FRAGMENTATION OPTIMIZATION: ADOPTING

MINE TO MILL FOR REDUCING COSTS AND

INCREASING PRODUCTIVITY
August – 2015
CONTENTS
• MINE GEOLOGY
• METHOD
• BLAST DOMAINS DEFINITIONS
• PSD REDUCTION
• M2M TESTS
• RESULTS
• CONCLUSION
MINE GEOLOGY – HIGH HARDNESS ROCK (COMPACT ORE)

3
MINE GEOLOGY – SEMI-COMPACT ORE

4
MINE GEOLOGY – FRIABLE ORE

5
METHOD

Fragmentation Optimization

Blasting Improvements M2M Tests

 Blast domains definition  Assessment of plant

 Blasting practices review performance
 P80 reduction  Geology validation
 Monitoring system  Understand benefits

6
BLAST DOMAINS DEFINITION

Cement with Apatite Cement with Barite and Quartz

Cement with Gohetite and Quartz Cement with Quartz

7
BLAST DOMAINS DEFINITION

Others Cements
Cement Apatite

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BLAST DOMAINS DEFINITION

CIMENT WITH QUARTZ

CIMENT WITH GOHETITE AND

QUARTZ
WS (With Silicates)

CIMENT WITH BARITE AND

QUARTZ

CEMENT WITH APATITE NS (No Silicates)

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BLAST DOMAINS DEFINITION

10
PROCESS STEPS TAKEN TO REDUCE THE PSD OF THE ORE

HISTORICAL DATA GEOLOGICAL VALIDATION

IMPLEMENTChanges
Implement CHANGES MEASURE RESULTS

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RESULTS

25 % P80 Reduction 40 % P80 Reduction

DRILLING GRIDS
ORE TYPES
Up to 2013 After 2014
Compact zone with silicate (WS) 3.0 m x 3.8 m 2.0 m x 2.6 m
Compact zone without silicate (NS) 3.0 m x 3.8 m 2.6 m x 3.2 m
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MINE TO MILL
TESTS
M2M TESTS

Mining ore Blend

Stockpiles Test 1
A 42% of blasted ore

30%
B 54% of blasted ore
40%
Cemented Types
Oxidized
friable and
micaceous
Foscorites and
Nelsonites

30%
Stockpiles
Test 2
C 38% of blasted ore
High Hardness Ore
Semi-compacted Ore
Friable Ore D 81% of blasted ore

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 M2M TESTS – DATA ACQUISITION IN THE PROCESS PLANT

2
Crusher

1 6 3
5
5
7 4
8

1 Crusher 3
2 Bar Mill 4
5 Ball Mill 5
6
7
8
9
15

Throughput / energy consumption Granular-chemical analyses

M2M TESTS – RESULTS

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CONCLUSIONS

• With historical data, geological information and blast campaign is possible define blast domains and
establish specific parameters for each one.

• Modifying the drilling grid for each blast domain made it possible to reduce P80.
• The gain regarding the quantity of blasted ore in each test enable the M2M concept to be validated.
• Others benefits in the downstream process can be measured by implement more instrumentation and
defining others data collection points.

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NEXT STEPS

• Establish a methodology to measure other gains: crusher and mill wear, water consumption, impact
crusher bars and rod mill consumption,

• Input geomechanical properties of rocks such as PLI and UCS for developing initiatives of
fragmentation optimization.

• Conclude the plant simulation (started in 2015).

• Use a DOE (Design of Experiments) methodology to assess optimal percentage of blasted ore in the
stockpiles.

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 THANK YOU

E-mail: paulo.martins@angloamerican.com
T: +55 64 34418210