Continuous Production Processes
Financial performance is influenced by changing operating conditions - operating conditions are defined by equipment efficiency and effectiveness, production process characteristics, ore characteristics and people (decision-making).
Decision-making impacts financial performance within processing plants i.e. high-quality decision-making can realize substantial value without the need of capital investment. Pre-requisites for improving decision-making quality include:
A) Obtain precise insight into different operating conditions and matching performance.
B) Generate real-time and automated interpretation of operating conditions. The objective is to provide early warningof deteriorating performance facilitating pro-active management of conditions.
C) Change management.
Projects are executed following the MESA International endorsed Time-in-State methodology. The following list references applications:
Milling Circuit: Monitoring Real-time monitoring of milling circuits to detect deviation from the optimum state. Observations triggered further investigation that resulted in >7% increase in throughput.
Flotation Performance: Utilized analytics to derive an optimum recipe (reagent dosing rate, mass pull, cell level and concentrate grade). Results contributed to >2% increase in recovery.
Thickener Monitoring: Provide real-time quantification of thickener condition by interpreting rake torque, underflow density and flow.
Secondary Crushing Circuit Performance: Evaluation of a complete crushing circuit to identify root causes for sub-optimal performance. Used information to determine the viability of a project to increase decoupling capacity.
Business Planning: Execute an assessment to determine an operating plant’s capability to comply with the business plan. Results assisted in generating a realistic stretch target. The latter contributed toward buy-in from operational personnel.