A Cut-Off of Liberated and Selected Ore Minerals Optimisation Based On The Geometallurgy Concept
A Cut-Off of Liberated and Selected Ore Minerals Optimisation Based On The Geometallurgy Concept
ABSTRACT
An improvement to cut-off grade optimisation theory based on geometallurgy has been completed.
The improvement fundamentally consisted of taking into account mineralogical and textural
characteristics instead of grades. These characteristics are related to the spatial variability of
mineral abundance, association, particle size and liberation properties. Additionally, the improve-
ment considered the spatial variability of mineral processing liberation and selectivity properties
associated with mineralogy and texture. The enhanced optimisation enables estimation of the
economic value of mining operations based on an optimum cut-off policy attributed to liberated
and selected ore minerals.
The enhanced optimisation was developed as an essential component of a joint cut-and-fill
mining and mineral processing methodology based on mixed integer mathematical programming.
The formulation considers static and dynamic modifying factors that vary over the projected life of
mining. The objective function of the mathematical formulation consists of maximising the realistic
expected economic value of concentrates or products of liberated and selected ore minerals,
whilst minimises liberated and selected gangue minerals. The optimal solution is obtained when
the objective function is subject to geological, mining, processing, marketing, smelting, refining,
environmental and financial constraints. The methodology accesses geometallurgical multivariate
resource models, which integrate the spatial variability of mineralogical and textural characteristics
and mineral processing liberation and selectivity properties.
The geometallurgical process concurrently optimises stope geometries, ore reserves, mining
sequences, and mining and mineral processing production based on the enhanced cut-off of
liberated and selected ore minerals. In addition, the process considers additive and non-additive
transfer functions associated to mutually exclusive geometallurgical spatial domains. The transfer
functions also take into consideration the blending of mineralogical and textural characteristics
with mineral processing liberation and selectivity properties.
This contribution presents an example of cut-off grade optimisation via mineralogical and
textural characteristic, and liberation and selectivity processing parameter optimisation for a
spatially variable orebody.
INTRODUCTION
The most important objective of the strategic mine planning However, a realistic expected economic value can be
process consists in maximising the expected economic determined by considering the spatial variability of mineral-
or net present value (Davis and Newman, 2008). This is ogical and textural characteristics and associated liberation
achieved by mining and processing the ore reserves, and and selectivity properties (Turner-Saad, 2010). In addition,
the marketing, smelting and refining of the concentrates or reliable static and dynamic assumptions can be made of the
products over the projected mine life. The maximisation of the modifying factors over the projected mine life.
expected economic or net present value can be determined by The straightforward principle of determining the expected
applying current state-of-the-art cut-off grade optimisation economic value of mining, processing and marketing the
methodologies (Lane, 1964, 1979, 1988; Rudenno, 1979; concentrates or products of two independent discrete ore
Lane et al, 1984; Dagdelen,1993). These methodologies are reserve blocks is described. The most important assumption
fundamentally based on the spatial distribution of orebody is that the two ore reserve blocks with the same volume,
grades. In addition, account can be made of reasonable static bulk density, grade, dilution and static mineral processing
and dynamic assumptions on some of the modifying factors in recovery will produce the same recovered metal content.
converting mineral resources to ore reserves (eg JORC, 2004; Nevertheless it is likely that the real recovered metal content
Napier, 1983; Baird and Satchwell, 2001; Asad, 2005). of these two discrete blocks will be different. This is due to the
1. Executive Geometallurgical Consultant, CAE Mining, Level 23, 333 Ann Street, Brisbane Qld 4000. Email: gts@datamine.co.uk
THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011 263
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difference in the mineralogical and textural characteristics, variability of mineralogical and textural characteristics, and
and mineral processing performance of the two blocks. In liberation and selectivity mineral processing properties of an
general terms, the mineral processing recovery is a function orebody.
of the abundance, association, grain size and liberation The purpose of the proposed methodology consists of assess-
characteristics and product size properties of ore and gangue ing the realistic expected economic value of mining operations
minerals. It is convenient to emphasise that concentrates or by defining ‘what if’ strategic, tactical and operational
products are constituted by liberated and selected ore and scenarios. The assessment can be performed by defining
gangue minerals. and varying geological, mining, processing, marketing,
On other hand, underground mine optimisation method- smelting, refining, environmental and financial scenarios and
ologies relate to stope geometries, mining sequences and assumptions over the projected mine life.
mining production have been developed as isolated stages
by a number of researchers as is shown in Figure 1 (Murray METHODOLOGY
and Magri, 1978; Trout and Grice, 1993; Alford, 1995; Ovanic
In this study, the objective of the geometallurgical optimisation
and Young, 1995; Ataee-pour and Baafi, 1998; Van Leuven,
process is to maximise the expected economic value of under-
1998; Thomas and Earl, 1999; Rahal et al, 2003; Smith,
ground cut-and-fill mining and mineral processing operations.
Sheppard and Karunatillake, 2003; Topal, Kuchta and
The estimation of expected economic value throughout
Newman, 2003; Grieco, 2004; Smith and O’Rourke, 2005).
These mathematical formulations did not take into account this methodology is based a function of static and dynamic
the combined relationship of the underground mining technical and financial factors over the projected mine life.
stages either for single or multiple commodity deposits. The essence of the methodology resides in defining optimum:
Additionally, there are no publications on the integration of mining, blending, stockpiling and processing of reserves
the geometallurgical concept, and specifically for underground with different mineralogical and textural characteristics,
cut-and-fill mining. and mineral processing liberation and selectivity proper-
ties; and
marketing, smelting and refining concentrates or products
Mineral Geometallurgical with different liberated and selected ore and gangue
Resources Resources
minerals,
where optimisation is in agreement with geological, mining,
Mining Mining processing, marketing, smelting, refining, environmental and
Design Design financial constraints.
The development of the geometallurgical optimisation
process is based on five activities, inclusive of:
Ore Ore
Reserves Reserves 1. accessing geometallurgical multivariate resource models
of a deposit;
2. defining the strategic, tactical and operational scenarios;
Mining Mining 3. defining the static and dynamic modifying factors over the
Sequence Sequence
projected mine;
4. optimising simultaneously stope geometries, ore reserves,
Mining Mining mining sequences, mining and mineral processing
Production Production productions; and
5. assessing the realistic expected economic value.
Optimisation is an iterative process due to the unlimited
Processing Processing
number of ‘what if’ strategic, tactical and operational
Production Production
scenarios that can be considered and because of the unlimited
number of assumptions of the modifying factors.
Smelting Smelting The iterative optimisation process is based on concurrent
Production Production integration of stope geometries, ore reserves, mining
sequences, mining and mineral processing productions over
the projected mine life as is shown in process diagram of
Refining Refining Figure 1.
Production Production
The methodology is based on a mixed integer mathematical
programming formulation developed in AMPL A Mathematical
FIG 1 - Process diagrams of the isolated (left) and concurrent Programming Language (Fourer, Gay and Kernigham, 1993)
(right) mining and mineral processing optimisation. and using the IBM ILOG CPLEX Optimizer solver (IBM, 2011).
A summary of the objective function and geological, mining,
A geometallurgically integrated and iterative underground processing, marketing, smelting, refining, environmental and
cut-and-fill mining and mineral processing optimisation financial constraints of the mathematical formulation are
methodology based on a mixed integer mathematical program- described in the next sections.
ming has been developed. The methodology described is
an extension and enhancement of the research previously Objective function
published by Turner-Saad and Smith (2006) and Turner- The objective function consists in maximising the realistic
Saad (2011), which integrates geometallurgical multivariate expected economic or net present value of concentrates
resources models of mineral deposits. This extended and or products of liberated and selected ore minerals whilst
enhanced methodology takes into consideration the spatial minimising liberated and selected gangue minerals.
264 THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011
A CUT-OFF OF LIBERATED AND SELECTED ORE MINERALS OPTIMISATION BASED ON THE GEOMETALLURGY CONCEPT
The maximisation is controlled by a cut-off of liberated and on whether the mineral processing recovery is treated as a
selected ore minerals optimisation methodology, which it is static, dynamic additive or non-additive transfer function.
an adaptation and enhancement of the original cut-off grade In summary, the formulation uses transfer functions to
optimisation theory (Lane, 1964). determine the recovered metal content when the net smelter
The estimated annual cash flows or profits are determined return value is computed for each concentrate or product.
by means of a dynamic update of the net smelter return value
that varies over the projected mine life. The dynamic net Marketing constraints
smelter return value is computed for concentrate or product The quantity of liberated and selected ore and gangue minerals
types by applying the defined static and dynamic modifying in concentrates or products are limited by this group of
factors (Liimatainen, 1998; Wellmer, 1989). constraints and based on the market demand or smelters and
refineries short, medium- and long-term sales agreements.
The formulation enables consideration of additive and non-
additive transfer functions that correlate the mineralogical
Smelting constraints
and textural characteristics with liberation and selectivity
This group of constraints restricts the quality of liberated and
processing properties for each geometallurgical domain.
selected ore minerals in concentrates. These constraints also
Geological constraints limit the production capacity of the smelter.
The aim of the geological constraints consists of selecting Refining constraints
orebodies, domains and resource categories in a specific time
The refining constraints group controls the quality of liberated
period of the projected mine life. Consequently, a variety of
and selected ore minerals in concentrates or products. In
scenarios can be analysed with this group of constraints.
addition, this group of constraints limits the production
Mining constraints capacity of the refinery.
The mining constrains simultaneously define the stope geo- Environmental constraints
metry, reserves, mining sequence and production of ore and
The main purpose of this group of constraints consists
gangue minerals over the projected life of mining operations.
limits the quality of liberated and selected gangue or delet-
It is performed by constraining the quantity and quality of ore
erious minerals abundance in waste materials, tailings
and gangue minerals.
and concentrates or products, that in some way have an
The mining constraints define the level intervals, stope environmental impact.
dimensions and locations, cut heights, pillar dimensions and
locations for each orebody. The levels, stopes and cuts can be Financial constraints
also selected in a specific time period to assess any particular This group of constraints controls the mining, processing,
mining scenario. marketing, smelting, refining and environmental fixed
In addition, a number of mining constraints related to the and variable operating costs for each time period over the
underground cut-and-fill mining cycle (Hustrulid and Bullock, projected mine life.
2001) were established in the formulation. Furthermore, mine
capacity, level, stope and cut productivities, mineralogical and APPLICATION
textural characteristics, internal and wall dilution and cut-off
of liberated and selected ore minerals are also considered. A case study was considered to demonstrate the capability of
The stope geometry is then generated by differential cut-off integrating the cut-off of liberated and selected ore minerals
of liberated and selected ore and gangue minerals that vary and the joint cut-and-fill mining and mineral processing
in both horizontally and vertically directions across levels, optimisations. The assessment of the integrated optimisation
stopes and cuts. was performed throughout the definition of several scenarios.
Each scenario included the combinations of static and
The reserves consist of those blocks included in the mining
dynamic modifying factors over the projected mine life.
production of ore and gangue minerals. The optimal solution
defines the quantity and quality of the diluted and blended The geologic setting of the case study consists of several
reserves blocks to be mined and processed for each time mesothermal and pyrometasomatic replacement orebodies in
period and by orebody, domain, level, stope and cut. a thick limestone sequence. The mineralisation is composed
of mainly massive galena and sphalerite with amounts
Processing constraints of chalcopyrite associated with pyrrhotite, arsenopyrite,
The quantity and quality of liberated and selected ore and silicates, sulfates and carbonates.
gangue minerals in concentrates or products is controlled by Two structural and geometric types of orebodies have been
a group of constraints based on mineral processing liberation identified within the project:
and selectivity parameters. 1. a gently dipping sheet, and
The additive and non-additive transfer functions defined 2. steeply plunging chimneys.
for each domain calculate the quantity and quality of the The sheet orebodies comprise a combination of silicates
concentrates or products according to the mineral processing and sulfides, whilst the chimneys are dominated by sulfides
capacity. with or without silicates. One of the irregular sheet orebodies
Normally, a static mineral processing recovery function is was used as the case study, which represents a metasomatic
applied to determine the recovered metal content of specific replacement system. A long-section model of the orebody is
commodity. However, dynamic mineral processing recovery shown in Figure 2.
transfer functions can be applied in the formulation based on A geometallurgical multivariate resource model of
the geometallurgical characteristics and properties of the ore the orebody was previously generated and accessed as
minerals in each domain (Bojcevski, 2003). The expected net fundamental to the optimisation process. The resource
smelter return value could then vary significantly depending model comprised the spatial variability of mineralogical and
THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011 265
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FIG 3 - The galena abundance (per cent), association (per cent), particle size (microns) and liberation (per cent) spatial models of the case study orebody.
266 THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011
A CUT-OFF OF LIBERATED AND SELECTED ORE MINERALS OPTIMISATION BASED ON THE GEOMETALLURGY CONCEPT
FIG 4 - The feed size F80 (mm), product size P80 (microns), throughput (t/h) and energy consumption (kWh/t) spatial models of the case study orebody.
processing constraints: limits of the mineral processing liberation or comminution
static limits of ore production capacity; properties.
static limits of ore minerals abundance; Scenario 2:
dynamic limits of liberation or comminution processing constraints:
properties; and static limits production capacity of ore,
dynamic limits of selectivity or flotation properties; static limits of ore minerals abundance,
marketing constraints: static limits of liberation or comminution properties –
static limits of marketing costs; energy consumption (kWh/t), and
static limits of shipping costs; and dynamic limits of selectivity or flotation properties.
static limits of treatment costs; Scenario 3:
smelting constraints: processing constraints:
static limits of concentrates production capacity; and static limits production capacity of ore,
dynamic limits of ore minerals abundance. static limits of ore minerals abundance,
refining constraints: static limits of liberation or comminution properties –
static limits of products production capacity; and energy consumption (kWh/t),
dynamic limits of ore minerals abundance. static limits of liberation or comminution properties –
throughput (t/h), and
environmental constraints:
dynamic limits of selectivity or flotation properties.
static limits of deleterious minerals abundances in
Scenario 4:
waste;
static limits of deleterious minerals abundances in processing constraints:
tailings; and static limits production capacity of ore,
static limits of deleterious minerals abundances in static limits of ore minerals abundance,
concentrates or products; static limits of liberation or comminution properties –
financial constraints: energy consumption (kWh/t),
static limits of liberation or comminution properties –
static limits of mining, processing, smelting and
throughput (t/h),
refining fixed and variable operating costs;
static limits of liberation or comminution properties –
static limits of discount rate; and
product size P80 (microns), and
dynamic limits of metal prices.
dynamic limits of selectivity or flotation properties.
The geological, mining, marketing, smelting, refining, In summary, the objectives of the four scenarios consisted of
environmental and financial constraints of scenarios 2, 3 assessing the impact of relaxing and constraining the energy
and 4 were similar to scenario 1. The only difference was in the consumption (kWh/t), throughput (t/h) and product size P80
processing constraints and specifically in defining the static (microns).
THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011 267
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0.0 0.5 1.0 1.5 2.0 2.5 3.0 Product:Material Ratio Refinery:Mine Capacities Ratio
Abundance [%]
Probability Density Function Cumulative Distribution Function Liberated and Selected Galena
FIG 5 - The dynamic probability density function (per cent) and cumulative
distribution function (per cent) of the galena abundance (per cent) of each
time period over the projected mine life.
268 THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011
A CUT-OFF OF LIBERATED AND SELECTED ORE MINERALS OPTIMISATION BASED ON THE GEOMETALLURGY CONCEPT
Optimum Cut-Off of Liberated and Selected Galena [%] Average of Galena Abundance [%]
0 5 10 15 20 0 5 10 15 20
Time Period [y] Time Period [y]
FIG 9 - The dynamic optimum cut-off of liberated and selected galena (per cent) (left) and average of galena abundance (per cent) (right)
over the projected mine life.
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Scenario 1 Scenario 2
0 5 10 15 20 0 5 10 15 20
Time Period [y] Time Period [y]
Material [t] Ore [t] Product [t] Profit [$] Material [t] Ore [t] Product [t] Profit [$]
Scenario 3 Scenario 4
0 5 10 15 20 0 5 10 15 20
Time Period [y] Time Period [y]
Material [t] Ore [t] Product [t] Profit [$] Material [t] Ore [t] Product [t] Profit [$]
FIG 10 - The dynamic material (t), ore (t), concentrate or product (t) productions and profits ($) over the projected mine life.
Energy Consumption of the Liberation Process [kWh/t] Throughput of the Liberation Process [tph]
0 5 10 15 20 0 5 10 15 20
Time Period [y] Time Period [y]
0 5 10 15 20
Time Period [y]
FIG 11 - The energy consumption (kWh/t) (top), throughput (t/h) (middle) and product size P80 (microns) (bottom) of the liberation process over the projected mine life.
270 THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011
A CUT-OFF OF LIBERATED AND SELECTED ORE MINERALS OPTIMISATION BASED ON THE GEOMETALLURGY CONCEPT
Scenario 1 Scenario 2
Scenario 3 Scenario 4
FIG 12 - The stope geometries and mining sequences of a cut-and-fill mining over the projected mine life.
Scenario 1 Scenario 2
Scenario 3 Scenario 4
FIG 13 - The spatial distribution of the cut-off of liberated and selected galena (per cent) of a cut-and-fill mining over the projected mine life.
THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011 271
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