Online Analysis for mining and minerals industry€¦ · Irymple Melbourne 5 sites Werribee 2 sites...
Transcript of Online Analysis for mining and minerals industry€¦ · Irymple Melbourne 5 sites Werribee 2 sites...
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Online Analysis for mining and minerals industryIICA, 11 May, 2016
MINERALS DOWN UNDER
Mike Millen | Group Leader, (On-line Analysis),Minerals Resources
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Introduction
• CSIRO ( general comments)
• Mining and Minerals processing industries (challenges)
• On-line Analysis (OLA) Group
- what we do
- how we operate
- how we co-operate
- how we make impact
• Some examples of developments by OLA
• Few words on technology transfer & industry engagement
Investing in Australia’s mineral future | Nick Cutmore2 |
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3 |
64% of our people hold
university degrees over
2000 hold doctorates
over 500 hold masters
CSIRO
Darwin
Alice Springs
Geraldton 2 sites
Atherton
Townsville2 sites
Rockhampton
Toowoomba
Gatton
Myall Vale
Narrabri
Mopra
Parkes
Griffith
Belmont
Geelong
HobartSandy Bay
Wodonga
Newcastle
Armidale2 sites
Perth3 sites
Adelaide3 sites Sydney 5 sites
Canberra 7 sites
Murchison
Cairns
Irymple
Melbourne 5 sites
Werribee 2 sites
Brisbane6 sites
Bribie Island
People ~5000
Sites ~50
Flagships 9
Budget $1B+
We develop 832postgraduate research students with our university partners
CSIRO: positive impact | Presentation title | Presenter name
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Our operating model
4 |
SUPPORT SERVICES
Year in review: Annual performance 2013-14
NATIONAL FACILITIES & COLLECTIONS
Infrastructure and biological collections managed by CSIRO for the benefit of research and industry.
IMPACT SCIENCE
Nine National Research Business Units with a focus on the biggest challenges facing the nation.
CSIRO SERVICES
Commercial, customer-centric products and services for industry, government and the community.
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DIGITAL PRODUCTIVITY AND SERVICES (DATA 61)
BIOSECURITY ENERGY
Business units (formerly Flagships)
5 |
OCEANS AND ATMOSPHERE
FOOD AND NUTRITION
AGRICULTURE
MINERAL RESOURCES
MANUFACTURINGLAND AND WATER
CSIRO: positive impact | Presentation title | Presenter name
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Presentation title | Presenter name6 |
Industrial drivers• Industrial Automation
- Mining, security, petroleum, mineral processing and manufacture- Revolution in mining: automation, selective mining, ore sorting
• National Priorities (CSIRO)
- Better utilization of Australia’s resources, lower environment impact , energy efficiency
-The resources industry currently contributes 9% of Australia’s GDP and 48% of Australia’s exports.
(However, both decreasing productivity and a softening demand threaten this contribution)1
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On-line analysis for precision processing
7 |
SmeltingElectrowinning
Elution
Flotation/concentration
Grinding
Crushing
SortingMine/stockpile
Tailings disposal + water recovery
ProductAcoustic monitoring
Gamma activationX-ray diffractionX-ray fluorescenceMicrowave res.
Neutron analysis
On-stream monitoring for ore-sorting, plant monitoring and assay | James Tickner
Feed monitoring
Dat
a an
alyt
ics
and
mac
hin
e le
arn
ing
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Investing in Australia’s mineral future | 8 |
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Investing in Australia’s mineral future | Nick Cutmore9 |
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Mining Program Goal
Rapid resource characterisation
Down hole tools…
Intelligent mining and ore management
Mine mapping…
Process productivity
On-line analysers…
To develop and implement transformational technologies that support the long term productivity, efficiency and safety of the
mining industry
………….enabling ore differentiation for selective mining, reducing the cost of miningand processing, enabling the extraction of previously uneconomic ores and
removing people from hazardous areas.
10 | Investing in Australia’s mineral future | Nick Cutmore
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On-line analysis (OLA) group
We are a Science Driven Technology Innovations
Group
24 staff (3 teams) + students
1. Radiofrequency & acoustics
2. Nucleonics
3. Productisation
Core business
• Development of on-line measurement technologies
• World leader in development of on-line analysis systems
Presentation title | Presenter name11 |
Air cargo scanner
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Nucleonics – science team 1
Team ( 8 staff)
Team leader (manager/business development)
Physicists and engineersDevelop new measurement technology
X-ray, gamma ray and neutrons interaction with matter
Modeling skills (Condor)
Software skills
Data analytical
(business/customer skills)
Presentation title | Presenter name12 |
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Radio Frequency and Acoustics – science team 2
Presentation title | Presenter name13 |
Particle size analyser based on ultrasonic's
Team ( 8 staff)
Team leader (manager/business development)Physicists and engineersDevelop new measurement technologyRadio waves, passive and active acousticsRF engineering - build high power systemsSoftware skillsData analytical (business/customer skills)
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Productisation team (engineering team)
• Team ( 6 staff)
In house design
• 2 mechanical engineers
• 3 electronic/electrical engineers
• 1 software engineer
Target
Design laboratory
to an advanced pre-commercial prototype
Presentation title | Presenter name14 |
Prototype acoustic analyser
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Development path
• Our industry advisors/clients provide focus for potential impact
• Industry demonstration projects demonstrate client and commercial value and leverage the technology development
• Strong METS partnerships are critical in achieving impact
15 | Investing in Australia’s mineral future | Nick Cutmore
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Presentation title | Presenter name16 |
Technologies developed in last 7 years
1. Moisture analyser2. Air Cargo3. Elemental analyser4. Particle Size analyser5. Acoustic Emission
analyser
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How we work partners
universities...
...collaborate in R&D aligned with medium-long termUNSW, Wollongong
METS companies ...
...for the commercialisation of technologies and the delivery of services for impact
Industry companies...
...partner with industrial in the co-development and trial of technology
Complimentary R&D organisations:e.g.CRC Ore II (October 2015)
17 | Investing in Australia’s mineral future | Nick Cutmore
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CRC Ore II - (optimizing resource extraction)
• “The ‘Millennium Super Cycle’ of commodity pricing from 2003-2011 resulted in an unprecedented period of accelerated growth in production and investment for the global minerals industry across a broad range of commodities”.1
• More tonnes to the mill is no longer the most effective approach to sustain growth
• Advent of grade engineering
- sorting
• - differential blasting
• 1 new initiatives to transfer mining - CRC Ore
Participants
• Research (CSIRO, universities)
• Industry
• METS (mining equipment and technology services)
Investing in Australia’s mineral future | Nick Cutmore18 |
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High Tonnage Ore Sorting
MINERALS DOWN UNDER FLAGSHIP
Using Magnetic Resonance
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High Tonnage Mining- Challenges
High Tonnage Ore Sorting | David Miljak20 |
• Cutoff grades have fallen to meet metal demand.• Technology advances have allowed processing of lower grade cutoffs over time• Current high tonnage mining model is exposed to energy and water costs / constraints.
R. Schodde, MinEx Consulting, 2010 MEMS conference
Copper GradeCopper grade (%)
Where to next?
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Ore Sorting Technology
High Tonnage Ore Sorting | David Miljak21 |
Nickel ore sorting, Applied Sorting Solutions, http://www.appliedsorting.com.au/
Modern ore sorting:• successful at low tonnages on selected applications…
BUT• stretched technology
Technological Advance
Mechanical separation
SensorsComputers
Bulk handling
“When, either through ignorance or carelessness, the miners while excavating have mixed the ore with earth or broken rock...it should be examined, and that part of the ore which is rich in metal sorted from that part of it which is devoid of metal”.. Agricola, De Re Metallica 1556
Hand ore sorting 16th century, De Re Metallica, Book VIII.
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CSIRO Sorting: Exploiting In-Situ Variability
High Tonnage Ore Sorting | David Miljak22 |
• Measurement on primary conveyors (continuous flow), installed close to mining process • Independent batches of rock measured (as low as 0.5 tonne)• Rely on deposit inhomogeneity at small scale to provide ore grade variability• Divert ore batches using conventional technology.
“conventional” ore handling
groups of rocks measured at the same time
primaryconveyor
fast, bulk sensor
No suitable sensing technology available !
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Bulk Ore Sorting
Investing in Australia’s mineral future | Nick Cutmore23 |
Bulk sorting
• Rapid analysis of grade of conveyed material in few-ton lots at 1000’s of tons per hour
• Diversion of high/low grade material
Magnetic resonance (copper minerals)• Newcrest trial at Cadia (NSW) in 2013• Detection of chalcopyrite with resolution of better
than 0.05 wt%• Measurement of grade variability over 6 months
on few-second timescale
- CSIRO & partner entered agreement to exploit the technology
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On Line Magnetic Resonance | David Miljak24 |
Research / science challenges• How do we develop practically realisable large volume magnetic
resonance measurement systems relevant to industry?
High static magnetic field
Protons of hydrogen atom
Shielded lab apparatus
CSIRO Capability
Expert system ~ minutes
“Zero Field”
Transition metals e.g. copper
Constrained shielding
On-Line Analyser ~ 1-5 sec
Conventional Magnetic Resonance
Magnetic Resonance for Industry
H1
Sensitivity
Cu63 As75
Some elements give“free internal magnetism”
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CSIRO Sorting : Science
High Tonnage Ore Sorting | David Miljak25 |
Magnetic Resonance (MR)Challenges for CSIRO• Radio spectroscopy for selected Cu, Fe, As minerals • Discovery of mineral resonances• Massive engineering scale-up• High radio power sensor• Noise rejection• Practical installation constraints.
magnetic loop sensor
radio excitation
radio detection
cubanite
chalcopyrite
tenorite
cuprite
covellite
Frequency (MHz)
10 20
chalcocite
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MR belt analyser (for Chile)
Investing in Australia’s mineral future | Nick Cutmore26 |
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CSIRO Sorting : Commercialised Impact Detail
High Tonnage Ore Sorting | David Miljak27 |
Ore sorting applied to one 20Mt p.a. operation, 0.5wt% grade, 100kt Cu :Mill 25% less
• 39000t CO2e mitigation per annum
• 78 GWh electrical savings per annum
• 20% water usage reduction, tailings
Mine 25% more; mill 25%
• 25% production increase (25kt Cu), for same capital and operating intensity.
• Value > $100M p.a.
AUSTRALIAMt Isa, Ernest Henry
Olympic DamProminent HillCadia, Telfer
625kt, 65% Aust production
WORLDChile, Peru, China, USA..
15Mt total
Escondida 1Mt
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CSIRO Sorting : Industry Engagement
High Tonnage Ore Sorting | David Miljak28 |
Highlights
• Cu-as-chalcopyrite detection limit (3-sigma) 1200ppm, resolution 350ppm.
• Lot size ~ 7 tonnes• Excellent static blind verification result
0.2 0.3 0.4 0.5 0.6 0.70.2
0.3
0.4
0.5
0.6
0.7
MONM
SEDL
VOLL
MONL
VOLM
MONH
VOLH
SEDM
MIX
SEDH
Cu-as-chalcopyrite, assay (wt%)
Cu-a
s-c
halc
opyrite
, M
R (
wt%
)
0:00 6:00 12:00 18:00 24:000
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
time (hh:mm)
Cu-a
s-c
halc
opyrite
(w
t%)
9/6/13
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On stream slurry analysis
MINERALS DOWN UNDER FLAGSHIP
Using X-ray analysis
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Slurry analysis - froth flotation
• Ore is moved around plant in slurry from (40 wt%)
• Water + ground particles
• Air bubbles fed into tank
• Chemicals added
• Chemistry makes mineral particles attach to bubbles
• Bubbles flow up to form froth
• Analysis is required by metallurgists
Investing in Australia’s mineral future | Nick Cutmore30 |
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Commercial XRF (x-ray florescence) system used in mineral processing
• Measure the slurry elements by XRF (x-ray fluorescence)
• System by Thermo (Adelaide)
• Combined sampler and analysis station
• Widely used in minerals processing
• Slurry (40wt% solids)
• Hand up to 22,000 m3/hr
Investing in Australia’s mineral future | Nick Cutmore31 |
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CSIRO working with - Thermo Research driver
• On-stream, real-time analysis is essential for plant monitoring, fault-detection, optimisation and control
On-stream trace element analysis | James Tickner32 |
100%10%1%0.1%100ppm10ppm1ppm100ppb10ppb1ppb
Fe SiTiMnCrPbMoCdPGEs, AuCrustal
abundancesBi
Commercial, on-stream XRF
Laboratory analysis on prepared samplesSynchrotron
Target of this research
Base metals
Precious metals
Environmental
Iron
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Precious metals – gold and PGMs (platinum, palladium )
• Both commodities mined commercially at low levels• Feed grades of a few ppm
• Tailings grades of 0.1-0.5 ppm
• No existing on-stream commercial analysers available• Sampling + lab assay with few day turn-around times
• Recoveries typically range from 65 to 85%• $150-500 m of product per concentrator lost to tailings annually
• Target• 5% recovery improvement worth $50m annually per plant
• Installed instrumentation cost of <$1-2m
• Global annual production (2011): Gold 2500 tons, PGMs 484 tons
33 | On-stream analysis of precious metals | James Tickner
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X-ray fluorescence (XRF)
Investing in Australia’s mineral future | Nick Cutmore34 |
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Challenge: X-ray fluorescence analysis at low concentration
On-stream trace element analysis | James Tickner35 |
X-ray source
X-ray detector
Sample
0 2 4 6 8 10 12 14 16 18 20
102
103
104
105
106
Energy, keV
Co
un
ts/b
in
Careful optimisation of:• X-ray source• Detectors• Geometry• Filters …
30ppb for Platinum, >250 ppb for Au
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The solution : X-ray optics
On-stream trace element analysis | James Tickner36 |
dq
l
Bragg’s law: Reflection from crystal occurs
when l = 2d sinq
Energy
Energy
Highly-oriented pyrolitic graphite
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Results
On-stream trace element analysis | James Tickner37 |
0 2 4 6 8 10 12 14 16 18 20
102
103
104
105
106
Total count rate = 1.6 kcps
Signal = 3063.3
Background = 1166.8
Error = 21.2 ppb
Energy, keV
Counts
/bin
0 2 4 6 8 10 12 14 16 18 20
104
105
106
107
Total count rate = 80.0 kcps
Signal = 342.0
Background = 37351.2
Error = 567.6 ppb
Energy, keV
Counts
/bin
Signal = 342Background = 37351Error = 570 ppb
Signal = 3063Background = 1166Error = 21 ppb
Without“crystal focus”
With“crystal focus”
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CSIRO advanced field prototype
For plant optimisation and control:
• Problem: • Need sub ppm precision!
• Solution:• Feed analyser installed MGK
North (South Africa):
– XRF: ±70 ppb (1sd) in 1 hour
• Tailings analyser installation next week:
– XRF: ± 30 ppb(1sd) in 1 hour
Investing in Australia’s mineral future | Nick Cutmore38 |
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Impact (realised and potential)
On-stream trace element analysis | James Tickner39 |
0 20 40 60 80 100
1
2
3
4
5
Recovery (%)
83%71%Gold Copper
5 days’ data from Au/Cu plant
12% improvement = $270k/day
32% improvement = $700k/day
• Analyser installed in flotation plant• Measures Pt, mineralogy and particle
size in feed stream• During 2013 plant audit, analyser was
critical in optimising floatation parameters, resulting in ~15% improvement in recovery, valued at approximately $150M pa
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R & D focus now
• In-stream gold analysis at ppb levels (UltraTrace) • Move to direct analysis on plant pipes• Plug and play type instrument• New service model – no on site servicing ; if unit fails return to base; use spare at plant
40 | Investing in Australia’s mineral future | Nick Cutmore
400mm * 200mm diameter1.5 * 2m platform
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Machine learning for plant optimisation
• Use machine learning on historical plant data to develop ‘virtual expert’
• Consortium approach:
• CSIRO
• Thermo Fisher (instrumentation)
• Innodev (software + integration)
• Amazon Web Services (cloud computing)
• Anglo American
• Other miners
• Field demonstration of new technology planned for Q4 2015
Investing in Australia’s mineral future | Nick Cutmore41 |
Real-time plant data
Historical plant data
Data aggregation and integration
CSIRO Secure Portal
Modeling & analysis
Cleaning & feature ID
Display & reporting
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Industrial engagement
• Design and build prototype instruments for industrial evaluation• Feasibility
• Lab demonstration
• Industrial installation
• In house design
• Outside design & manufacture
• Funded by clients to demonstrate stage
• Clients get early access to commercial unit
42 | On-stream analysis of precious metals | James Tickner
Commercialisation routes1. Standard licensing2. Joint ventures3. Spin-off4. Co development with
manufacturing partner
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Summary
• Industry shift towards more sophisticated monitoring & control
• Effective control ⇒ rapid, accurate, on-stream measurement
• Key instrumentation: some available, rapidly developing• Low grades (current DLs in tens-hundreds of parts-per-million range)
• Increased production costs
• CSIRO delivers impact through:• Development of underpinning science
• Design of new measurement techniques and instruments
• Industry engagement
• Development and installation of industrial prototypes
• Commercialisation
43 | On-stream analysis of precious metals | James Tickner