Process
Process optimization and engineering of mining production equipment
Process optimization for the mining industry
Haladjian Minerals Solutions has extensive experience in the crushing and grinding industry for the mining industry.
Our goal is to leverage our solid field experience in mining processes and the expertise of our technical and engineering teams on mining production equipment to analyse and organize mining circuits process optimization with the primary objective of reducing the cost per-tonne of the fixed mining plant while increasing its recovery of concentrate.
Given the cyclical nature of the mining industry, we want to cut costs for our customers and to increase their mining production for it to be the most suitable whatever the industry cycle.
To do so, it takes strategic mine planning by process optimization and engineering of mining production equipment. Our teams of engineers are fully committed to providing you the best recommendations for your mining production processes issues. Especially since ore prices are so fluctuant.
In order to cope with the volatility of ore prices, mines must be as optimized as possible in order to lower their operating costs to absorb the lowest ore price while still being the most productive when the ore price is high.
In order to cope with the volatility of ore prices in the mining industry, the process optimization of the mines production and equipment must be as efficient as possible in order to allow our customers, on one side, to lower their operating costs to absorb the lowest ore price, and on the other, to still be the most productive when the ore price is high.
That’s where Haladjian Minerals Solutions comes in. We help our customers challenge their own mining process circuit and implement the right strategies for their mining production equipment productivity.
Our methodology in mining process optimization and engineering of mining production equipment
We first carry out a complete diagnosis of the crushing and grinding circuit, in which all the parameters of the circuit are considered, as well as the identification of all the bottlenecks in the circuit. Following this diagnosis, we present a complete report and mining process study containing all the recommendations based on the current process results and the recommended changes in mining operating methods or mining production equipment in order to make the mining process optimization a success.
Our technical report includes modelling and simulation work with surveys, mass balancing analysis and basic models to confirm the feasibility of our mining process optimization simulation. This will enable us to implement our process optimization and mining production equipment engineering orientations.
Our methodology is broken down into five phases:
Phase 1
Definition of areas for mining production improvement and economy, checking with customers
Phase 2
Definition of an action plan for each solution proposed
Phase 3
Analysis of potential mining industry suppliers’ solutions along with quotes to implement the actions
Phase 4
Comparative analysis (standard concept versus optimized concept
Phase 5
Analysis of the savings and of the mining productivity output with the projects.
Decision at integration level and return on capital invested
According to customer’s decisions, Haladjian Minerals Solutions can implement the actions listed for the process optimization with detailed engineering and supervision of the results.
Example of mining process optimization and of mining operating methods
Drill & Blast optimization or checkup of
actual methods
Review the design of the apron feeder chutes underneath primary gyratory
Design installation of Sparmat unit sets on transfer point from apron feeder to conveyor 1
Transfer chute conveyor 1 to conveyor 2
Analysis of current methods, evaluation and study
Checking with customers of different ore blending options
Modify apron feeder chutes to allow extra bed thickness to increase throughput
Design and select the units to be installed – Higher tonnage
Redesign completely the wear point in order to avoid any possible accidents. Better rock on rock and slow material transfer speed to conveyor 2. Higher tonnage to be processed
Design installation of Sparmat unit sets on transfer point from conveyor 1 to conveyor 2
Increase power in conveyor 2
Pebble crushing circuit
Analysis and survey of Ball Mills performance
Design and select the units to be installed – Higher tonnage
Higher tonnage to be processed (over 35%) requires higher power to convey the material to stockpile
Higher capacity, lower P80 and reliable control of stable P80 in order to feed directly Grinding Ball Mills
How to increase Grinding Mills capacity if fed with lower F80?
Flotation circuit
Thickening
Filtering
Tailing Pump System
IPPC – In Pit Crushing and Conveying
Flotation Cells circuits required to cope with higher throughput
Review the thickening requirements so that we may process higher throughput.
Existing Filtering will not cope with higher capacity. Defnition of the requirements and sizing new units to be installed.
Evaluation of capacities to be handled after performance increase.
New options to pump or convey the tailings
Due to mine characteristics (ore grades in different areas and level, distance to primary crusher, utilization of high number of expensive dump trucks (specially expensive on maintenance) we do believe we can come up with a IPCC system with 3 to 4 units (different ores and different levels) and a set of conveying systems (mix of extendable and overland conveyors)
Estimation of the output of all change’s implementation:
Estimated operational savings/year:
$ 2,500,000 or $ 10,500,000 after IPPC implementation.
Estimated production increase:
$ 101,000,000.
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