Comminution Energy Consumption
Transcript of Comminution Energy Consumption
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Coalition for Eco-Efficient Comminution
Elizabeth Lewis-Gray, Chairman, CEEC
Presentation to SAIMM, February 2012
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Vision Accelerate eco-efficient comminution strategies
through promotion of research, data and industry benefits
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CEEC Activities • International focus
• Website
– Central data base
– Easy access for technical and engineering staff
• Highlight issue to industry leaders through promotional activities
– Present papers
– Conferences
– Magazine and online media articles
• Promote new comminution strategies
• Encourage discussion and debate
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CEEC Medal
• Prestigious International Award
• Best technical paper presented or published in last twelve months
• Seeking nominations via website
• 15 March deadline
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The opportunity: Comminution Energy Consumption
4 % world electrical energy
consumption 30 – 40% total mine
Source: DOE 1980, CSRP Eco-Efficient Liberation – Outcomes and Benefits 2003-2010
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Comminution Energy Consumption
CO2 contributions for the stages of copper concentrate production, Source: Norgate and Haque, 2010
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1999 Leinster Nickel Operations CO2 Emissions
Sulphur
Kerosene
Coke
LPG
Petrol
Diesel
Electricity
Natural
Gas
Typical site comminution energy footprint
Source Le Nause, Temos 1992
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• Review and improve performance at existing operations
• Importantly, apply knowledge to new circuit design
How should industry respond?
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• Energy accounts for 25 – 30% of direct operating costs each year
• $200/oz
• Barrick has targeted improving energy efficiency by 8% through 2012
Existing operations - Barrick
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Identify opportunity, measure, analyse
Source: Buckingham,Dupont ,Blain,Brits ,JStieger Improving Energy
Efficiency in Barrick Grinding Circuits, ppt, SAG 2011
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SAG 2011 – Improving Energy in Barrick Grinding Circuits Buckingham et al
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SAG 2011 – Improving Energy in Barrick Grinding Circuits Buckingham et al
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SAG 2011 – Improving Energy in Barrick Grinding Circuits Buckingham et al
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SAG 2011 – Improving Energy in Barrick Grinding Circuits Buckingham et al
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• Analyse the grinding circuits for improvement opportunities
• Seek to optimize the throughput
• Feed crushing
• SAG mill operation including breakage functions and “pumping” capacities
• Pebble crushing
• Classification
• Ball milling
Barrick’s areas of focus
Source: Buckingham,Dupont ,Blain,Brits ,JStieger Improving Energy
Efficiency in Barrick Grinding Circuits, ppt, SAG 2011
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Barrick - Energy reduction and saving from three improvement events
• 60 million kWh annual savings = 216,000 GJ • 0.5% net efficiency improvement for Barrick global
• Average improvement of 3.7% of the 3 mine sites’ total energy
• Average of 8% improvement of the processor’s footprint
• Average improvement of 5.3% for 3 mine sites’ total energy.
• $5.2 million annual direct electrical savings
• $1.1 million potential future annual savings
Source: Buckingham et al
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• Investigate new and more energy efficient technologies
• Coarser grind size
• More crushing less grinding
• New flow sheets and feed preparation
Greenfield plant opportunities
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• Fine crushing
– VSI
– HPGR
• Fine Screening
• Ore Sorting
• Gravity – continuous & batch
– InLine Pressure Jig
– Centrifugal Concentrators
• Coarse Flotation
1. Improving & new technologies
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Selection of the coarsest possible grind size
2. Coarser grind size
1.E-01
1.E+00
1.E+01
1.E+02
1.E+03
1.E+04
1.E+05
1.0E-02 1.0E-01 1.0E+00 1.0E+01 1.0E+02 1.0E+03 1.0E+04
Particle Size (micron)
En
erg
y (
kW
h/t
)
Source: Hukki RT, 1961
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Energy Consumption increases with finer grinding
Source: Newcrest CEO Presentation, Feb 2012
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Optimum liberation
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Coarser grind may improve recovery
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3. More crushing – less grinding
• Ball mills only apply 5% of energy used to particle size reduction
• Fine crushing is more energy efficient
• Energy more expensive
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Castlemaine Goldfields plant 3 stage crushing, no grinding
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• Gangue Rejection
• Pre-concentration
• Blasting – Optimise fragmentation to maximise
fines in ROM ore
– “Bricks and mortar”
• Screening: – ahead of, and in, the grinding circuit
4. Improved ore presentation and flow sheets
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“The most efficient way
to break rock, is not to
break rock at all”
Dr Rob Morrison, JKMRC
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Pirquitas –gangue rejection 2-12mm
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The high potential of Witswaterand ore Preconcentration using continuous gravity and flotation at coarse particle sizes
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Key Benefits of new flow sheets
• Lower Capital Cost for Greenfields Installation
• Net reduction in energy consumption
• Increased gold recovery
• Increased gold production
• Reduced $/oz operating cost of gold produced
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CEEC – Website Home Page
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CEEC – Key Papers
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CEEC LinkedIn discussion page
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CEEC LinkedIn Discussions
• Ore sorting
• Microwave technology
• Blasting techniques
• Comminution research
• Conference blogs
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Act Now!
• Become an advocate
• Check out website
• Email colleagues
• Join linked in CEEC and contribute to discussions
• Share success stories
• Publish papers
• Become a sponsor***
• Encourage discussion and debate
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End