Ore Processing Facility Infeed Control

Home   >  Projects   >  Ore Processing Facility Infeed Control

The ore processing facility (OPF) sources its ore feed from multiple sources. The different feed sources are kept fed with ore loaded by front end loaders and/or dump trucks.

The control system was set up such that down-stream sources of feed would be used to make up for the variation in feed rate from the upstream sources. This generally meant that when the upstream feed source was not able to deliver the required rate, the downstream feed source would run extra hard to compensate.

This led to an asymmetrical stockpile drawdown (shown below) and also missed opportunities in production due to rates being missed when downstream feed sources could not deliver the required rates.

New control algorithms were designed that were able to react to loader/truck cycles and re-distribute ore between all sources and was completely configurable to operational and mining requirements.

It also allowed rate re-allocation between any feed sources which meant production rates missed on downstream sources could now be compensated for by upstream feed sources. This also led to more control in stockpile draw which lead to even stockpile drawdown (shown below):

Benefit

  • Production capacity improvement of 1.2MT P.A. With iron ore at $80/t this increases capacity by $96,000,000 P.A.
  • Cost savings of $200,000 P.A. for fuel/loader maintenance due symmetrical stockpile draw and thereby less movement required to feed ore to the plant.
  • Savings of CO2 emissions on loader and dump truck operation.
  • Savings of $3.6M P.A. in ore quality control. Having more control over stockpile draw has allowed better control over the ore produced by the plant and thereby fewer instances of producing ore below quality specifications.

Optimisation and automation for safety, production output and efficiency