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1 So what does a Professor of Comminution lie awake thinking about? Malcolm Powell CEEC workshop June12
1
So what does a Professor of Comminution lie awake thinking about?
Malcolm Powell
CEEC workshop June12
2
DRIVERS
Energy
Water
Massive low-grade ore bodies
Increasing demand
3 What are the economic implications of all this?
Six caveats that will change mining culture & design
Mining Industry
Simon Michaux
4
Mine site energy audits
Value chain assessments
Industry averages
0%
20%
40%
60%
% comminution energy
Grant Ballantyne
No cheating
The fixed relationship of Energy per production of surface area
6
No short cuts
Hilden
y = 6.0571x + 0.53R² = 0.995
0
10
20
30
40
50
60
70
80
0 5 10 15
Cum
ulat
ive
% -7
5um
in P
rodu
ct
Cumulative Specific Energy, kWh/t
Ideal limit Laboratory
site
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Robust
Robustness Vs
performance
1970 Alfa Romeo Stirred mill
V8 motor Ball / SAG mill
Size
Rate
Opportunity
9
On-site reality – be there
Connection to reality on site
10
On-site reality ∆
design to reality
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Individual machinery is useless
Individual models don’t provide the full picture or circuit performance
Circuit response
Circuits
? ?
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Autogenous Hybrid + screen classification
=
SecondaryCrusher
AGMill
PebbleMill
PrimaryCyclones
withscreen
CCC CC C 2mm
ROM
Smart Blast Design
80mm20mm
5mm
HPGR
PrimaryGyratory Crusher
PebbleRejection
Coarse Waste
Sorting
P/W
SortingRejects
CoarseGangue
To Flotation
StirredMill
Tert Grind
Cyclones
P/W
Simulation / design input Multi-component Ore characterisation Grade differential Liberation Competence range Sorting on Mineralogy Change in competence Fine grinding Fine classification Multi-comp HPGR Bimodal SAG feed Abnormal ball mill feed Multi-comp cyclone Fine screen
30% less energy 3 % more recovery Would you build it?
35% more production ½ operating cost Would you build it?
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Engineering companies
Transform complexity into elegance
Step change ?
?
Stair case to step change
???? ??? ???? Multi-component modelling Progressive upgrade Integrated simulation Liberation modelling Improved equipment Sorting Coarse gangue removal Transport options Smart-blasting Mine plan geomet
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Our process is in circuits Our capability must be in total circuit modelling and simulation
Our capacity must be considerable
To design the circuits beyond 2020
Global comminution collaborative
Cape town Univ. Rio
