An integrated understanding of the Comminution processing chain

Malcolm Powell

JKMRC, SMI, University of Queensland, Brisbane Australia. malcolm.powell@uq.edu.au

Abstract
Predicting the performance of the whole mining process is surely the holy grail of predictive simulation. I
call this ‘integrated process prediction’.

The objective is to be able to predict the response of the processing chain, from mining to concentration, to
changes in the ore type. This can apply to greenfields design – selecting processing options to optimise the
overall mine performance within the constraints and aspirations of the greater community and
environment; expansion and optimisation of existing plant to deal with changes in economic drivers and
ore types; and on-line control – predictive reaction to ongoing changes in ore processing types in an
operation.

In order to achieve this there are several broad key components that are required: ore characteristics based
on in-situ rock properties; prediction of how the rock fragments; the ability to predict and track progressive
mineral liberation of the rock through the reduction process; the response of rock to separation processes
as a function of the rock mineralogical properties. Applying improved process knowledge is far cheaper
than adding equipment and then increasing consumables, energy and water consumption. The GCC has
assisted a site gain 20% more throughput and plotted the path to a further 20% increase – which the site is
well on the way to achieving – without any additional equipment. Furthermore, the ability to expand the
circuit to 70% greater throughput than the original throughput with only 15% more power has been
designed in detail based on dynamic circuit simulation.

This keynote will look at the value of this integrated approach; the challenges it poses; the technology and
capability we require. Specifically, I will address how linking the power of deep knowledge of world experts
into a single team of the GCC to address the linked issues along the comminution process can provide the
applied route to increase production through maximising the utilisation of the circuit as a whole.