Real-time online analysis of iron ore, validation of material stockpiles and roll-out for overall elemental balance as observed in the Khumani iron ore mine, South Africa.

With the increasing demand for quality-specific ores, coupled to the reality of even more complex minable iron ore reserves, there is a growing need for real-time online material analysis of plant feed and product. These real-time online elemental scans, located at key positions, enable the mining and plant operators to make informed decisions in a timely manner, therefore ensuring product outcomes and optimising operations where material grade and its control are important. Deployed after the primary crushing circuit, an analyser acts in two ways: guaranteeing mining production and processing facility feed blends. The analysers on the product conveyors guarantee saleable product. The analysers on the low-grade conveyor and tailings line complete the elemental balance and identify the potential of the low-grade ore and tailings for future processing. The system losses (accumulation) are calculated to determine the amount of material lost during the processing stage and can be used as a measure of the efficiency of the plant. A further advantage is that immediate intervention can be taken in the event that the product is not of saleable-product grade requirements. In the Khumani iron ore mine run-of-mine, product and control analysers were included. Run-of-mine and product stockpiles are certified; low-grade material is not currently directly measured but is calculated from the internal control loops. Iron units are reconciled between product and feed material.
With the increasing demand for quality-specific ores, coupled to the reality of even more complex minable iron ore reserves, there is a growing need for real-time online material analysis of plant feed and product. These real-time online elemental scans, located at key positions, enable the mining and plant operators to make informed decisions in a timely manner, therefore ensuring product outcomes and optimising operations where material grade and its control are important. Deployed after the primary crushing circuit, an analyser acts in two ways: guaranteeing mining production and processing facility feed blends. The analysers on the product conveyors guarantee saleable product. The analysers on the low-grade conveyor and tailings line complete the elemental balance and identify the potential of the low-grade ore and tailings for future processing. The system losses (accumulation) are calculated to determine the amount of material lost during the processing stage and can be used as a measure of the efficiency of the plant. A further advantage is that immediate intervention can be taken in the event that the product is not of saleable-product grade requirements. In the Khumani iron ore mine run-of-mine, product and control analysers were included. Run-of-mine and product stockpiles are certified; low-grade material is not currently directly measured but is calculated from the internal control loops. Iron units are reconciled between product and feed material.