Mining Plant Optimization | Ensuring Efficiency and Productivity
In mining, plant efficiency is a decisive factor for ensuring the economic and operational viability of projects. However, many plants face challenges over time due to changes in ore characteristics and the lack of technological updates.
At Plus Natural Resources (+NR), we offer a holistic approach to identifying and solving chronic design and modernization issues in mining plants, maximizing the investment value for operators.
Mass Balance Review and Volumetric Analysis
The first step to optimizing a mining plant is to perform a detailed review of the mass balance and volumetric analysis. Often, plants are designed based on specific reserve samples, without considering that, over the years, new deposits are explored and processed within the same facility. These differences in volume and mass can cause production issues, leading to operational bottlenecks, loss of efficiency, and reduced productivity.
Our work involves thoroughly reviewing these balances, identifying critical points and operational bottlenecks. Through precise analysis, we adjust operational parameters and reassess equipment to ensure the plant operates efficiently, even with variations in ore characteristics such as moisture, granulometry, and mineral composition.
Process Flowsheet Updates and Equipment Replacement
In many mining plants, updating the Process Flowsheet (flowsheet) is essential to keep up with changes in the processed ore and to optimize operational efficiency. This can involve replacing outdated equipment with more efficient technologies and making specific adjustments to enhance material handling and separation performance.
A relevant example is the modification of screen inclinations to increase material residence time, improving classification and ensuring more efficient sorting. Additionally, changing the screen openings may be necessary to adapt the system to the new granulometric characteristics of the ore, ensuring that smaller particles are not wasted and larger particles do not overload downstream processes. At the same time, adjustments in the inclination and design of chutes enhance material fluidity and utilization during processing, increasing screening efficiency, especially for materials with varying granulometry and moisture content.
Another crucial improvement is the modernization of crushing systems, where replacing conventional crushers with impact or high-pressure grinding roll (HPGR) technologies can increase efficiency and reduce energy consumption. To enhance material transportation efficiency, replacing old conveyor belts with intelligent models equipped with automated speed and load control systems ensures a consistent flow and minimizes downtime.
Additionally, the integration of automated classification technologies and optical sorting enables more precise separation of valuable minerals from waste, increasing the mineral grade of the final product. This modernization also includes the installation of smart sensors for continuous monitoring of equipment performance, allowing real-time adjustments and reducing the risk of unexpected failures.
DEM Analysis: Material Flow and Fluidity
The use of DEM (Discrete Element Method) analysis is fundamental for studying the flow dynamics of bulk materials within the plant. This tool allows for evaluating material fluidity in chutes, conveyors, and screens, identifying accumulation points, excessive wear, and low transport efficiency.
Moreover, DEM analysis assists in verifying residence time, ensuring that materials remain for the required duration in screening and classification equipment. This approach enables precise adjustments in inclination settings, chute design, and feeder positioning, ultimately improving the overall plant efficiency.
See example below:
The animations above show the first 20 seconds of the mass flow simulation (at 840 ton/h) reaching a steady state. The ore initially falls rapidly and then slows as it moves forward, driven primarily by the screen's stroke and gravity, especially near the horizontal section. Minimal stratification occurs at the end.
The new screen, designed as a Dual-Slope with a Flat Deck Screen with a 10-to-zero-degree configuration, primarily moves the material through the screen stroke rather than gravity. This design achieves greater material screening efficiency due to the increased residence time on the deck, allowing for more effective separation.
Below is an example of a simulation we performed to analyze material transfer between chutes and conveyor belts, aiming to reduce speed and prevent damage to the conveyor belt.
The primary objective was to optimize the flow trajectory and minimize impact forces during the transfer process. By carefully adjusting chute angles and the positioning of deflectors, we achieved a controlled deceleration of the material as it transitions from one conveyor to the next.
This approach not only protects the integrity of the conveyor belt but also reduces wear and tear on critical components, thereby increasing the system's operational lifespan and reliability.
Plant Modernization and Adaptation to New Mineral Realities
Another critical point often overlooked is the periodic updating of plants to accommodate the ore actually being processed. In practice, many facilities continue operating with configurations designed for a specific ore type without considering mineral profile changes over the years.
This lack of adaptation results in plants that fail to meet expected performance. Changes in moisture, granulometry, and concentrate types can directly impact production capacity and process efficiency. Our approach proactively identifies these issues, proposing updates that ensure continuous high-efficiency operation, even when the ore profile changes significantly.
Customized Solutions for Mining Plants
At +NR, our mission is to identify and resolve chronic design and operational issues in mining plants. From initial diagnosis to practical solution implementation, we work closely with our clients to ensure that each plant operates at maximum efficiency, even when faced with new challenges.
If your mining plant is not delivering the expected returns, get in touch with us. We can help diagnose the problems and propose solutions that bring long-term productivity and efficiency. Visit our website to learn more about our innovative solutions and how we can support the modernization of your operation.