Mine to mill optimization for increased efficiency and reduction of circulating load in the tertiary crusher circuit

  • Customer : ENAEX |
  • Pain point : Mine to mill optimization |
  • Market segment : Open-Pit |
  • Solution : Blasting engineering |
  • Location : Brazil |
Situation

In the state of Minas Gerais, Brazil, one of our clients operates an open-pit phosphate mine. They have observed a high circulating load rate in the tertiary crushing stage, directly impacting the productivity of the beneficiation plant. Given this, they partnered with Enaex to conduct a Mine to Mill optimization study and implement rock fragmentation enhancement techniques to improve operational efficiency in the ore beneficiation plant.

To optimize fragmentation and the energy efficiency of the blasting processes, in order to increase the proportion (%) of fragments smaller than 19 mm.

User Testimonial

We are immensely satisfied with the results of the study. This work will bring significant operational benefits to our plant.

Planning Manager

Solution

Mine to Mill Optimization

The first stage consisted of an evaluation of the rock fragmentation at two mining fronts. This process involved gathering actual blasting parameters, such as mesh size, hole length, bench height, stemming length, applied charge, blasting sequence, and bench conditions. Additionally, images were captured for photogrammetric analysis, and mid-material samples were collected for granulometric analysis in the laboratory.

Using this comprehensive dataset and granulometric results, fragmentation estimation models were constructed, considering various scenarios. These stages used the following software tools: O-Pitblast, Paradigm, Portametrics, and Split.

The analysis led to the scenario that would yield the best results for the client, both in terms of rock fragmentation and the expected financial outcomes with the new blasting plan. To optimize the rock blasting process, it was suggested that they replace the non-electric initiation system with the DaveyTronic® electronic initiation system, also proposing changes in the drilling pattern, booster type, and stemming.

Key features
Results

Excellent particle size distribution results aligned with the projected forecast

There was a 10% increase in the portion of material with dimensions smaller than 19 mm, achieving the target objective. This increase directly impacts the reduction of circulating load in the tertiary crusher. With a higher proportion of material within the desired particle size range, the efficiency of the tertiary crushing process improved, resulting in increased plant productivity. Additionally, other benefits included reduced operational costs, greater consistency in the quality of the final product, and a decrease in circulating load.

Stronger bonds

By effectively collaborating in the optimization of rock fragmentation during blasts, Enaex demonstrated its commitment to understanding the client’s specific needs. This tailored approach resulted in measurable improvements in operational efficiency and the circuit’s fragmentation capacity. It also enabled the successful application of the Enaex Mining Technical Solutions (EMTS) team’s technical expertise to address the client’s specific challenge.