Ausenco’s process optimization and debottlenecking team optimized a comminution circuit, which was highly constrained due to highly competent feed and an inadequate operating strategy. Through fit-for-purpose design solutions, modifications, and optimized process control and operating strategies, the overall circuit saw a significant increase in capacity compared to the baseline.
The Challenge
The comminution circuit, a conventional SAG-based flowsheet with scalped feed augmented by secondary crushing to supplement the SAG mill’s primary crusher product feed, presented significant challenges. These challenges were throughput-related due to a combination of increasing high-ore competency in the mine plan, suboptimal operational strategies, and inadequate process control for a complex comminution circuit.
The Better Way
Ausenco’s optimisation approach is to challenge the norm by fully using the installed comminution power, efficiently. Achieving the optimized solution is realized through a combination of fit-for-purpose engineering solutions, improved operating parameters and a revised operating strategy with clear process-driven objectives.
The Outcome
Debottlenecking solutions include:
- Maintaining high coarse ore stockpile levels to maximize the augmented crushing circuit operation
- Optimized control strategy to maintain process stability in the crushing circuit
- Maximizing HPGR operation by increasing the feed rate
- Redesigned SAG shell mill liners to maximize operating loads and mill speeds
- Optimized SAG mill load to increase breakage rates
- Process performance-focused operator training to maximize equipment operability and use