The Case: AllScan | Elemental Analysis, Nickel Ore, Feedback Control & Load Out.
Introduction.
Optimising ore grade control is vital for enhancing downstream processing and reducing costs in mining operations. This case study examines how a nickel mine in South America used the AllScan system to improve real-time management of their screening plant operations, resulting in better product grade and increased operational efficiency.
The Challenge.
The nickel mine encountered significant challenges due to the highly variable composition of their mined material, which included fluctuations in magnesium (Mg), nickel (Ni), and moisture content. These variations increased downstream processing costs and complicated the management of the screening plant. Relying on sample analysis for infeed material had considerable lag, preventing real-time decision-making. This limitation hindered the mine’s ability to maximize ore upgrades and effectively control deleterious components.
The Solution.
Real Time Instruments implemented the AllScan system to measure the quality of material fed from the mine in real time, allowing for immediate adjustments to stockpile builds and providing direct feedback to mining operations. This enabled real-time changes to infeed quality.
By determining the levels of Ni, Fe, SiO2, MgO, and other elements in the mined ore, the customer gained real-time oversight of the infeed to the ore upgrading process. This data allowed them to make informed decisions about pit operations and screening processes, thus controlling and maximising the grade of stockpiled material.
RTI’s approach began with understanding the customer’s specific challenges. The AllScan was calibrated to report material parameters most useful for decision-making, such as SiO2/Mg, Fe/Ni, and Ni/Co ratios. RTI collaborated with the customer to validate the AllScan’s performance, ensuring the data generated reliably informed process control decisions.
The Result.
The tailored integration of the AllScan system yielded significant benefits:
- Real-Time Monitoring: The customer could directly monitor feed material from mining operations, enabling immediate adjustments.
- Enhanced Ore Upgrade: Real-time control of the ore upgrade process led to a 50% increase in the grade of the product at the furnace infeed.
- Reduced Variability: The system significantly reduced variations in deleterious components, positively impacting power consumption costs and CO2 emissions.
By providing a customised, integrated solution with the AllScan system, RTI enabled the nickel mine to enhance ore grade control, resulting in improved product quality and more efficient operations.