kansanshi - Cu
WMC - Ni
Goldfields,St. Ives - Au
Impala, Zimplats - Pt
BHO, Cannington – Pb/Ag
Oz, Minerals - Zn
Barrick, Cowal – Ouro/ Cu
Xstrata, Ernest Henry - Au