320 linking the full value chain chemical crushing and ... · 9models vibration 9determines costs....
TRANSCRIPT
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320 Linking the FULL Value Chain – Chemical Crushing and Mechanical Crushing
Scott Giltner & Charles Hillmann
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321 Linking the FULL Value Chain – Chemical Crushing and Mechanical Crushing
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Comminution or Breakage
100000%
20%
40%
60%
80%
100%
0.1 1 10 100 1000Size mm
Cum
% p
assi
ng
In-situROM
Crusher Product
Chem
ical
mec
hani
cal
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$ $
“Optimal
Zone”
Chemical Crushing Mechanical CrushingTransport
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Fines Reduction Project 2010
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Blast Models
HSBM (Hybrid Stress Blast Model)3-D Blast model‘High end’ engineering toolSuitable for surface, underground, & block modeling
FAS-BlastBlast design & modeling tool‘Every day’ tool for blasters & engineersPrimarily applicable for surface applications
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Blast Models
HSBM (Hybrid Stress Blast Model): 3-D blast modelModels:
Dynamic forcesFracture mechanismsFace velocityFragmentationMuckpile distribution
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Blast Models
FAS-BlastDesigns blastModels fragmentationModels vibrationDetermines costs
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HSBM (Fracturing around blasthole)
Fracturing around blasthole Fragment displacement
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HSBM (Timing Effects on fracturing)
0 ms delay 10 ms delay
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HSBM Model of Quarry Blast
Fractures
Velocity
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FAS-Blast Model Scenarios
GraniteBench height – 60 ftJoint spacing of 4 ft (dipping out of face)
Scenario Hole Diameter Explosive#1 6 inch ANFO
#2 4 ½ inch 50/50 blend
#3 4 ½ inch Large diameter packaged
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FAS-Blast
Model Simulations
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Drilling & Blasting Costs
Scenario Hole Diameter Explosive Pattern Powder Factor D&B Cost
#1 6 inch ANFO 14x14 1.76 ton/lb $0.302/ton
#2 4.5 inch 50/50 Blend 9x13 1.38 ton/lb $0.317/ton
#3 4.5 inch Large diameter packaged 11x15 1.66 ton/lb $0.553/ton
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ANFO(Coarse)
50/50(Medium)
Packaged(Fine)
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ANFO(Coarse)
50/50(Medium)
Packaged(Fine)
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Coarse Blast Medium Blast Fine BlastPrimary Crusher 60” x 44” 48” x 44” 48” x 32”Setting CSS (In) 6.5 6.5 6.5
Cost ( $US) 850,000 550,000 450,000
Secondary Crusher S4800 S4800 S4800Setting CSS (In) 1.9 1.9 1.9
Cost 500,000 500,000 500,000
Tertiary Crusher 2 x H6800 2 x H6800 2 x H6800Setting CSS (In) 0.65 0.65 0.65
Cost 1,000,000 1,000,000 1,000,000
Cost: Steelwork/Electrics 6,000,000 4,000,000 4,000,000
Capital Cost 8,350,000 6,050,000 5,950,000
Blasting Cost/ton 1.4 1.5 1.8Crushing Cost/ton 1.95 1.75 1.65
Payback over 5 Years/ton 1.00 0.70 0.68Total Cost per ton 4.35 3.95 4.13
TPH Handled 650 650 650TPYHandled 1,950,000 1,950,000 1,950,000
If Average product Price = $7 5,167,500 5,947,500 5,596,500Operating Potential/year = 22,478,625 23,492,625 23,113,545
Optimal Profits = -1,014,000 379,080 -379,080
Total Costs
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Total Costs
Scenario D&B Cost Crushing Cost Payback over 5 yr Total Cost
#1 (coarse) $0.302/ton $1.95/ton $1.00/ton $3.252/ton
#2 (med) $0.317/ton $1.75/ton $0.70/ton $2.767/ton
#3 (fine) $0.553/ton $1.55/ton $0.68/ton $2.783/ton
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Blast Curves
0
10
20
30
40
50
60
70
80
90
100
1 10 100 1000Size (mm)
Cum
. % p
assi
ng
VFBFB (62)MBCBVCB (63)
3/8” 3/4” 4”
LFB
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Rock Breakage Chemical & Mechanical
100000%
20%
40%
60%
80%
100%
0.1 1 10 100 1000Size mm
Cum
% p
assi
ng
Insitu
Energy $
Mechanical
Chemical
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Blasted End Product
100000%
20%
40%
60%
80%
100%
0.1 1 10 100 1000Size mm
Cum
% p
assi
ngFine Blast Large Hole Diameter
Medium Blast Smaller Hole Diameter
¼” ½¾1” 2” 4“
Range
Of P
roduc
ts
Crusher Discharge Curves
Waste
Waste decrease
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Effects on Production Yield related to Chemical Crushing
Under Break = Chemical Secondary Handeling Secondary BreakageRe-handling Reduced ProductionIncreased Energy UsageWaste
Loss =+/- Available Profit Ton
Over Break = ChemicalSecondary Handling WasteLost Energy In ProcessWaste Pile ManagementReduced ProductionReduced Product ResistanceIncreased wear
Loss =+/- Available Profit Ton
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Lowest Operation Costs Long Term
$/t
D&B costDigging cost
Hauling cost
Total $/t
OptimumProduct Yield & Utilization
Total Mine Cost
Waste
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$ $
“Optimality Zone”
Chemical CrushingMechanical Crushing
Makeing The Right Stuff !
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Fines Reduction Through Chemical & Mechanical Adjustments
Size MM Blast Blast Total Fines
Fine Medium Fine Reduction
1" 25 65 60
3/4" 19 55 38 68 0
1/2" 12.5 40 26 48 0
3/8" 9.5 28 20 35 0
# 4 4.75 15 11 18 5
# 8 2.36 10 6 12 4
# 16 1.18 5 4 8 2
# 30 0.6 4 3 4 2
# 50 0.3 3 2 3 1
# 100 0.15 2 1 2 1
# 200 0.075 1 0 1 0
15
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Feed
Properties1. Loading in2. Max size3. Feed cap4. Feed PSD5. Wi6. AI7. Moisture
Primarystation
Intermediatestation
Finalstation Products
Properties1. Process2. Quantity3. Quality4. Prod cap5. Prod PSD6. Loading out
Influence1. High2. High3. High4. High5. High6. Medium
Influence1. Medium2. Medium3. Medium4. Medium low5. Medium low6. Low
Influence1. Medium low2. Low3. Low4. Low5. Low6. Low
Influence1. High2. High3. Medium high4. Medium high5. Medium6. Medium7. Medium
Influence1. Low2. Low3. Medium low4. Medium low5. Medium high6. Medium high7. Medium low
Influence1. Low2. Low3. Low4. Low5. High6. High7. Low
Mechanical Crushing Influence On Product
B
L
A
S
T
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Aggregate Production & Costs of Waste
Combined Annual Productions 1.6 Billion Tons USC !About 30 % is either Under or over desired Spec 25% Under / 5% Over !30% costs twice as much as its worth ?Potentially 15-25% is wasted or Half of Canada’s Annual requirements !
USA Annual Productions
1.2 Billion Tons “BLASTED”
Canada Annual Productions(Highest Annual Stone consumption Per Capita)
400- Million Tons “BLASTED”
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Take home messages
”Prepare” Your Organization for a Long ProcessGeology will Challenge the results @ TimesWork with the Geology & adjust as neededThe Powder factor / Pattern will require small adjustmentsVideo & Review @ Blast / Belt Cuts @ Before secondary ”Must”Gather Production data , Plant and Product ’Manage well”Adjust The Crushing stages individually Flow Chart and set the Model , track the Changes .Capacity normally Can decrease when Blast Fraction Increases , remeber its Yield Not through Put .Balance between Sheared Particles & Crushed Particles
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