outotec oremet optimizer - min-guide · outotec oremet optimizer 18.5.2017, luleå, sweden outotec...

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Outotec OreMet Optimizer18.5.2017, Luleå, Sweden

Outotec Minerals Processing,Antti Remes

Vesa-Pekka TakaloMatti Talikka

© Outotec – All rights reserved

OreMet Optimizer for mining value chainanalysis – ore to metal• Geometallurgical modelling of

concentrator plant for each ore typesand plant operating scenarios

• The main discrete events, starting fromextraction and ending up withconcentrate storage – are evaluatedseparately

• Their throughputs and streamcompositions are simulated with thedigital plant model• corresponding operating expenses

(OPEX) in $/ton of each stage are usedfor the calculation model

• The value of the final concentrate iscalculated using the Net Smelter Return(NSR) formula

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© VPTakalo

Determination of Value

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EXPLOITABLE BLOCK

• Volumetric capacity• Properties of the rock• Rock mineralogy• Official authorization• Social license to operate

ORE CONCENTRATE

• Dry metric tonnes• Metal and other valuable contents• Deleterious and disturbing element contents• Moisture• Treatment charge• Freight

• CapEx• OpEx

Public | OreMet Optimizer


Example: average orebody vs. domains

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Domain 12 500 000 tonnes. Similar to average ore body.

Domain 22 000 000 tonnes @ 0.60 % CuAmenable to ore sorting:

30 % mass reduction @ recovery 95 % CuFlotation recovery 80 % Cu

30 % shorter milling time or smaller milling capacity

Domain 34 000 000 tonnes @ 0.83 % Cu, 0.6 ppm AuRecovery 84 % Cu, 65 % AuGravity circuit / flash flotation increases the overallgold recovery by 5 %

Average orebody8 500 000 tonnes @ 0.75 % Cu, 0.3 ppm AuRecovery 83 % Cu, 60 % AuBWi 20

Additional domain 41 500 000 tonnes @ 0.45 % CuNot feasible to process without sensor-based sortingAmenable to ore sorting:

60 % mass reduction @ recovery 70 % CuBWi 14 (hard waste rock removed)Flotation recovery 80 % Cu

60 % shorter milling time or smaller milling capacity


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Challenging the traditional mine value chainwith geometallurgy

• An average ore body does not exist!• Traditional approach:

• Single value/point does not represent the average oreboby.

• Does not recognize variations in operationalcircumstances.

• Information silos. Poor communication betweendisciplines and systems.

• Geometallurgical approach:• A holistic approach, which intergrates geological, mining,

metallurgical, environmental, economic and otherrelevant information with an aim to optimize theefficiency of utitization of an ore body.

• Aim to optimize the mining value chain.- Economic return, CO2 emissions, energy and water

consumption, …- Supports risk management.

• Communication with different disciplines is essential.

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60.065.070.075.080.085.090.095.0

0.15 0.20 0.25 0.30 0.35

Head grade, Ni%

Rec

over

y%



Simulation of the processing scenarios andvalue chain analysis

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Example: Average orebody vs. domainsRecovery• Average ore body, 83%• Domains 1-3, 81.5%

• Domain 1: No changes• Domain 2: Add ore sorting• Domain 3: Add gravity circuit and

flash flotation• Domains 4, 79%

• Domain 4: Add ore sorting

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Value (NSR, non-discounted)• Average ore body, 115 MUSD• Domains 1-3, 143 MUSD

• Value increases 28 MUSD• Domain 4, 145 MUSD

• Value increases 2 MUSD.• Extends LOM

Aim to maximize the value over themining cycle.



Outotec OreMet Optimizer

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A unique ability to simulate the full processingcycle from ore to metal

Based on HSC Chemistry software includingOreMet Optimizer module

Optimization can be based on e.g. economics,flowsheet performance, CO2 emissions, waterand energy consumption, LCA, and enables theselection of most sustainable process route

Enables time reduction in greenfield projectse.g. for scoping level and preliminary economicstudies

Quick and transparent way to comparepotential development scenarios including highlevel opex and capex estimations with mainequipment list

Simulation, optimization and modifications ofexisting brownfield operations

Ore charac-terization

Digital concentrator plant


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Process economical viability study

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Value of the concentrate is calculated usingthe Net Smelter Return formula

Operating expenses (OPEX, $/ton) for eachprocessing stage are utilized

Total operating costTotal operating profit (non-discounted)

VALUE ADDING CHAIN:



Simulation from ore to concentrate


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Case example

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Greenfield caseexample: Cu sulphide

concentrator


Two processing options

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Bench scale flotation test for twogrind sizes

Regrind in 20 or 10 micronsSimulation models for twoprocessing options

different concentratesdifferent OPEX / CAPEX


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Cu sulphide plant OreMetoptimization study: phase I

14.9 15.5 EUR/tonINCREASE IN OPEX

73.2 84.6 %INCREASE IN RECOVERY

15.7 MEUR/yearINCREASE IN

OPERATING PROFIT



Cu sulphide plant OreMet optimizationstudy: phase II

• The preliminary results were good

• Next the process optimization is continued with

intermediate regrinding size (15 microns)more detailed flotation and dewatering CAPEX / OPEX studiesdifferent ore types


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SUMMARY


Discrete event based approach – OreMet Optimizer – incorporatinga digital plant, provides a tool to assess the significance of individualevents and their response to the optimization throughout the miningvalue chain

Fast comparison between different processing sequences becomestransparent

An example how this platform is used to define the most economicaland sustainable process route for the project, with a fast turnaroundtime, was shown

outotec oremet optimizer - min-guide · outotec oremet optimizer 18.5.2017, luleå, sweden outotec...

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