GeoMetso: A site-specific

methodology to optimize production

and efficiency over the life-of-mine

Achieving significant and measureable improvements in the overall performance of a mining operation requires an integrated and strategic methodology. Short to medium term gains can be achieved through a detailed
assessment and optimization of all processes from the mine to the plant.

Suzanne Lynch-Watson, Roberto

Valle, Kristy Duffy, David La Rosa
and Walter Valery. Metso Process
Technology and Innovation,
Australia and Peru

This holistic approach allows significant improvement of the entire production chain. In order to maintain these benefits in the long term, it is necessary
to be able to accurately predict the performance of the comminution and
separation circuits based on the feed ore characteristics and mining practices.
This requires a detailed understanding of the entire operation, from the ore
properties and their spatial distribution in the deposit through to the corresponding circuit response.
Metso Process Technology and Innovation (PTI) have developed the GeoMetsoTM program as a structured, site-specific methodology aimed at helping
operations achieve ongoing optimal performance with a long-term perspective.
This paper outlines the steps which are required to initiate and implement
this kind of program. It describes the data required and how that data must
be assessed and incorporated into the program. A crucial part of the entire
methodology is the use of SmartTag TM ore tracking, which provides a real-time
link between the source ore and the process response, and allows on-going
updating and validation of the predictive models. This allows strategic planning and optimization for different ore sources in order to maximize the
profitability of the operation over the Life-of-Mine (LOM).

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INTRODUCTION
High grade ore bodies are rapidly being depleted, and remaining deposits are generally lower
grade and more difficult to extract. This, in combination with a growing concern regarding
sustainability, has driven the mining industry to look for more efficient technologies and practices
for extracting valuable minerals.
In order to know how best to extract a valuable mineral, it is necessary to understand as much as
possible about the mineral and the host rock. It is important to understand the physical and
compositional properties of the ore body, where the valuable mineral is located within it, and what
mineral associations exist between the valuable mineral and the gangue. This combination of
geology and metallurgy to create a geologically or geotechnically based predictive model for
mineral processing plants is known as geometallurgy. This technique provides a link between the
performance of the process, or efficiency of the extraction, and the physical properties of the source
ore. This allows strategic planning and optimization for different ore sources in order to maximize
the profitability of the operation in the long term.
For over 15 years, short to medium term benefits have been realized within the mining industry
through successful application of Process Integration and Optimization projects from the mine to
the plant. Many operations worldwide have achieved results in the range of 5-25% increase in
plant throughput with little or no capital expenditure. This methodology can also be applied in
combination with geometallurgical modeling to predict and optimize production performance over
the longer term. This enables ongoing corrective measures to be taken, and strategic planning to
maximize profitability over the life of the mine.
For geometallurgical modeling to be effective it is necessary to have a high degree of confidence in
the data collected, and to link the plant performance with the ore properties. Metso PTI has
developed the GeoMetsoTM methodology, which uses the SmartTag ore tracking system to link
plant performance data to the sites geological, geotechnical block models and mine planning. This
technology allows parcels of ore to be tracked from the mine, through the crushing plant and into
the grinding mills so that the throughput, recovery, grade and other operating parameters can be
linked with the original ore source. This technology generates reliable data to update the block
model on-line and is a cost-effective approach to geometallurgical modeling, as it eliminates the
need to increase the number of ore characterization tests to ensure representative results. A
specifically designed software system is used to manage the data and feed back into the block
model, continuously populating it with real time plant performance results (throughput, recovery,
grade, etc).

GEOMETALLURGICAL MODELLING
To remain viable and competitive in the face of increased challenges in extracting valuable
minerals, the mining industry requires methodologies and tools to mitigate risks, and ensure the
highest operational profitability throughout the Life-of-Mine (LOM). To maintain high profitability
in the long term, it is crucial to be able to accurately predict the future performance of the process as
well as the interaction with mining practices. This requires an accurate understanding of how each
circuit behaves, as well as a detailed knowledge of the relevant rock properties of the ore body.

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The concept of geometallurgy integrates the disciplines of geology, mining and metallurgy with the
aim of developing proactive operating strategies as a function of the ore variability.
Geometallurgical modeling requires a detailed understanding of the relevant rock properties, and
models of how these ore properties will affect the performance of the blasting, crushing, grinding
and separation stages, in terms of throughput, recovery and product grade.

METHODOLOGY
Overview
GeoMetsoTM is a new structured, site-specific methodolgy developed by Metso PTI for
geometallurgical modeling to help mining operations achieve optimal performance with a longterm perspective. The methodology uses the existing block models and SmartTag ore tracking to
link the plant performance data to the ore source and update the block model with real, measured
plant performance data.
The basic concept is shown schematically in Figure 1. Ore domains are defined in the block model
based on initial ore characterization tests. Ore tracking and detailed auditing of the blasting and
processing practices are used to develop site specific predictive models for each operation (blasting,
comminution, separation). Using these predictive models, the blast design is optimized for
different ore domains, and a cookbook is generated which provides a recipe i.e.: an optimized
blast design for each ore domain. The models also allow prediction of throughput and recovery
performance for each ore domain, and can be used for planning and optimization purposes.

Figure 1 Schematic of the methodology

SmartTagsTM are then used to continuously track ores from the mine through the process, and when
linked with data from the plant DCS, can provide actual plant performance data (throughput,
recovery, grade, etc) for each ore type and blast conditions. These data are automatically compared
with model predictions and updated in the block model. The actual plant data is incorporated into

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the block model in real time which eliminates the need for further expensive ore characterization
tests. The blasting cookbook can be adjusted and updated if necessary, to generate optimal Run-ofMine (ROM) fragmentation for all ore types. With more accurate data in the block model, mine
planning can be improved, and the plant receives advance notice of the ore type about to be
processed. Adjustments can then be made to operating conditions to optimize plant performance.

SmartTagTM ore tracking in GeoMetsoTM

The ore tracking system allows parcels of ore to be tracked from the mine, through crushing and
finally into the grinding mills. The SmartTags are built around robust passive radio frequency
transponders (RFID tags), and are available as standard or mini sizes as shown in Figure 2. They
survive blasting and do not have an internal power source, so they can remain in stockpiles and
ROM pads for extended periods of time.

Standard SmartTag

TM

Reading range up to 1.2 m

Mini SmartTag

TM

Reading range up to 40 cm

Figure 2 SmartTagsTM

Antennas to detect the tags are located at critical points in the process ahead of the milling circuit;
tags can be detected a number of times and provide valuable information on material movements.
In particular, they make it possible to link the physical ore properties associated with the ore in the
mine to the time-based performance data of the plant.
In the methodology, plant performance data (tonnage, recovery, grade) is collected from the
process control system (DCS or plant historian) when a tag passes an antenna, and is linked to the
ore source. This information is compiled in the database and automatically updated in the block
model. Ore domains are assigned in the block model based on ore characteristics (grades, recovery
and throughput, etc.). This process is illustrated schematically in Figure 3.

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Tph, Recovery, Grade

(7)
Ore
Class
AuO
CuP
AuP
PyL
PyH
CuT
AsT
CuA
CpD
CcD
GRN
AMB
RED

Block Model

(5)
(6)
PI Data
(Tph, Recovery, Grade)

Smart Tag Database

(x,y,z)

time

(1)

Plant
(3)

(ID,x,y,z)

(2)
(ID, time)

(4)

(ID, time)
ID, x,y,z)

(1) SmartTags

TM

placed in drill holes

(5) Plant data DCS (Tph, recovery, grade)

TM

(2) Ore fed to comminution circuit

(6) Data stored in SmartTag

database

(3, 4) Tags detected in comminution circuit

(7) Block model automatically updated

Figure 3 The flow of data for block model population and validation

Implementation
One of the first steps in the methodology is to characterize the ore for each block in terms of
structure, strength, comminution and separation properties. Rock structure measurements include
Rock Quality Designation (RQD), Fracture Frequency and joint mapping. The main rock strength
measurements include Point Load Indices (PLi), Unconfined Compressive Strength (UCS) and Drop
Weight Indices (DWi). These are used to characterize the ore in terms of breakage behavior in the
blast and comminution stages which will drive throughput. Assays, liberation and laboratory
flotation test results are used to determine the behavior of the ore in flotation processes and will
determine recovery. A summary of key ore characterization measurements and tests is provided in
Table 1.

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Table 1 Ore Characterisation Measures and Tests

Rock Structure

Rock Strength

Flotability

Variables used in the PTI Blast

Fragmentation Model

Variables used for comminution

circuit modelling

Variables used for flotation modelling

Rock Quality Designation

(RQD)
Fracture Frequency
Joint and Plane Mapping with
Sirovision System

Drop Weight parameters

(A,b,ta)
Drop Weight Index (DWi)
Unconfined Compressive
Strength (UCS)
Point Load Index (PLi)
Bond Ball Mill Work Index
(BBMWi)

Assay measurement
Liberation measurement using FEI,
MLA or QemSCAN systems
Assay by size
Laboratory flotation tests

MLA Mineral Maps

Point Load Tester for PLi by

Geotechnical Systems Australia Pty
Ltd

Rock structure analysis using

Sirovision
Laboratory Flotation Tests

To understand how these ore characteristics affects each stage of the operation, comprehensive
audits of drilling and blasting are conducted, and process surveys are conducted when the
detection of tags indicates the audited ore is being treated in the plant. This allows correlations to
be developed between plant performance, ore type and ROM fragmentation. Historical data and
data from PTIs extensive database (which includes data from more than 350 projects around the
world) are also analyzed and benchmarked against the performance of the operation.

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Site specific models are developed for each operation and calibrated using a combination of
historical production data and detailed information from audits and surveys. The models are used
to predict plant performance (throughput, size reduction, recovery, and product grade) for each ore
type. Together, these models indicate how the whole process will respond to different ore types and
operating conditions in the mine and the plant. The models enable production forecast for the
LOM based on the mine plan. They can also be used to identify potential bottlenecks, process
constraints and opportunities for improvement. Data analysis, models and site experience are used
to develop proactive, integrated operating strategies to maximize production, reduce costs, and
minimize energy consumption while maintaining product quality.
Ore domains are defined based on ore characterization, and using the site-specific models, blast
designs are optimized for each ore domain, resulting in a blasting cookbook. Blasting according to
this cookbook provides a more consistent and optimized feed size distribution to the downstream
processes, increasing throughput, process stability and efficiency. Following the cookbook avoids
excessive blasting in softer ore domains, thus reducing energy consumption and costs, and
preventing the excessive production of ultrafines that can be detrimental to some downstream
processes (e.g. in heap leach operations or flotation).
The SmartTagTM system links the process control system and the block model to improve mine
planning and circuit operation. The process data collected with the system is fed back into the
block model automatically, thus ensuring the most recent and accurate data is available in the block
model at all times. The plant data is compared with the predictive models. The blasting cookbook
can then be adjusted and updated if necessary, reflecting the most recent data. Another benefit is
that the plant receives advance notice of the ore type about to be processed and adjustments can be
made to operating conditions to optimize plant performance.

CASE STUDIES
Case Study 1: Throughput Forecasting at Newmont Batu Hijau, Indonesia
Owned by Newmont Mining Corporation, Batu Hijau is a copper and gold porphyry deposit
located in the province of Nusa Tenggara Barat, Indonesia. In 2003-2004, Metso PTI assisted
PTNNT Batu Hijau to develop a comprehensive model for forecasting and optimizing throughput
(Burger et al; 2006). A review was conducted of ore hardness and blast fragmentation and used to
define ore domains on the basis of hardness and structure. At Batu Hijau, this resulted in a matrix
of nine ore domains.
Metso PTI developed site-specific models for blast fragmentation and the comminution. Using
these models, the blast design was optimized for each ore domain, resulting in a blasting cookbook,
shown in Figure 4. Implementation of the optimized blast designs improved fragmentation size in
harder ores, as shown in Figure 5. This resulted in increased throughput and improved operation
in downstream processes.

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Figure 4 Blasting Cookbook for Batu Hijau (after Burger et al; 2006)

Figure 5 Improvement in ROM fragmentation due to optimized blast designs (after Burger et al; 2006)

The resulting predicted throughputs for each ore type were combined according to the ore blending
information to provide throughput predictions for daily, monthly, yearly or LOM production
scenarios.
Validation indicated the need to retain lithology as a parameter in ore domain definition for
throughput forecasting, and when combined with the hardness domains resulted in 16 domains.
The Metso modeling approach was applied to each domain using blast designs from the cookbook
and domain-specific ore breakage parameters in the SAG mill model. The 16-Domain Model

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throughput rates were applied to the daily ore delivery blends for the year 2004 and compared well
on a monthly and annual basis as demonstrated in Figure 6. The final throughput model predicted
monthly throughputs within an accuracy of 5% and has been extensively used for LOM business
planning, optimization of the entire mining and milling processes and for expansion studies.

Figure 6: Actual Mill Throughput Versus 16-Domain Model Predictions (after Burger et al; 2006)

Initially the model was good predictor, but a gap developed between actual and predicted over
time and was found to be related to copper grade. A grade correction term was added to account
for the observed grade effects. A similar grade-throughput effect has been observed for other
copper porphyry deposits such as Ernest Henry, Bougainville Copper and Ok Tedi (Wirfiyatal and
McCaffery, 2011). The use of SmartTagsTM to feed plant data back into the block model addresses
issues like this, where a change in the ore over time affects process response.

Case study 2: Updating a block model with real plant data

More recently, Metso PTI has been implementing an optimization, throughput forecasting and
geometallurgical modeling project at a mine in South-East Asia using the GeoMetsoTM
methodology.
Metso PTI used ore characterization test results and conducted a complete audit and survey from
the mine through the comminution circuit to develop site-specific models of the blasting, crushing
and milling processes. The RQD and UCS data (estimated from PLi) for every 10m x 10m x 10m
block from the geotechnical block model (shown in Figure 7) were used to define nine blasting
domains. Blast designs were optimized for each domain by adjusting burden, spacing and
stemming to optimize ROM fragmentation.

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Figure 7 Geotechnical Block Model and Final Pit Shell

Preliminary throughput predictions were performed based on the design phase mine plan. The
budget delivery schedule data was linked with the geotechnical block model coordinates to assign
each period with an average RQD, PLi and DWi. Each data point in the schedule was also assigned
one of the nine domains based on these ore characteristics allowing throughput predictions with
the calibrated site specific blasting and comminution circuit models.
Throughput forecasts for the LOM are now being conducted using the models. The system has
been installed and is currently being linked to the plant DCS and block model.

CONCLUSION
As the mining industry faces lower grade and more difficult to extract deposits, there is a growing
need for more efficient technologies and practices for extracting valuable minerals.
Geometallurgical modeling integrates the disciplines of geology, mining and metallurgy with the
aim of developing proactive strategies to optimize operations over the long term. This requires an
extensive understanding of ore characteristics and their effect on blasting, comminution and
extraction processes.
The GeoMetsoTM methodology uses SmartTagTM ore tracking to link blasting and plant performance
to ore properties and spatial location in the block model. The system continuously collects plant
performance data and automatically updates the block model. This allows the mine plan to be
adjusted in order to maintain optimal overall performance, and eliminates the need for further
expensive ore characterization tests. The plant receives advance notice of the ore type about to be
processed and adjustments can be made to operating conditions to maximize throughput, reduce
costs, minimize energy consumption and improve overall process performance. The methodology
also enables strategic planning and optimization of the mine plan to maximize the profitability of
the operation over the LOM.

REFERENCES
Burger, B., McCaffery, K., Jankovic, A., Valery, W., McGaffin, I. (2006), Batu Hijau Model for Throughput
Forecast, Mining and Milling Optimisation and Expansion Studies, SME 2006.
Wirfiyatal, F. and McCaffery, K., (2011), Applied Geo-Metallurgical Characterisation for Life of Mine
Throughput Prediction at Batu Hijau, Proceedings of the Fifth International Conference on Autogenous
and Semiautogenous Grinding Technology, SAG2011, 25-28 September 2011, Vancouver, Canada.

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