USING SMARTTAGTM TO TRACK ORE IN PROCESS …€¦ · in the total process, understanding the...

The Southern African Institute of Mining and Metallurgy

Platinum 2012

871

E. Isokangas, B. Sönmez, M. Wortley, W. Valery

USING SMARTTAGTM

TO TRACK ORE IN PROCESS INTEGRATION AND

OPTIMIZATION PROJECTS: SOME CASE STUDIES IN A VARIETY OF

APPLICATIONS

E. Isokangas Metso Process Technology & Innovation

B. Sönmez Metso Process Technology & Innovation

M. Wortley Metso Process Technology & Innovation

W. Valery Metso Process Technology & Innovation

Abstract

A mine is essentially a series of operations, including drilling and blasting, crushing, milling,

flotation, and leaching, that are interconnected and therefore interrelated, with the

performance of one operation affecting the performance of another. Optimizing each stage

separately without considering the whole system often causes potential economic benefits and

energy savings to be missed. However, the PIO methodology is a thorough approach which

considers these individual process activities within the context of the whole process. The basic

principle is to optimize the process as a whole, rather than each process step in isolation from

the others.

Metso’s Process Technology and Innovation (PTI) group offers a global consulting service for the

mining and construction industries. A significant amount of this consulting work involves

process integration and optimization (PIO) studies. When conducting a PIO study, every aspect

of the process is considered. In addition to drilling and blasting, transportation, handling and

storage, crushing, screening, grinding, flotation, separation, and recovery, other aspects

including equipment utilization and energy consumption and even greenhouse gas emissions

are also included if necessary.

In a PIO project, it is very important to understand what type of material is being processed at

any point in time. That is, which domain or domains is the material part of? This is necessary in

order to observe the effect of different ore sources (and the blending of sources) on

concentrator performance. Linking the ore from the pit to the concentrator required the

development of an ore tracking system. As a result, PTI developed a radio-frequency based

material tracking system called SmartTag™. This system allows tracking of ore from its source

through blasting, run-of-mine (ROM) pads, crushers, intermediate stockpiles, and finally into

the concentrator.


Platinum 2012

872

Using the SmartTag™ system, definitive correlations can be made between the performance of

the plant and the plant feed characteristics, including the domain from which the feed ore

originated. Since its commercialization in 2007, SmartTag™ has been used in the majority of

PTI’s consulting projects and several permanent systems have been installed worldwide1.

Successful applications of the SmartTag™ system have encouraged development to allow the

system to be used in a wider variety of plants, in particular plants with finer crushing and

screening stages.

This paper describes how the SmartTagTM system is being utilized by PTI and the benefits being

gained by its use in PIO projects, as well as presenting some case studies.

Keywords: Integration, optimization, simulation, modelling, mine-to-mill, ore tracking

Introduction

Metso Process Technology and Innovation (PTI) is a group providing total process integration

and optimization (PIO) services for the mining and construction industries. The term ‘total

process’, is used to encapsulate the mining (drill and blast), comminution, flotation, leaching,

and dewatering processes, and PTI studies aim to optimize each process within the constraints

imposed by the operation of the other process. The objective of PIO projects is to maximize the

overall profitability of a mining operation by fully exploiting the interaction between the mine

and mill.

The PIO methodology, developed by Metso PTI, is a result of working with operations around

the world over the past fifteen years to increase their production rates, reduce operating costs,

and improve overall process, energy, and water efficiency.

Implementation of the PIO methodology has delivered significant improvements in mine

efficiency, increases in the production of the operations with little or no capital expenditure,

and reduced operating costs at mines around the world2. These increases typically range from 5

to 20 per cent, representing millions of dollars in increased revenue.

PTI have also developed and commercialized our own innovative products such as SmartTag™,

SmartEar™, and SmartSAG™. These products are designed to enhance the operation of mineral

processes.

Ensuring the quality and specifications of an ore product requires high accuracy in process

control, from the properties of raw materials to customer delivery. In mining operations, this

control involves characteristics of ore geology, content, hardness, process parameters such as

size, power, inputs, and finally the logistics for storage and transportation. In a number of

mining companies, the size of the particles and the contents are used to classify the quality of

products very strictly, valuing or devaluing each ton processed and immediately impacting the

revenue of the company.


Platinum 2012

873

One way to control the characteristics of the product is to track the raw material through the

process. To increase the accuracy of this ore tracking from blasting to the plant, Metso PTI

developed a system, SmartTagTM, which is based on hardened RFID (Radio Frequency

Identification) tags. This will be described in more detail in the following sections.

SmartTag™ was commercialized in 2007 and won the Queensland State iAward in the category

of Industrial Application, competing alongside world leading-edge technologies in 2010. The

system has been used by PTI in PIO and mine to mill projects to determine with great precision

the origin of the material that feeds the plant during sampling campaigns and to associate plant

performance with the characteristics of the material. Over 20 such projects have used this

technology. Some other applications include measuring the residence time of stockpiles and the

transit period of a circulating load, and estimating dilution and pile´s launching at blasting.

Since 2007 there have been significant advancements in RFID technology that have allowed PTI

to extend the reach of SmartTag™ beyond secondary crushing to tertiary crushing and

screening. This has been achieved by drastically reducing the size of the SmartTags from a

diameter of 60 mm to 13 mm. The new smaller RFID tags have been successfully used in several

studies.

PIO methodology

Investigations have shown that all the processes in the mine to mill value chain are inter-

dependent and the results of the upstream mining processes (particularly blast results such as

fragmentation, muck pile shape and movement, and damage) have a significant impact on the

efficiency of downstream milling processes such as crushing and grinding3.

The ‘mine-to-mill PIO’ approach involves the identification of the bottlenecks and opportunities

in the total process, understanding the leverage each process has on the downstream

processes (e.g. the impact of drill and blast results on load and haul and crushing/grinding

processes), and then using that leverage to de-bottleneck the total process and maximize the

overall profitability of the operation rather than just the individual process.

The objective of mine-to-mill PIO methodology is to develop and implement site-specific mining

and milling strategies to minimize the overall cost per ton treated and maximize company profit

in a sustainable manner.

The methodology involves a number of steps: benchmarking, rock characterization,

measurements, modelling/simulation, and where required, material tracking. A PIO project is

normally comprised of a number of site visits spaced over a few months. Typically during the

first site visit, project objectives are defined, data is collected to establish current operating

practice, and plans are made for conducting detailed audits, sampling for rock characterization,

and plant surveys.


Platinum 2012

874

This is followed by data analysis, modelling, and simulation studies to determine how to exploit

hidden inefficiencies. Recommendations are followed by further site visits to implement

changes, monitor results, and ensure improvements are maintained over time. The PIO

methodology is shown in Figure 1.

Ore tracking from mine to mill

In a mine, different ore characteristics have a direct impact on subsequent processing, the

objective of which is to separate and concentrate minerals of economic interest. SmartTagTM is

a tool to identify and track with great accuracy the origin of the ore and its characteristics

through the mining processes. The system uses integrated circuits equipped with RFID

technology, encased for protection in a highly-resistant polymer capable of withstanding

blasting and subsequent transportation, storage, and size reduction processes, such as crushing

and screening.

Figure 1-Schematic of the PIO process

A SmartTag™ RFID tag travels through a mine and mineral processing plant in a series of steps.

Initially, the tag and insertion location is logged using a hand-held computer or PDA, then it is

inserted into the rock mass in the same holes where blasting explosives are placed. The tag

travels with the ore through digging, transport, and processing, before being detected by

special detectors that are positioned along conveyor belts, when the time and specific tag is

recorded. The RFID tag data is then loaded into a database and analysed as required. Figure 2

demonstrates the application of the SmartTagTM system for a typical flow of ore from a blast

through to a concentrator.


Platinum 2012

875

Figure 2-Schematic of RFID tag-based material tracking system

Metso PTI are currently extending the application of the SmartTagTM system to mark and track

ore from mines through ports to final destinations offshore, allowing not only optimization of

the mining process, but also monitoring and optimization of the transport logistics to final

consumers, such as iron and steel producers in the cases of iron ore and coal4.

The use of the SmartTagTM system allows tracking and correlation of the ore characteristics and

quality with important operating parameters in the mine and processing plant, such as ore

dilution, fragmentation, stockpile residence times, segregation, energy consumption, metal

recovery, etc. With such knowledge, operating parameters can be optimized to respond rapidly

to changes in ore characteristics, reducing operating costs and increases the profitability of the

business.

The benefits of using SmartTag™ include linking spatial mine data to time-based processing

data, increased confidence in measuring ore blend, proactive process changes for known ore

types, identifying material-handling logistics issues, and accurate measurement of residence

times in stockpiles and bins.

SmartTag™ system overview

As can be seen in Figure 3, the SmartTag™ system consists of five main components:


Platinum 2012

876

1. SmartTagTM tag

2. Portable reader (PDA)

3. Antenna

4. Tag reader and data logger

5. Database and software applications.

Figure 3-Schematic view of SmartTagTM

system

RFID Tags

A SmartTag™ is a passive radio-frequency identification chip contained within a ruggedized

protective casing. All internal electronics are passive and require no power source to be

connected. When in use, the operational power is drawn from safe levels of electromagnetic

energy that emanates from the reader antennas. Due to this feature, the SmartTag™ has a

theoretically infinite shelf life.

The SmartTags come in four sizes, the super SmartTag (90mm Ø x 60mm), the Standard (60mm

Ø x 30mm) the Mini (20mm Ø x 10mm), and the Micro (14 x 8 x 5mm). Figure 4 shows the

different tag types.

T

T

T

Th

de

ap

Mi

use

un

By

siz

ind

siz

an

fix

the

Bo

pla

be

we

ins

ins

Th

ho

thi

RF

for

en

allo

Th

ste

the

wit

e S

tec

pli

icro

ed

de

re

e o

duc

e o

in

ing

e a

oth

ace

tw

ere

sta

sta

e s

w

is w

ID

r p

cas

ow

e t

em

e ta

th

Sta

cte

cat

o t

if

ergr

edu

of

ced

of t

suf

g th

nte

sy

ed

wee

e fo

llat

llat

sec

to

was

tag

pro

sin

ws t

tag

mi

ag

its

Fig

nd

ed

tio

ag

f n

rou

ucin

th

d fo

the

ffic

his

en

yste

un

en t

ou

tio

tio

con

pr

s to

gs,

tec

g i

the

gs c

ng

be

or

gur

ard

up

ns

is

nec

und

ng

e a

or a

e R

cien

iss

na

em

nde

the

nd

n,

n m

nd c

ote

o e

an

ctin

n e

em

can

g co

eing

rigi

re 4

d t

p t

w

de

ces

d a

the

ant

a g

FID

nt

sue

clo

ms

ern

e ta

to

a

me

cha

ect

enc

nd

ng

epo

to

n b

olu

g e

na

4-S

ag

o

he

esig

ssa

pp

e s

ten

give

D ta

rea

e; o

ose

we

ea

ags

o h

si

tho

alle

t th

cas

alt

th

oxy

pa

e i

mn

ejec

l p

ma

ca

a

re

gne

ry.

plic

ize

nna

en

ag

ad

one

er t

ere

th

s an

hav

ng

od

eng

hem

e t

tho

he

y, t

ass

ins

n. T

cte

arc

artT

an b

dis

sc

ed

T

ati

e of

a in

fie

is

ran

e m

to t

te

th

nd

ve

le

.

ge f

m s

the

oug

RF

he

ea

ert

Thi

ed f

cel

Tag

be

sta

ree

to

The

on

f th

n t

ld

red

nge

me

the

est

he

the

si

an

fac

suf

e RF

gh i

ID

M

asil

ted

s m

fro

of

g™

de

nc

eni

o pa

e S

s w

he

the

str

duc

e fo

tho

e R

ed

co

e a

mi

nte

ced

ffic

FID

it is

ta

Mini

ly t

d in

min

om

f or

typ

ete

e

ing

ass

Sup

whe

RF

e R

ren

ced

or

od

FID

at

onv

ant

lar

enn

d in

ien

D ta

s ti

ags

i Sm

thr

nto

nim

th

re,

pes

cte

of

g o

s th

per

ere

FID

FID

ngth

d. T

the

wa

D ta

t a

vey

en

r d

na

n in

ntly

ags

ime

. D

ma

ou

o th

mize

e b

so

s. Le

ed

40

r s

hro

r S

e lo

ta

D t

h. T

Thr

e s

as

ags

an

yor

na

det

lo

nco

y to

s in

e-c

Diff

rtT

gh

he

es

bla

th

eft

fro

00

sec

oug

Sm

ong

g, t

tag

The

rou

stan

to

s.

iro

be

. B

ect

cat

orp

o s

n a

con

fer

Tag

sc

ste

the

st

his i

to

om

m

on

gh

mar

g fa

the

is

ere

ugh

nda

us

on

elt

Bot

tio

ted

ora

urv

tw

nsu

en

gs h

cree

em

e c

in

is a

o rig

a

mm

da

10

tTa

alls

e s

d

efo

h in

ard

se t

ore

(r

h a

n

d u

atin

viv

wo-

umi

t e

hav

ens

mmi

cha

the

an

ght

dis

. T

ry

0 m

ag™

s ca

ize

ire

ore,

nve

d S

tw

e m

rath

app

ca

und

ng

ve a

pa

ing

enc

ve a

s w

ing

anc

e s

im

t: N

sta

The

cr

mm

™

an

e of

ctl

, th

esti

ma

o a

min

her

pro

pa

de

th

a b

rt e

g an

cas

a d

with

g of

ce o

stem

po

Norm

nce

e M

ush

sc

ha

be

f th

y p

he

iga

artT

ant

ne.

r t

oac

bili

r t

e M

blas

epo

nd

sing

diam

h a

f th

of t

mm

orta

ma

e o

Min

hin

cre

as

ex

he

pro

rea

tio

Tag

ten

. F

tha

he

ity

the

Min

st.

oxy

ex

g m

me

pe

he

the

min

ant

al, M

of 1

ni

ng

en

be

xpe

an

opo

ad

on,

gTM

nna

or

n

s, d

. H

e b

ni R

A m

y. T

xpe

ma

ete

ertu

bl

e b

ng.

t co

Min

1 m

an

pre

s.

een

ecte

ten

ort

ran

thM

in

as w

th

ab

du

How

bel

RFI

me

The

ens

ter

r o

ure

ast

las

It

ons

T

ni,

m, w

nd

ecl

M

n d

ed

nna

ion

nge

e 2

nst

wh

he

ov

al a

we

t

D t

eth

e m

ive

rial

of 2

es d

t at

st s

mu

side

The S

Mi

wh

M

ud

Mixt

dev

in

a in

nal

e o

20

alla

hile

sec

e t

ant

eve

wa

tag

od

met

e it

ls a

20 m

dow

t a

sho

ust

era

Sout

cro

ile

icr

des

tur

vel

or

n t

to

of a

mm

atio

e th

con

the

ten

r,

as

gs i

pr

tho

is

are

mm

wn

app

ock

t be

atio

ther

o, a

th

o

th

res

lop

e p

he

o th

a R

m R

on

he

nd

e b

nna

ba

ch

nto

rev

od

cu

e s

m. T

to

pro

k w

e a

on.

rn Af

and

e M

tag

he

of

ped

pas

RF

he

FID

RFI

. P

sec

ap

bel

as o

ase

hos

o t

viou

wo

rre

still

Th

o 25

xim

ave

ass

.

frica

d Su

Min

gs

us

f d

d t

sse

FID

am

D ta

ID

TI

con

ppr

t)

or

ed

en

he

usl

ork

ent

l b

e s

5 m

mat

e d

um

an In

upe

ni a

ar

e o

iffe

to

s.

D ta

mo

ag

tag

tria

nd

roa

to

clo

pu

a

Sm

y u

ks w

tly

bein

size

mm

tel

dam

med

nstit

er (

and

re

of

ere

im

ag i

oun

wi

gs w

alle

m

ach

re

ose

ure

as

ma

use

we

the

ng

e of

m.

y t

mag

d th

tute

not

d M

ge

the

ent

mpr

is a

nt o

ll b

we

ed

eth

h, t

edu

er a

ly

the

rtT

ed

ll f

e p

inv

f th

the

gin

hat

of M

t to

Mic

ne

e l

ta

rov

also

of

be r

ere

tw

hod

the

uce

ant

on

e

Tag

by

or

pref

ves

he

e m

ng t

t th

Mini

o sc

cro

eral

arg

ag s

ve

o re

ch

red

fo

wo m

d w

e a

e t

en

n t

ne

gTM

PT

pr

fer

stig

M

mid

the

he

ng a

cale

o ta

lly

ger

size

su

ed

arg

duc

oun

me

was

nte

the

na

the

w

sy

TI t

ote

rre

gat

ini

po

e d

tag

and

Plat

e)

ags

us

r ta

es

urv

uce

ge

ced

nd t

eth

s to

en

e d

di

e e

st

yste

to a

ect

d m

ted

RF

int

ev

g r

Met

tinum

ca

sed

ag.

ca

viva

ed.

th

d as

to

hod

o p

na

ist

sta

eas

tan

em

ach

ting

me

d. A

FID

t of

ice

em

tallu

m 20

87

an b

d f

Th

n b

al

. Th

hat

s th

hav

ds f

pla

w

an

anc

se

da

m w

hie

g th

tho

Aft

ta

f th

e an

mai

urgy

012

77

be

for

he

be

in

he

is

he

ve

for

ce

was

ce

ce,

of

rd

was

ve

he

od

ter

gs

he

nd

ns

T

T

T

T

A

T

87

Th

ore

Up

pro

thr

Po

Th

Sm

a s

‘lis

Fo

Th

RF

Th

on

po

nu

the

Sm

An

Th

bo

tag

ap

8

e t

e th

pon

ote

rou

orta

e S

mar

safe

sten

r th

is s

ID

e P

e.

we

mb

en

mar

nten

e n

th

g.

pli

tag

hro

n a

ect

ugh

abl

Sm

rtTa

e le

n’ a

he

sys

rea

PDA

W

er,

ber

as

rtTa

nn

nex

ind

An

cat

gs c

oug

cti

ive

h cr

le r

art

ags

eve

and

ini

stem

ade

A’s

he

clo

r o

sso

ag™

a

xt c

duc

nte

tio

can

gho

vat

e ca

rus

rea

tTa

s™

el o

d r

itia

m c

er.

s G

n t

ose

f t

cia

™.

com

ces

enn

n,

n al

out

tio

asi

she

ade

ag™

wi

of e

reco

al p

con

PS

the

e-r

he

ate

mp

s a

nas

sin

so

t it

n,

ng

ers

er

™ p

ith

ele

ord

plac

nsi

un

e u

an

Sm

d w

pon

ch

c

ngle

be

s jo

the

g is

an

ort

th

ctr

d th

cem

sts

nit

se

ge

ma

wit

nen

harg

an

e o

e p

our

ey

s st

nd s

tab

e b

rom

he

me

s of

loc

r h

si

rtT

th

nt i

ge

b

or m

lac

rne

tra

tro

sto

ble

bla

mag

re

ent

f a

cat

hold

gn

Tag

the

n t

on

be

mu

ced

ey,

ans

ng

ock

re

st

gne

spo

of

ru

es

ds

al

g™

e l

the

n th

m

ltip

d o

be

sm

en

kpil

ad

ho

eti

ons

a S

gge

Fig

th

th

to

is

oc

e sy

he

ou

ple

n t

ein

mit t

no

es.

er

le

c e

se

Sm

ed

gur

e t

e S

po

the

ati

yst

RF

nte

an

the

g a

the

ug

.

(Fi

(or

ene

fro

mart

ize

re 5

hre

Sm

ow

en

on

em

FID

ed

nte

e po

acti

eir

h t

igu

r ot

ergy

om

tTa

ed h

5-Sm

ee

art

wer

tr

. T

m, t

tag

a

enn

ost

iva

un

to

ure

the

y t

th

ag™

han

ma

ne

tTa

an

ans

This

the

g a

bo

nas

t-b

ated

niq

pro

5)

er l

o a

he S

™ in

ndh

artT

ear

ag™

nd

sm

s p

e a

and

ove

ca

las

d o

ue

ote

is

oc

act

Sm

n t

hel

Tag

est

™ t

ac

mitt

pro

nte

d al

o

an b

st m

only

e id

ect

us

ati

iva

mart

he

ld c

g™ p

t lo

o t

ctiv

ted

oce

enn

lso

or

be

mu

y b

den

t th

ed

on

ate

tTa

m

com

por

oca

the

vat

ba

ss

na,

o re

be

us

ck

by t

ntif

he

to

n) t

th

ag™

ine

mp

rta

atio

e to

te t

ack

is

, is

ece

elow

ed

pil

the

fica

ta

o as

hey

e S

™, w

e, t

put

ble

ons

op

the

k to

re

lo

eive

w

.

le o

e Sm

atio

g f

sso

y a

Sm

wh

the

er

e re

s, fr

of

e S

o t

pe

cat

es a

th

T

or

ma

on

fro

ocia

are

art

hich

e Sm

(PD

ead

rom

f th

Sm

the

ate

ted

a tr

e

The S

RO

artT

co

m

ate

pla

tTa

h is

ma

DA

der

m w

he

art

e PD

ed

d a

ran

co

Sout

OM

Tag

de

th

th

ace

ag™

s its

artT

A) w

sys

wh

PD

tTa

DA

fo

t t

nsm

onv

ther

pa

g™

be

e s

he u

ed

™ tr

s u

Tag

with

ste

ich

DA,

ag™

A. T

r e

he

mit

vey

rn Af

ads

re

efo

sho

uni

in.

ran

niq

g™

h in

em

h th

th

™.

Th

eac

co

ted

or

frica

s. T

ad

ore

ock

iqu

. Th

nsm

que

po

nb

he

he

Th

e S

ch

onv

d s

b

an In

Th

er

e sw

k o

ue i

he

mitt

e id

orta

uilt

use

rea

he

Sm

loc

vey

ign

elt

nstit

e t

an

wit

of b

ide

po

ter

den

abl

t G

er

ade

un

art

cat

yor

nal

t.

tute

tag

nte

tch

bla

ent

orta

r. T

ntif

le r

GPS

sel

er

niq

tTa

tion

be

ba

De

of M

s t

nn

ing

sti

ific

abl

The

fica

rea

S an

lec

sen

que

ag™

n t

elts

ack

pe

Mini

he

as.

g b

ng

cat

e r

e re

atio

ade

nd

ts t

nds

e id

™ ID

ha

s. T

k fro

end

ng a

n f

.

bac

an

ion

rea

ead

on

er i

Sm

the

s o

den

D n

t r

The

om

ding

and

Plat

foll

k o

nd

n co

ade

der

co

s u

mar

e re

out

ntif

num

req

e a

m th

g o

Met

tinum

low

off.

tr

od

er e

rs t

ode

use

rtT

ele

t a

fica

mb

quir

nte

he

on

tallu

m 20

w th

. Th

an

e o

em

he

e.

d.

ag™

eva

low

atio

ber

res

enn

RF

th

urgy

012

he

he

sit

of

its

n

™

nt

w-

on

is

s a

na

FID

he


Platinum 2012

879

For most single-antenna systems, as seen in Figure 6, the antenna is mounted below the belt

and is connected to the reader via a single 2-core cable. The cable cannot exceed 3 m in length,

as the performance of the antenna will drop off significantly past this length. The antenna must

be positioned as close as possible to the conveyor belt.

Figure 6-A single SmartTag™ antenna

The design of the antenna is determined by two parameters, which are its size and its

robustness. The size of the antenna dictates the size and the strength of the field it radiates. For

this application the area of field strong enough to charge the RFID tag should be as large as

possible; therefore, the antenna used for the SmartTagTM system is the largest available for this

frequency of RFID system.

Tag reader and data logger

An RFID tag reader decodes the signal from the antenna and determines the ID of the RFID tag

passing the antenna. Later versions of the readers also have auto-tuning capabilities which

ensure that the maximum possible read distance is achieved at all time. In the SmartTagTM

system, the reader then transmits the ID using serial communications.

A data logging or buffer stage improves the reliability of the systems and also makes movable

systems possible. The data logger receives data directly from the RFID reader, stores the IDs

with the time they were detected, and monitors vital system parameters, such as the tuning

state of the antenna. The data logging stage also makes SmartTagTM less reliant on

communication links (such as wireless) as the data is stored at the detection point until a link is

established to the software applications. The critical communications links, such as the one

between the antenna and the reader, are all wired and very reliable.


Platinum 2012

880

Database and software applications

The core of the SmartTagTM software is an SQL database. The database, located on a dedicated

server, stores all the information about the detection points, detected RFID tags, and original

locations. There are several SmartTagTM software applications for entering and managing the

data and visualizing, reporting, and transferring the data to other applications and systems.

Using SmartTagTM

in PIO projects

The two case studies summarized below were chosen to illustrate the applications of the

SmartTagTM system by PTI and the benefits being gained by its use in PIO projects. The second

case study also demonstrates several advantages of using the Mini RFID tags rather than the

normal size RFID tags in secondary crushing circuits.

Case study 1: Application of SmartTags™ at a gold mine

PTI undertook a PIO project at an open pit gold mine and SmartTagsTM were used to track ore

from the audited blast through to the SAG mill5. As part of the mine–to-mill PIO study, one test

blast was conducted in the pit and ore from this blast was mined in two flitches (top and

bottom) and campaigned through the mill.

To quantify the effect of changes in blasting conditions, the PIO study processed the top and

bottom flitch material separately into the grinding circuit. Following detonation of the audited

blast, the top flitch material was mined and placed in a segregated stockpile on the ROM pad,

ahead of the primary crusher. The bottom flitch material was dumped directly into the primary

crusher.

It was planned to perform two grinding circuit surveys: one on the top flitch and the second on

the bottom flitch. Ore tracking with SmartTagTM was used to physically confirm that the audited

primary ore was being processed through the grinding circuit at the time of the survey, thus

allowing correlation between fragmentation results and plant performance.

SmartTags™ were placed on the muck pile prior to mining as well as added to the ROM

stockpile. A total of 200 tags were placed in each of both flitches – numbers 0 to 199 were used

for the bottom flitch and 200 to 399 for the top flitch. Two antennae were used at the site, one

on the primary crusher product belt and one after the stockpile on the SAG mill feed belt.

Tag detection results

Top flitch material was sent exclusively to the primary crusher starting at around 1:30 pm on 28

January and was to be sufficient to supply the primary ore mill feed for around 12 hours. The

mill was to process this material until the 12-hour shutdown starting at 8:00 am on 29 January –

immediately following the first grinding circuit survey.


Platinum 2012

881

When the mill came back up around 9:30 pm, the bottom flitch material (again around 12 hours

of mill feed) was direct dumped into the crusher and the plan was to continue crushing this

exclusively until the morning of 30 January after the second grinding circuit survey.

Figures 7 and 8 show the tag detection times for the primary crusher and SAG mill feed. The

blue diamond points represent the top flitch while the purple square points represent the

bottom flitch.

SmartTags™ were steadily detected at the primary crusher until the mill shutdown.

Unfortunately, the coarse ore stockpile was drawn down ahead of crushing this material and

the pile height fell steadily for the whole period when top flitch tags were detected. Comparing

Figures 7 and 8 shows that the tags were picked up on the SAG mill feed belt very soon after

being detected ahead of the stockpile.

In contrast, tags were detected for only 2½ hours with direct dumping of the bottom flitch into

the primary crusher. All of the bottom flitch material was crushed during the mill shutdown as

shown in Figure 7. After the mill started up again at 9:30 pm on 29 January, the majority of the

bottom flitch tags passed through the SAG mill prior to 4:00 am on 30 January – well before the

scheduled time for the second grinding circuit survey. After 4:00 am, the frequency of tag

detections diminished, indicating that the mill feed was then a blend of bottom flitch with other

unknown material.

Figure 7-Primary crusher product tag detection times (before stockpile)


Platinum 2012

882

The difference in tag detection times between the SAG mill feed and primary crusher antennae

can be used to estimate the coarse ore stockpile retention time. Figure 9 shows the residence

time of the pile over the period when SmartTags™ were being detected. For the top flitch

material, the time between detections slowly reduced from 3 to 4 hours down to a few minutes

as the pile height dropped. It is also possible that, with such a short retention time, other

material may have been falling into the cone above the feeders, in particular, very coarse rocks

from the outside of the stockpile.

Figure 8-SAG mill feed tag detection times (after stockpile)


Platinum 2012

883

Figure 9–Coarse ore stockpile estimated residence time (based on tag detections)

For bottom flitch material, the stockpile was steadily built up following the mill shutdown and

the residence time increased from a few minutes to 18 hours when the pile was full.

The use of SmartTags™ provided clear evidence that the audited material was entering the

grinding circuit and the frequency of tag detections was used to indicate whether any other ore

polygons were inadvertently being sent to the primary crusher. Placing antennae both ahead of

and after the coarse stockpile allowed live retention time to be estimated.

Case study 2 – high-pressure grinding circuit

PTI was contracted to assess the performance of a circuit at a mine located in South America.

The flowsheet for the operation including the locations of the SmartTagTM detection points is

shown in Figure 10. The SmartTagTM system was used in this application to allow the PTI

engineers to know exactly when a surveyed blast was being processed6. For this reason,

detection points were located on conveyor belts carrying the product of the primary crusher,

the output of the stockpile and the high-pressure grinding roll (HPGR) feed.


Platinum 2012

884

Figure 10-Crushing and grinding circuit and locations of detection points

As the blast was being audited, RFID tags were deposited into 68 blast holes, using an even split

of 34 normal tags and 34 mini tags. A further 50 tags were later added into the trays of 25

trucks at the primary crusher, using one of each of the two different types of tags in each truck.

Figure 11 shows the layout of the holes in the blast and the type of tag that each hole received.

Results

A total of 68 tags were identified at the primary crusher product detection point, 23 at the

stockpile output detection point, and 41 at the HPGR feed detection point. Figure 12 shows the

cumulative number of tags detected over time at each detection point.

Figure 11-Holes where the RFID tags were placed

T

T

Th

de

of

Th

(tw

pro

Du

we

typ

As

e s

co

tag

e b

wo

oce

urin

ere

pe

sta

sto

mm

gs a

bla

m

ess

ng

e m

an

ate

ckp

mis

aft

st

mon

s ov

thi

min

d t

ed

pile

ssio

ter

oc

nth

ver

is p

i ta

the

ea

e a

one

th

cu

hs

r a

per

ags

e or

rlie

F

nte

ed

is d

rre

lat

pe

rio

s. T

rigi

er,

Figu

enn

by

dat

ed o

ter)

erio

d,

Tab

in (

the

ure

na

y an

te.

on

). T

od o

a t

ble

(m

e s

e 12

wa

n o

22

Th

of

tot

I s

ine

stoc

2-C

as

ove

2 Ja

e

30

tal

sho

e o

ckp

um

ins

rsi

anu

Sm

ho

of

ow

r tr

pile

mula

stal

zed

ua

mar

our

67

ws t

ruc

e a

ativ

lled

d ro

ry

rtTa

rs.

7 d

the

ck)

nte

ve

d a

ock

an

agT

diff

e n

.

enn

nu

abo

k o

d tTM

ere

um

na

mb

ove

on 1

the

sy

ent

mbe

wa

ber

e th

16

e e

yste

t ta

er

as d

r of

he b

Ma

xca

em

ags

of

dam

f RF

bel

arc

ava

m m

s w

ta

ma

FID

lt r

ch.

atio

mo

wer

gs

age

tag

rath

Th

on

nit

re d

de

ed a

gs

her

his

of

tore

det

ete

and

T

det

r th

ex

f th

ed

tec

ecte

d t

The S

tec

han

pla

he

th

cte

ed

his

Sout

cted

n u

ain

mu

he

d;

fo

s tr

ther

d d

und

s w

uck

m

33

or e

un

rn Af

duri

der

why

k p

mat

3 w

eac

cat

frica

ing

th

y th

ile

eri

wer

ch

ted

an In

g th

e b

her

be

al

e o

de

d th

nstit

e t

bel

re w

etw

pa

of

tec

he

tute

test

t, a

wa

wee

ass

no

ctio

re

of M

t

and

as n

en

sing

rm

on

sul

Mini

d w

no

15

g t

mal

po

lts

ng a

was

de

5 -

thr

siz

oin

in

and

Plat

s

tec

17

ou

ze

t, t

Ta

Met

tinum

ctio

M

gh

an

the

ble

tallu

m 20

88

on

Mar

th

d 3

e t

e I.

urgy

012

85

ch

he

34

ag


Platinum 2012

886

Table I-Detected RFID tags at each detection point

Tags Primary crush product Stockpile HPGR feed

60 mm, truck 22 of 25 14 of 22 11 of 22

20 mm, truck 21 of 25 3 of 21 15 of 21

60 mm, mine 11 of 34 2 of 11 3 of 11

20 mm, mine 10 of 34 1 of 10 8 of 10

Total 60 mm 33 16 14

Total 20 mm 34 4 23

Total 67 20 37

Recovery 60 mm total 55.9% 48.5% 42.4%

Recovery 20 mm total 52.5% 12.9% 67.6%

For the stockpile and HPGR feed detection points, the recovery was calculated with reference

to the 64 distinct tags detected at the primary crusher. Of the normal tags detected at the

primary crusher detection point, 42.4 per cent were then detected at the HPGR feed detection

point; whereas for the mini tags 67.6 per cent of tags detected at the primary crusher were also

detected at the HPGR feed. This shows that the survival of the mini tags in the circuit is higher

than the normal tags. In a hypothetical situation, where the secondary screening mesh is

smaller than 50 × 50 mm, normal tags certainly would not reach the HPGR.

The detection of tags at the primary crusher was also affected by the removal of the

SmartTagTM system before the entire blast was processed (for logistical reasons).

The RFID tags were used to track the material during an optimization campaign at the plant.

The blast map in Figure 13 shows that during the plant survey the material that fed the plant

originated from the central portion of the blast.

An unexpected result was that three of the mini tags were twice detected at the HPGR feed

detection point. An explanation for this is that they survived the HPGRs and returned with the

circulating ore (screened to +5 mm). The transit times of these three tags are shown in Table II.

The differences in the transit times in the circuit are probably due to different levels in the

HPGR feed bins.


Platinum 2012

887

Table II-Transit time through the HPGR circuit

ID tag Transit time (min)

335 86

224 23

251 2

Figure 13-Detected RFID tags during the period of sampling

Conclusions

The concept of mine-to-mill has been applied in the mining industry now for over a decade.

Metso PTI have been involved with many of these projects and developed a proven

methodology called Process Integration and Optimisation. The methodology involves

benchmarking, rock characterization, measurements, modelling/simulation, and where

required, material tracking. The rock characterization step defines blasting domains and allows

different blasting and crushing strategies to be developed.


Platinum 2012

888

This methodology has been used in a wide range of applications from conventional circuit

optimization, throughput forecasting, and greenfield operations. For existing operations,

significant increases in performance have been realized through the application of this

methodology.

PTI have successfully developed an ore tracking system for use in both open pit and

underground mining operations. The tags are used to track ore as it flows from the blast to the

downstream processes. This ensures that the spatial origin of material being processed is

accurately known at all times and that important ore properties are able to be tracked. The use

of RFID tags in this manner also allows the estimation of other operational parameters such as

ore dilution, stockpile residence time, and segregation.

PTI has successfully incorporated a smaller or ‘mini tag’ into their SmartTagTM system. The

changes to the system installation are minor and increase the reliability of the system as a

whole. In several examples the mini tags have proven to be, on average, more robust than

normal sized RFID tags.

PTI envisage that the successful incorporation of the mini tags into the SmartTagTM system it

will allow applications for the system to be expanded. These new applications could include a

wider use in the iron ore industry, where size is the critical material quality. PTI is now working

on proving the reliability of the next size of tags, the even smaller ‘micro tag’, which can pass

through a 10 mm mesh screen.

With the decreasing size of RFID tags and the development of SmartTagTM into a truly

distributed system SmartTagTM can be extended past the mine to cover the whole minerals

supply chain. Detection points can now be located in the plant, the port, and even at the

location of the customer, such as the feed to a blast furnace.

References

1. La Rosa, D., Valery, W., Wortley, M., Ozkocak, T., and Pike, M., The use of the radio

frequency ID tags to track ore in mining operations. APCOM 2007. Proceedings of the 33rd

International Symposium on Application of Computers and Operations Research in the

Mineral Industry, Santiago, Chile, 24-27 April 2007. Magri, E.J. (ed.). pp. 601-610.

2. Dance, A., Valery Jnr., W., Jankovic, A., La Rosa, D., and Esen, S., Higher productivity

through cooperative effort: a method of revealing and correcting hidden operating

inefficiencies. SAG2006 – HPGR, Geometallurgy, Testing. International Conference on

Autogenous and Semiautogenous Grinding Technology, Vancouver, Canada, 2006. vol. 4,

pp. 375 – 390.


Platinum 2012

889

3. Kanchibotla, S. and Valery, W. Mine to mill process integration and optimisation - benefits

and challenges. Proceedings of the 36th

Annual Conference on Explosives and Blasting

Technique, Orlando, Florida, 7–10 February 2010. International Society of Explosivse

Engineers, 2010. Vol. 1, pp. 169–182.

4. Wortley, M, Nozawa, E, and Riihioja, K, Metso SmartTagTM – the next generation and

beyond. APCOM 2011. Proceedings of the 35th International Symposium on Application of

Computers and Operations Research in the Minerals Industry, Wollongong, Australia, 24–

30 September 2011. pp. 841-851.

5. Dance, A., Mwansa, S., Valery, W., Amonoo, G., and Bisiaux, B., Improvements in SAG mill

throughput from finer feed size at the Newmont Ahafo operation. SAG 2011, Proceedings

of the Fifth International Conference on Autogenous and Semiautogeneous Grinding

Technology, Vancouver, Canada, 25–29 September 2011.

6. Nozawa, E., Corsini, J., La Rosa, D., Valery, W., and Allport, A. SmartTag system

improvements for increase of ore tracking performance from mine to mill and other

applications. Proceedings of the Tenth Brazilian Symposium on Iron Ore, Ouro Preto.

Brazilian Association of Metallurgy, Materials and Mining, 2009.

The Authors

Dr Erik Isokangas, Manager PTI Centre – Europe, Africa, Middle East, Russia/CIS, Metso

Minerals Inc.

Dr. Erik Isokangas manages the Process Technology & Innovation (PTI) Centre for Europe, Russia

/ CIS, the Middle East, and Africa, developing the PTI business in this region and providing local

support for consulting, research, and innovation systems.

Erik graduated in 1996 with a doctorate (PhD) in process control in the mineral sands industry

from the JK Mineral Research Centre, University of Queensland. He also holds a Bachelor

Degree in Electrical Engineering from the University of Queensland.


Platinum 2012

890

Over the past 20 years in the industry, Erik has worked for companies such as BHP Australia

Coal, Thiess Pty Ltd, and Ground Probe in Australia, and Hochtief in Germany. He has had a

wide variety of roles including: the development and delivery of various mining technologies,

project management, consulting, and information systems management.

Erik has also specialised in simulation and modelling, particularly in material handling systems

and construction planning, developing unique solutions that are used on mine sites to solve

complex delivery issues.

Dr Birol Sönmez, PTI Manager – Turkey, Metso

Birol Sönmez joined Metso at the end of 2010 as Manager of Process Technology & Innovation

for Turkey. He manages the regional centre, which will provide local support for consulting

(continuous improvement and asset optimisation activities), internal R&D and innovation

systems (hardware and software).

He is responsible for collection of process data from industrial mining plants as well as

application and development of mathematical models and simulations for the process

Integration and Optimisation projects.

Before joining Metso, he was employed at a number of companies at which he acquired

experience in plant audits, sampling, mass balancing, modelling and simulation of the mineral

processing circuits -totalling more than 15 years of experience. He has been involved in several

mineral processing projects and gained site/practical experience in quarry and beneficiation

plant operations improvements.

Birol joined the mineral processing department of Hacettepe University in Turkey as a MSc

student in 1989. He attended to three of postgraduate courses, namely "Computer

Applications in Mineral Processing", "Instrumentation Control and Modelling in Mineral

Processing" and " Mineral Processing Simulation". He also worked as research assistant in the

department from 1989 to 2000. He assisted mineral processing lectures laboratories and

supervised final year dissertation projects.


Platinum 2012

891

In 2000, he spent eight years at Eregli Iron & Steel Works which is the largest iron and steel

company in Turkey as a R&D Engineer and Chief of Supply Strategies. During his time at Eregli,

Birol managed several waste utilization research projects and gained valuable expertise in

developing strategies for the purchasing steel plant raw materials.

In 2008, Birol worked at Demirexport Copper-Zinc, Iron, Chromium and aggrega operations as a

head of Process Technologies, taking part in projects for optimization of the crushing, grinding

and flotation circuits, and aggregate production plant. In addition he was in charge of the

metallurgical evaluations of all the production circuits contributing to the continuous

improvement of the process.

He got his PhD from the University of Hacettepe, Turkey in 1999 with a thesis titled

"development of a simulation package for coal washing plants".


Platinum 2012

892

USING SMARTTAGTM TO TRACK ORE IN PROCESS …€¦ · in the total process, understanding the...

Documents

Transcript of USING SMARTTAGTM TO TRACK ORE IN PROCESS …€¦ · in the total process, understanding the...