An operation of |
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A few examples of SmartMining |
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Reasons to target substantial energy savings |
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Reasons to target substantial energy savings TOP |
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Mining, and gold mining in particular, |
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| The changing mining environment - expanding the 'profitable zone' TOP | |
It is not an ideal world. The immediate major issues (with large increase profit potential) include: (1) mines are getting deeper, (2) the finite resources are harder to exploit, (3) finding the new resources by exploration can be expensive, (4) energy prices are no longer stable, (5) safety can be expensive (like ventilation, lighting & roof bolting) (6) environmental protection puts new demands on 'bottom line', and (7) trucking fleet tyre costs, (can determine vehicle availability). |
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| The 4 Classic Zones in Gold Mining (as shown above left), illustrates the PROFITABLE ZONES of mining. With oil (energy) price prises, safety issues, deeper mining. reduction of the rich zones and less expenditure on exploration, the profitable zone is under stress. For the MONEY Engineers, the above dynamics creates opportunities: (A) The acquisition price of a particular mining company can be forced down. (B) The ore body asset value can be increased if the extraction cost can be reduced. For the applied technology MINING Engineers, with the hands-on capability, this creates MAJOR opportunities to 'cherry pick' the best opportunities, and apply the appropriate technologies, to maximise the returns and minimise the input costs. This expands the all important Profitable Mining Zone. (See right). TOP |
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| SAG Mills - big opportunities for energy savings & more production TOP | |
A series of Marginal Savings can have a dramatic positive effect on the bottom line. For example, when large SAG mills processing ore generate $40,000 of gold/hour, a typical cumulative shut down of 250 hours in a year is a loss of $10 million in production that cannot be regained in that same year. Simple procedures can reduce the lost time and boost income, like attention to detail on seals, bolt tensioning, retightening procedures and ways of avoiding down-time leaks and internal mill inspections. SAG - Semi Autogenous Grinding Marginal Savings can also be achieved by small changes to the grinding circuit. This is usually site-specific but practical benchmarking mining experience gained in multiple minesites can be combined with other technologies for considerable energy savings and grinding material cost reductions. (See indicative sketch below) |
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| Many 'tweaks' and changes to the internal SAG Mill liner and lifter bars are used to maximise the efficiency of the SAG Mill grinding process. To this, different mill rotational speeds, a cocktail of grinding ball sizes and ball numbers, and other additives continue to be trialled. The suggested interim fix involves innovative ore shaping and blending before being added to the SAG Mill. Energy input savings, extended mill lining and lifter life, and a more effiicient mill ore processing can make worthwhile savings. As part of Smart Mining, the suggested interim designs (shown above) are just part of the immediate changes that can be made to a mill processing chain to save around 1.5% in total mining costs, or around A$3 million per year. (Repayment on expenditure is around 10 weeks).
The full Smart Mining solution is a more comprehensive package.
The SAG Mill is re-engineered together with the ore extraction and haulage replacement techniques. The substantial savings are more than 15% of total mining costs or A$25 million per year in a 500,000 oz of gold per year mine site. |
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| For security of the intellectual property, detail is not given here.
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| Iron ore & coal train operating improvements - Another award software application | |
The strategic approach to the gold mining industry can also pay off in a range of other mining activities. Imagine the capital savings and operational benefits of being able to run longer, heavier & faster trains on existing tracks with greater safety and accountability. Iron ore & coal train gains are worth consideration.  |
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| Donald YATES / CEO BAppSc BCommEng CertRenewEngy |
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MINE Automations Systems Technology Pty Ltd |
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