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AMIRA P9Q Project Summary2016 - 2018

Project Brief ConfidentialP9Q: Translating research to industry tools:

Validated Multi-Component Mineral Processing Simulator

AMIRA International LimitedLevel 2 271 William St Melbourne VIC 3000 AustraliaPhone: +61 3 8636 9999Email: [email protected] Website: www.amirainternational.com

Hacettepe UniversityUniversity of Queensland

University of Cape Town University of Rio de Janeiro

Chalmers University Cooperative Research Centre

Confidential

P9Q Project Brief

Translating research to Industry tools for Operational improvement

Executive SummaryMining companies are responding to the price adjustment in commodities markets by implementing cost savings and operational improvement in mineral processing plants. As a result projects focussing on operational improvement must produce tangible bottom line results within an 18 to 24 month timeframe in order to attract investment funding and management attention.

AMIRA International and the Research partners are responding to this environment by proposing the P9Q Translation Project.

The Research Partners will take the newly developed and partially validated multicomponent (multi-mineral and multi-ore) models delivered in the P9P Project, validate them to a defined operational window and verify the outputs. The researchers will provide demonstration circuit simulations of four operational flow sheets in the Integrated Extraction Simulator (IES) platform for uptake by sponsors at sponsor review meetings. These can be used by sponsors for varying ore conditions and flow sheet configurations using historic data with some additional analysis to establish operational range and capability.

The CRC ORE2 personnel will, in cooperation with the researchers, upgrade the IES platform to allow firstly, full uptake of the multicomponent data requirements; secondly provide similar mass balancing, model fitting and data capabilities in IES as currently available in JKSimFloat and JKSimMet; and thirdly improvement in operator interface with IES to ease use of the P9Q models at sites for optimisation.

P9Q is an ambitious project designed for the times. It will require:

Innovation from researchers to fully implement multicomponent capability. Coordination with CRC ORE2 to ensure models are imported accurately into IES. Focussed development work in IES to provide upgraded interfaces for the models. Collaboration and teamwork between researchers and sponsors to ensure speedy uptake of

simulation techniques and procedures.

The P9Q Project will:

Run over 3 years and seek to integrate 12 to 18 improved models (sponsorship dependent). Allow sponsors free access to IES online during the entirety of the project term. Update sponsors every 6 months with the latest P9 model enhancements in IES. Offer exclusive access for sponsors to the validated P9Q models within the IES simulator during

the project and for 18 months after the end of the project. Insure more rigorous level of accountability through improved project management

Sponsorship options for P9Q will be simpler than previous P9 Projects as the focus of work will be on validation of the models based on existing datasets gathered in previous P9 Projects. In order to reduce project costs, limited on-site work is included in P9Q focussed around supplementing validation data for specific equipment. Additional one-on-one work by direct arrangement with the researchers is encouraged to leverage further direct operational benefit, productivity improvements and quantitatively assess expansion options.

Sponsorship Benefits Fee1

Major Producer All P9Q models in IES simulator, sponsor meetings, reports + equipment-specific survey or application of IES to historic circuit survey data. 4. 2 - 6 IES seats3. $160,000

Producer All P9Q models in IES simulator, sponsor meetings, reports. 1-3 IES seats3 $100,000Super Supplier Supplier + own equipment surveyed, performance review and modelled. 2 IES seats $90,000

Supplier All P9Q models in IES simulator, sponsor meetings, reports. 1 IES seat $50,000

CRC ORE2 Contribution2 $500,000

1. Annual fee in AUD indexed over the 3 years at 5% per annum2. CRC ORE2 generates Australian Government funding to uplift Industry funding by up to AUD 500,000 per annum provided a AUD 1M

per annum industry funding target is reached - arising from the AMIRA–CRC ORE agreement to fund additional research based on P9Q funds flowing through CRC ORE.

3. Licence seats for use of P9Q models in IES. Number of seats is dependent on company size.

Confidential

P9Q Project Brief


P9Q Translation Project OverviewA three year project combining P9P researcher and CRC ORE2 expertise to deliver the following capabilities: Quantify the processing plant performance, in terms of throughput, recovery and grade for different

blends of tested ores Simulate the outcome of different optimisation strategies Simulate new plant designs under known conditions Greatly enhanced confidence in prediction of processing response to changes in equipment

operation for wet & dry screens, crushers, cyclones, SAG & ball mills, and flotation cells Integrate physical separation units, such as gravity and magnetic, in process simulations

These capabilities will flow from validation and verification of 12 P9P models, potential inclusion of up to 6 more models, as well as upgrading of the CRC ORE Integrated Extraction Simulator (IES).

P9Q Scope

Model SpecificationThe specification and capability matrix of each model needs to be reviewed before implementation. The model developers will specify model functionalities, input/output parameters and ranges of operating conditions plus stream structure.

Model ValidationThe models will be validated against a relevant industrial dataset. Validation will be carried out within historic P9 circuit surveys only. The certified validation of a consolidated dataset of different ore types/commodities will constitute a unique researchers database with the highest industry standards.

Model Verification and TestingModel verification, or model testing, is the first stage of IES implementation. The models delivered by the model builders - either researcher or P9 historical models- will be programmed by the CRC ORE2 IES development team. The model builders will then assist in verifying that the model implementation is correct and test the model in a standalone flow sheet (unit on its own).

Model Integration TestingThe model is then tested in a closed circuit to test interaction with other models. Specific tests scenarios can be used, such a closed circuit configuration or different component distribution.

Demonstration in Four Test Circuits relevant to sponsorsFour appropriate circuits from Major sponsor sites will be used for the circuit demonstration studies. The sponsors will receive fully modelled and tested simulation in IES ideal for process optimisation and options studies. The experiences from these simulation outputs and the matrix of 4 test circuits with 4 ore types will be used to demonstrate the modelling capabilities to all sponsors and form the basis of training sessions over the course of the project.

One-on-One OptionsCircuit optimisation – sponsors can build off the simulation outputs or unit surveys to leverage further direct operational benefit by contracting the research team to provide targeted optimisation outcomes.

Operational Improvement – The direct observations and process understanding of the researchers can be further utilised to apply direct operational recommendations and build off the simulation to provide quantitative assessments of potential productivity improvements and expansion options.

This additional work can be directly contracted with the research team, noting that the P9Q models are available to sponsors only. One-on-one work will be accomplished on a balanced priority basis with the main P9Q Translation Project scope of work managed by the P9Q Project Advisory Group.

One-on-One Options

P9Q Scope

Confidential

P9Q Project Brief


P9P Success Stories

P9P achieved significant benefits for sponsors illustrating the potential for creating further value from the P9Q Translation Project.

Newcrest Cadia Confirmed that the circuit can maintain current operating performance with a new ore. Potential to increase material in floatable range (-150 m) while maintaining throughput,

achievable by improved utilisation of comminution circuit power and classification efficiency. Exposure of site metallurgists to P9 tools to identify and quantify process opportunities.

Glencore Ernest Henry Mine Identified potential flexibility in circuit to manage changes in head grade and recover losses

to tails. Assessment of circuit sampling points for future surveys. Identified potential to improve the quality of future survey data collection.

AngloGold Ashanti Sunrise Dam Recovery of full throughput with competent underground feed source replacing open pit. Identification of bottlenecks and inefficiencies in the comminution circuit. Potential to increase revenue with 10% increase in throughput. Intensive training of operators in advanced comminution, survey procedures and analysis. Simulations delivered in IES for value-chain improvement.

Vale Timbopeba Iron Ore Operations Training and experience in best practise flotation circuit diagnostics and optimisation. Identification of cause of haematite loss and poor cleaner / recleaner selectivity. Clear description of optimisation scenarios to resolve these haematite losses. Optimisation of hydrodynamic regime in collaboration with ITV using APBS measurements.

Rio Tinto Kennecott Copper Identified a 10% throughput improvement with competent ore and an increased recovery

can be achieved. Identified how to debottleneck ball mill circuit to maximise SAG mill utilisation. Gas dispersion measurements highlighted areas within the flotation circuit that can provide

improved performance. Identified potential to divert to bulk concentrate, reducing operating costs and metal loss.

Confidential

P9Q Project Brief


P9Q Benefits to SponsorsStrategic process planning benefits and on-site process optimisation recommendations using reliable multi-component simulations can be achieved by applying “What if” scenarios to integrated circuit design and optimisation through using world-class best available modelling capability.

SPONSOR VALUE: Recovering more metal out of the ore = increased profits.

Minimise the negative impact of ore variability andpre-tune the circuit for a change in ore types and or blends for rapid optimisation,through applying simulation-based process performance prediction.

P9Q will benefit sponsors in the following ways: Pioneer implementation of secure cloud based multicomponent mineral processing simulation,

providing a head start in learning how to effectively implement the new technology. Training of metallurgists in the use of the simulator and developing future experts in this field. The ability to simulate the whole process chain i.e. comminution, separation and recovery in a

single simulation platform that addresses multicomponent behaviour. On-going access to the commercially supported version IES and expert support.

SuppliersThe P9Q project provides access to and training in the models, simulator and tools in use by the sponsoring mining companies and in the company of those utilising the tools. The research knowledge and models from the project provide suppliers with cutting-edge technology and models. Access to site work via arrangement with producer sponsor sites.

Super-Suppliers Have the opportunity to conduct purpose-designed equipment surveys at site of choice alongside research experts to produce independently verified performance data and then partner in customised model development on their own products.

Mining Company Enterprise level Minimising the negative impact of ore variability, especially through rapid plant optimisation as the

ore type changes based on prediction of process performance. For CRC ORE2 members, simulate the potential of Grade Engineering® in the mining and its

downstream impact on comminution, classification, physical separation and flotation for current operations and future circuit design.

Technology evaluation and selection for brownfield retrofitting or expansion. Circuit options and selection for greenfield projects based on extensive database of operating sites

and models that can respond to variability in the feed ore.

Mining Company Managerial level Estimate high level output of concentrator performance for a given type of ore – based on plant-

specific calibrations and robust models. Decision making tools at concentrator operational level.

Metallurgist level Evaluation of comminution and flotation for a given ore type Obtaining the operating regime that is suitable for a given ore type Debottlenecking the circuit to improve overall performance Evaluating process improvement options for ores of differing competence and recoverability.

Operator level Assist in linking comminution and flotation circuits at optimal conditions

Predictive response to rapidly adjust to changing ores

Confidential

P9Q Project Brief


For Major Producer Sponsors, technology transfer on the impact of different operating strategies.

P9Q Target Models and CapabilitiesFor full sponsorship the following models and capabilities are targeted:

Model Capability1. Cone Crusher Semi-mechanistic. Response to CSS, speed, chamber design

2. HPGR Piston and Die breakage. Verified on fully liberated material

3. Dry Screen Multiple decks, variable inclination, Aperture +2mm. Response to generic media, throw, frequency. PSD predicted at every point on screen.

4. Fine Wet Screen Aperture 50µm to 2 mm. Equipment. Response to aperture size, inclination, % solids.

5. VR2 SAG/AG Mill Accurate throughput-filling relationship. Power based breakage, improved discharge and slurry holdup.

6. RoM Ball Mill Same as VR2 with high ball load

7. Ball Mill Using JKFBC test and appearance function. Breakage based on power draw

8. Mechanistic Mill Using particle fracture tests. Inherently multi-component and predictive. Response to liner design, ball size and general mill conditions

9. Hydro-cyclone Cut-size, separation and water split. Response to cont. density distribution

10.Inventory Predictive models for bin, conveyor, pump, sump and Stockpile

11.Component Floatability

Enhanced predictive properties added based on rheology, froth stability, entrainment and turbulence

12.Mechanistic Flotation

Independent models of Pulp and Froth Zonesi. mechanistic froth transportationii. - predict the effect of particle attributes and operating conditions on

mineral entrainment and water recovery 13.Magnetic

Separator Inherently multi-component. Response to magnetic susceptibility

14.Jig Response to component density, relative cut height, jig area, throughput15.Dense Medium

Separator Basic equipment model

If additional sponsorship received beyond full budget16.Flash Flotation Froth depth, gas rate, bubble size, rheology, water recovery

17.Gravity separator Inherently multicomponent. Response to SG of components

18.Pebble Mill Mill model. Response to pebble abrasion rate

IES Simulator Example

P9P multicomponent modelsas demonstrated in May ‘15

Confidential

P9Q Project Brief


P9Q DeliveryP9Q is about fast track delivery of tools and techniques to assist sites to achieve maximum benefit in the shortest possible time frame using the latest technologies, as outlined below:

The set of fully functional validated multi-component models in a commercially supported IES platform.1

4 challenging circuit configurations will be chosen with sponsors with 4 ore types to use this matrix of 16 scenarios to validate the capability and demonstrate the value of multi-component process prediction.

Ore and mineral types include porphyry coppers, banded iron formation, magnetite, haematite, itabirite, sedimentary, gold, platinum group elements (Platreef, UG2, Merensky), bauxite, …

IES updated biannually, including new P9 models, and made available to sponsors online. Sponsors will have immediate access to P9 models to test, familiarise and provide feedback.

Fast tracked delivery through Using existing P9 site survey data sets where possible to reduce time and expense. Undertaking partial site surveys to gather only data necessary for unit models only. Collaborating with CRC ORE2 to support parallel engineering of new functionality in IES. CRC ORE2 dedicating resources to ensure models can be continuously updated in IES. High value technology and skill transfer in rapid intervals. Sponsor training at each annual two-day Sponsors Review Meeting (SRM).

o Day1: project progress report. o Day2: demonstration and training of the P9 models and new IES features.

Differentiation of P9Q from CRC ORE2CRC ORE2 provides a specific approach to enhanced productivity via Grade Engineering® along with the IES simulation platform to support the whole-of-enterprise assessment of mining and processing decisions. P9Q provides the most advanced models within the mineral processing portion of the mining chain. In contrast to the current JK simulators, these models are suited to dealing with multi-mineral composition and multi-ore feed types. In addition, many are new to the simulation suite or present considerable usability advances over the existing models. These will provide enhanced usability and accuracy of predictions for developing new processing options, such as through the application of grade engineering. Without the development in P9Q, these validated, verified models will not be available for use by the industry; the IES will be dependent upon historic JKSimMet and JKSimFloat models that deal with average ore types and conventional circuit applications.

IP and CommercialisationP9Q Model IP belongs to the research institute that developed the model and is provided for use by the sponsors in their internal operations. The translation of P9Q models into a commercially available simulator is via IES, which will be enabled by a contracted head licence agreement with the relevant Institutes. This will ensure on-going access to the P9Q models in the IES.

The embedding of P9Q models into a commercially available simulator, the IES, will be enabled through appropriate licence agreements with the research Institutes. This will ensure on-going access to the P9Q models in the IES. Mining Company and Supplier Sponsor’s rights are fully addressed and protected in the P9Q project proposal.

The P9Q collaboration is a new focussed initiative designed to deliver value to you quickly

P9Q Project Structure1 This could range from 12 to 18 models depending on the level of sponsorship received. See table.

All P9Q Sponsors receive online access to IES and the P9Q models based on qualifying license seats for the duration of the project with exclusive use of these models extending for

18 months after the official end of the project.

Confidential

P9Q Project Brief


Project areas Description1: Validation database Consolidation of historic survey data for model validation2: Comminution, Separation &

Flotation Models Upgrading, validating and testing the models in IES

3: IES upgrade Specification to upgrade IES for new modelling capabilities

4: IES developers Implementation of models in IES by CRCORE - IES development team (funded by CRC ORE leveraged income)

Administration and Project Management

Leadership

- Independent Project Manager (IPM) – delivery (manpower, progress, mitigation), financials and quarterly reports

- Research Leader (RL) – overall research leadership, technical coordination between project areas and Research institutes

- Lead Technical - interface between researchers and IES team

Sponsor feedback

Project Advisory Group – Sponsor managed with quarterly review and oversight based on IPM and RL reports Annual sponsor meetings – project progress and technical training on IES updatesSix-monthly technical and management reports

Project oversight with AMIRA

AMIRA Program Manager

Finalise research agreements, facilitate sponsor-researcher interaction, arrange and manage: Monthly meetings - researcher & management teleconferences Quarterly – Project progress update and financial reporting

ResponseAMIRA and the Research Partners are currently meeting and giving presentations/demonstrations to potential sponsors following the circulation of the project proposal. Relevant contacts are listed below.With a number of companies already having expressed commitment to the project, it is envisaged that with sufficient sign-up by the end of March 2016, to allow the Project to start in late Q1 or early Q2 2016.A threshold start-up funding with associated project ramp-up has been developed to facilitate an early start without the risk of over stretching the research beyond committed funds.

P9Q Commencement timeline January 2016 - full project proposal circulated with sponsorship offer letter Q1 2016 AMIRA will be seeking to secure P9Q Confirmation of Sponsorship Agreements Anticipated start at end of Q1 or start Q2 2016

Research Collaborative and Key ContactsKey contacts

AMIRAChris Ward [email protected] Braden [email protected] Mann [email protected]

JKMRC - University of Queensland - Australia Malcolm Powell [email protected] - University of Cape Town - South Africa Martin Harris [email protected] - Chalmers University of Technology - Sweden Magnus Evertsson [email protected] - Hacettepe University - Turkey Hakan Benzer: [email protected] - Federal University of Rio de Janeiro - Brazil Marcelo Tavares [email protected] ORE - Australia Nick Beaton [email protected]

mailto:[email protected]








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