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Sensor-based ore sorting of low-grade gold sulphide deposits
Name: Lütke von Ketelhodt – Steinert US Inc.Dr Tony Parry - OreSort Solutions Date: November 2018
Colombia Gold Symposium 2018
CONTENT
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Introducing Steinert01
Ore sorting in gold mining and processing operations – an economic analysisCase study 1 – Brownfields plant
02
Case study 2 – Low-grade Stockpile03
Mill pebble sorting04
Conclusion05
01
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Introducing Steinert
Our Solutions01
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STEINERT provides innovative solutions for the separation of valuable materials,
increasing customer profitability through higher recovery & reducing operational costs.
Secondary resource sectorResource Recovery
Primary resource sectorMiningIndustrial Minerals
Silica, Feldspar, Limestone
Ores
Iron ore
Base metals (e.g. Nickel, Copper)
Precious metals (Gold, Silver, Platinum)
Coal
Precious Gemstones
Diamonds
Scrap
Electronic Scrap
Shredder Scrap
Waste
Municipal Solid Waste
Waste to Energy (WfE)
Substitute Fuels
Other
Incineration Slag
Waste wood
Demolition Waste
Global network02
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Subsidiaries: USA, Australia, Brazil, Japan, Germany, Africa Sales cooperations: more than 50 worldwide
Agent Mexico
Agent Peru
Agent Chile
Sensor-based sorting01
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Differentation using the electromagnetic spectrum for separation material by shape, colour
and density,elements
STEINERT ISS
UNISORT FLAKE
STEINERT XSS F STEINERT XSS T
STEINERT KSS
STEINERT KSS
UNISORT FLAKE UNISORT C
UNISORT PR
Gamma- ray
x-ray
UV
VIS
NIR
IR
Micro- wave
Radio- wave
Radio waves (1 m – 1 km)
Microwaves (1 mm – 1 m)
Infrared radiation (1000 nm – 1 mm)
Near-infrared radiation (700 – 2000 nm)
Visible light (400 – 700 nm)
Ultraviolet radiation (10 – 400 nm)
Soft + hard X-rays (0.1 – 10 nm)
Gamma rays (wavelength: λ < 1 pm)
Incr
easi
ng w
ave
leng
th
Incr
easi
ng e
nerg
y in
tens
ity
Magnet-based sorting01
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Differentation using magnetic field intensity
Low intensity
Medium intensity
High intensityUNISORT CanMasterSTEINERT WDS STEINERT EddyC
STEINERT BR STEINERT WDS STEINERT HGF
STEINERT HGS
STEINERT MT ANOFOL CoilsSTEINERT UM/AM
Inductions Sorting SystemISS (electromagnetic properties of entire particle)
X-Ray Sorting SystemXSS-T (XRT) (Atomic density of entire particle)
3D Laser Sorting System3DS (Surface detection of brightness/particle size)
Combined Colour and 3D Sorting SystemKSS (Surface detection)
01
8
Test Center Steinert US
02
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Ore sorting in gold mining and processing operations – an economic analysis
02 Sorting Principle - XRT
10
Poly-metallic Sulphides
Waste Rock
02 Sorting Principle - XRT
11
Waste RockSulphide product
Sorting tasks are getting increasingly more complex, requiring combination of information on different
characteristics of the material detected by more than one sensor system becomes necessary.
Different sensors provide broad variations of the scanned spectra which can be combined and overlaid to
detect different material characteristics.
12
Multi-Sensor Sorting02
13
Multi-Sensor Sorting02
Sulphide Product
Waste Rocks
QuartziteProduct
14
Test Methodology02Test No.Mass: 305 kg
Size: -50 +10 mmAu grade 0.25 g/t
Sulphur 0.35 %
Mass 268 kg 87.9% Mass 37 kg 12.1%
Au grade 0.14 g/t Au grade 1.05 g/tSulphur 0.28 % Sulphur 0.86 %
Test No.
Mass 207 kg 77.2% Mass 61 kg 22.8%Au grade 0.13 g/t Au grade 0.15 g/tSulphur 0.28 % Sulphur 0.28 %
Test No.
Mass 139 kg 67.1% Mass 68 kg 32.9%Au grade 0.16 g/t Au grade 0.07 g/tSulphur 0.26 % Sulphur 0.32 %
Test No.
Mass 94 kg 67.6% Mass 45 kg 32.4%Au grade 0.22 g/t Au grade 0.05 g/tSulphur 0.24 % Sulphur 0.31 %
Test No.
Mass 87 kg 92.6% Mass 7 kg 7.4%Au grade 0.10 g/t Au grade 1.66 g/tSulphur 0.23 % Sulphur 0.39 %
Test No.
Mass 84 kg 96.6% Mass 3 kg 3.4%Au grade 0.09 g/t Au grade 0.45 g/tSulphur 0.23 % Sulphur 0.22 %
6
Waste Product
Waste Product
5
Waste Product
Waste
1
Product
2
Waste Product
3
Waste Product
4
15
Results – Grade/Recovery02
16
Results – Grade/Recovery02
02 Case Study 1 – No Sorter
17
1.40 g/t
Cart to MillCart to MillROM Stockpile
1.40 g/t
MINE OUTPUT
50,000 t/m
0 kilometres
Base Case – No Pre-Concentration – Total ROM Milled
Brownfields Expansion Of Existing Operations
02 Case Study 1 – With Sorting
18
1.40 g/t
Cart to MillCart to Mill
ROM Stockpile
1.81 g/t
MINE OUTPUT
69,444 t/m
0 kilometres
Jaw CrusherJaw Crusher
Cone Crusher
Cone Crusher
ScreenScreen
+60mm
-20mm
30%
48,611 t/m
70%
Stockpile
Stockpile
Stockpile
+20mm -60mm
SORTER FEED
REJECTS
PRODUCT
48,611 t/m
ORE SORTER74 tph 90%
avail.
ORE SORTER74 tph 90%
avail.
ACCEPTS60%29,167 t/m
1.40 g/t
20,833 t/m
0.35 g/t
50,000 t/m
KEY INPUTS
Sorter reject rate: 40%Sorter gold recovery: 90%
1.40 g/t
REJECTS
40%
19,444 t/m
2.10 g/t
(39% more)
02
19
Case Study 1: Gross Cash Flow
No Sort Sort 40% Reject0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
18,131,458
26,645,970
Increase in Gross Cash flow with Ore SorterBrownfields Expansion 600,000tpa Mill
Ann
ual G
ross
Cas
h Fl
ow (A
$)
03
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Case Study 2 Low Grade Stockpile Treatment
03 Low Grade Stockpile Treatment
21
0.70 g/t
Cart to MillCart to MillStockpile
0.70 g/t
LOW GRADE
60,000 t/m
20 kilometres
Base Case – No Pre-Concentration – Hauling 20 km to Mill– Total Run of Dump Milled
03 Case Study 2 – With Sorting
22
0.70 g/t
Cart to MillCart to Mill
Stockpile
1.28 g/t
LOW GRADE
60,000 t/m
20 kilometres
Jaw CrusherJaw Crusher
Cone Crusher
Cone Crusher
ScreenScreen
+60mm
-20mm
30%
42,000 t/m
70%
Stockpile
Stockpile
Stockpile
+20mm -60mm
SORTER FEED
REJECTS
PRODUCT
42,000 t/m
ORE SORTER65 tph 90%
avail.
ORE SORTER65 tph 90%
avail.
ACCEPTS30%12,600 t/m
0.70 g/t
18,000 t/m
0.10 g/t
36,600 t/mKEY INPUTS
Sorter reject rate: 40%Sorter gold recovery: 90%
0.70 g/t
REJECTS
70%
29,400 t/m
2.10 g/t
RECLAIM
(39% less)
03 Case Study 2: NPV
23
No Sort Sort 70% Reject0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
1.81
12.81
Increase in Pre-Tax NPV with Ore Sorter720,000tpa @ 0.7g/t
Pre-
Tax
NPV
(A$m
)
NPV based on five year project life and 10% discount rate
04
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Mill Pebbles Sorting
03 Mill Pebble Circuit
25
Flotation/CIL Feed
SAG Mill
Sizing Screen
Steinert Ore Sorter
Pebble Crusher
Oversize
Ball Mill
Short conveyor
Waste Stockpile
Undersize
03 Mill Pebbles - Copper Sulphides
26
Summary of test work results
• COPPER SULPHIDE SORTING (+50 – 100mm)
• Waste rejection: 20 – 25%
• Cu (%) Recovery: 99%
• Cu (%) upgrade: Feed = 5.87% → 7.43% (Discard = 0.23%)
03 Mill Pebbles – Gold Ore
27
Summary of pilot plant results
• Gold sulphide sorting (+12 – 25mm) and (+25 – 45mm)
• Waste rejection: 50 – 90%
• Au (g/t) Recovery: up to 93%
• Au (g/t) upgrade: Feed = 1.4g/t → 4.4g/t (Discard = 0.5g/t)
1 2 3 4 5 6 7 8 90
10
20
30
40
50
60
70
80
90
100
-1
1
3
5
7
9
11
13
15
Gold Recovery (%) Yield (%) Conc. grade (g/t) Feed grade (g/t)Tails grade (g/t)
Re
cove
ry/Y
ield
(%
)
Go
ld c
on
cen
trati
on
(g/
t)
Type 1 (Coarse material) Type 2 (Coarse material)Type 3 (Coarse material)
05
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Conclusion
Conclusion05
29
Multi-Sensor Sorting provides flexible solution for beneficiation of ores.
2 Case Studies comparing No-Sort vs. Sort Scenarios
• The Brownfields as well as the Low-Grade Dump treatment studies have shown significant improvements in profitability by adding a sorting process to the operation
• Removing waste rock before milling and reducing the amount of unnecessary comminution of barren hard rock is the biggest cost saver.
• Reducing transport cost by hauling less waste rock also contributes to the profitability
Mill-Pebble Sorting
• Reduces pebble crusher load
• Reduces recirculating mill load – resulting in higher mill-feed capacities.
• Don’t mill the Waste Rocks, Sort them!
Thank you very much for your attention
Lütke von Ketelhodt
Engineer. MSc (Eng)
Steinert US Inc.
Email [email protected]