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Mineral Processing Challenges

This document discusses challenges and future directions for mineral processing. Current challenges include processing lower grade, more complex ores that require finer grinding and more energy. Conventional processing plants struggle to adapt to new orebodies. Future directions include utilizing ore variability through responsive process design, flexible strategies, and optimizing individual processes and the whole process chain through data analytics and integrated process prediction. Digital technologies also present challenges of effective utilization and data transparency that future applications aim to address through intelligent sensors, cross-disciplinary collaboration, and translating data into transparent decision-making tools.

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411 views23 pages

Mineral Processing Challenges

This document discusses challenges and future directions for mineral processing. Current challenges include processing lower grade, more complex ores that require finer grinding and more energy. Conventional processing plants struggle to adapt to new orebodies. Future directions include utilizing ore variability through responsive process design, flexible strategies, and optimizing individual processes and the whole process chain through data analytics and integrated process prediction. Digital technologies also present challenges of effective utilization and data transparency that future applications aim to address through intelligent sensors, cross-disciplinary collaboration, and translating data into transparent decision-making tools.

Uploaded by

rodmonsal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Mineral Processing

Challenges and Future


Directions

A. Prof. Mohsen Yahyaei


SMI-JKMRC
An era of new challenges
• Low grade ores
• Complex and multi mineral ore bodies
• Lower cut off grade
• Processing 150-200% ore for the same amount of metal
• Finely disseminated minerals
• Hard ore
• Fine grinding
• Comminution energy
• Recovery
• Increased cost of production
• Energy
• Water
• Licence to operate
• Low commodity price
Current approach in industry
Optimising existing plants
and
building mega plants

Gigantism

Recovering less metal from processing more ore


An unsuccessful approach
• Reducing variability into a number (an average)
• Losing the ore variability information
• Single processability number
• Designing for a blended ore
• Inappropriate comminution energy
• Unfavourable condition in recovery process
• Using conventional circuits
• Conventional models and design locked into current
inefficiency

Conventional processing plants can’t respond to new orebodies

Forced to modify or upgrade processing plants over life


Future directions

Conventional circuits work with their historic issues and limitations


• Utilising ore variability
• Responsive process design
• Including uncertainties in financial models
• Flexibility tools & strategies
Operating the processes based on the processability of what has been
selectively extracted
Conventional
Inefficient and expensive
Product
cyclone

Ball Mill
SAG
Sump Pump
RoM

Product
cyclone

2 x expansion
Ball Mill
SAG
Sump Pump
Future
Novel implementation of conventional equipment

Gigantism
Using ore variability as
an advantage
• Controlled feed size
• Efficient utilisation
• No grinding media
• 20% less energy
Staged comminution - separation
Ore sorting
Staged comminution
and recovery

Screening
Loading and haulage
Energy Water

Process Low
performance prediction for
Hard
grade Mining
optimisation and control
ore
ore

Social
Fine
perfor-
grind
mance
Local modelling and optimisation of each process

Mining

Processing

Tailings
Optimising the performance of the whole process chain

Mining
Mining

Processing
Processing

Tailings

Tailings
Opportunities
Model-informed process prediction
Integrated Process Prediction

Ore processability data

Process data

Data
analytics

History Future

Current
Challenges of the Digital era
Digital technologies – The challange
• Autonomous Trucks
Effective utilisation

Petty et al., 2017, AusIMM Bulletin December 2017

Surprisingly low effective unitisation of autonomous trucks

Technology does not buy a good operation


Digital technologies – The challange
• Drones and augmented reality glasses

Data islands
Lack of transparency between units

More data does not bring improvement


Application of digital technologies
Managing

Mine survey
Process data management
Fleet management
Environment

Mining Hauling Processing Disposing


Translating data to information
Road condition
Fragmentation
Ore grade Crusher availability Tailing dam stability
Production plan Recycle water

Mine survey
Process data management
Fleet management
Environment

Mining Hauling Processing Disposing


Transparency in information

Managing
Source
of information

Mine survey
Process data management
Fleet management
Environment

Mining Hauling Processing Disposing


Mining Sustainability Wheel
• Growth • Waste
• Circular Economy • Resources
• Taxes • Biodiversity
• Mine closure

Economy Environment

Process /
Society
Business
• Integration • Community
• Innovation • Health and Safety
• Optimisation • Legal rights
Digitisation Wheel
• Sensors • Intelligent sensors
• Automation • Cross disciplinary
labs
• Blockchain • Joint cognitive
• Robotics systems
• etc.
Data to
Technology
Information

Process of
Transparency
Business
• Mathematical • Big data
modelling • AI
• Operation systems • Decision making
• Business dynamics tools
Sustainability Wheel and Digitisation
Wheel
The digital mine strategy
Thankyou

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