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HRL Technology Group Pty Ltd ABN 89 609 887 327 [email protected] hrl.com.au Melbourne Level One Unit 4 677 Springvale Road Mulgrave VIC 3170 Phone +61 3 9565 9888 Fax +61 3 9565 9879 Morwell Tramway Road Morwell VIC 3840 Phone +61 3 5132 1500 Fax +61 3 5132 1580 Queensland Unit 2 33-37 Rosedale Street Coopers Plains QLD 4108 Phone +61 7 3423 4300 Fax +61 7 3345 5937 1 Optimising minerals processing hrl: Optimising minerals processing Using technology to minimise energy used and maximise resources recovered Challenges Mineral processing plants need to economically and sustainably separate valuable minerals from waste. Numerous challenges exist for the optimisation of mineral processing plants in a cost effective and energy efficient manner. Specific challenges include: • the maintenance or increase in throughput through the mineral processing circuits whilst ensuring recovery and grade of products are acceptable commensurate with consistent cash flow and minimisation of energy usage and production costs • ensuring that maintenance, lifetime and utilisation of equipment is consistent with cash flow and profit requirements • using and/or development of sensor technologies so that process variables for the mineral processing assets are determined accurately, reproducibly and precisely. This requirement facilitates correct determination of process performance indicators as well as opportunities for improved process control • reducing energy and water consumption • reducing environmental impacts • improving processing technology so that marginal ore bodies are accessible for processing • the understanding of the ore body and how its characteristics influence its processing (geometallurgy) • the understanding of the process products and how they influence the subsequent steps such as smelting/refining. The challenge in improving the overall process is that making even small changes to optimise one section of the flowsheet can have unintended or unwanted impacts on several other sections. The key is to understand exactly what is happening within each area of a plant and with each aspect of the processing being undertaken. Solutions An understanding of the mineral processing flow sheet, the ore mineralogy and unit operations provide valuable insight into the optimisation that may be required. This insight can be obtained using plant surveys, appropriate sensor measurements and an understanding of the processing route. In some situations the sensor or measurement approach needed for plant optimisation may not yet be available. Mineral sands, like other mineral processing industries, faces numerous challenges in optimising plant performance. However, a particular way of thinking about the process – using mathematical models and multiple types and numbers of sensors – may yield the information needed for targeted optimisation. The fundamental science supporting the diverse processes associated with minerals processing is common to many industries, allowing knowledge from other industries to be applied. The requirements of energy efficiency and sustainability are also common to many industries. Where necessary the researching and developing of new technology is also available.

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Page 1: Optimising minerals processing - Amazon S3s3-ap-southeast-2.amazonaws.com/wh1.thewebconsole... · 4/30/2017  · Optimising minerals processing Using technology to minimise energy

HRL Technology Group Pty Ltd ABN 89 609 887 327 [email protected] hrl.com.au

Melbourne Level One Unit 4 677 Springvale Road Mulgrave VIC 3170 Phone +61 3 9565 9888 Fax +61 3 9565 9879

Morwell Tramway Road Morwell VIC 3840

Phone +61 3 5132 1500 Fax +61 3 5132 1580

Queensland Unit 2 33-37 Rosedale Street Coopers Plains QLD 4108 Phone +61 7 3423 4300 Fax +61 7 3345 5937

1

Optim

isingmineralsprocessing

hrl:

Optimisingmineralsprocessing

UsingtechnologytominimiseenergyusedandmaximiseresourcesrecoveredChallengesMineralprocessingplantsneedtoeconomicallyandsustainablyseparatevaluablemineralsfromwaste.Numerouschallengesexistfortheoptimisationofmineralprocessingplantsinacosteffectiveandenergyefficientmanner.Specificchallengesinclude:• themaintenanceorincreaseinthroughputthroughthe

mineralprocessingcircuitswhilstensuringrecoveryandgradeofproductsareacceptablecommensuratewithconsistentcashflowandminimisationofenergyusageandproductioncosts

• ensuringthatmaintenance,lifetimeandutilisationofequipmentisconsistentwithcashflowandprofitrequirements

• usingand/ordevelopmentofsensortechnologiessothatprocessvariablesforthemineralprocessingassetsaredeterminedaccurately,reproduciblyandprecisely.Thisrequirementfacilitatescorrectdeterminationofprocessperformanceindicatorsaswellasopportunitiesforimprovedprocesscontrol

• reducingenergyandwaterconsumption• reducingenvironmentalimpacts• improvingprocessingtechnologysothatmarginalore

bodiesareaccessibleforprocessing• theunderstandingoftheorebodyandhowits

characteristicsinfluenceitsprocessing(geometallurgy)• theunderstandingoftheprocessproductsandhowthey

influencethesubsequentstepssuchassmelting/refining.Thechallengeinimprovingtheoverallprocessisthatmakingevensmallchangestooptimiseonesectionoftheflowsheetcanhaveunintendedorunwantedimpactsonseveralothersections.Thekeyistounderstandexactlywhatishappeningwithineachareaofaplantandwitheachaspectoftheprocessingbeingundertaken.

SolutionsAnunderstandingofthemineralprocessingflowsheet,theoremineralogyandunitoperationsprovidevaluableinsightintotheoptimisationthatmayberequired.Thisinsightcanbeobtainedusingplantsurveys,appropriatesensormeasurementsandanunderstandingoftheprocessingroute.Insomesituationsthesensorormeasurementapproachneededforplantoptimisationmaynotyetbeavailable.

Mineralsands,likeothermineralprocessingindustries,facesnumerouschallengesinoptimisingplantperformance. However,aparticularwayofthinkingabouttheprocess–usingmathematicalmodelsandmultipletypesandnumbersofsensors–mayyieldtheinformationneededfortargetedoptimisation.Thefundamentalsciencesupportingthediverseprocessesassociatedwithmineralsprocessingiscommontomanyindustries,allowingknowledgefromotherindustriestobeapplied.Therequirementsofenergyefficiencyandsustainabilityarealsocommontomanyindustries.Wherenecessarytheresearchinganddevelopingofnewtechnologyisalsoavailable.

Page 2: Optimising minerals processing - Amazon S3s3-ap-southeast-2.amazonaws.com/wh1.thewebconsole... · 4/30/2017  · Optimising minerals processing Using technology to minimise energy

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hrl:canalsoprovideworld-classexpertanalyticalservicesinrelationtooptimisingmineralsprocessingplantoperation.Drawingonmorethanthreedecadesexperience–includingextensiveonsiteworkonmineralprocessing,sugarprocessing,coalandpowerstationoptimisation–hrl:personnelcanassistwiththekeystepsusedinmineralprocessingoperationssuchascomminution,gravityconcentration,anddewatering. Benefits hrl:world-classexpertanalysisservicesassistclientdecision-makingbyprovidinginformedpredictionsofthedownstreamprocessingperformanceofspecificores–informationthatiscriticalinevaluatingaresource,andintakingthedecisiontodevelopthatresource. Clientsbenefitfromhrl:world-classexpertanalyticalservicesthathelppredicttheperformanceoftheirprocessingplant. Clientsenjoyprocessoptimisationthathelpsdeliver‘concentrate’tomeettheirneedforcost-effectiveorehandling,transportandfurtherprocessing.hrl:analyticalservicesincludingassistanceto:• developmethodstoallowcost-effectiveprocessingof

low-gradeorproblematicores• optimiserecoveryratesofvaluablemineralsfromore

processed• transformmaterialintoaphysicalformthathelpsto

optimisedownstreamprocessing• removeminorortoxicelementstoimprovegrade,

recoveryanddownstreamprocessing• reduceprocessinginputsincludingenergy• reduceenvironmentalimpacts.

Needmoreinformation?Gotohrl.com.au

Thecompany’sNATAAccreditedLaboratoriesnumberis561.

HRLTechnologyGroup’sISO9001QualityManagementis

certifiedbyBSIundercertificateFS605116

Ó2016HRLTechnologyGroupPtyLtd

V20170430QA848B


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