Low-grade mineral deposits lead to a very high tonnage excavation with the adherent economical and environmental problems belong to gas emissions and minerals recovery costs, which, accompanied by the higher operational and equipment costs and the higher demand for the mineral resources, lead to increasing of mineral commodities prices, especially metals. These challenges can be overcome through mine planning optimization. Therefore, an approach for the global optimization of the integrated mining and processing operations is designed by a dynamic and simulation model construction. By applying a case study and through mining selectivity strategy, deeply investigation of the ore parameters (especially mineral liberation grain size and hardness), and proper arrangements for the plant facilities, mineral production is realized, with better quality, lower environmental impacts, lower costs, and higher economic benefits.:Table of Content
List of Figures ………………………………………………………………………….……… V
List of Tables …………………………………………………………………………….…… IX
List of symbols and Abbreviations …………………………………………………............ XII
List of Appendices …………………………………………………………..……............ XVIII
1. Justification and Importance of the Mine Planning Optimization ……………………….. 1
1.1 Introduction ............................................................................................................................... 1
1.2 Urgent need for general mine planning optimization ............................................................... 2
1.2.1 Overall costly low-grade ore deposits ................................................................................... 2
1.2.2 World markets ........................................................................................................................ 3
1.2.3 Sustainability requirements in mining, environmental and social issues .............................. 5
1.2.4 The strategic importance of the mining industry ................................................................... 6
2. State of the Science and General Outline for Mine Planning Optimization Concepts …... 8
2.1 The mine planning optimization concepts ................................................................................ 8
2.1.1 Improvements for the interconnected mining and processing operations ............................. 8
2.1.2 Urgent demand for the unit-operations cost reduction through holistic optimization ......... 12
2.1.3 Expenditures of size reduction operations ........................................................................... 13
2.1.4 The Mill as a critical point in the product supply chain ...................................................... 17
2.2 Critical review of researches for the (Mine-to-Mill) optimization field ................................. 18
2.2.1 Mill throughput optimization ............................................................................................... 18
2.2.2 Intelligent assistant systems and processes automation and monitoring …………………. 19
2.2.3 Scheduling software and operationally holistic modules ……………………………...…. 20
2.3 The aim of work and the thesis layout .................................................................................... 22
3. Suggested Approach for a Holistic Mine-to-Mill Optimization ……………………….… 25
3.1 Introduction and scope …………………………………………………………………….. 25
3.2 The methodology plan …………..………………………………………………………….. 26
3.3 Assignment of the operational parameters inter-acting the integrated optimization ……….. 29
3.3.1 Mining and processing activities …………………………………………………………. 29
3.3.2 Mining and processing operational parameters …………………………………………... 31
3.3.3 Mining and processing special indicators ………………………………………………… 42
3.4 Introduction to the dynamic modeling and simulation softwares ………………………...… 45
3.5 Particular concepts belonging to the chosen modeling software ………………………...…. 46
3.6 Main tools, components and constituents of the used software …………………………..… 49
3.7 Assumed case study for the model construction ……………………………………….…… 51
4. Calculation Basics for Applying Dynamic Modeling and Simulation for the Mining and Processing Operations ……………………………………………………………………….... 53
4.1 The modeling construction strategy ………………………………………………………… 53
4.2 Construction of the [Reference-Mode] model …………………………………………….... 54
4.2.1 Dynamic modeling and simulation for the drilling and blasting operation ………………. 54
4.2.2 Dynamic modeling and simulation for the loading and hauling operations …………..….. 62
4.2.3 Dynamic modeling and simulation for the crushing and grinding operations …………..... 71
5. Case Study Application and the Model Output and Assessment ……………………...… 82
5.1 Main physical properties of the ore deposit under study ………………………………..….. 82
5.2 Principal technological and operational parameters within the case study ……………....… 83
5.3 Processing of the data from the case study ………………………………………………… 86
5.4 [Reference-Mode] model results and assessment ………………………………………...… 87
5.4.1 Preliminary main results of the mining activities sub-models ………………………...….. 87
5.4.2 Preliminary main results of the processing activities sub-model ……………………..….. 97
5.4.3 Further model optimization requirements ……………………………………………….. 105
6. The Model Optimization, Validation and Practical Applications ………………..…….. 107
6.1 Model further optimization plan …………………………………………………….…….. 107
6.2 The ore deposit characteristics and details …………………………………………….….. 108
6.2.1 Tonnage distribution and cut-off-grade for the ore deposit ……………………………... 108
6.2.2 Liberation size and microscopic grain size distribution for the ore deposit …………….. 112
6.3 Mining selectivity and processing mixing scenarios …………………………………….... 113
6.3.1 Blending triangle design for choice of the annual mining contribution scenarios ……… 113
6.3.2 Planed processing strategies according to the pre- and post-grinding mixing ………..… 115
6.4 An Excel calculation tool for preparing the new detailed inputs to the modified model .… 118
6.4.1 The need for new prepared and detailed inputs to the modified model ……………….… 118
6.4.2 Description and benefits of the designed Excel calculation tool ……………………..…. 118
6.4.3 The main outputs of the Excel calculation tool ……………………………………….… 120
6.4.4 The Excel calculation tool outputs as inputs to the modified Vensim model ………….... 120
6.5 The model modification through the new added mathematical and functions ……………. 123
6.6 [Controlled] model results and the comparable discussion of the processing strategies ..… 129
6.6.1 General notifications for the model handling and the results presentation …………….... 129
6.6.2 Results of the mining section of the model …………………………………………….... 130
6.6.3 Results of the processing section of the model ……………………………………….…. 132
6.6.4 Comparison between the three data processing and arrangement methodologies ……..... 142
6.6.5 Comparison between scenarios ………………………………………………………….. 149
6.6.6 Extreme cases versus the chosen Organized Method ………………………………….... 153
6.7 Optimization evolution overview across the operations improvement steps …………...… 157
7. Conclusion and Recommendations …………………………………………………...… 163
References …………………………………………………………………………………… 168
Appendices ……………………………………………………………………………...…… 179
| Identifer | oai:union.ndltd.org:DRESDEN/oai:qucosa:de:qucosa:22856 |
| Date | 19 April 2013 |
| Creators | Ahmed, Ayman Abdelfattah Mahmoud |
| Contributors | Drebenstedt, Carsten, Niemann-Delius, Christian, Elwageeh, Mohamed, Technische Universität Bergakademie Freiberg |
| Source Sets | Hochschulschriftenserver (HSSS) der SLUB Dresden |
| Language | English |
| Detected Language | English |
| Type | doc-type:doctoralThesis, info:eu-repo/semantics/doctoralThesis, doc-type:Text |
| Rights | info:eu-repo/semantics/openAccess |
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