the innovation pathway - crc ore · the innovation pathway john marsden sme 2016, top ten lists for...
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Model in CRC Ore Consistent with Others’ Experience e.g. Metso CRC ORE
CRC ORE commenced mid-2010 and was recently awarded a further six year Federal funding term - total government and industry support over next term will exceed A$100m
CRC ORE’s prime directive is to identify, integrate and implement innovation that can improve operational value and reverse the trend of declining productivity in the mining industry
CRC ORE has an applied technology development and transfer focus with an emphasis on large scale site deployment and horizontally integrated optimisation
Model in CRC Ore Consistent with Others’ Experience e.g. Metso Where we have come from – Some outcomes from CRC “One”
GRADE ENGINEERING®
Use of coarse separation in themine to mill interface to reverse thetrend of declining feed grades.
Grade Engineering is an integratedmethodology based on improvingoverall system value andprofitability.
INTEGRATED EXTRACTION SIMULATOR (IES)
Next generation cloud basedsoftware for integrating andinteracting existing unit operationsimulators which allows whole ofsystem simulation and optimisation.
CHARACTERISATION TOOLKITS
The amenability of ores to coarseseparation and also new techniques toassess acid generation. A range of labscale and bulk testing protocols havebeen developed.
Outcomes can be used to populateblock models with predictive attributes.These feed into simulation andscheduling applications.
SITE IMPLEMENTATION
Technology needs to undergo asite-based cycle of demonstrate-validate-implement. This requiressupport and collaboration with site.
CRC ORE’s Innovation DeliveryGroup provides an intermediaryentity that spans the prototype toproduct challenge.
Model in CRC Ore Consistent with Others’ Experience e.g. Metso Innovate, Integrate and Implement – How will we be judged?
1. To fundamentally change the Energy, Production, Cost and Water signatures of our Miners Operations – financial return & societal expectations
2. To provide completely new business opportunities and markets for our Mets Participants
3. To provide a demonstrably successful innovation pathway for real implementation for our Research Community
Key currency of success is to fast track Co‐Creation of Highly Disruptive Technologies
5 years
Cumulative Production
Prod
uctio
n co
st $
/tonn
e
Technology Can Lower The Whole Cost Curve In A Way That Delivers No Relative Competitive Advantage To
Individual Companies. Fast-followers just follow the curve.
New TechnologyAvailable to all
Lowers cost curve
Hypothetical Example
Engagement is key: The cost curve – one view of technology dislocation
Model in CRC Ore Consistent with Others’ Experience e.g. Metso The myth of the “fast follower” J. Marsden (SME 2004)
Examples of three “step changes” in the 20th Century – ALL showed a minimum 15 - 20 year advantage:
1. Large scale Open Pit Mining: Utah Copper (1907) ; El Teniente (1927); Chuquicamata(1927) ; Morenci (1942) ……………
2. Flotation : Broken Hill (1907); Inspiration (1915); 50% of Industry by 1930
3. SX-EW: 1980 – slow take up for 15-20 years, today widely accepted
YET : “fast follower” thinking would directly impact our ability to pursue step change technology development
AND: “bleeding edge” companies need to keep innovating to stay ahead – this speaks to our engagement models with the supplier as well as the research community
Model in CRC Ore Consistent with Others’ Experience e.g. Metso We have to show this for our mining participants!
Cumulative Production
Prod
uctio
n co
st $
/tonn
e
Targ
etM
ine
Model in CRC Ore Consistent with Others’ Experience e.g.
This is not an academic exercise!
Model in CRC Ore Consistent with Others’ Experience e.g. Metso A suppliers perspective: the “normal” development cycle
• With current product development model, time to market can be unacceptably long.
• In most cases, the risk is carried by supplier and payback period is long.
• With long development cycle times, barriers to copy (IP) can be low.
• Mining companies are generally risk averse – the business is tremendously capital intensive with no margin for error (a first‐to‐be‐second approach to new technology).
Novel Con
cept or
Application
First P
rototype
in In
dustry
Second
Prototyp
e in
Indu
stry
First P
roven
Commercial
Installatio
n
Market
Pene
tration
For HPGR and the VertiMill® in mining, the development cycle was ~15 years.
Model in CRC Ore Consistent with Others’ Experience e.g. Metso “Fifteen years to five” is possible
•Our recent endeavors in co‐creation have led to a focus on this model of product development.
• In 2011 we entered into a 3 year agreement with JKMRC for a project aimed developing a better and more fundamental understanding of the VertiMill® On the whole, both sides have seen this as a good success.
• In 2009 we started a development project for a Metso HPGR. This was influenced by FCX as they had been talking novel circuitry, mainly aimed at substantial energy reductions.
• In 2010 we agreed on a joint development project for an HRC3000, and a comprehensive pilot plant project to examine design and wear solutions, along with novel circuitry.
• In 2014 the HRC3000 was commissioned at site.
CRC ORE combines both of these approaches in its business and operational model.
Value of academia around projects with a high degree of novelty.
Value of experienced industry partners around operability, controllability and maintainability.
Model in CRC Ore Consistent with Others’ Experience e.g. Metso Modular thinking & Learn from Others – Anglo American
• Mining Industry is 20 years behind in modular thinking (e.g. Ikea, Nestle, Coca Cola, Siemens)
• It is characterised by “bespoke” thinking by “Regions” & “Operations”
• We need modular mines and process plants & new ways of thinking.
• All these companies indicated they achieved a <50% reduction in capital, but the main reason for “going modular” was the agility to introduce new technology innovations (“plug & play flexibility”)
• The main problem with modularity are the flows between modules (data etc.). Suppliers are often resistant (they think they make more money out of bespoke technologies). SYSTEM BASED THINKING is needed
The Implementation Council can fast track promising early TRL research outcomes
Research Programs – underpin existing & develop new technologies
CRC ORE DELIVERY THEMES ‐ INTEGRATED SOLUTION STACKS
DEVELOPMENTPROGRAMS
DELIVERY THEMES
COMMERCIALIMPLEMENTATION
introduce.
integrate.
Concept
Laboratory
Realistic World
Real World
Real Business
CRC ORE’s Innovation Pathway: Holistic Approach
TECHNOLOGYDEVELOPMENT
TECHNOLOGYDELIVERY
COMMERCIALDEPLOYMENT
Model in CRC Ore Consistent with Others’ Experience e.g. Metso Impact for our Miners: a joint effort with METS & Researchers
1. Operational Excellence in e.g.” whole of system extraction”; mill circuit control; new classification systems; coarse particle separation; water recovery technologies; “opportunity costing” & Control
2. Unlock value in mass simulations / scenario analysis with IES
3. Grade Engineering is now a One Billion Dollar Value Proposition with RaptORE. Combine this with e.g. Throughput Engineering
4. Fast track gangue rejection with sensor based sorting and / or new Australian precision breakage technology (A RaptORE crusher)
5. Make the changes sustainable and meet societal needsCombine these approaches & build e.g. the WA Hub
5 years
• Drive the “Integration Agenda” through the Implementation Council
• Co‐creation partnerships with Miners & METS & aggressively implement
• Productivity catalysts – whole of system mine & process improvements
1. To fundamentally change the Energy, Production, Cost and potentially Water signatures of our Miners Operations
2. To provide completely new business opportunities and markets for our Mets Participants
3. To provide a demonstrably successful innovation pathway for real implementation for our Research Community
The Innovation Pathway
Model in CRC Ore Consistent with Others’ Experience e.g. Metso John Marsden SME 2016, Top Ten lists for Process Engineers
1. New materials handling – RaptORE
2. New ways to remediate tails & wastes
3. New crusher technologies ahead of a Tower Mill
4. Work with Curtin on e.g. MSC Glycene leaching
5. Work with Anglo on CPF
6. Mass simulation for circuit optimization
7. Sensor based sorting
8. A liberation analyzer
9. New classification approaches
10. Co creation partnerships
Model in CRC Ore Consistent with Others’ Experience e.g. Metso Thank You
Making innovation stick
introduce.integrate.
SESSION 1
CRC ORE Annual Assembly 2016