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Rikastustekniikan innovaatioilla kestävää liiketoimintaa
Oulu Mining Summit 2016Rikastustekniikan edistysaskelia ja kokemuksia
Oulun yliopistoKari Knuutila23.-24.8.2016
© Outotec – All rights reserved
What does the industry want?
Economicalperformance
Environmentalfriendliness
Socialresponsibility
What does it mean?Ability to create wealth
sustainablyMinimal impact to
surrounding natureProvision of safe and
secure jobs
What complicates it?
• Decreasing revenues• Rising costs• Unclear investment
horizon• Undetermined business
risks• Volatile shareholder
value creation
• Outdated productionprocesses
• Inefficient equipment• Tightening regulations• Poor operation
practices• Declining raw material
grades, complex oreswith harmful impurities
• Hazardous workplace• Cyclical business• Inflexible job market• Scarcity of talent• Insufficient utilization of
human potential
23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila2
© Outotec – All rights reserved
The world is not yet ready; innovations are neededto address the increasing industry challenges
23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila3
Produce more
• Larger capacities• Better recovery• Less production breaks
Produce with less
• Smaller fixed costs• Smaller variable costs• Restricted investments
Consume less
• Minimal water use• Energy efficiency• Less land use
Emit less
• SO2 and CO2• Ash and other dust• Wastewater
Improve safety
• Safe workplace• Hygienic conditions• Minimal stress level
Maintain stability
• Reliable employer• Creation of jobs• Avoidance of cuts
© Outotec – All rights reserved
Energy saving opportunities in comminution and betteroperation in flotationChallenges
• Optimizing comminution stages as a part of theconcentrator process
• More ore to be grinded, energy efficiency• More slurry is coming to the flotation cells
• Need for bigger units and economy of scale
• Need for better selectivity and recovery of metals
Some innovations
• Pre-concentration with grade engineering and sorting• Outotec® HIGMills
• 30-60% energy reduction
• Outotec® TankCell 630• Less energy and a simpler plant layout• Outotec FloatForce®’s slower rotation speed, lower power
consumption
• Outotec® cPlant Flotation• Containerized flotation processing plant
• Automation solutions for better selectivity andrecovery• Outotec ® Courier, PSI, Chena FrothSence, LevelSence,
CellStation, Courier, Advanced Process Control, Proscon ®
Ore Crushingand Milling Flotation De-
wateringSmelting
andconverting
Anodecasting
Electro-refining
23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila4
Process chain for copper from sulfidic ore to metal
© Outotec – All rights reserved
Laiva Gold mine in FinlandCustomer case, ore sorting
23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila5
Study indicates that the Outotec ore sortingsolution enables reopening the mine:
“The economic assessment for the LaivaGold Mine indicated the potential forrestarting the site, which can be operated ona long-term basis at a broad range ofcommodity prices. Base-case net presentvalue of €77 million, producing 529,000 troyounces of gold over a seven-year mine life.”
© Outotec – All rights reserved
HIGmill fine grinding for FQM KevitsaCustomer case, comminution
Customer benefits:• HIGmill improved overall plant performance• Copper loss to nickel circuit improved
from 12% to 8%• Overall copper recovery increased by up to 1.5%
• 1.5% increase represents around $1million increase in finalcopper value, after smelting and refining to produce LME gradecopper
• Improved concentrate grades• Less nickel in final copper concentrate• Less copper in final nickel concentrate
• Installed & commissioned without effectingproduction
• HIGmill allowed coarser primary grind and hencehigher plant throughput
• More metal out of same ton of ore < 2 year payback
23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila6
© Outotec – All rights reserved
Stabilizing and optimizing processes through automationand advanced process control
23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila5
© Outotec – All rights reserved
A modular plant design offers a fast, effective, and affordable solutionfor small mine sites, or sites requiring additional capacity
23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila8
20% lowercapital
investment
30% lesslabor in
installation
Easy and costefficient totransport
enabling reuseat other mine
sites
OutoteccPlant
Flotation
© Outotec – All rights reserved
The efficiency of process equipment is a critical factor inmaximizing productivity• Drivers for modernization
• Outdated technology
• Poor metallurgical performance
• Frequent mechanical failure
• Ore processing challenges
• Plant expansion
• Drive to improve energy efficiency
• Use of non-optimal equipment
23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila9
http://www.outotec.com/en/Products--services/Process-equipment/Flotation-cells/Flotation-modernization-guidebook/
© Outotec – All rights reserved
Treating waters requires a systematic approach and advancedprocess technology
Challenges
• Scarcity and cost of water• Increased volumes of water needed to
process larger volumes of declining ores• Large volumes of tailings are produced
• more water lost• growing size of tailings dams• Increased risk of environmental incidents
Some innovations
• Systematic mine water management, recyclingof water
• Water efficient concentrator solutions to takewater recycling up to 90%
• Paste thickening and filtration of the tailings• Paste thickening slurry for mine back filling• Dry stacking of tailings to reduce size of tailings
area
Ore Crushingand Milling Flotation De-
wateringSmelting
andconverting
Anodecasting
Electro-refining
23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila10
Process chain for copper from sulfidic ore to metal
© Outotec – All rights reserved
Holistic mine site water management saves operatingcosts and minimizes environmental surprises
23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila11
Watersaving
andManage-
ment
Waterbalances,negative
or positive
Flow,SS,
pH, uS,mV etc
Safety issues,environ-mental
follow-up
Remotemonitoring
andassessmentcapabilities
Reporting,prediction
andoptimization
apps
© Outotec – All rights reserved
Applying best practices in tailings management will bringsignificant operational cost savings and reduces safetyrisks• Paste and dry stacking technologies
combined with closed water loops arethe best available technologies forconserving water within theconcentrator environment
• The short- and long-term risks can besignificantly reduced by reducing theamount of water in the surface tailingsstorage facility
23.8.2016 Rikastustekniikan innovaatioilla kestävää liiketoimintaa, Kari Knuutila12
PASTEBACKFILL
DRYSTACKING
Footprint= 12%OPEX= 37%
PASTE
Footprint= 53%OPEX= 58%
THICKENEDTAILINGS
Footprint= 72%OPEX= 75%
WETTAILINGS
Footprint= 100%OPEX
= 100%