Ultramax Corporation 1 Advanced Process Management™ (APM™) 1.
From Drill Core to Metal – A Multi-Disciplined Approach to ... · • METSIM™ Outputs METSIM™...
Transcript of From Drill Core to Metal – A Multi-Disciplined Approach to ... · • METSIM™ Outputs METSIM™...
10/7/2014
A GLENCORE Company 1
From Drill Core to Metal –A Multi-Disciplined Approach to Flowsheet Development
Quantitative Mineralogy, Mineral Processing,
Process Mineralogy
On-site Support Services in
Plant Support
Pyrometallurgical and Hydrometallurgical Modeling,
Extractive Metallurgy
Mika Muinonen
Dominic Fragomeni
Virginia Lawson
Jorge Oliveira
Norman Lotter
Process Optimization,Controller &
Control Solutions
Process Control
Mineral Processing,Sampling & Statistics
On-site Support Services in Start-up & Commissioning
Hydrometallurgical Modeling, Testing and Piloting
Materials Selection & Equipment Failure Analysis
& Prevention
Materials Technology
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Presentation Summary
• Flowsheet Development usesTwo Domains:
– Process Mineralogy to sample, characterise and test the drill core
– Extractive Metallurgy to convert the Concentrate to Saleable Metal
• Modern Process Mineralogy Platform
– Geology, GeoMetallurgy, Sampling, Quantitative Mineralogy, Metallurgical Testing/Piloting
– Effectively and Efficiently Develops the Flowsheet to Saleable Concentrate– Effectively and Efficiently Develops the Flowsheet to Saleable Concentrate
• Modern Extractive Metallurgy Platform
– Thermodynamic characterization
– Powerful Modeling and predictive Tools
– Bench and Pilot Scale Plant
• Economics drive decisions
• Case Study: Nickel Rim South, Sudbury
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XPS Process Mineralogy
• Fully equipped Mineral Processing Lab focused on quality
− Flowsheet Development
− Crushing/blending and sample preparation
− Pre-concentration
• Modern Quantitative Mineralogy
• New QEMSCAN FEGMicroprobe …
Sampling & Statistics
Process
Developing and Optimizing Flowsheets for YOUR ore…”
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− Benchscale flotation testwork(rougher, open circuit cleaner, LCT and High Confidence Testing)
− Mini Pilot Plant (MPP)
− Sample sizing for mineralogical analysis
− Physical separations, magnetic, gravity
− Refractory gold, Au cyanidation
• SEM, Semi-Quantitative XRD Analysis
• Expert interpretation of results
• Process reviews and Due Diligence
• Base metals, precious metals, rare earths and some industrial minerals
Process Mineralogy
• Minerals not Metals…
• Gangue and PaymineralMineralogy
• Strategic Optimization of Existing Operations
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XPS Extractive Metallurgy
Bench scale test
work Modeling
METSIM ®
Pilot
Furnaces/Roasters
Strategic Process Development, Operational Support & Implementation
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Benchmarking / Analysis Implementation
Charge 196, before converter roll
1124 MSCF, 17500 SCFM, 2113 F
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Point 4
Charge 196, after converter roll
1124 MSCF, 17500 SCFM, 2113 F
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Po
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ComSol
Define Process
Change
Chemsheet
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Equipment and Methods – The Right Tools
Sampling and Geomet Selection Sample Preparation
Quantitative Mineralogy QEMSCAN
Quality Flotation TestingMini Flotation Pilot Plant
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Equipment and Methods – The Right Tools
NETZSCH™ TGA with Mass Spec 300 kW DC Arc Furnace
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Nickel Rim South Case StudyLocation
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Nickel Rim South Case StudyCross-Sectional View
Upper Footwall Mineralization
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Nickel Rim South Case Study
Footwall Cu GeoMet Units
Background
PGMs/PMs
Pentlandite
Millerite
Chalcopyrite
Bornite
Pyrrhotite
Pyrite
Quartz
Feldspar
Chlorite
Mica
Epidote
Actinolite/Tremolite
Pyroxene
Carbonates
Fe Oxides
Other
Main Footwall Upper Pyrrhotite Rich Footwall Fringe Footwall Low Sulphur PGM Footwall
Sublayer Breccia Footwall Breccia
Contact Zone GeoMet Units
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Staged Grind and Flotation (MF2)80% - 300 um
80% - 75 um
80% - 25 um
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Strathcona Mill Rougher FlowsheetRougher Circuit
Lime Lime, PIBX, Dowfroth
PIBX
SulphuricAcid, PIBX
pH 9.2
56% - 75 um
Primary Ro Conc
Secondary Ro Conc
Scavenger Conc
pH 9.2
pH 8.0
Scav Tails
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NRS Grade/Recovery PerformanceFlotation Responses of NRS Geomet Units to Standard Strathcona Flotation
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Cum
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Cu
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Footwall Breccia
Sublayer Breccia
Upper Footwall
Main Footwall
Fringe Footwall
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Cum. Ni Recovery %
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Cum
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Ni+
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Footwall Breccia
Sublayer Breccia
Sublayer Breccia CMC
Improved Flotation Response with CMC Depressant
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Strathcona Mill Pre-Float CircuitCopper Pre-Float Circuit
Ni Ore
Lime Lime, PIBX, Dowfroth
PIBX
SulphuricAcid, PIBX
pH 9.2
pH 9.2
7677787980818283848586
No Pre-Float
Ni Recovery %
Cu Ore
1 Ro Conc
2 Ro Conc
ScavConc
pH 8.0
ScavTails
Cu Pre- Ro Conc
pH 9.2
Cu Pre- Ro Tails
Lime
No Pre-Float With Pre-Float
8889909192939495969798
Cu Recovery %
Lime, PIBX, Dowfroth
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Mini-Pilot Plant Campaigns
2x7-Day Continuous Campaigns Performed with:
• Strathcona Flowsheet
• Strathcona FlowsheetCu Pre- Float
• Staged Grinding for Improved PGE Recovery
All runs on NQ drill coreat 10 kg/hr
Total sample mass consumed = Only 4 t of core sample!
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Other flowsheet features…….
• Cu/Ni Separation
– Production of 2 concentrates, Cu and Ni maximize value and increase capacity of the Ni smelter to process Ni bearing concentrates and custom feeds
– Depression of non—payable Ni and Co in Cu concentrate and understanding of Ni mineral species and relative flotability (Millerite versus Pentlandite)
• Pyrrhotite (Po) Rejection
– Rejection of Ni bearing Po in the Strathcona Mill cleaner circuits
• Achieved with intensive regrinding and pH control
• Cu Pre-Float a requirement, eliminating Cu in the Po rejection
circuit
– Requirement for capacity at the Ni smelter
– Requirement to achieve SO2 emission targets
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Sudbury Smelter
• Sudbury Smelter
– Primary Feeds from Sudbury & Raglan (with a robust custom feed business)
– Final product is Bessemer matte containing Ni, Cu, Co and PM’s for refining in Nikkelverk
• Constraints
– Processing capacity of nickel through the Sudbury smelter [Ni grade, Po & rock rejection]
– Limit of Cu and Fe capacity at Nikkelverk refinery
Nickel Rim Project – Holistic Approach
– Limit of Cu and Fe capacity at Nikkelverk refinery
• Roast Reduction Smelting
– Deeper roast to reduce SO2 emissions
– Increasing the sulphur deficiency of the furnace
matte with deep roast and reduction
– More matte movements through the converters
• Process was optimized to balance Mill metal
recovery vs. downstream process constraints
SCV SMC FV FV
slag
concentrate
Roasters
matte matte
Electric Furnace slag
slag
matte granulation
Acid Plant
Off-gas
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Modern Tools for FlowsheetDevelopment
• Powerful Thermodynamic Modeling Tool
• A large database of thermodynamic information coupled with a powerful software engine
– Complex chemical equilibria
– Multicomponent phase diagrams
• Pre-select optimum test parameters to accelerate laboratory test programs
• Interpretation of process challenges
FACT SAGE™
“Why spend 2 hours in the library when you can spend 2 weeks in the lab…”
wt% Fe
wt%
S
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25
5 10 15 20 25 30 350
70 60 50 40
wt% M.G.
700 o C750 o C 800 o C
850 o C 900 o C950 o C
1000 o C1050 o C
1100 o C
1150 oC
1200 o C
45556575
EFSCV
SMC
Bessemer Matte
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Modern Tools for FlowsheetDevelopment
• A powerful flow sheet simulation tool
– Thermodynamic database for heat and mass balance including circulating loads
– Customizable and adaptable to plant data (XPS custom thermodynamic database)
• Essential to Calibrate using available data
– Benchmark plant data, new laboratory or pilot plant data
– Metallurgical simulation with FACT SAGE™
• METSIM™ Outputs
METSIM™
– Generates process stream data
– Engineering of process systems including, plant conveyances, gas cleaning etc.
• Avoid These Traps
– Understand the tool
• Basis of assumptions (plant data, lab data etc.)
• Check for reasonableness – Hand calculations, real world data
• Are stream data sufficiently accurate for equipment sizing?
– (process surges, requirement for inventory, start up, shutdown)
– Resist temptation to over analyze
• Minor process changes within the normal variation of the plant
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Modern Tools for FlowsheetDevelopment
• Discrete Event Analysis Software
• Allows modeling of events for simulation and debottlenecking of processes, particularly batch process
• Sudbury Smelter Converter aisle
– Electric furnace Matte tapping
– Crane aisle ladle movements and lifts
– Granulation of product matte
ARENA
– Converter mouth chipping
• Develop and calibrate model
– More advanced models define events with a statistical distribution of duration
• Evaluation of proposed upgrades on process
– Larger ladles
– More or upgraded process vessels
– Higher converter air enrichment
– Process practices
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Modern Tools for FlowsheetDevelopment
• Bench scale programs to demonstrate process feasibility and optimize parameters at reasonable cost
– Define process feasibility and potential fatal flaws
Laboratory Tools
TGA DTA for Preliminary Process Testing RoF Ferrochrom e produced through lowtemperature solid state reduction
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Modern Tools for FlowsheetDevelopment
• Pilot testing to demonstrate process and further reduce project risk
– Define engineering design criteria
• Modern Data Acquisition & Control
– Demonstrate both metallurgy and control philosophy
Pilot Scale Testing
Tapping RoF Ferrochrome from the XPS DC Furnace XPS 100 mm diameter Fluidized Bed Reactor
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Process Flow sheet Development
• Plant Testing
– Minimum process risk
– Minimize implementation time
– Cost and risk must be considered in planning plant test
• XPS provides resources for round the clock monitoring of process
– Plant scale test planning and preparation
– Operator engagement and training
Plant Testing
– Operator engagement and training
– Intensive sampling, data collection
– Technical support
– Analysis and learning
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Conclusions
• Metallurgical flow sheet development is more effective when a holistic, multidisciplinary approach is used to achieve the best economic outcome– In this example, this includes geologists/mineralogists, mineral processors and
extractive metallurgists…..engineering and design
• Modern tools available to metallurgists accelerate process development and find drivers that move the process towards the economic optimumand find drivers that move the process towards the economic optimum
• Computer modeling and mineralogical tools must be complemented by high quality, real world testing in the laboratory, pilot plant and or commercial scale.
• Plant optimizations studies, sampling and analysis and should be carried out post start-up to further refine and define flowsheet configurations to maximise value extracted from the ore