John Visser - METS Engineering
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Transcript of John Visser - METS Engineering
Midas Engineering Group Pty Ltd
NSW | QLD | VIC | WA
ABN 72 159 772 675
W: www.midasengineering.com.au
John Visser
Slide Owner:
BD
Concentrate Transporting Magnetite Concentrate From Mine to Port
Informa Conveyors 2014 September 2014
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLS HIRE
> DISCLAIMER With respect to all the information contained herein, neither Mineral Engineering Technical Services Pty Ltd, nor
any officer, servant, employee, agent or consultant thereof make any representations or give any warranties,
expressed or implied, as to the accuracy, reliability or completeness of the information contained herein, including
but not limited to opinions, information or advice which may be provided to users of the document. No
responsibility is accepted to users of this document for any consequence of relying on the contents hereof.
> COPYRIGHT © Passing of this document to a third party, duplication or re-use of this document, in whole or part, electronically or
otherwise, is not permitted without the expressed written consent of Mineral Engineering Technical Services Pty
Ltd.
> ACKNOWLEDGEMENTS This document is a dynamic record of the knowledge and experience of personnel at Mineral Engineering
Technical Services. As such it has been built upon over the years and is a collaborative effort by all those
involved. We are thankful for the material supplied by and referenced from various equipment manufacturers,
vendors, industry research and project partners.
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLS HIRE
Key Attributes
• Working globally since 1988
• Dynamic and innovative niche consultancy
• Dedicated team providing customised service
• Specialist in Mineral Processing & Engineering Projects
• Unique solution finder
• Part of the Midas Engineering Group
Pragmatic, efficient, complete engineering through
quality, personalised & exceptional service delivery
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLS HIRE
Agenda
• Do you truck, rail or pump the milled ore?
• Do you crush it and rail, truck or convey it?
• Can you perform a cobbing process?
• Do you concentrate the milled ore before pumping it?
• If you pump concentrates, do you return the water to the mine?
• How remote is the mine?
• How rough is the terrain between the mine and the port?
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Agenda
• Test work – Mineralogy
– Materials handling
– Rheology
• Processes – Size of particle
– Dry vs. wet processing
• Water
• Distance between mine and port
• Size of operation
• Capital cost
• Operational cost – Labour
– Power
– Consumables
– Maintenance
• Company balance sheet and income statements
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Test Work
• Mineralogy – Liberation size: higher milling costs for smaller size: typically
– Recovery at different grind sizes: cobbing options
– Clays: remove early
• Rheology: may not be worth pumping
• Erosion: Pipelines
• Compressibility: Bulk density
• Adhesion & Wall Friction
• Fluidisation/De-aeration
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Erosion
Erosion
• Erosion (Impact abrasion) testing is performed according to
ASTM76 in a small dilute phase pneumatic system. The angle of
the wear plate can be varied between 15° and 90° and it is generally
recommended to perform impact wear comparisons at different angles.
• A sub-sample of the bulk material can be used as the erosive material
in this tester. In order to determine the exact wear properties, the
weight loss of each wear liner plate samples is monitored and quoted
versus the quantity of bulk material spent.
• This test work can be performed on a selection of wall lining materials.
Further, the attrition of the sample due to impact abrasion may also be
determined through a comparison between the wet laser particle size
distribution of the fines portion of the retained sample (impacted with
the wall plate) and the magnetite sample prior to testing.
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Bulk Density/Compressibility
Lump Bulk Density/Compressibility
• The density and compressibility (density as a function of head of
consolidation) of a lump material (top size no greater than 37.5mm)
can be measured in a large bulk density tester.
• This test work may be performed at different moisture contents in order
to determine the effects of moisture on the compressibility and bulk
density.
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Adhesion
Dynamic Impact Build-up (Adhesion)
• This test work is performed using a drop tube where material is
dropped with zero initial velocity through a tube from a given height
which matches a desired impact velocity of either 5m/s (high speed) or
2m/s (low speed).
• The drop height is tuned based on speed measurements using light
sensors. The material impacts with an inclined wall surface and any
build-up effects on the plate canbe visually observed and measured.
• This test work can be performed at two inclination angles (15° and 30°
measured from the vertical axis) using a selection of wall liner
materials used in item 4. The moisture content of the bulk material
can be varied to investigate the effects of moisture on adhesion
properties.
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Full Size Adhesion & Wall Friction
Full Size Adhesion and Wall Friction
• The difficulty associated with the Jenike direct shear wall friction test
included under item 2 is that the lowest pressure that can be obtained is
limited by the weight of the ring and the contained bulk solid plus the
weight of the cover, which prevents to measure adhesion and cohesion in
this tester. An inverted shear tester overcomes this problem.
• This tester has a much larger piston diameter of
300mm, allowing a sample with a top particle size of up to 37.5mm to
be tested. Further, it is also possible to measure wall friction at zero
normal load with this machine and therefore determine the cohesion,
but it is also possible to measure the wall friction into the tensile normal
stress zone to determine the adhesion.
This provides information as to which wall material may exhibit least
cohesion/adhesion, i.e. least hang-up in static conditions such as
reclaimer buckets or truck trays.
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Fluidisation/Dearation
Fluidisation/De-Aeration
• When very fine and dry materials are stored in a hopper of bin, a
fluidisation analysis may be required, especially if aeration is
considered as a means of flow promotion.
• This test work includes graphical output of pressure drop per unit
length versus superficial fluidisation velocity and the de-aeration time
for this sample.
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Size of particles
• Lump and fines (>1mm) can be moved as
per the usual methods: rail, truck, conveyor
• Magnetite concentrate two products
– Dry cobbing product: rail, truck, conveyor
– Wet concentrates: pump, rail, truck,
conveyor
• Dry cobbing product
– Typically < 3mm
– Dry process which is relatively cheap
– Conveyor head pulley magnetised: Savage
River
• Wet magnetic concentrates
– Typically < 75micron
– Milling required so expensive
– LIMS (low intensity magnetic separation)
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Cobbing
• Typically dry magnetic separation process – This removes gangue only, i.e. design for high
recovery
• Reduced volumes: truck, conveyor, rail
• Larger particle sizes for transport: truck,
rail, conveyor
• Smaller particles: all, but dustiness if dry
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Water Quality and Availability
• Quality: mine vs. port – High TDS and/or salinity can lead to product rejection
– Treatment is expensive, so where is the best quality?
• Availability: mine vs. port – Crushing and screening
– Dry cobbing
– Transport
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FiFo Operation?
• Skills – Typically higher in larger centres
• Infrastructure – power availability
• Access to mine – Cost of delivering consumables
– Cost of transporting staff
• May be better to simply wash clay and then rail/truck/convey the ore
and treat near the port
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Distance Between Mine and Port
• Short distances: truck and pump
• Longer distances: Pump, rail, conveyor
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Terrain Between Mine and Port
• Access to mine
• Rail requires low profiles
• Road requires moderate
profiles
• Pipeline requires
moderate profiles
• Ropecon conveyors
cover any terrain
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Port Facilities and Available Space
• Tailings storage: negative
• Power availability: positive
• Power cost: positive
• Labour availability : positive
• Labour cost : positive
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Pipeline equipment
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Typical Port Equipment
Pumping
• Filters
• Tanks
• Pumps
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Maintenance
• Rail – Typically near the port
• Truck – Port and mine
• Pump
• Conveyor
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TML
Transportable Moisture Limit (TML)
• The Transportable Moisture Limit (TML) is determined using the flow
table method described in the International Maritime Organizations,
‘Code of Safe Practice for Bulk Solid Cargoes – 2004’ and AS4974.
• The TML will give an indication of the maximum moisture content
permissible for moving the bulk cargo by sea.
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Fines Dust Extinction Moisture
Fines Dust Extinction Moisture (DEM) Testing (-6.3mm)
• The moisture content at which a material is deemed to emit no dust is
determined using a procedure set down in Australian Standard AS-
4156.6-2000.
• This standard was written specifically for coal but has been utilised for
other bulk materials by modifying the quantity of sample placed in the
test rig. The actual weight of the sample is taken into account when
determining the dust number.
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Company Finances
• Capex: pump and conveyor options – Higher capital cost increases debt > can be negative for smaller operators
– Usually rail and truck can be off balance sheet
– Savage River Pipeline Bridge
Savage River, Tasmania, Australia
413 feet high / 129 meters high
1,440 foot span / 439 meter span
1967
• Opex: NPV analysis required for all options – Rough terrain
• Longer distances: truck and rail
• Steeper profiles: higher power costs conveyor and pump
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLS HIRE
Various projects
Company CITIC Pacific Mining Gindalbie Metals Grange Resources Asia Iron Holdings Australian Resources
Project Sino Karara Southdown Extension Hill Balmoral South
Development Stage Construction/Production Production Definitive Feasibility Study Construction Feasibilty Study
Resources/ Reserves ~2000 Mt Resource 1853 Mt Resource
522 Mt Reserve
654 Mt Resource
388 Mt Reserve
245 Mt Resource 1600 Mt Resource
859 Mt Reserve
Planned Production Date August – December 2012 Q4 2012 - October late 2015 2014 Q2-Q3 2013
Production Mining Rate
Concentrate Rate
80 Mtpa feed rate
22Mtpa
20 Mtpa, up to 75
8 Mtpa initial, up to 30
Mtpa in stages
22 Mtpa
6.6 Mtpa initial, with plans
up to 10 Mtpa
5 Mtpa initial, up to 10 & 20
Mtpa in stages
5 Mtpa concentrate
7 Mtpa BF pellets
Product Type Concentrate and pellets Concentrate Concentrate Concentrate Concentrate and pellets
Product Grade 67.5% Fe, 5.5% SiO2 68.2% Fe, 4.8% SiO2,
0.1% Al2O3, 0.01% P
67.7% Fe, 3.0% SiO2,
1.5% Al2O3, 0.01% P,
0.43% S
68.7% Fe, 4.5% SiO2,
0.1% Al2O3, 0.01% P
69.0% Fe, 3.9% SiO2,
0.1% S, 0.01% P
Total power required (MW) 6 lines each 44 = 264 120 180
Power requirement (kWh/t) 28
Product Grind Size (P80
micron)
25 25 38 38 32
Distance to Port ~25 km from port ~200 km E of port ~90 km NE of port ~300 km E of Geraldton ~30 km from port
Port Cape Preston Geraldton/ Oakajee Albany Geraldton/ Oakajee Cape Preston
Potential Product Market Citic Ansteel Jiangsu Shagang Asia Iron Shougang Corporation
Transport method to port Pipeline: 25km Rail Buried slurry pipeline:
110km
Slurry pipeline Slurry pipeline
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Various project cont’d
Company Iron Road Centrex Metals Atlas Iron Atlas Iron Sinosteel Midwest
Project Central Eyre Bungalow Yerecoin Ridley Koolanooka
Development Stage PFS (completed) Scoping (pending)? PFS (pending) PFS (complete) Feasibility Study
Resources/ Reserves 328 Mt Resource
-
127 to 417 Mt
Exploration Target
187 Mt Resource
-
2010 Mt Resource
970 Mt Reserve
430 Mt Resource
-
Planned Production Date -TBA -TBA -TBA -TBA Started
productionApril 2010
Production Rate 10 Mtpa -TBA 2.5 Mtpa 15 Mtpa 20 Mtpa
Product Type Concentrate Concentrate Concentrate Concentrate -
Product Grade 68.5 % Fe, 2.4% SiO2 70.1% Fe, 2.8% SiO2 70.1% Fe, 2.1% SiO2,
0.4% Al2O3, 0.004% P
68.3% Fe, 4.3% SiO2,
0.03% Al2O3, 0.01% P,
0.01% S
-
Product Grind Size (P80
micron)
106-125 µ m 32 75 29 -
Distance to Port ~160 km NW of port ~90 km N of port ~120 NNE of port ~75 km from port ~190 km E of Geraldton
Port Sheep Hill Sheep Hill Kwinana Port Hedland Oakajee
Potential Product Market Baoutou Iron & Steel - - Sinosteel
Transport method to port Rail or slurry pipeline -
TBA
TBA TBA Slurry pipeline TBA
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THANK YOU
www.metsengineering.com
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www.midasengineering.com
THANK YOU
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