Scott Bensley, Rio Tinto Iron Ore: Rio Tinto’s Iron Ore Pilot Plant Experience
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Transcript of Scott Bensley, Rio Tinto Iron Ore: Rio Tinto’s Iron Ore Pilot Plant Experience
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RTIO Pilot Plant Experience FeTech 2013
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26 November 2013 RTIO Pilot Plant Experience 2
Recent Pilot Plant History
• 2003 Yandi Scrubbing Pilot Plant
• 2005/6 Marra Mamba BWT Pilot Plant
• 2009 & 2011 IronX Pilot Plant
• 2011 Hybrid Sizer Pilot Plant
• 2012 Low Grade Pilot Plant
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2003 Yandi Low Grade Scrubbing
26 November 2013 RTIO Pilot Plant Experience 3
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2006 Marra Mamba Desliming
26 November 2013 RTIO Pilot Plant Experience 4
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2009 & 2011 IronX
26 November 2013
RTIO Pilot Plant Experience 5
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2011 Hybrid Sizer
26 November 2013
RTIO Pilot Plant Experience 6
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26 November 2013
RTIO Pilot Plant Experience 7
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2012 Low Grade Beneficiation
26 November 2013
Presentation Title 8
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Feed Prep Plant
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Fines Plant (-1mm)
26 November 2013
Presentation Title 10
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Jig Plant
26 November 2013
Presentation Title 11
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Site selection
• Self sufficiency vs integration with Ops (MOU’s)
• Feed sourcing & transport
• Waste disposal
• Land, power, water
• Travel and accommodation availability
26 November 2013
Presentation Title 12
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Low Grade Pilot Plant at Brockman 4
26 November 2013
RTIO Pilot Plant Experience 13
LGPP
BS4 Ops
BS4 LG
BS4 Mine
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HSE learnings
• HSE
– Dust in eye incidents
– Rocks falling
26 November 2013 RTIO Pilot Plant Experience 14
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Falling rock hazard
26 November 2013 RTIO Pilot Plant Experience 15
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HSE learnings
• HSE
– Dust in eye incidents
– Rocks falling
– Isolation procedures
– Access platforms
– HSE support staff
26 November 2013 RTIO Pilot Plant Experience 16
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Plant Design
• Site and Plant design
– Layout – HME separated from plant/operators
26 November 2013 RTIO Pilot Plant Experience 17
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Separating HME, LV and Pedestrians
26 November 2013 RTIO Pilot Plant Experience 18
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Plant Design
• Site and Plant design
– Layout – HME separated from plant/operators
– Scaleability of unit processes
– Matching capacities
– Sampling – Experienced team members to review designs
• Floor spillage and flow interruption
– Flowsheet with flexibility
26 November 2013
RTIO Pilot Plant Experience 19
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Management
• Setting expectations for staff early
• Crew roster and structure
• Staggered crew members or 9/5 for better handovers
• Accommodation! Remember Maslow’s Hierarchy
• Preparation of Safety and Operating systems – allow a skeleton crew
• Early managers safety audit just prior to commissioning
• Control systems support staff
• Deadlines – budget, accommodation, people
• Project finishes when report is complete
26 November 2013 RTIO Pilot Plant Experience 20
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Management (cont.)
• Extent of Laboratory services
– Everything on site (what turnaround)
– Prep on site or send to Perth
• Have all the equipment you might need available
– EWP, water cart, forklift, loaders (IT), trucks, service trailer
• Schedule the construction/commissioning/operations transition
• Plan for decommissioning/removal or care and maintenance
26 November 2013 RTIO Pilot Plant Experience 21
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Feed Collection & Preparation
• Feed collection and homogenisation
– Many oretypes & sufficient quantity
– Incremental shovelling of feed piles
– Use of crushing and screening contractors or production plant
26 November 2013 RTIO Pilot Plant Experience 22
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Stockpiles at the Low Grade Pilot Plant
26 November 2013 RTIO Pilot Plant Experience 23
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Collecting samples with a belt plough
26 November 2013 RTIO Pilot Plant Experience 24
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Feed Collection & Preparation
• Feed collection and homogenisation
– Many oretypes & sufficient quantity
– Incremental shovelling
– Use of crushing and screening contractors or production plan
– Moisture
26 November 2013
RTIO Pilot Plant Experience 25
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Wet Feed
26 November 2013
RTIO Pilot Plant Experience 26
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Feed Collection & Preparation
• Feed collection and homogenisation
– Many oretypes & sufficient quantity
– Incremental shovelling
– Moisture
• Sampling and quality control of feed preparation
– Sizing – regular checks to ensure lump and fines are on spec
– Contamination – preserving a ‘stockpile base’
– Oversize – incorporate trash removal in design
26 November 2013
RTIO Pilot Plant Experience 27
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Marra Mamba Pilot Plant – Oversize Issues
26 November 2013
RTIO Pilot Plant Experience 28
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Low Grade Pilot Plant Oversize and Contamination in Lump
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Things you get right but don’t realise the importance at the time • Sample hoists
26 November 2013
RTIO Pilot Plant Experience 31
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Fines Plant Material Hoist
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Things you get right but don’t realise the importance at the time • Sample hoists
• Distributors
26 November 2013
RTIO Pilot Plant Experience 33
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Things you get right but don’t realise the importance at the time • Sample hoists
• Distributors
• Data historians
• Belt filter operation
26 November 2013
RTIO Pilot Plant Experience 34
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Important things you discover
• Up Current Classifier pulsating discharge to filter
26 November 2013
RTIO Pilot Plant Experience 35
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Allflux discharge
26 November 2013
RTIO Pilot Plant Experience 36
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Important things you discover
• Up Current Classifier pulsating discharge to filter
• Retreating primary cyclone overflow prior to WHIMS
• Sand filters on process water
26 November 2013
RTIO Pilot Plant Experience 37
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Important things you discover
• Up Current Classifier pulsating discharge to filter
• Retreating primary cyclone overflow prior to WHIMS
• Sand filters on process water
• Pumping UCC underflow
– Unstable slurry at 35% solids v/v (65% w/w)
26 November 2013
RTIO Pilot Plant Experience 38
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26 November 2013
RTIO Pilot Plant Experience 39
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Technical
• It’s not just a mini gravel washing plant!
• Conveyor weightometer setup and test calibration
• Can’t have too much instrumentation
• Testwork Program
– This can and will change
– Consider duplicates and statistical design
– Plackett Burman, Factorial, Central Rotatable Composite
– Understand variability
• Mass balancing and data analysis
• Take lots of bulk samples
26 November 2013
RTIO Pilot Plant Experience 40
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Questions?
26 November 2013
RTIO Pilot Plant Experience 41