angloamerican ppt standard version - adimb · 2 grelhas vibratórias (metso) 3.982 t/h/und* 2...

PROCESS DEVELOPMENT

VISÃO GERAL DO PROCESSO

* Capacidade nominal

4 peneiras tipo banana

MF-12’x28’ DD (Metso)

2.608 t/h/und*

1 espessador 90 m(Flsmidth)

3.452 t/h*

343-525 km

11+1 Ceramec (Larox) 144 m² 255 t/h/und*

1 clarificador 50 m (Flsmidth) 50 t/h*

Recuperação

de água

2 grelhas vibratórias (Metso) 3.982 t/h/und*

2 britadores Mandíbula C140 (Metso) 557 t/h/und*

Pilha de estocagem 123,177 m³

Taxa de est. 7.964 t/h Taxa retom. 6.492 t/h

4 britadores

cônicos

(Metso)

617 t/h/und*

3 prensas de rolos 26’ x 42’ (Polysius)

2.164 t/h/und*

2 moinhos bolas 26’ x 42’(Metso)

3.246 t/h/und*

22 células de flotação

160m³

5 estágios

(Flsmidth)

16 Vertimills

VTM-1500 (Metso)

190 t/h/und*

1 espessador 57 m (Flsmidth)

3.040 t/h *

7+1 bombas deslocamento positivo TZPM 2000 (Weir GEHO)

301 m³/h/und* e 18,3 MPa

8+2 bombas deslocamento

positivo TZPM 2000

(Weir GEHO)

263 m³/h/und* 20,6 MPa

8 loops com 2 válvulas cada

0-235 km

235-343 km

2 pilhas

1 espessador 50 m

(Flsmidth)

3.080 t/h*

88 deslam. prim. 15” 152 m³/h/und *

480 deslam. sec. 4” 19 m³/h/und*

(Krebbs)

32 ciclones 33” (Krebbs)

618 m³/h/und*

32 ciclones 20” (Krebbs) 131 m³/h/und*

32 ciclones 20” (Krebbs)

131 m³/h/und*

STANDARD TESTS

DEFINE METALLURGICAL

PARAMETERS

INPUT PROCESS

PARAMETERS IN

BLOCK MODEL

GEOMETALLURGICAL

BLOCK MODEL

WITH LARGE

SAMPLES

(PILOT TESTS)

GEOMETALLURGICAL

BLOCK MODEL WITH

DRILLHOLE SAMPLES AT

MINI PILOT PLANT

AND BENCH SCALE TEST

GEOMETALLURGICAL MODELLING

0 to 5 years Pit

6 to 10 years Pit

11 to 15 years Pit

12kg to

Standard test.

~23kg to Pilot

tests per

period (pit).

(~35kg)

GEOMETALLURGICAL MODELLING - SAMPLING

2 METALLURGICAL

PARAMETERS ROM

6660544842363024

Fe ROM (%)

Mean 40,22

StDev 7,795

Histogram of Fe ROM (%)Normal

6660544842363024

Fe ROM (%)

Mean 40,22

StDev 7,795

Histogram of Fe ROM (%)Normal

605040302010

SiO2 ROM (%)

Mean 40,34

StDev 11,83

Histogram of SiO2 ROM (%)Normal

605040302010

SiO2 ROM (%)

Mean 40,34

StDev 11,83

Histogram of SiO2 ROM (%)Normal

9,07,56,04,53,01,50,0-1,5

Al2O3 ROM (%)

Mean 1,313

StDev 1,287

Histogram of Al2O3 ROM (%)Normal

9,07,56,04,53,01,50,0-1,5

Al2O3 ROM (%)

Mean 1,313

StDev 1,287

Histogram of Al2O3 ROM (%)Normal

0,240,200,160,120,080,040,00

P ROM (%)

Mean 0,02125

StDev 0,01928

Histogram of P ROM (%)Normal

0,240,200,160,120,080,040,00

P ROM (%)

Mean 0,02125

StDev 0,01928

Histogram of P ROM (%)Normal

0,750,600,450,300,150,00-0,15

Mn ROM (%)

Mean 0,04429

StDev 0,09179

Histogram of Mn ROM (%)Normal

0,750,600,450,300,150,00-0,15

Mn ROM (%)

Mean 0,04429

StDev 0,09179

Histogram of Mn ROM (%)Normal

121086420

LOI ROM (%)

Mean 0,4853

StDev 0,8044

Histogram of LOI ROM (%)Normal

121086420

LOI ROM (%)

Mean 0,4853

StDev 0,8044

Histogram of LOI ROM (%)Normal

STANDARD TESTS

Chemical analyses

Size analyses

Mineralogical

analyses

730 SAMPLES TESTED

-Reserved to checking:

- 70 tests

STANDARD TESTS

2 METALLURGICAL

PARAMETERS 2

62,550,037,525,012,50,0-12,5

SiO2 PFF A (%)

Mean 6,143

StDev 10,94

Histogram of SiO2 PFF A (%)Normal

62,550,037,525,012,50,0-12,5

SiO2 PFF A (%)

Mean 6,143

StDev 10,94

Histogram of SiO2 PFF A (%)Normal

2520151050-5

SiO2 PFF B (%)

Mean 1,549

StDev 2,899

Histogram of SiO2 PFF B (%)Normal

2520151050-5

SiO2 PFF B (%)

Mean 1,549

StDev 2,899

Histogram of SiO2 PFF B (%)Normal

1815129630

SiO2 PFF C (%)

Mean 0,8100

StDev 1,431

Histogram of SiO2 PFF C (%)Normal

1815129630

SiO2 PFF C (%)

Mean 0,8100

StDev 1,431

Histogram of SiO2 PFF C (%)Normal

2,01,61,20,80,4-0,0

Al2O3 PFF C (%)

Mean 0,2342

StDev 0,1809

Histogram of Al2O3 PFF C (%)Normal

2,01,61,20,80,4-0,0

Al2O3 PFF C (%)

Mean 0,2342

StDev 0,1809

2,01,61,20,80,4-0,0

Al2O3 PFF C (%)

Mean 0,2342

StDev 0,1809

2,42,01,61,20,80,40,0

Al2O3 PFF A (%)

Mean 0,2855

StDev 0,2032

Histogram of Al2O3 PFF A (%)Normal

2,42,01,61,20,80,40,0

Al2O3 PFF A (%)

Mean 0,2855

StDev 0,2032

Histogram of Al2O3 PFF A (%)Normal

2,01,61,20,80,4-0,0

Al2O3 PFF B (%)

Mean 0,2168

StDev 0,1718

Histogram of Al2O3 PFF B (%)Normal

2,01,61,20,80,4-0,0

Al2O3 PFF B (%)

Mean 0,2168

StDev 0,1718

Histogram of Al2O3 PFF B (%)Normal

FLOTATION

• Three separated flotation using 100, 140 and 180 g/t of amine (flotation A, B and C,

respectively) and 500 g/t of starch.

Mineralogy METALLURGICAL

PARAMETERS 2

0,74 27,81

29,56 39,92 1,98

0,77 1,55 1,21

ROM Fe (%); SiO2 (%); Al2O3 (%); P (%); Mn (%);

LOI (%); CaO (%); TiO2 (%); MgO (%); K2O

(%); Na2O (%)

% above 25mm

% above 3mm

Mineralogy: Specularite (%); Goethite (%);

Hematite (%); Quartz (%); Others (%)

GRINDING • Feed (%): +1000μm; +500μm; +150μm;

+75μm; +45μm; -45μm

• F95 (μm); F80 (μm); F50 (μm)

• Grinded (%): +1000μm; +500μm; +150μm;

+75μm; +45μm; -45μm;

• P95 (μm); P80 (μm); P50 (μm)

• Grinding kWh/t (Rowland)

DESLIMING • Mass Recovery (%)

• Fe (%); SiO2 (%); Al2O3 (%); P (%); Mn (%);

LOI (%); CaO (%); TiO2 (%); MgO (%); K2O

(%); Na2O (%)

FLOTATION

• Three separated flotation using 100, 140 and

180 g/t of amine (flotation A, B and C,

respectively) and 500 g/t of starch.

• Froth for 1 minute and then till 10 minutes

• Mass Recovery (%)

• Fe (%); SiO2 (%); Al2O3 (%); P (%); Mn (%);

LOI (%); CaO (%); TiO2 (%); MgO (%); K2O

(%); Na2O (%)

• Mineralogy to concentrate B: Specularite (%);

Goethite (%);Hematite (%); Quartz (%); Others

REGRINDING • Feed (%): +45μm

• Regrinded (%): +45μm

HISTOGRAM AND PROBABILITY PLOT IS

AVAILABLE PER EACH PARAMETER

PARAMETERS PRESENTED

METALLURGICAL

PARAMETERS 2

INPUT PROCESS

PARAMETERS IN

BLOCK MODEL

INPUT PROCESS

PARAMETERS IN

BLOCK MODEL

Standard test’s Amine Consuption (g/t)

INPUT PROCESS

PARAMETERS IN

BLOCK MODEL

PF Standard Test - SiO2 + Al2O3

INPUT PROCESS

PARAMETERS IN

BLOCK MODEL

PF Standard Test - SiO2 + Al2O3 > 3,0%

INPUT PROCESS

PARAMETERS IN

BLOCK MODEL

DRILLHOLE 148

Massa: 71.719t

DRILLHOLE 28

Massa: 65.852t

Total Concentrate Mass SiO2 + Al2O3 >3.0% in

standard test: 137.571t of ~1bi = 0,014%

INPUT PROCESS

PARAMETERS IN

BLOCK MODEL

DRILLHOLE 28: Interval from 63.0m to 78.0m

Block mass SiO2+Al2O3> 3.0: 65.852t

INPUT PROCESS

PARAMETERS IN

BLOCK MODEL

Grade of SiO2 e Al2O3 in the ROM

INPUT PROCESS

PARAMETERS IN

BLOCK MODEL

Log description - SEFDSP28

Drill Hole SEFDSP 28

From 49,60 To 74,85

Friable itabirite with levels stronger siliceous.

Locally with specularite. Lenses of schists are founded.

Comments – This interval of friable itabirite with lenses of

schist are located closed of shear zone that is

characterized by quartz and specularite associated a

hydrothermal process. This process and mineralogy

(white mica) of schist are probable responsible for values

of alumina. The chemical formula is

KAL2Si3AlO10(OH,F)2 and the composition is 11.82%

K2O, 38,38%Al2O3,45,23%SiO2,4,29%H2O

INPUT PROCESS

PARAMETERS IN

BLOCK MODEL

Photos of drillcore box that show lenses of quartz-sericite schist interlayer with friable itabirite. In according with sampling procedure lenses of waste material with thickness less than 1 meter, it is sampling together with itabirite.

4 CHECK GEOMETALLURGICAL

BLOCK MODEL WITH

DRILLHOLE SAMPLES AT STD

TEST AND

MINI PILOT PLANT

Drillhole

Sample tested

RFe = “y”%

RFe = “x”%

RFe = “z”%

According

geometallurgical

To check An example with

iron recovery

Process

parameters

variability

trough deposit

Actual Status

GEOMETALLURGICAL

BLOCK MODEL

WITH LARGE

SAMPLES

(PILOT TESTS)

Comparison

between

bench scale

test, MPP and

pilot test

MAIN PILOT PLANT RESULTS

17 Sections Study

• Pilot and bench tests per each

section and global sample

completed for IF and ISC.

• IC study already commenced

(Fund. Gorceix): Liberation study

and WI in process

• Initial program: 800 standard tests.

Samples collected across all

mineral body in X, Y and Z position.

•Both Geological and Process

parameters modelling - Pioneer

application at this level of detail in

Iron ore mining.

First 5-years pit Program

• Pilot and bench tests finished.

• PF sent to regrinding tests in

Metso/USA. Acceptable levels of

energy.

•In progress: Pipeline/Rheology

studies and Pilot Larox Ceramec

Filter.

MINAS RIO GLOBAL STUDIES

MINAS RIO SPECIFIC STUDIES

6 to 10 years pit Program 11 to 15 years pit Program

Global Sapo Sample- IF+ISC 6t Geometallurgical Modelling

• Pilot test with a global sampling,

representative of first 5 years pit

finished.

•Part of each interval sampled from

drillcore sample have been sent to

standard test

representative of 6 to 10 years pit

finished.

standard test

representative of 11 to 15 years

pit finished.

•Part of each interval sampled

from drillcore sample have been

sent to standard test

CONTENTS

Sampling per drillcore: 1

samples for each lithology

per drillhole

Bench test program

for each sample per

section

Part of sample per

section composed a

“General sample” per

lithology considering all

17 sections

2) Blending per section

3) General blending

for each litotype

Pilot test Program:

- 3 general pilot test (IF,

ISC and IC) ~1t per test Drillcore blending

composing a general

sample for each lithology

per section

17 SECTIONS STUDY

Mass Fe

P Feed

ROMP Conc

7.909.600.IF.TP 51% 80% 43,69 68,73 33,36 0,59 2,41 0,39 0,041 0,026 0,272 0,209 0,87 0,22

7.909.000.IF.TP 45% 72% 43,55 68,71 34,84 0,53 1,72 0,44 0,034 0,025 0,121 0,186 0,81 0,29

7.908.400.IF.TP 36% 71% 34,82 68,43 47,47 0,78 1,47 0,48 0,039 0,045 0,025 0,039 0,89 1,31

7.907.800.IF.TP 45% 76% 40,87 67,97 37,78 1,07 2,09 0,57 0,045 0,043 0,257 0,252 1,06 0,59

7.907.200.IF.TP 43% 80% 37,05 69,11 45,21 0,69 1,06 0,19 0,019 0,009 0,059 0,022 0,40 0,11

7.906-000.IF.TP 52% 85% 42,64 69,02 37,31 0,54 0,87 0,14 0,019 0,013 0,268 0,389 0,44 0,16

7.906.600.IF.TP 42% 78% 37,34 68,93 44,54 0,73 1,30 0,28 0,017 0,009 0,029 0,035 0,60 0,26

7.905.400.IF.TP 52% 85% 42,12 69,01 38,64 0,83 0,86 0,31 0,017 0,018 0,020 0,024 0,12 0,08

7.904.800.IF.TP 58% 84% 47,75 69,06 31,07 0,94 0,26 0,11 0,022 0,013 0,019 0,009 0,26 0,11

7.904.200.IF.TP 43% 71% 42,59 69,74 37,51 0,47 0,92 0,23 0,018 0,014 0,023 0,031 0,51 0,11

7.903.000.IF.TP 44% 83% 36,42 69,09 46,45 0,65 1,08 0,35 0,015 0,013 0,010 0,020 0,26 0,05

7.902.400.IF.TP 50% 86% 40,79 69,30 40,64 0,55 0,70 0,25 0,014 0,011 0,010 0,009 0,20 0,01

7.900.600.IF.TP 45% 85% 36,36 68,72 46,95 1,40 0,59 0,13 0,010 0,009 0,020 0,029 0,31 0,09

7.900.000.IF.TP 52% 88% 40,71 69,25 41,29 0,66 0,26 0,17 0,009 0,009 0,020 0,022 0,11 0,04

7.899.400.IF.TP 62% 92% 45,96 68,30 33,12 2,02 0,64 0,12 0,017 0,009 0,048 0,041 0,30 0,05

7.898.800.IF.TP 52% 89% 40,42 69,02 41,12 0,75 0,65 0,29 0,012 0,009 0,020 0,026 0,28 0,17

7.909.600.ISC.TP 30% 63% 32,87 68,53 52,02 0,51 0,73 0,18 0,009 0,010 0,010 0,031 0,10 0,13

7.908.400.ISC.TP 42% 84% 34,42 68,71 49,67 0,92 0,73 0,35 0,042 0,066 0,024 0,041 0,19 0,25

7.906.600.ISC.TP 40% 82% 33,01 68,28 52,16 1,84 0,43 0,36 0,010 0,009 0,024 0,037 0,09 0,07

7.905.400.ISC.TP 35% 68% 34,91 68,22 49,60 0,46 0,35 0,31 0,010 0,013 0,030 0,031 0,04 0,11

7.904.800.ISC.TP 39% 73% 36,29 69,12 47,26 0,16 0,45 0,26 0,040 0,014 0,079 0,015 0,15 0,23

7.903.600.ISC.TP 43% 78% 38,04 68,51 43,84 1,37 1,15 0,38 0,019 0,013 0,033 0,009 0,43 0,11

7.903.000.ISC.TP 37% 82% 30,71 68,51 54,68 1,34 0,86 0,33 0,013 0,010 0,029 0,053 0,34 0,09

7.898.800.ISC.TP 36% 82% 30,47 68,86 55,71 0,99 0,44 0,34 0,014 0,011 0,079 0,084 0,11 0,01

Global Average 45% 80% 38,49 68,80 43,43 0,87 0,92 0,29 0,021 0,017 0,064 0,069 0,37 0,19

IF Average 48% 81% 40,82 68,90 39,83 0,83 1,06 0,28 0,022 0,017 0,076 0,084 0,46 0,23

ISC Average 38% 77% 33,84 68,59 50,62 0,95 0,64 0,31 0,020 0,018 0,039 0,038 0,18 0,13

Recovery (%)

Section

Grade (%)

STANDARD TEST

17 Section Study – Standard Test Results

17 SECTIONS STUDY PILOT TEST - IF

Minas Rio Expected (%)

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

46,8 80,0 39,8 68,0 40,4 0,90

Minas Rio Pilot Test IF (%)

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

47,6 81,5 39,7 68,3 42,3 1,3 0,93 0,11 0,019 0,015 0,42 0,17

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

46,8 80,0 39,8 68,0 40,4 0,90

Minas Rio Pilot Test ISC (%)

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

44,2 77,4 35,0 69,2 49,8 0,95 0,64 0,18 0,020 0,020 0,30 0,10

17 SECTIONS STUDY PILOT TEST - ISC

17 Sections Study

and WI in process

Iron ore mining.

energy.

Filter.

finished.

standard test

finished.

standard test

pit finished.

CONTENTS

GLOBAL SERRA DO SAPO SAMPLE:

A PILOT PROCESSING WITH DEPOSIT’S GLOBAL SAMPLE - 6t

2) Chemical

analyses

35kg per sample

During 07-08 drilling campaign

6,300 samples, collected in

drillcores intervals with 5m,

~35kg each one, were sent to

chemical analyses.

(6,300 x ~35kg = ~220t)

X-Ray 100g

Chemical analyses result:

Input Geological model

5) Beneficiation

Pilot test:

Grinding

Desliming

flotation (check

criterias)

Pilot test at

Ouro Preto/BRA

7) Filtering

6) Regrinding Test

Pilot test at

York/USA

Concentrate

1) Drilling

3) Anglo

ferrous file

~34kg x 6,300 =

~210t avaiable

to be tested

4) Blending sample

2.329 samples were blended

bulding a representative sample

of “Serra do Sapo” deposit (6t)

GLOBAL SERRA DO SAPO SAMPLE:

A PILOT PROCESSING WITH DEPOSIT’S GLOBAL SAMPLE - 6t

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

46,8 80,0 39,8 68,0 40,4 0,90

Minas Rio Pilot Test ISC + IF (%)

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

50,2 87,3 39,3 68,5 41,7 0,57 1,05 0,24 0,014 0,021 0,35 0,19

17 Sections Study

and WI in process

Iron ore mining.

energy.

Filter.

finished.

standard test

finished.

standard test

pit finished.

CONTENTS

First five

years pit • Blending of 4t samples from

drillcore representing first five

years ROM

• Processing in pilot scale

evaluating process behavior.

Pilot Plant

Minas Rio Pilot Test “Pit Five Years sample”

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

P Conc LOI

46,8 79,7 40,14 68,40 39,80 1,21 1,25 0,42 0,018 0,015 0,38 0,11

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

46,8 80,0 39,8 68,0 40,4 0,90

First 5-years Program

17 Sections Study

and WI in process

Iron ore mining.

energy.

Filter.

finished.

standard test

finished.

standard test

pit finished.

CONTENTS

6 to 10

years pit

• Blending of 4t samples from

drillcore representing first five years

Pilot Plant

6 to 10 years pit Program

Minas Rio Pilot Test “6 to 10 Years pit sample”

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

P Conc LOI

47,4 83,5 38,5 67,8 42,5 1,0 1,15 0,31 0,019 0,019 0,21 0,17

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

46,8 80,0 39,8 68,0 40,4 0,90

17 Sections Study

and WI in process

Iron ore mining.

energy.

Filter.

finished.

standard test

finished.

standard test

pit finished.

CONTENTS

11 to 15

years pit • Blending of 4t samples from

drillcore representing first five

years ROM

Pilot Plant

11 to 15 years pit Program

Minas Rio Pilot Test “11 to 15 Years pit sample”

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

P Conc LOI

46,1 85,1 36,9 68,1 43,8 1,0 1,20 0,33 0,020 0,019 0,58 0,80

Recovery

Metalurgical

Recovery

Fe ROM Fe Conc SiO2

46,8 80,0 39,8 68,0 40,4 0,90

17 Sections Study

and WI in process

Iron ore mining.

energy.

Filter.

finished.

standard test

finished.

standard test

pit finished.

CONTENTS

Pellet Feed - Main Results Obtained in Pilot Tests

Fe SiO2 Al2O3

P P.F. RM RFe

Global S. Sapo sample 68,5 0,57 0,24 0,81 0,021 0,19 50,2 87,1

17 sections - global IF 68,3 1,29 0,11 1,41 0,015 0,17 47,6 81,5

17 sections - global ISC 69,2 0,95 0,18 1,13 0,020 0,10 44,2 77,4

First 5 years pit 68,4 1,21 0,42 1,63 0,015 0,11 46,8 79,7

6 to 10 years pit 67,8 1,00 0,31 1,31 0,019 0,17 47,4 83,5

11 to 15 years pit 68,1 1,00 0,33 1,33 0,019 0,80 46,1 85,1

Products

MINERAL LAB AND PILOT PLANT

Geology

Drillcore file -

Lab and Pilot

600m2 Screening and

Crushing

Leasure Square -

future

GALPÃO CÓRREGO PEREIRA

Laboratories and Pilot Plant – Overview

concentrado

Curva de recuperação

Y = 45,842 Ln(x) – 122,06

Lab e Pilot Plant – Overview

Minas Rio

Industrial Plant

Crushing and Screening – External Area

Minas Rio Pilot Plant

Grinding, Deslaming e Flotation – Internal Area

Grinding e Deslaming – Internal Area

Flotation – Internal Area

Jigging

Magnetic Separation

Lab Preparation e Bench Flotation – view 1

Lab Preparation e Bench Flotation – view 2

Flotation

Laboratório Análise Química – Raio X

X-Ray Lab – Sample Preparation

Mineralogy

Mini Pilot Plant

THANK YOU!

Contact :

carlos.magalhaes@angloamerican.com

roney.sandrelli@angloamerican.com

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