Improving and Optimizing Operations: Things That Actually Work!

Plant Operators’ Forum 2004
Edited by Edward C. Dowling Jr. and John I. Marsden Published by the Society for Mining, Metallurgy, and Exploration, Inc. 8307 Shaffer Parkway Littleton, CO 80127

Society for Mining, Metallurgy, and Exploration, Inc. (SME) 8307 Shaffer Parkway Littleton, Colorado, USA 80127 (303) 973-9550 / (800) 763-3132 www.smenet.org SME advances the worldwide mining and minerals community through information exchange and professional development. SME is the world’s largest association of mining and minerals professionals. Copyright © 2004 Society for Mining, Metallurgy, and Exploration, Inc. All Rights Reserved. Printed in the United States of America. Information contained in this work has been obtained by SME, Inc., from sources believed to be reliable. However, neither SME nor its authors guarantee the accuracy or completeness of any information published herein, and neither SME nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SME and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are requested, the assistance of an appropriate professional should be sought. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Any statements or views presented here are those of the authors and are not necessarily those of SME. The mention of trade names for commercial products does not imply the approval or endorsement of SME. ISBN 0-87335-235-1 Library of Congress Cataloging-in-Publication Data Plant Operators Forum (2004 : Denver, Colo.) Improving & optimizing operations : things that actually work! : Plant Operators Forum 2004 / editors, Edward C. Dowling, Jr., John I. Marsden. p. cm. Includes bibliographical references and index. ISBN 0-87335-235-1 1. Ore-dressing—Congresses. I. Title: Improving and optimizing operations. II. Title: Plant Operators Forum 2004. II. Dowling, Edward C. IV. Marsden, John I. V. Title. TN497.P53 2004 622'.7—dc22 2004041641

Contents
PREFACE SECTION 1
v

THE ART OF MINING TO PROCESSING RECONCILIATION OR HOW THE MINE DEPARTMENT LIES ABOUT PRODUCTION AND HOW THE METALLURGIST CATCHES THEM 1 Control of Blasting for Ore Blending and Autogenous Mill Performance at Hibbing Taconite Company—Preliminary Findings Peter R. VanDelinder, Jack W. Eloranta, and Michael J.T. Orobona 3 Mining Company Performance Improvement Programs and Results— Summary of Benchmarking Study Peter Fordham 19

SECTION 2

MANAGEMENT SYSTEMS FOR OPERATIONS IMPROVEMENT OR MANAGEMENT SYSTEMS THAT ACTUALLY WORK (NO HARVARD MBAS ALLOWED!) 25 How Good Is My Maintenance Program? John D. Katsilometes 27 Value Creation Through Effective Project Management William S. Brack 39 Are You Really Using Your Information to Increase the Effectiveness of Assets and People? Osvaldo A. Bascur and J. Pat Kennedy 47 Knowledge Management: Does the Right Hand Know that the Left Hand Is Mining? Charles A. Weinstein 63

SECTION 3

PEOPLE AND ORGANIZATION OR TREATING PEOPLE LIKE HUMANS! Engineered Management Processes Francis R. McAllister 77

75

Managing with Workforce Culture in Transition Gregory E. Mahoski and Ronald D. Mariani 87 Linking HR Systems for Better Performance and Employee Involvement at Kennecott Utah Copper Chris Crowl 89

iii

SECTION 4

MANAGEMENT OF PROCESS TECHNOLOGY DEVELOPMENT OR WHAT FUN DOES THE FUTURE HOLD? 93 Has Minerals Industrial Technology Peaked? Robin J. Batterham 95 Managing Technology Development in a Changing Business Environment R.D. La Nauze and R.C. Shodde 103 Minimization of Delays in Plant Startups Terry P. McNulty 113 How to Sell R&D in Your Organization—Without Begging Steven A. Elmquist 121 Technology Development and Competitive Advantage: Sustainable or Short Term? John O. Marsden 127

SECTION 5

ALTERNATIVES TO SAG MILLING OR SAG MILLING! HAVE WE EVOLVED? ARE WE STUCK? State of the SAG James L. Vanderbeek
141

139

Fully Autogenous Grinding from Primary Crushing to 20 Microns R.E. McIvor and T.P. Weldum 147 HPGR—The Australian Experience R. Dunne, D. Maxton, S. Morrell, and G. Lane INDEX
163 153

iv

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