P009P - The Optimisation of Mineral Processes by Modeling and Simulation
Value
AUD $13,283,010
Commencement Date
April 2012
Duration
4 years
Program Manager
Terry Braden
Research Providers
Julius Kruttschnitt Mineral Research Centre (JKMRC); Chalmers University of Technology; CRC ORE (Optimising Resource Extraction); Hacettepe University (Benzer); Universidade Federal do Rio de Janeiro; University of Cape Town
Sponsors
Alcoa of Australia Limited; Anglo American; AngloGold Ashanti Limited; Barrick Gold Corporation; BHP Billiton Base Metals; COREM; FLSmidth Minerals; Glencore Xstrata Copper Limited; LKAB; Lonmin PLC; Magotteaux Australia Pty Ltd; Metso Minerals Process Technology; Minerals and Metals Group Ltd (MMG); Newcrest Mining Limited; Newmont Mining Corporation; Outotec SEAP; Polysius AG; Rio Tinto Technological Resources Pty Ltd; Russell Mineral Equipment; Senmin South Africa (Pty) Ltd; Teck Resources Limited; Tenova Bateman Sub Saharan Africa; Vale Australia
PROJECT SUMMARY
P9P has been a challenging project, both technically and due to a shortfall of committed funds against the initial proposed research program. A combined effort between the researchers, sponsors and AMIRA however ensured that the revised outcomes still produced the highest quality research with a high potential impact factor to the sponsor operations.
The P9P program is organised around three themes: ore characterisation, comminution and flotation. The intention is to bring these themes together via the integrated extraction simulator platform delivered by CRC ORE, in part through applying it to operating plants through the case study and site work programs. Case studies allow the devotion of significant resources to undertaking extended site surveys or other work for partner-level sponsors, and the site work programs provide in-depth surveys of a plant belonging to major-level sponsors. The site work provides data essential to model development, growth of knowledge and important opportunity for people development.
P9P has carried out extensive scientific research into the fundamentals of processes and unit operation phenomenon to underpin the development of unit operation models. Validation will be achieved by in-plant surveys and analysis undertaken within P9P. Where possible and appropriate, P9P will also provide for the development of on-line instruments and measurement devices which will also facilitate the development and application of the models. These developments, fundamental understanding and site activities will of themselves greatly benefit sponsors by direct application, training and technology transfer.
In contrast to P9O where research activities focused on obtaining the necessary knowledge that would aid a deeper understanding of mineral processes, P9P put a high premium on addressing industry challenges that were identified in collaboration with sponsors during the development phase of the research proposal. These were:
- Shortages in skilled, trained metallurgists to apply research outcomes, tools and know-how
- Application of research outcomes to sponsor operations to deliver direct value
- Ability to access and apply models developed by the Research Team
HIGHLIGHTS/DELIVERABLES/ADDITIONS
One example of delivery of value to a P9P sponsor follows:
When changing from open pit to underground ore, a reduction in circuit throughput due to an increase in ore competence was observed by one of the P9P sponsor’s operations. Determining the root causes of this was the focus of the P9P on-site survey. Results from the on-site work included recommendations to allow:
- Recovery of full throughput with competent underground feed source that are replacing open pit
- Clear identification of bottlenecks and inefficiencies around the comminution circuit allowing for additional throughput
- Potential increase in revenue of A$35 million per year if 10% increase in throughput is realised
- Intensive training of site personnel in advanced comminution, survey procedures and analysis
- Simulations delivered in the Integrated Extraction Simulator (IES) for value-chain improvement, enabling future simulations that include mine to metal.