I-271 I-272

INTRODUCTION

SAG PJV recognized that the optimization of drill and blast practices to
maximize the productivity of mine and mill operations would contribute
2001 to its profitability. PJV and explosive supplier Dyno Nobel embarked on
this project with the goal of optimizing fragmentation for downstream
MINING AND MINERAL PROCESS ENGINEERING processes. The initial aim was to increase SAG mill throughput when
UNIVERSITY OF BRITISH COLUMBIA milling hornblende diorite. The process is tonnage constrained on this
Vancouver, B. C., Canada ore. The JKMRC was sub-contracted to provide technical expertise.

The results of an audit and survey provided a benchmark of current

MAXIMIZING SAG MILL THROUGHPUT AT PORGERA GOLD MINE
BY OPTIMIZING BLAST FRAGMENTATION
Mike Lam, Senior Metallurgist, Porgera Joint Venture
Dr. Aleksandar Jankovic, Julius Kruttschnitt Mineral Research Centre
Dr. Walter Valery, Julius Kruttschnitt Mineral Research Centre
Sarma Kanchibotla, DynoConsult – Dyno Nobel Asia Pacific
performance. From this data, site specific models of the process from
blasting to SAG milling have been calibrated. These models were
linked and simulations performed to study the effect of blast
fragmentation on SAG mill throughput. A modified blast design at a
higher powder factor was selected to produce a finer feed to the primary
crusher and SAG mill. Two modified blasts were fired and an increase
of 15% in the mill throughput was measured. The results of the surveys
were close to the predictions of the model. Implementation of blast
optimization for the milling process is underway at Porgera.

BACKGROUND INFORMATION ABOUT PORGERA

ABSTRACT

Porgera Joint Venture is a gold mine located in the remote and rugged
Porgera Joint Venture (PJV) and Dyno Nobel initiated a project to highlands of Enga Province in Papua New Guinea (see Figure 1).
optimize drilling and blasting practices for downstream operations. The
SAG mill was identified as a production bottle neck when treating
hornblende diorite ore. Consequently, it was agreed that the project
would focus on optimizing the fragmentation size distribution for the
crushing and SAG milling circuits. The Julius Kruttschnitt Mineral
Research Centre (JKMRC) was sub-contracted to investigate the impact
of blasting on SAG mill throughput.

Rock characterization, blast and mill surveys were conducted on

hornblende diorite. The data was used to build site specific models for
blast fragmentation, primary crushing, and SAG and ball milling. The
models were linked and simulations performed to investigate the
influence of ROM fragmentation on SAG mill throughput. Based on
these simulations, modifications were made to blasting practices and
primary crusher settings. Two additional surveys were conducted to
validate the models. This paper discusses the methodology and results
achieved.

Figure 1: Location of Porgera and Placer Dome Asia Pacific Mines

 I-273
The operation employees about 2,000 people. The mine is operated by
Placer Dome and produced over 900,000 oz of gold in calendar year
2000.
The Porgera Gold Mine moves over 210,000 tonnes per day of material
including about 18,000 tonnes of ore. Mobile equipment consists of 36
Cat 789 haul trucks, 8 Cat 777 haul trucks, 6 OK RH200’s, 2 Cat 992
loaders, 1 OK RH40, 3 Cat 16G graders, 3 Cat 824 wheel dozers and
auxiliary contractor equipment. The mine runs 24 hours per day utilizing
3 shifts per day.
After blasting, the ore is loaded and hauled to the primary crusher or run-
of-mine (ROM) stockpiles. At the primary crushing plant, the ore is
reduced to minus 150 mm size material in a single pass through a
gyratory crusher to produce a SAG mill feed.
Apron feeders draw the crushed ore from a coarse ore stockpile to feed
two parallel primary grinding lines. Each line consists of a variable
speed SAG mill measuring 28 feet in diameter by 11 ft long. The mill
motors are rated at 5,500 HP. At the discharge of each SAG mill is a
pair of vibrating screens. The screen oversize material from both SAG
mills is conveyed to a shared pebble crushing circuit consisting of two
Omnicone crushers.
The SAG screen undersize from both SAG mills is pumped to a common
distributor where it is split to feed three parallel ball milling circuits. The
ball mills are in closed circuit with hydrocyclones. The grinding circuit
product measures 80% passing 106 microns and feeds the flotation
plant.
A bulk flotation process using conventional cells produces a gold-bearing
sulphide (mainly pyrite) concentrate. The concentrate is thickened
before it is pumped to the pressure oxidation circuit. Oxidized slurry is
re-circulated to destroy most of the carbonates prior to the concentrate
being fed to four parallel autoclaves. In the autoclaves, the sulphides are
decomposed to expose the gold. The autoclave discharge is cooled,
thickened and washed. After pH adjustment, the oxidized slurry is
cyanide leached in a leach/CIP circuit. The loaded carbon is stripped,
and the gold and silver are electrowon from the pregnant solution.
Bullion is poured on site.
WHAT DOES A MINE TO MILL PROJECT INVOLVE?
The “Mine to Mill Blasting” approach involves identifying the leverage
that blast results have on different downstream processes and then
I-274
optimizing the blast design to achieve the results that maximize the
overall profitability rather than individual operations.
Identification of each opportunity to increase process efficiency is very
important to the success of the approach. Potential areas of impact
include, but are not limited to:
q Increase in comminution efficiency leading to higher mill throughput,
q Improvement in loader/excavator productivity due to better
diggability, and fill factors,
A typical mine to mill blast optimization project involves several phases
such as:
1. Scoping
2. Auditing
3. Modeling and Simulations
4. Validation
5. Implementation
SCOPING
The mine to mill blast optimization project is interdisciplinary in nature
and it impacts on several aspects of mining and milling operations. This
means a team approach is required with members from the mine and
the mill, and a project champion to drive the project. At Porgera, the
initial scope of the mine to mill project was limited to maximizing the
SAG mill throughput by altering blast design and crusher settings to
provide an optimum feed size distribution to the mills. Hornblende
diorite was chosen for the study because it is the hardest ore at
Porgera.
The impact of blasting results on the efficiency of load and haul
operations was investigated, but the details of that study are not
covered in this paper. Likewise, the effect of blasting on ore body
dilution and damage to the pit walls will be studied separately.
AUDITING
During this phase, an audit of all the processes from drilling and blasting
to milling was conducted. A trial blast (#340319) was conducted on
hornblende diorite in May 2000 with the standard design and the ore
from this blast was processed through the mill without any blending.
During this trial all critical input and output parameters from drilling and
 I-275 I-276

blasting to SAG milling were monitored, especially the size distribution of In this test the ore was broken in a range of sizes under a range of
ore from in situ to the final product of the grinding circuit. energies. The relationship between t10 and the specific breakage
energy is defined by Equation 1.
Rock / Ore Characterization

Generally ore domains are classified based on grade and geology and t10 = A (1- e-bEcs) (1)
do not take into account the breakage characteristics. The breakage
characteristics of rock /ore are very important for the design and where A and b = ore specific parameters,
optimization of any mine to mill process. Therefore, it is essential to Ecs = specific breakage energy (kWh/t),
understand these differences and characterize the rock mass in terms of t10 = percent passing 1/10th original particle size.
its blastability as well as comminution properties.
th
By convention, t10 is the percent passing 1/10 of the original particle
th
Blastability size, whilst the t50 is the percent passing 1/50 etc.

Blasting loosens the existing rock mass structure to liberate rock blocks
and creates new fractures within the intact material. Fines are produced
by the crushing action of the explosion in a zone that surrounds each drill
hole. Blastability is a function of mechanical properties of intact rock (eg.
stiffness and strength) and the rock mass structure (size of ‘insitu
blocks’). Zones within a mine that are of similar strength and structure
should blast in a similar way and hence form a blasting domain. It
should be recognized that the blasting domains may be different from the
current geological domains.
Drill and Blast Audit
A blast auditing exercise was undertaken to understand the
implementation of blast design, the explosive performance and to
quantify fragmentation, throw and back break. The designs for the trial
blast and subsequent modified blasts are given in Table 1.
Table 1. Blast Design Parameters
Blast 340319 Blast 320314 Blast 310316

The structural characteristics of ore in the trial blast were estimated from (Bench mark) Oct 2000 Dec 2000
the scan line mapping and face photographs. The mean in situ block Bench height m 10 8.6 10
size was estimated to be between 0.5m to 0.6m.
Burden m 5.3 4.5 4.5
Cores from the ore samples collected from the trial blast were subjected
to various rock mechanic tests to measure the strength and stiffness Spacing m 6.3 5.5 5.5
properties. Rock samples were also subjected to point load testing to Hole depth m 10.6 9.1 10
estimate the strength.
Column height m 5.3 3.6 5.15
Comminution Characteristics
Stemming height m 5.3 5.7 4.7
The micro fracture network, grain size and grain characteristics may be Subdrilling m 0.6 0.5 0.5
important in comminution processes such as crushing and grinding. It is
necessary to understand the comminution properties of different ore Explosive Titan 4070 Titan 4070 Titan 4070
types to optimize the integrated mine-to-mill operation
Density 1.25 1.25 1.25
The JKMRC use a ‘drop weight test’ to determine the breakage VOD 5100 4900 -
characteristics of rocks. A detailed description of the tests for
determining the comminution properties is given by Napier-Munn et al RWS 80 80 80
(1996).
Powder factor kg/t 0.242 0.31 - 0.35 0.38
 I-277 I-278

The actual blast design parameters such as hole depth, burden, spacing
and stemming height for each hole was measured and compared with
7 SAG mill scates

the design parameters.

40,000 tonnes
Crusher SAG #1&2 disch (+12mm)

The results indicate good control in drilling during collar positioning.

ore stockpile 8
crusher product

However in case of maintaining the drill depth, 20% of the holes were
either drilled 0.5m deeper or shorter than the design depth. This CV12
1 SAG

variation in the drilled depth causes either severe damage to the floor MILL

5
(excessive drilling) or leaves toe (short drilling) therefore producing an screen

SAG#1&2 disch (-12mm)

uneven floor. The lack of control in maintaining the stemming heights 3

sampling points
can result in oversize from the collar (excessive stemming) or in weightometers 4

stemming ejection (less stemming) both resulting in undesirable blasting

results.
2

Fragmentation Assessment
During this trial, photographs were taken of the muck piles and at the
rear of trucks while the ore is dumped at the primary crusher. These
photographs were analyzed with the Split image analysis system to
estimate the fragmentation size of ROM material. Approximately twenty
images from the muck piles and thirty five images from the rear of trucks
were analyzed. The images taken at the primary crusher dump pocket
provided a better estimate of the ROM fragmentation size. This is
because the surface of the muck piles are not true representations of the
entire blast.
Mill Survey #1
The first survey was conducted on 28 May 2000 to provide a baseline of
current practice and performance. The blast (#340319) was un-modified
and the primary crusher gap was set between 120 and 180 mm to
maintain crusher throughput.
CV108
SAG
MILL
6
screen
Figure 2: Schematic of Porgera Primary Crushing and SAG milling
Circuits with sampling points
After the steady state portion of the survey, the SAG mill circuit was
crash stopped to collect samples from the belt conveyors, to allow
inspection of the mill interior and to carry out load measurements.
Subsequently, the SAG mills were ground out to determine the ball
load. Photographs were taken to estimate the rock and ball size
distribution of the muck load using the Split system.
Cameras were also installed to monitor the SAG feed conveyor belts for
subsequent feed size distribution determination using the Split imaging
system.

The ore from the trial blast was campaigned through the mill without any All samples were processed through the lab to determine % solids, and
blending and a full mill survey was conducted. SAG mill throughput was size distribution. Portions of the sized SAG mill feed were collected and
maximized at 673 dmtph of fresh feed. When the mill reached steady sent to JKMRC for drop weight and Bond Ball mill work index tests. The
state, samples were collected from various locations in the circuit every results of these ore characterization tests are summarized in Table 2.
15 minutes over a period of one hour. The major circuit variables were
also monitored and collected from the control system. Figure 2 page I- Table 2. Comminution Characteristics of Hornblende Diorite
278 illustrates the primary crushing and SAG milling circuits, and the
sampling locations. Survey Blast A b ta Wi (Kwh/t)
1 340-319 61.3 0.66 0.29 18
2 320-314 63.3 0.65 0.32 18.5
3 310-316 63.2 0.65 0.33 19.8
 I-279 I-280

The results of the mill survey are summarized in Table 3. Mill survey #2 SAG Feed Size Distributions (Survey #1)
and #3 results are also shown; these will be discussed under their own
section. 100

90
survey 1, SAG 1

Cumulative Wt% Passing

Table 3. Summary of Mill Survey Results 80
survey 1, SAG 2
70
Survey 1 2 2 3
60
Blast # 340-319 320-314 320-314 310-316
SAG 1 Muck Load, vol % 26.3 22.8 - 26.9 50

Ball Load, vol % 11.0 13.8 13.8 13.2 40

Ball Size, mm 150 125 125 125 30

Power, KW 4550 4650 3970 4310 20
Bearing Pressure, 3900 3740 3720 3927 10
kpa
0
Mill Speed, rpm 11.42 11.42 10.79 11.50 10 100 1,000 10,000 100,000 1,000,000
SAG 2 Muck Load, vol % 30.4 34.0 - 32.6
Size (um)
Ball Load, vol % 12.1 12.7 12.7 12.7
Ball Size, mm 150 125 125 125 Figure 3: SAG Feed Size Distribution (Survey #1)
Power, KW 4350 4400 4100 4350
Bearing Pressure, 4190 4120 4100 4045
kpa
Mill Speed, rpm 11.42 11.42 11.42 11.5 MODELING AND SIMULATIONS
Screen Size (mm) 12 12 12 12
Scats Treatment Crushed Recycled Rejected Crushed
Scats to Mill, dmtph 372 501 0 290 Understanding the mechanisms and interaction between different
SAG 1 dmtph 400 285 485 387 processes in the Mine-to-Mill chain, modeling key processes and
SAG 2 dmtph 273 346 450 387 integrating them is a key feature of the integrated mine to mill
Total (Actual dmtph) 673 631 935 774 optimization. Based on the information gathered during the
benchmarking audit and survey, the blasting, crushing and milling
processes have been modeled. These models were linked to
It can be seen that SAG #1 feed rate was substantially higher than for
investigate the impact of blast fragmentation on SAG mill performance.
SAG #2.
Blast Fragmentation Modeling
This difference in milling rate is primarily due to the fact that the feed size
distribution for SAG #1 was finer than the feed of SAG mill #2 (see
Figure 3 page I-280). This happens because the feed belt conveyor of The ore properties and the blast design parameters measured during
SAG #1 is located at the center of the coarse ore stockpile where as for the audit for the trial blast, were used in the JKMRC blast fragmentation
model to predict the ROM fragmentation. Photographs were taken of
SAG #2 it is offset from the center. Because of segregation on the
the post blast muck piles and at the rear of trucks. These images were
stockpile, SAG #2 tends to receive coarser feed.
processed using the Split system to obtain the size distributions of
ROM. A comparison of ROM size distributions predicted by the models
The total charge measurements are consistent with the bearing pressure
and by the Split system indicates that the model predictions are very
measurements. However, SAG #2 drew less power than SAG #1
close to the ROM size distributions estimated by the Split.
despite having a higher load. This apparent discrepancy is likely
explained by the worn out condition of SAG #2 belly lifters which were
changed out only one month after survey #1.
 I-281
Mill Modeling
The JKMRC has been conducting considerable research in this area for
the past three decades and developed a number of models to simulate
different stages of comminution. These models are encapsulated in a
simulator called JKSimMet. A detailed description of these models is
given by Napier-Munn et al (1996).
The data collected from the mill survey was mass balanced and then
used to calibrate the crushing and grinding circuit model at Porgera. The
ball milling circuit was included in the survey to provide a model of the
entire grinding circuit.
The breakage rates for the two SAG mills are plotted in Figure 4. For
survey #1, the breakage rates are similar for both mills. There is a drop
in the breakage rates in the size range of 20 to 75 mm. A noticeable
difference is that SAG #2 breakage rates do not rise back up at the
coarse end. This may be due to the large amount of coarse material in
the feed that could not be broken with the available mill charge, the worn
lifters, or poor representation of the mill load size distribution based on
which the breakage rate is calculated.
SAG Mill Breakage Rates
I-282
VALIDATION
Mill Survey #2
The second survey was conducted on 17 October 2000. The powder
factor of this blast (#320314) was about 40% greater than for survey #1
(see Table 1) and the primary crusher gap set at 110 mm. The ore was
similar for both surveys #1 and #2 as indicated by the results of the ore
characterization tests (see Table 2). So the results of the two surveys
can be compared.
Unfortunately, a pebble crusher was not operating during this survey.
So, it was decided to conduct the mill survey without a pebble crusher
under the following two scenarios.
1. by re-circulating the uncrushed scats ( the worst case) and,
2. by rejecting/dumping the scats to ground (the best case).
A full mill survey was conducted for the first case (re-circulating
uncrushed scats). The second case was run at steady state but a full
circuit survey was not done. Operating variables were recorded.
The finer SAG feed size distribution achieved in survey #2 (compared to
survey #1) is illustrated in Fig 5. Survey #3 feed is also shown.

100 SAG Feed Size Distributions

100
90
Survey #1
80

Cum. Wt% Passing

Survey #2
Breakage Rate

70
Survey #3
10 60
Survey 1, SAG 1 50
Survey 1, SAG 2 40
Survey 2, SAG 1
30
Survey 2, SAG 2
20
Survey 3, SAG 1
Survey 3, SAG 2
10
1 0
0 1 10 100 1,000
10 100 1,000 10,000 100,000
Size (mm)
1,000,000

Figure 4: SAG Mill Breakage Rates Size (microns)

Simulations were run to predict the influence of different blast designs on Figure 5: Effect of High Powder Factor on SAG Feed Size
SAG milling throughput. A tighter drill pattern was selected as the Distribution
method to increase the amount of fines in the SAG mill feed. The key The results of the mill survey were summarized in Table 3. The SAG
parameters of the blast designs were shown in Table 1. mill throughput with the modified design and no pebble crusher running
 I-283 I-284

was only about 5% less than the benchmark throughput achieved with an
unmodified blast but a pebble crusher running. When the scats were
dumped to the ground, the SAG throughput increased by 48%. Mill
throughput with a pebble crusher running would have been between 631
and 935 dmtph for the feed size distribution achieved by this blast
design. The results of the two scenarios clearly demonstrate the
negative impact of uncrushed scats on SAG mill throughput.
Because the pebble crusher was unavailable, the following simulations
were run to compare the predicted and the actual throughput:
higher during survey #2, probably due to the return of uncrushed scats
to the mill which would enhance abrasion type breakage. This is
consistent with survey #2 exhibiting a finer SAG mill product (smaller
transfer size) to the ball milling circuit than survey #1 (See Figure 6).
SAG Screen Undersize Size Distributions
100
90
80

Cum Wt% Passing

1. The two scenarios sampled during survey #2 (i.e. scats recycled and 70
scats dumped),
60
2. The standard blast design (blast #340319) without a pebble crusher
and recycling the scats (worst case). 50 SAG 1, survey 1
SAG 2, survey 1
3. The modified design (blast #320314) with a pebble crusher running. 40 SAG 1, survey 2
SAG 2, survey 2
30 SAG 1, survey 3
A comparison of the predicted and actual SAG mill throughputs are SAG 2, survey 3
summarized in Table 4. The right most column is survey #3 data. 20
10
Table 4. Summary of Actual and Simulated Throughputs 0
Blast 340-319 Blast Blast Blast
10 100 1,000 10,000 100,000
(Bench mark) 320-314 320-314 310-316
Ball load SAG 1 11.0 13.8 13.8 13.2 Size (microns)
SAG 2 12.1 12.7 12.7 12.7
Scats Treatment Crushed Recycled Rejected Crushed Figure 6: Comparison of SAG Screen Undersize Size Distributions
SAG 1 dmtph 400 285 485 387
These results were very encouraging, but a third survey was deemed
SAG 2 dmtph 273 346 450 387 desirable to fully validate the models.
Total throughput 673 631 935 774
actual (dmtph) Mill Survey #3
Total throughput 673 656 910 803
simulated (dmtph) The third survey was conducted on 15 Dec 2000. The goal was to
Actual % Increase vs 15% provide more robust validation of the models with the pebble crusher
benchmark running.

Simulations of the two scenarios during survey #2 predict throughputs
within about 5% of the actual results. The models predict that the mill
throughput would have been 803 dmtph if the pebble crusher had been
running. Furthermore, the simulations predict a throughput of only 530
dmtph on the standard blast (#340319) with no pebble crusher,
compared to 673 dmtph (standard blast with a pebble crusher).
Surveys #1 and #2 exhibited different breakage rate curves (see Figure
4) in the fines fraction. This is attributed to the different conditions in the
mill. The breakage rate of particles less than 10 mm in size is much
In blast #310316 the powder factor achieved was very close to the
design (design powder factor was 0.4 kg/t). The stemming height in the
modified blast was reduced from 5.7m to 4.7m because some oversize
blocks were noticed from the stemming region of the previous blast.
The ore from this blast was campaigned through the mill. Unlike in
survey #1 or #2, there were no oversize blocks. From visual
observation the fragmentation looked very fine. The crusher ran with a
100 mm closed side setting and the power draw was consistent. There
 I-285
were no crusher motor trips and the throughput was good with no
queuing of trucks at the crusher
A full mill survey was conducted and samples processed. As expected,
the SAG feed size distribution was finer than the baseline survey and
somewhat finer than what was achieved in survey #2 (see Figure 5).
The results of survey #3 were summarized in Table 3 along with the
survey #1 and #2 results. During survey #3 a milling rate of 774 dmtph
was achieved. This represents a 15% increase in throughput compared
to the baseline (survey #1), and is also within 5% of the throughput
predicted by the model.
Ore characterization were performed and established the ore to be
similar to the survey #1 and #2 material (refer to Table 2).
Consequently, the SAG mill throughput increase can be attributed to the
finer feed size distribution produced by the high powder factor of the
blast and tighter primary crusher setting.
In general, the breakage rate curves were similar in shape to the
previous surveys (see Figure 4). The breakage rate in the fines fraction
is somewhat less than for survey #2, which is expected since the scats
were crushed in survey #3.
The mill inspections once again showed that there was packing between
the belly lifters. Mill trajectory simulations also indicate that some
grinding balls are being thrown well over the toe of the charge. PJV is
now looking to optimize shell lifter design in terms of the face angle and
number of lifter rows.
MILL SIMULATIONS
The purpose of the “Mine-to-Mill” project was to determine the impact of
blasting on SAG mill feed size distribution and hence mill throughput. It
was also important to establish if the milling rate could be increased by
making modifications to the operation of the existing circuit instead of
altering the feed size distribution. The effects of changing several major
circuit variables were simulated.
Different grate size openings were simulated and the results indicated
that an opening smaller than 70 mm would be detrimental to SAG mill
throughput. This prediction is not surprising if the breakage rate curve is
examined (Figure 4); the 20 to 75 mm material does not break efficiently
in the SAG mill. A smaller grate opening will result in lower throughput
I-286
because critical size material will occupy more mill volume and not
break efficiently. It is better to remove this material from the mill and
crush it. PJV are currently using grates with 75 mm openings.
Simulations were also run with several different SAG discharge screen
aperture sizes. The simulations suggested that SAG mill throughput
gains would be marginal by increasing the screen aperture dimensions.
Also, the transfer size to the ball milling circuit would increase.
However, since each SAG mill has two parallel screens on its
discharge, one screen has been fitted with 12 mm aperture panels and
the other unit with 15 mm aperture panels. This arrangement provides
operating flexibility depending on the feed being milled and which part
of the grinding circuit is the bottleneck. So far the operating evidence
suggest that the ball milling circuit can handle the coarser transfer size
from the SAG mill when the screen fitted with 15 mm aperture panels is
run.
The choice of ball size is normally dictated by the hardness and size
distribution of the feed. The simulator predicts higher SAG throughputs
with the 125 mm ball compared to the 150 mm ball. The 125 mm ball
can provide the necessary energy level to break the rocks. Since the
number of 125 mm balls for a given volume is greater than for 150 mm
balls, the number of breakage events is more for the 125 mm ball (other
mill variables being equal). This translates into a higher breakage rate
with the 125 mm ball. Industrial trials are continuing to resolve this
issue.
According to simulations, SAG mill throughput can be increased by
running with a higher ball charge. However, the total (ball and rock)
charge would have to be reduced so as not to further exceed the motor
rating. A higher ball charge and lower rock load would tend to promote
impact breakage and reduce the amount of abrasion breakage. These
factors would lead to a coarser transfer size. PJV is running the SAG
mills at approximately a 12% ball charge and the ball milling circuit is
not often constrained.
The effect of the pebble crusher’s closed side setting (CSS) was also
simulated. Increasing the CSS does not appear to reduce the SAG
feed throughput by much. Nevertheless, the smallest CSS possible is
targeted without causing excessive crusher vibration. Bypassing of the
crusher does have a significant negative impact on SAG throughput as
shown by survey #2 results and predictions.
 I-287 I-288

FUTURE MINE TO MILL WORK ACKNOWLEDGEMENTS

The “Mine-to-Mill” project is being implemented at Porgera. Hornblende The authors would like to thank the management of Porgera Joint
diorite is being blasted at the higher powder factor and mill throughput Venture, Dyno Nobel and JKMRC for their permission to present this
monitored. The blast design for hornblende diorite continues to be paper. We also wish to gratefully acknowledge all those who
refined. contributed to the work presented.

Other ore types will be characterized so that blast optimization can be

expanded. REFERENCES

The opportunity to improve fragmentation of black sediments is being

explored to determine if this material can be sent to erodable dumps. 1. Grundstrom, Cam et al, 2000, “Blast Fragmentation for
PJV personnel have identified significant cost savings if this proves Maximising the SAG Mill Throughput at Porgera Gold Mine”, ISEE
feasible. Conference.

Optimization of waste blasting is being investigated. The high stripping 2. Jankovic, A., Valery, W., Kanchibotla, S. et al, 2001, “Mine-to-
ratio (10:1) at Porgera offers huge potential benefits. Mill Optimization at Porgera Gold Mine” Research Report, JKMRC

The impact of blasting at higher power factors on ore dilution and wall 3. Napier-Munn et al, 1996, Mineral Comminution Circuits, JKMRC
damage is also being investigated. Monograph Series in Mining and Mineral Processing, 2nd edition.

CONCLUSIONS

Team work has been critical to the success of this project.

The Mine-to-Mill project has indicated that the milling rate of hornblende
diorite can be increased by improving the feed size distribution. From the
surveys, it is clear that the blast fragmentation has an impact on primary
crusher and mill performance. An increase in the powder factor of the
blast by tightening the drill pattern, and running the primary crusher at a
smaller closed side setting has resulted in a measured 15% increase in
the milling rate of hornblende diorite ore.

A model has been calibrated for hornblende diorite ore. This model has
been able to predict the circuit’s response to changes in feed size
distribution. Simulations also suggest that improving the feed size
distribution by optimizing the blast design will increase the SAG mill
throughput more than modifying the configuration of the existing circuit.

Blast optimization of hornblende diorite at a higher powder factor is being

implemented and the SAG mill throughput is being monitored. The blast
design for hornblende diorite will continue to be refined.