sensor-based ore sorting of low-grade gold sulphide deposits¼tkevonketelhodt.pdf · 04 mill pebble...

Sensor-based ore sorting of low-grade gold sulphide deposits

Name: Lütke von Ketelhodt – Steinert US Inc.Dr Tony Parry - OreSort Solutions Date: November 2018

Colombia Gold Symposium 2018

CONTENT

2 11/17/2018

Introducing Steinert01

Ore sorting in gold mining and processing operations – an economic analysisCase study 1 – Brownfields plant

02

Case study 2 – Low-grade Stockpile03

Mill pebble sorting04

Conclusion05

01

3 11/17/2018

Introducing Steinert

Our Solutions01

4 11/17/2018

STEINERT provides innovative solutions for the separation of valuable materials,

increasing customer profitability through higher recovery & reducing operational costs.

Secondary resource sectorResource Recovery

Primary resource sectorMiningIndustrial Minerals

Silica, Feldspar, Limestone

Ores

Iron ore

Base metals (e.g. Nickel, Copper)

Precious metals (Gold, Silver, Platinum)

Coal

Precious Gemstones

Diamonds

Scrap

Electronic Scrap

Shredder Scrap

Waste

Municipal Solid Waste

Waste to Energy (WfE)

Substitute Fuels

Other

Incineration Slag

Waste wood

Demolition Waste

Global network02

5 11/17/2018

Subsidiaries: USA, Australia, Brazil, Japan, Germany, Africa Sales cooperations: more than 50 worldwide

Agent Mexico

Agent Peru

Agent Chile

Sensor-based sorting01

6 11/17/2018

Differentation using the electromagnetic spectrum for separation material by shape, colour

and density,elements

STEINERT ISS

UNISORT FLAKE

STEINERT XSS F STEINERT XSS T

STEINERT KSS

STEINERT KSS

UNISORT FLAKE UNISORT C

UNISORT PR

Gamma- ray

x-ray

UV

VIS

NIR

IR

Micro- wave

Radio- wave

Radio waves (1 m – 1 km)

Microwaves (1 mm – 1 m)

Infrared radiation (1000 nm – 1 mm)

Near-infrared radiation (700 – 2000 nm)

Visible light (400 – 700 nm)

Ultraviolet radiation (10 – 400 nm)

Soft + hard X-rays (0.1 – 10 nm)

Gamma rays (wavelength: λ < 1 pm)

Incr

easi

ng w

ave

leng

th

Incr

easi

ng e

nerg

y in

tens

ity

Magnet-based sorting01

7 11/17/2018

Differentation using magnetic field intensity

Low intensity

Medium intensity

High intensityUNISORT CanMasterSTEINERT WDS STEINERT EddyC

STEINERT BR STEINERT WDS STEINERT HGF

STEINERT HGS

STEINERT MT ANOFOL CoilsSTEINERT UM/AM

Inductions Sorting SystemISS (electromagnetic properties of entire particle)

X-Ray Sorting SystemXSS-T (XRT) (Atomic density of entire particle)

3D Laser Sorting System3DS (Surface detection of brightness/particle size)

Combined Colour and 3D Sorting SystemKSS (Surface detection)

01

8

Test Center Steinert US

02

9 11/17/2018

Ore sorting in gold mining and processing operations – an economic analysis

02 Sorting Principle - XRT

10

Poly-metallic Sulphides

Waste Rock

02 Sorting Principle - XRT

11

Waste RockSulphide product

Sorting tasks are getting increasingly more complex, requiring combination of information on different

characteristics of the material detected by more than one sensor system becomes necessary.

Different sensors provide broad variations of the scanned spectra which can be combined and overlaid to

detect different material characteristics.

12

Multi-Sensor Sorting02

13

Multi-Sensor Sorting02

Sulphide Product

Waste Rocks

QuartziteProduct

14

Test Methodology02Test No.Mass: 305 kg

Size: -50 +10 mmAu grade 0.25 g/t

Sulphur 0.35 %

Mass 268 kg 87.9% Mass 37 kg 12.1%

Au grade 0.14 g/t Au grade 1.05 g/tSulphur 0.28 % Sulphur 0.86 %

Test No.

Mass 207 kg 77.2% Mass 61 kg 22.8%Au grade 0.13 g/t Au grade 0.15 g/tSulphur 0.28 % Sulphur 0.28 %

Test No.


Test No.


Test No.


Test No.


6

Waste Product

Waste Product

5

Waste Product

Waste

1

Product

2

Waste Product

3

Waste Product

4

15

Results – Grade/Recovery02

16

Results – Grade/Recovery02

02 Case Study 1 – No Sorter

17

1.40 g/t

Cart to MillCart to MillROM Stockpile

1.40 g/t

MINE OUTPUT

50,000 t/m

0 kilometres

Base Case – No Pre-Concentration – Total ROM Milled

Brownfields Expansion Of Existing Operations

02 Case Study 1 – With Sorting

18

1.40 g/t

Cart to MillCart to Mill

ROM Stockpile

1.81 g/t

MINE OUTPUT

69,444 t/m

0 kilometres

Jaw CrusherJaw Crusher

Cone Crusher

Cone Crusher

ScreenScreen

+60mm

-20mm

30%

48,611 t/m

70%

Stockpile

Stockpile

Stockpile

+20mm -60mm

SORTER FEED

REJECTS

PRODUCT

48,611 t/m

ORE SORTER74 tph 90%

avail.


avail.

ACCEPTS60%29,167 t/m

1.40 g/t

20,833 t/m

0.35 g/t

50,000 t/m

KEY INPUTS

Sorter reject rate: 40%Sorter gold recovery: 90%

1.40 g/t

REJECTS

40%

19,444 t/m

2.10 g/t

(39% more)

02

19

Case Study 1: Gross Cash Flow

No Sort Sort 40% Reject0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

18,131,458

26,645,970

Increase in Gross Cash flow with Ore SorterBrownfields Expansion 600,000tpa Mill

Ann

ual G

ross

Cas

h Fl

ow (A

$)

03

20 11/17/2018

Case Study 2 Low Grade Stockpile Treatment

03 Low Grade Stockpile Treatment

21

0.70 g/t

Cart to MillCart to MillStockpile

0.70 g/t

LOW GRADE

60,000 t/m

20 kilometres

Base Case – No Pre-Concentration – Hauling 20 km to Mill– Total Run of Dump Milled

03 Case Study 2 – With Sorting

22

0.70 g/t

Cart to MillCart to Mill

Stockpile

1.28 g/t

LOW GRADE

60,000 t/m

20 kilometres

Jaw CrusherJaw Crusher

Cone Crusher

Cone Crusher

ScreenScreen

+60mm

-20mm

30%

42,000 t/m

70%

Stockpile

Stockpile

Stockpile

+20mm -60mm

SORTER FEED

REJECTS

PRODUCT

42,000 t/m


avail.


avail.

ACCEPTS30%12,600 t/m

0.70 g/t

18,000 t/m

0.10 g/t

36,600 t/mKEY INPUTS

Sorter reject rate: 40%Sorter gold recovery: 90%

0.70 g/t

REJECTS

70%

29,400 t/m

2.10 g/t

RECLAIM

(39% less)

03 Case Study 2: NPV

23

No Sort Sort 70% Reject0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

1.81

12.81

Increase in Pre-Tax NPV with Ore Sorter720,000tpa @ 0.7g/t

Pre-

Tax

NPV

(A$m

)

NPV based on five year project life and 10% discount rate

04

24 11/17/2018

Mill Pebbles Sorting

03 Mill Pebble Circuit

25

Flotation/CIL Feed

SAG Mill

Sizing Screen

Steinert Ore Sorter

Pebble Crusher

Oversize

Ball Mill

Short conveyor

Waste Stockpile

Undersize

03 Mill Pebbles - Copper Sulphides

26

Summary of test work results

• COPPER SULPHIDE SORTING (+50 – 100mm)

• Waste rejection: 20 – 25%

• Cu (%) Recovery: 99%

• Cu (%) upgrade: Feed = 5.87% → 7.43% (Discard = 0.23%)

03 Mill Pebbles – Gold Ore

27

Summary of pilot plant results

• Gold sulphide sorting (+12 – 25mm) and (+25 – 45mm)

• Waste rejection: 50 – 90%

• Au (g/t) Recovery: up to 93%

• Au (g/t) upgrade: Feed = 1.4g/t → 4.4g/t (Discard = 0.5g/t)

1 2 3 4 5 6 7 8 90

10

20

30

40

50

60

70

80

90

100

-1

1

3

5

7

9

11

13

15

Gold Recovery (%) Yield (%) Conc. grade (g/t) Feed grade (g/t)Tails grade (g/t)

Re

cove

ry/Y

ield

(%

)

Go

ld c

on

cen

trati

on

(g/

t)

Type 1 (Coarse material) Type 2 (Coarse material)Type 3 (Coarse material)

05

28 11/17/2018

Conclusion

Conclusion05

29

Multi-Sensor Sorting provides flexible solution for beneficiation of ores.

2 Case Studies comparing No-Sort vs. Sort Scenarios

• The Brownfields as well as the Low-Grade Dump treatment studies have shown significant improvements in profitability by adding a sorting process to the operation

• Removing waste rock before milling and reducing the amount of unnecessary comminution of barren hard rock is the biggest cost saver.

• Reducing transport cost by hauling less waste rock also contributes to the profitability

Mill-Pebble Sorting

• Reduces pebble crusher load

• Reduces recirculating mill load – resulting in higher mill-feed capacities.

• Don’t mill the Waste Rocks, Sort them!

Thank you very much for your attention

Lütke von Ketelhodt

Engineer. MSc (Eng)

Steinert US Inc.

Email [email protected]

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