Scott Bensley, Rio Tinto Iron Ore: Rio Tinto’s Iron Ore Pilot Plant Experience

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Scott Bensley, Principal Metallurgist Processing - Resource Development/Metallurgical Development, Rio Tinto Iron Ore delivered this presentation at the 2013 FE Tech Conference. The event focussed on the economics of processing and the beneficiation of iron ore. In light of the slowdown in demand for iron ore and pricing decreases, the need to process more efficiently and cost effectively is a challenge. The conference examined on how we can achieve greater value from the iron ore supply chain, with topics addressing optimisation and streamlining processes, applying improved technologies, understanding the ore body and how to properly characterise it, knowing the steel makers needs. For more information please visit the conference website: http://www.informa.com.au/fe-tech

Text of Scott Bensley, Rio Tinto Iron Ore: Rio Tinto’s Iron Ore Pilot Plant Experience

  • 1. RTIO Pilot Plant Experience FeTech 2013

2. Recent Pilot Plant History 2003 Yandi Scrubbing Pilot Plant2005/6 Marra Mamba BWT Pilot Plant2009 & 2011 IronX Pilot Plant2011 Hybrid Sizer Pilot Plant2012 Low Grade Pilot Plant26 November 2013RTIO Pilot Plant Experience2 3. 2003 Yandi Low Grade Scrubbing26 November 2013RTIO Pilot Plant Experience3 4. 2006 Marra Mamba Desliming26 November 2013RTIO Pilot Plant Experience4 5. 2009 & 2011 IronX26 November 2013RTIO Pilot Plant Experience5 6. 2011 Hybrid Sizer26 November 2013RTIO Pilot Plant Experience6 7. 26 November 2013RTIO Pilot Plant Experience7 8. 2012 Low Grade Beneficiation26 November 2013Presentation Title8 9. Feed Prep Plant 10. Fines Plant (-1mm)26 November 2013Presentation Title10 11. Jig Plant26 November 2013Presentation Title11 12. Site selection Self sufficiency vs integration with Ops (MOUs)Feed sourcing & transportWaste disposalLand, power, waterTravel and accommodation availability26 November 2013Presentation Title12 13. Low Grade Pilot Plant at Brockman 4BS4 LGLGPPBS4 OpsBS4 Mine26 November 2013RTIO Pilot Plant Experience13 14. HSE learnings HSE Dust in eye incidents Rocks falling26 November 2013RTIO Pilot Plant Experience14 15. Falling rock hazard26 November 2013RTIO Pilot Plant Experience15 16. HSE learnings HSE Dust in eye incidents Rocks falling Isolation procedures Access platforms HSE support staff26 November 2013RTIO Pilot Plant Experience16 17. Plant Design Site and Plant design Layout HME separated from plant/operators26 November 2013RTIO Pilot Plant Experience17 18. Separating HME, LV and Pedestrians26 November 2013RTIO Pilot Plant Experience18 19. 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 flexibility26 November 2013RTIO Pilot Plant Experience19 20. Management Setting expectations for staff earlyCrew roster and structureStaggered crew members or 9/5 for better handoversAccommodation! Remember Maslows HierarchyPreparation of Safety and Operating systems allow a skeleton crewEarly managers safety audit just prior to commissioningControl systems support staffDeadlines budget, accommodation, peopleProject finishes when report is complete26 November 2013RTIO Pilot Plant Experience20 21. Management (cont.) Extent of Laboratory services Everything on site (what turnaround) Prep on site or send to PerthHave all the equipment you might need available EWP, water cart, forklift, loaders (IT), trucks, service trailerSchedule the construction/commissioning/operations transitionPlan for decommissioning/removal or care and maintenance26 November 2013RTIO Pilot Plant Experience21 22. Feed Collection & Preparation Feed collection and homogenisation Many oretypes & sufficient quantity Incremental shovelling of feed piles Use of crushing and screening contractors or production plant26 November 2013RTIO Pilot Plant Experience22 23. Stockpiles at the Low Grade Pilot Plant26 November 2013RTIO Pilot Plant Experience23 24. Collecting samples with a belt plough26 November 2013RTIO Pilot Plant Experience24 25. Feed Collection & Preparation Feed collection and homogenisation Many oretypes & sufficient quantity Incremental shovelling Use of crushing and screening contractors or production plan Moisture26 November 2013RTIO Pilot Plant Experience25 26. Wet Feed26 November 2013RTIO Pilot Plant Experience26 27. Feed Collection & Preparation Feed collection and homogenisation Many oretypes & sufficient quantity Incremental shovelling MoistureSampling 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 design26 November 2013RTIO Pilot Plant Experience27 28. Marra Mamba Pilot Plant Oversize Issues26 November 2013RTIO Pilot Plant Experience28 29. Low Grade Pilot Plant Oversize and Contamination in Lump 30. Things you get right but dont realise the importance at the time Sample hoists26 November 2013RTIO Pilot Plant Experience31 31. Fines Plant Material Hoist 32. Things you get right but dont realise the importance at the time Sample hoistsDistributors26 November 2013RTIO Pilot Plant Experience33 33. Things you get right but dont realise the importance at the time Sample hoistsDistributorsData historiansBelt filter operation26 November 2013RTIO Pilot Plant Experience34 34. Important things you discover Up Current Classifier pulsating discharge to filter26 November 2013RTIO Pilot Plant Experience35 35. Allflux discharge26 November 2013RTIO Pilot Plant Experience36 36. Important things you discover Up Current Classifier pulsating discharge to filterRetreating primary cyclone overflow prior to WHIMSSand filters on process water26 November 2013RTIO Pilot Plant Experience37 37. Important things you discover Up Current Classifier pulsating discharge to filterRetreating primary cyclone overflow prior to WHIMSSand filters on process waterPumping UCC underflow Unstable slurry at 35% solids v/v (65% w/w)26 November 2013RTIO Pilot Plant Experience38 38. 26 November 2013RTIO Pilot Plant Experience39 39. Technical Its not just a mini gravel washing plant!Conveyor weightometer setup and test calibrationCant have too much instrumentationTestwork Program This can and will change Consider duplicates and statistical design Plackett Burman, Factorial, Central Rotatable Composite Understand variabilityMass balancing and data analysisTake lots of bulk samples26 November 2013RTIO Pilot Plant Experience40 40. Questions?26 November 2013RTIO Pilot Plant Experience41