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Mines process optimization by Haladjian Minerals Solutions for the mining industry

Process optimization and engineering

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.

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

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 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.

Our methodology is broken down into five phases:

mining process optimization phase 1

Phase 1
Definition of areas for mining production improvement and economy, checking with customers 

Process optimization phase 2

Phase 2
Definition of an action plan for each solution proposed 

Process optimization phase 3

Phase 3
Analysis of potential mining industry suppliers’ solutions along with quotes to implement the actions

Process optimization phase 4

Phase 4
Comparative analysis (standard concept versus optimized concept

Process optimization phase 5

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

mining process optimization drill and blast

Drill & Blast optimization or checkup of
actual methods

mining process optimization apron feeder

Review the design of the apron feeder chutes underneath primary gyratory

 

mining process optimization sparmat design

Design installation of Sparmat unit sets on transfer point from apron feeder to conveyor 1

mining process optimization transfer chute conveyor

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 sparmat mining process optimization

Design installation of Sparmat unit sets on transfer point from conveyor 1 to conveyor 2

mining process optimization increase power conveyor

Increase power in conveyor 2

mining process optimization pebble crushing

Pebble crushing circuit

mining process optimization ball mills performance

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?

mining process optimization flotation circuit

Flotation circuit

mining process optimization thickening

Thickening

mining process optimization filtering

Filtering

mining process optimization tailing pump system

Tailing Pump System

mining process optimization ippc

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:

mining production operational savings

Estimated operational savings/year:

$ 2,500,000 or $ 10,500,000 after IPPC implementation.

estimated production increase

Estimated production increase:

$ 101,000,000.

Find out more...

Read about the history and the values of the Haladjian Group and get to know more about the missions, the teams and the CSR policy of Haladjian Minerals Solutions.

You want more information about our services at Haladjian Minerals Solutions ? Read our pages about our  machine expertisemachine maintenance and rebuild machine solutions and find what is best for your mining project.

Your have issues with your aggregates production ? We could help by providing you with our aggregates process optimization and our design and engineering of quarry installations services. You need to work only on the production of aggregates ! Read about our performance contracts solutions.

Look at our mining spare parts catalog. You might find the mining wear parts or the mechanical parts you are looking for to upgrade or modernize your mining plant facilities.

Contact

Please contact us with any questions. Customer service: +33 (0)490 393 955 or clientshms@haladjian.fr