Transcript PPT 3.1MB - Energy Efficiency Opportunities

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
Overview
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”
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Unlocking Energy Efficiency in the Mining Process
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
Crushing
Grinding
Flotation
Ore characterisation
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Unlocking Energy Efficiency in the Mining Process
SmartTag™
SmartEar™
SmartSAG™
SmartRIP™
Development of an
Eco-Efficient Mining Process
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
New solution and
profit increase
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The PIO Approach
Blast Design
PTI Blast
Fragmentation
Model
Ore Characterisation
Lithology zones
Rock Strength
Blasting
Rock Structure
- Point Load Index
- SMC Tests
- Drop Weight Test results
- Work Indices
- Rock Quality, FF, Mapping
ROM Ore size
Distribution
Primary Crusher Model
(JKSimMet and PTI models)
SAG Feed Size
Distribution
Mineral Recovery
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Grinding Circuit Model
(JKSimMet and PTI models)
Throughput
• Production rate
Final Grind Size
• Final P80 size
Flotation Model
(PTI)
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
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Effect of Blast and Plant Changes on Throughput
Benefits of PIO
Case Study - Antamina
Antamina PIO
8000
14 kWh/t
Throughput (tph)
6000
10.7 kWh/t
5000
12
10
4000
4400 tph
3000
2000
8
6
2600 tph
4
1000
2
0
0
Before
Throughput
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Specific Energy (kWh/t)
7000
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After
Specific Energy
For more information refer to SAG 2011 PAPER:
OPTIMISATION AND CONTINUOUS
IMPROVEMENT OF ANTAMINA COMMINUTION
CIRCUIT
23% reduction in
grinding energy
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.
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Unlocking Energy Efficiency in the Mining
Process
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.
High Intensity Selective Blasting
Especially for large
volumes and large
distances.
In-Pit Crushing
and Conveying
PreConcentration
Comminution of ore
(crushing and grinding)
is the most energy
intensive stage of
mineral production.
Energy
Efficient
Comminution
Circuits
Energy
Efficient Dry
Comminution
If coarser particles could
be recovered by flotation,
less power would be
required for the previous
comminution stages.
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Coarse Particle Flotation
Water Recovery Optimisation
Unlocking Energy Efficiency in the Mining Process
Discarding barren waste
to significantly reduce
energy consumption of
downstream processes
The mining
industry typically
consumes
0.6 to 1.0m3
of water
for each ton of ore
processed by
flotation
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
PreConcentration
Energy
Efficient
Comminution
Circuits
Energy
Efficient Dry
Comminution
Coarse Particle Flotation
Water Recovery Optimisation
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Unlocking Energy Efficiency in the Mining Process
Summary
Continuous improvement
Detailed understanding
of the process and ore
Optimising the process
as a whole
R&D
Looking for the next
step
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Unlocking Energy Efficiency in the Mining Process
Unlocks energy savings
while improving business
profitability
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