Abstract
Mineral processing is one of the most energy-intensive stages of the overall mining beneficiation chain, with an increasing share of the industry footprint. This chapter examines how automation represents a practical means to significantly improve energy efficiency in mineral processing operations. It introduces the fundamentals of automation, hierarchical framework of automation systems, and how the multiple functions can be integrated into an energy management information system. The discussion also explains the rationale of process control and real-time optimization approaches that facilitates lower specific energy requirements from lower variability of key process variables, and determining more appropriate operating points. Case studies are presented to illustrate the current state of the art.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Similar content being viewed by others
References
Tromans D (2008) Mineral comminution: energy efficiency considerations. Miner Eng 21:613–620
CEEC (2013) Innovation—mining more for less. http://www.ceecthefuture.org/comminution-2/innovation-mining-less/, 2013
Norgate T, Haque N (2010) Energy and greenhouse gas impacts of mining and mineral processing operations. J Clean Prod 18:266–274
U.S. Department of Energy (2007) Mining industry energy bandwidth study. http://www.energy.gov/sites/prod/files/2013/11/f4/mining_bandwidth.pdf, 2007
Wei D, Craig IK (2009) Grinding mill circuits—a survey of control and economic concerns. Int J Miner Process 90:56–66
Kanchibotla SS, Valery W, Morrell S (1999) Modelling fines in blast fragmentation and its impact on crushing and grinding. Presented at the Explo ‘99–A conference on rock breaking, Kalgoorlie, Australia, 1999
Torrealba-Vargas J, Esteban R, Roy D, Runnels D (2016) Mine to mill approach to optimize power consumption in a process plant operation by modelling and simulation. In: International mineral processing congress—IMPC 2016, Quebec City, 2016
Morrell S (2009) Predicting the overall specific energy requirement of crushing, high pressure grinding roll and tumbling mill circuits. Miner Eng 22:544–549
Van Der Meer FP, Gruendken A (2010) Flowsheet considerations for optimal use of high pressure grinding rolls. Miner Eng 23:663–669
Nordell LK, Porter B, Potapor A (2016) Comminution energy efficiency—understanding the next steps. In: IMPC 2016, Quebec City, 2016
Lessard J, De Bakker J, McHugh L (2014) Development of ore sorting and its impact on mineral processing economics. Miner Eng 65:88–97
Awatey B, Skinner W, Zanin M (2015) Incorporating fluidised-bed flotation into a conventional flotation flowsheet: a focus on energy implications of coarse particle recovery. In: Powder technology, vol 275, pp 85–93, May 2015
Tbaybi H (2015) Impact de la flottation éclair sur l’empreinte énergétique d’un circuit de broyage – Cas de la mine Nyrstar – Langlois. M.Sc., Département de génie des mines, de la métallurgie et des matériaux, Université Laval, 2015
Silva DO, Vieira LGM, Lobato FS, Barrozo MAS (2012) Optimization of the design and performance of hydrocyclones by differential evolution technique. Chem Eng Process 61:1–7
Radziszewski P (2013) Energy recovery potential in comminution processes. Miner Eng 46–47:83–88
Radziszewski P, Hewitt D (2015) Exploring the effect of energy recovery potential on comminution efficiency: the Glencore Raglan Mine case. In: SAG conference 2015, Vancouver, British Columbia, Canada, 2015
Bouchard J, LeBlanc G, Germain Y, Levesque M, Tremblay N, Légaré B, Dallaire B, Radziszewski P (2016) The CMIC/CanmetMINES comminution energy recovery potential initiative—The Agnico Eagle Goldex Division Case. In: International mineral processing congress—IMPC 2016, Quebec City, 2016
Levesque MY, Millar DL (2015) The link between operational practices and specific energy consumption in metal ore milling plants—Ontario experiences. In: Minerals engineering, vol 71, pp 146–158, Feb 2015
Nunez E, MacPherson G, Graffi D, Tuzun A (2009) Self-optimizing grinding control for maximising throughput while maintaining cyclone overflow specifications. In: 41st Annual meeting of the Canadian mineral processors, Ottawa, Canada, 2009, pp 541–555
Engell S, Harjunkoski I (2012) Optimal operation: scheduling, advanced control and their integration. Comput Chem Eng 47:121–133
Bonavita N (2013) Can process automation increase energy efficiency? Hydrocarbon Process 92:71–75
Sbarbaro D, del Villar R (2010) Introduction. In Sbarbaro D, del Villar R (eds) Advanced control and supervision of mineral processing plants. Springer, Berlin
Bascur O, Dunne R, Karageorgos J, Ruel M, Sbarbaro D (2016) Process control, optimization and performance management in mineral and metallurgical processing. In: Young C, Dunne R (eds) SME Process control handbook
Byron JHH, Landry J, Hart D (2003) Energy management information systems: achieving improved energy efficiency: a handbook for managers, engineers and operational staff. Office of Energy Efficiency of Natural Resources Canada, 2003
Efficiency New Brunswick (2010) Energy management information systems: planning manual and tool. Office of Energy Efficiency of Natural Resources Canada, 2010
Seshan A, Gorain BK (2016) An integrated mining and metallurgical enterprise enabling continuous process optimization. In: Lakshmanan VI, Roy R, Ramachandran V (eds) Innovative process development in metallurgical industry. Springer, Berlin
Friedmann PG (2006) Automation and control systems economics, 2nd edn. ISA Press
Tanaka K (2008) Assessment of energy efficiency performance measures in industry and their application for policy. Energy Policy 36:2877–2892
White DC (2003) The economics of advanced automation. In: AIChE 2003 spring meeting, New Orleans, 2003
Funk GL, Smith DE (1979) Estimating economic incentives for computer control systems: an applications approach. IEEE Trans Ind Appl IA-15:394–398
Hodouin D, Jamsa-Jounela SL, Carvalho MT, Bergh L (2001) State of the art and challenges in mineral processing control. Control Eng Pract 9:995–1005
Wei D, Craig IK (2009) Economic performance assessment of two ROM ore milling circuit controllers. Miner Eng 22:826–839
Desbiens A, Nunez E, del Villar R, Hodouin D, Poulin E (2008) Using process control to increase the energy efficiency of mineral and metal processing plants. Int J Power Energy Syst 28:145–152
Numbi BP, Xia X (2015) Systems optimization model for energy management of a parallel HPGR crushing process. Appl Energy 149:133–147
Numbi BP, Zhang J, Xia X (2014) Optimal energy management for a jaw crushing process in deep mines. Energy 68:337–348
Numbi BP, Xia X (2016) Optimal energy control of a crushing process based on vertical shaft impactor. Appl Energy 162:1653–1661
Nunez E (2002) Filosofía de control para molienda y clasificación en la planta concentradora de Toquepala y diseño de una estrategia de control utilizando DCS. Bachelor, Universidad Católica de Santa María, Arequipa, Perú, 2002
Matthews B, Craig IK (2013) Demand side management of a run-of-mine ore milling circuit. Control Eng Pract 21:759–768
Rinne A, Peltola A (2008) On lifetime costs of flotation operations. Miner Eng 21:846–850
Lelinski D, Govender D, Dabrowski B, Traczyk F, Mulligan M (2011) Effective use of energy in the flotation process. In: 6th Southern African base metals conference, Phalaborwa, North West Province, 2011, pp 137–148
Evans CL, Coulter BL, Wightman E, Burrows AS (2009) Improving energy efficiency across mineral processing and smelting operations; a new approach. In: Publication series—Australasian Institute of Mining and Metallurgy, vol 6/2009, pp 9–13, 2009
Acknowledgements
D. Sbarbaro acknowledges the kind support of the support of Solar Energy Research Center (SERC-Chile) Fondap #15110019.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2018 Springer International Publishing AG
About this chapter
Cite this chapter
Bouchard, J., Sbarbaro, D., Desbiens, A. (2018). Plant Automation for Energy-Efficient Mineral Processing. In: Awuah-Offei, K. (eds) Energy Efficiency in the Minerals Industry. Green Energy and Technology. Springer, Cham. https://doi.org/10.1007/978-3-319-54199-0_13
Download citation
DOI: https://doi.org/10.1007/978-3-319-54199-0_13
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-54198-3
Online ISBN: 978-3-319-54199-0
eBook Packages: EnergyEnergy (R0)