We know that process optimisation is a long game. As metallurgists and engineers, we’re in this for the long haul. We aim to build excellence into our mineral processing operations through incremental improvements. But how do we create a process optimisation program that’s both strategic and sustainable, one that outlives individual team members and leadership changes?
This article explores what it takes to build a process optimisation program that drives continuous improvement. We’ll look at how to lay the foundations, engage the workforce, leverage technology and data, and embed optimisation into the culture.
There are no quick fixes or magic bullets. But with a coordinated effort across operations, maintenance and technical teams, we can play the long game to unlock our plant’s full potential.
The necessity for sustainable process optimisation in mineral processing plants
The global mining industry is dynamic, demanding adaptability and long-term vision. Large-scale mineral processing plants require efficient and effective processes to ensure continued viability. Precise measurement and control over process variables are crucial for optimising performance and establishing a sustainable operational foundation.
Sustainable process optimisation for long-term operational effectiveness
Sustainable process optimisation offers mineral processors a powerful tool to ensure the long-term health and effectiveness of their operations. Plants can establish a foundation for sustained success by focusing on process stability and efficiency. This includes optimising resource utilisation, minimising waste generation, and implementing preventative maintenance practices to maximise equipment lifespan. A sustainable process optimisation program fosters a culture of continuous improvement, ensuring that processes remain adaptable and responsive to changing conditions over time.
Driving continuous improvement and operational excellence
Optimised processes lead to continuous improvement across the entire operation, which increases productivity, efficiency, and reliability and, in the long term, creates greater value for the mineral processing plant.
Building a sustainable operational legacy
Mineral processors can achieve these goals through collaboration with experienced partners who can assist in overcoming unique challenges and implementing tailored solutions. Experts can design, configure, and advise on optimising assets to deliver sustained performance enhancements and a robust operational framework.
Mineral processors can build a sustainable operational legacy by investing in sustainable process optimisation. This approach ensures a manageable and effective long-term strategy for continued success and fosters the adaptability required to navigate the industry’s evolving demands. Optimising processes today secures a more robust and enduring future for the plant.
Challenges in process optimisation in mineral processing plant
Complexities of the process
Mineral processing plants are intricate systems with multiple interconnected unit operations. Each process step impacts the next, creating a complex web of dependencies. Minor fluctuations can ripple through and significantly impact overall plant performance.
Variability in feed characteristics
The characteristics of the mine ore feed, such as grade, mineralogy, and particle size distribution, are inherently variable. This variability poses a constant challenge in maintaining consistent process performance and product quality.
Ageing assets and equipment constraints
Many mineral processing plants operate with ageing assets and equipment constraints. Optimising processes within these limitations while minimising unplanned downtime requires a delicate balance. And with plants designed for the first five years of mine production and oxide zones being repurposed for differing ore mineralogy.
Diverse data streams
Process data is generated from various sources, including online analysers, laboratory assays, and control system historians. Integrating and reconciling these diverse data streams to derive actionable insights is a significant challenge.
Evolving market demands
Market demands for product specifications and recovery rates are continually evolving. An ongoing optimisation challenge is adapting processes to meet these changing requirements while maintaining efficiency and profitability.
Resource constraints
Mineral processing plants often face resource constraints like water scarcity, energy costs, and environmental regulations. Optimising processes while minimising resource consumption and environmental impact is a complex balancing act.
At Mipac, we understand these challenges intimately. Our experienced team can design, configure, and advise you on optimising your assets while considering your specific constraints. We are your partner in driving operational performance, ensuring sustainable production improvements and increased value generation.
Developing a process optimisation roadmap
Step One: Establishing a clear vision and goals
The first step is to establish a clear vision for process optimisation. This vision should be ambitious yet achievable and align with the mineral processing plant’s overall goals. For instance, the vision could be: “To become a leader in sustainable mineral processing by achieving a 10% improvement in overall recovery rates while reducing water consumption by 5% within the next two years.”
Once the vision is defined, specific and measurable objectives (SMART goals) should be developed for key performance indicators (KPIs). These KPIs are the metrics used to track progress towards achieving your process optimisation goals.
Factors to consider when choosing KPIs
- Relevance to overall goals: The KPIs should directly link to the program’s vision and objectives. For example, if the vision is to improve recovery rates, a relevant KPI would be “P80 target” or “metal recovery percentage.”
- Measurable: A clear and consistent method should be used to measure each KPI. Ensure the chosen metrics are readily obtainable through existing data collection systems or easily implemented measurement procedures.
- Actionable: The data obtained from the KPIs should provide insights that can be used to make process adjustments. For instance, monitoring “specific energy consumption” (kWh/t) in a grinding circuit can help identify opportunities for reducing energy usage.
- Timely: KPIs should be monitored frequently enough to identify trends and opportunities for improvement. Depending on the process and KPI, monitoring could be done hourly, daily, weekly, or monthly.
Step Two: Data collection and analysis
Data is the lifeblood of any process optimisation program. Here are some critical considerations for data collection and analysis:
- Implementing a data management system: A centralised system for storing and organising process data is essential for efficient analysis. Many plant information systems (SCADA) already have built-in data logging capabilities. However, if a dedicated system is needed, consider onsite historians that offer scalability and remote access.
- Using data visualisation tools: Visualising data through charts, graphs, and other visual representations can help identify trends, outliers, and areas for improvement. Modern data analysis software offers visualisation tools tailored to specific KPIs and process parameters.
- Focus on high-quality data: Ensure the accuracy and consistency of data collection procedures to avoid basing decisions on faulty information. Regular calibration
- Regular calibration of sensors and instruments is crucial for ensuring data accuracy.
- Standardise data collection procedures across the plant to eliminate inconsistencies.
- Implement data validation and error correction protocols to identify and address any anomalies in the data set.
Practical tips for data collection
- Leverage existing data sources from plant information systems (SCADA) and laboratory analysis. Most modern mineral processing plants generate a wealth of data that can be readily utilised for process optimisation.
- Standardise data collection procedures across the plant to ensure consistency. Develop clear protocols for how and when data is collected for each KPI.
- Implement protocols for data validation and error correction. Train personnel on how to identify and address potential errors in data collection.
Step Three: Selecting and implementing optimisation opportunities
Once you understand your plant’s performance through KPI analysis, it’s time to identify and prioritise optimisation opportunities.
- Start with low-hanging fruit: Focus on implementing simple operational changes or adjustments that yield quick wins. For example, optimising grinding mill discharge size or automating reagent dosages in a flotation circuit can often lead to significant improvements without major capital expenditure. These initial successes can help build momentum and buy-in for the program.
- Prioritise based on impact and feasibility: Evaluate potential improvements based on their expected impact on KPIs and the resources required for implementation. High-impact, low-cost opportunities should be prioritised to maximise the return on investment.
- Simulation: Test automation changes on simulation tools to improve implementation success
Building a culture of continuous improvement for sustainable process optimisation
Embracing a culture of continuous improvement
Achieving process excellence in mineral processing is not a singular accomplishment but an ongoing pursuit. It necessitates a cultural shift that permeates every facet of operations. Successful programs cultivate an environment where team members feel empowered to identify and champion optimisation opportunities. From frontline operators to senior engineers, a mindset of continuous learning, experimentation, and adaptation is fostered.
Leveraging data-driven decision-making
At the core of a sustainable process optimisation program lies data-driven decision-making. By harnessing the power of advanced analytics, mineral processors can gain deeper insights into their operations. Continuous monitoring of key performance indicators (KPIs) allows for identifying bottlenecks, inefficiencies, and areas ripe for improvement. This data-centric approach empowers informed choices, streamlines workflows, and eliminates non-value-adding activities, ultimately driving increased productivity and profitability.
Fostering cross-functional collaboration
Process excellence flourishes in an environment that fosters collaboration. To achieve this, breaking down organisational silos and promoting seamless communication and knowledge sharing across functions is crucial. Working in unison, cross-functional teams leverage diverse perspectives to develop holistic solutions. This collaborative approach ensures that improvements in one area do not have unintended consequences elsewhere. By fostering an integrated mindset, processes can be optimised end-to-end, delivering sustainable improvements.
Investing in continuous learning
Cultivating a culture of process excellence requires a steadfast commitment to continuous learning and skill development. By investing in comprehensive training programs, mineral processing plants can equip their teams with the latest tools, methodologies, and best practices. This ensures that employees stay ahead of the curve, empowered to drive innovation, challenge the status quo, and implement cutting-edge solutions that propel them to the forefront of mineral processing excellence.
Practical optimisation strategies
Here are some practical optimisation strategies that can be applied in various areas of a mineral processing plant:
- Comminution: Optimising grinding mill parameters (e.g., feed size, mill speed, liner configuration) can improve mineral liberation and reduce energy consumption. Regular mill performance monitoring and adjustments based on KPI data (e.g., specific energy consumption) can lead to significant efficiency gains.
- Flotation: Fine-tuning reagent dosages, air flow rates, and impeller speeds based on mineralogy and ore characteristics can enhance recovery and concentrate grade. Utilising online sensors for froth height, conductivity, and particle size distribution can provide real-time data for optimising flotation performance.
- Classification: Ensuring proper classifier efficiency to optimise particle size distribution in downstream processes like grinding or flotation is crucial. Regular monitoring of KPI data (e.g., cyclone overflow size distribution) and adjustments to classifier settings can significantly improve overall plant performance.
- Maintenance: Implementing preventative maintenance strategies (e.g., routine equipment inspections and oil analysis) can reduce equipment downtime and improve overall plant reliability. By scheduling maintenance based on equipment conditions rather than a fixed schedule, unplanned breakdowns and associated production losses can be minimised.
Here are the answers to some common questions we get asked
A sustainable process optimisation program goes beyond short-term gains. It focuses on building a culture of continuous improvement and adaptability. This includes:
Standardisation: Standardising procedures and data collection methods ensures consistency and facilitates future improvements.
Focus on maintainability: Optimisation strategies should consider long-term equipment health and maintenance requirements.
Employee buy-in: Involving employees in the program and fostering a culture of ownership fosters long-term commitment to optimised processes.
Data-driven decision making: Regularly monitoring KPIs and adapting the program based on data ensures it remains relevant and effective over time.
Resistance to change: Shifting away from established practices can be met with initial resistance. Effective communication and a focus on the long-term benefits are crucial.
Lack of resources: It is essential to allocate sufficient resources, including personnel and budget, for ongoing data analysis, training, and improvement implementation.
Short-term thinking: Focusing solely on meeting daily production quotas can overshadow the importance of sustainable, long-term improvements. Aligning performance metrics with long-term goals is key.
Failure to adapt: As ore characteristics, market conditions, and technologies evolve, the program must adapt to remain sustainable. Regularly reviewing goals and strategies is crucial.
A single metric does not measure success instead it requires combining factors that contribute to long-term operational effectiveness. Here are some key areas to consider:
Long-term trends in KPIs: Monitor changes in KPIs like recovery rates, production costs, and equipment uptime over time.
Improvement in overall equipment effectiveness (OEE): Track OEE, which considers availability, performance, and quality, to assess overall operational efficiency.
Employee engagement and ownership: Measure employee participation in improvement initiatives and overall program satisfaction.
Adaptability to changing conditions: Evaluate the program’s ability to adjust to new challenges and opportunities.
By focusing on these aspects, mineral processing plants can ensure their process optimisation program delivers sustainable improvements that contribute to long-term operational excellence.
Conclusion
Building a sustainable process optimisation program requires a commitment from management, metallurgists, and operational personnel. By focusing on clear goals, effective data utilisation, practical optimisation strategies, and continuous improvement, mineral processing plants can significantly improve recovery rates, reduce environmental impact, and enhance overall profitability.
The key lies in moving beyond simply collecting data and leveraging it to gain actionable insights that drive real-world improvements in plant performance. Remember, a successful program is not just about implementing the latest technology but about building a culture of continuous improvement that empowers everyone involved to contribute to a more efficient and sustainable operation.
Ready to unlock the full potential of your mineral processing plant?
At Mipac, we understand the unique challenges faced by today’s operations. Our team of highly skilled process engineers boasts extensive experience across all stages of mineral processing. We partner with clients to develop and implement sustainable process optimisation programs that deliver real results.
Don’t settle for incremental improvements. Let Mipac help you achieve operational excellence.
Schedule a free discovery call with one of our process optimisation experts today and discuss how we can help you optimise your plant's performance.
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