waste generation: reduce, reuse, recycle and the role of collaboration
TRANSCRIPT
Waste generation: reduce, reuse and recycle and the role
of collaboration
Minas e Minerăçao no Sėculo xxi
14 September 2016 Belo Horizonte
2Delivering solutions through collaboration
2Delivering solutions through collaboration
© AMIRA International Limited
• Mining industry trends & need for collaboration
• How does industry collaborate?
• What do we mean by waste?
• What is the waste is being generated and where?
• The changing nature of mining and what it means for waste generation
• Reduce, reduce, reuse and recycle
• Challenges abound – why collaborate
• Towards minimalist waste generation
• A roadmap to achieve a clean mine
• AMIRA International – an overview
Contents
3Delivering solutions through collaboration
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Mining Industry Trends & Drivers
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Mining Industry Trends & Drivers
Resource base
Capital availability
Cost competitiveness
Sustainability (HSEC)
Supply chain infrastructure constraints
Increased regulation and country risk
Mining deeper and/or at lower grades
Specialist labour and equipment shortages
Business Challenges
Commodity Prices
Top 6 Strategic ImperativesFor Mining Innovation*
Reduce operating costs
Develop and produce better and faster
Reduce capital costs
Find new reserves / resources
Reduce health, safety & environmental risk
Increase the viability of future projects
* Source: Mining State of Play 2014 – Virtual Consulting International – Listed in decreasing order of popularity (score) from a survey of 230 senior decision makers across 100 mining companies & suppliers.
2013 score 2014 score
Value Drivers
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While technological innovation has fundamentally transformed
many industries, but mining is lagging
Source:
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Mining industry trends and drivers
The mining industry needs to increase its operational maturity in line with other industries that use technology better.
This needs collaboration.
1 – Functional Excellence
2 – Site-wide Integration
3 – Asset/Partner Collaboration
4 – Extended Value Chain
5 – Full Network Connectivity
Mat
urity
& B
enef
its
Source: Farrelly et al (2012). The Network Centric Mine in International Mine Management 2012 conference
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How does Industry Collaborate
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So how is the mining industry collaborating?
Exploration / Discovery Mining
Closure / ReclamationProcessing
DevelopmentDesign/Construction
Operations
Co
llab
ora
tin
g P
artn
ers
One-to-many± Suppliers with
± research institutions
Mining Value Chain
Not an area suitable for multi-peer
collaborationBUT….
Typically not an area
suitable for multi-peer
collaboration
Open innovation
Internal/Proprietary R&D with ± external research providers ± Suppliers
Peer-to-peer± Suppliers with
research institutions
One-to-many± Suppliers with
± research institutions
Open innovation
Peer-to-peer± Suppliers with
research institutions
9Delivering solutions through collaboration
© AMIRA International Limited
So how is the mining industry collaborating?
Exploration / Discovery Mining
Closure / ReclamationProcessing
DevelopmentDesign/Construction
Operations
Co
llab
ora
tin
g P
artn
ers
One-to-many± Suppliers with
± research institutions
Mining Value Chain
Not an area suitable for multi-peer
collaborationBUT….
Typically not an area
suitable for multi-peer
collaboration
Open innovation
Internal/Proprietary R&D with ± external research providers ± Suppliers
Peer-to-peer± Suppliers with
research institutions
One-to-many± Suppliers with
± research institutions
Open innovation
Peer-to-peer± Suppliers with
research institutions
the Goldcorp Challenge and
recently the Integra Gold Rush
Challenge
AMIRA “co-opetition” modelAMIRA International's “co-opetition” model
10Delivering solutions through collaboration
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What do we mean by waste?
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What do mean by waste?
The Organisation for Economic Co-operation and Development defines two types of mine waste:
extraction waste and beneficiation waste
Source: https://stats.oecd.org/glossary * note its not “uneconomic” waste
Waste is all the unwanted* mineral and non-mineral solid, liquid or gaseous material, generated as a result of
exploration, extraction, haulage, processing, and transport of concentrate or metal to market
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What is the waste generated and where?
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What is the waste generated?
Waste material Description
Overburden Overburden includes the soil and rock that is removed to gain access to the ore deposits at open pit mines.
Waste rock Waste rock is material that contains minerals in concentrations considered to be uneconomic to extract.
Tailings Tailings are finely ground rock and mineral waste products of mineral processing operations.
Slags Slags are non-metallic by-products from metal smelting, and were historically considered to be waste.
Source: http://www.miningfacts.org/Environment/How-are-waste-materials-managed-at-mine-sites/
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What is the waste generated?
Waste material Description
Mine water Mine water is produced in a number of ways at mine sites, and can vary in its quality and potential for environmental contamination.
Water treatment sludge Sludge is produced at active water treatment plants used at some mine sites, and consists of the solids that had been removed from the water as well as any chemicals that had been added to improve the efficiency of the process.
Gaseous wastes GHG . Gaseous wastes include particulate matter (dust) and sulphur oxides (SOx). The majority of emissions to the atmosphere are produced during high-temperature chemical processing such as smelting, and vary in their composition and potential for environmental contamination.
Source: http://www.miningfacts.org/Environment/How-are-waste-materials-managed-at-mine-sites/
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Typical waste generated in a copper operation
Source: www3.epa.gov : Picture Los Bronces copper mine
Waste rock
Tailings
Spent Ore from Heap, Dump, and
Vat Leaching
Mine water
SX/EW Sludge
Spent Electrolyte
Spent leaching solution
Spent ore piles
Solution ponds
Dust
Greenhouse gases
Etc
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Exploration / DiscoveryMining
Closure / Reclamation
Exploration by prospectors and
companies leads to discoveries that could become
mines.
Discovery depends detailed field
surveys, technical studies and finally
drilling.
Includes pre-feasibility, feasibility
and engineering studies, raising
capital and construction.
1 - 5 years
Includes milling & processing /
metallurgy to produce
concentrate or metal to market
Reclamation of sites to productive use
begins during operation and continues after
closure
Processing
Includes extraction, haulage, and stock
piling
DevelopmentDesign/Construction
Operations
1 - 10 years or more decade to perpetuity 2 - 100 years
The Generalised Minerals Value Chain: where is waste generated?
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Exploration / DiscoveryMining
Closure / Reclamation
Exploration by prospectors and
companies leads to discoveries that could become
mines.
Discovery depends detailed field
surveys, technical studies and finally
drilling.
Includes pre-feasibility, feasibility
and engineering studies, raising
capital and construction.
1 - 5 years
Includes milling & processing /
metallurgy to produce
concentrate or metal to market
Reclamation of sites to productive use
begins during operation and continues after
closure
Processing
Includes extraction, haulage, and stock
piling
DevelopmentDesign/Construction
Operations
1 - 10 years or more decade to perpetuity 2 - 100 years
TimeTota
l was
te g
ener
ate
d:
no
t to
sca
le
loga
rith
mic
sca
leThe Generalised Minerals Value Chain: where is waste generated?
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loga
rith
mic
sca
le
Exploration / DiscoveryMining
Closure / Reclamation
Exploration by prospectors and
companies leads to discoveries that could become
mines.
Discovery depends detailed field
surveys, technical studies and finally
drilling.
Includes pre-feasibility, feasibility
and engineering studies, raising
capital and construction.
1 - 5 years
Includes milling & processing /
metallurgy to produce
concentrate or metal to market
Reclamation of sites to productive use
begins during operation and continues after
closure
Processing
Includes extraction, haulage, and stock
piling
DevelopmentDesign/Construction
Operations
1 - 10 years or more decade to perpetuity 2 - 100 years
TimeTota
l was
te g
ener
ate
d:
no
t to
sca
le
In 2011 Rio Tinto alone generated about 1,535 million tonnes of mineral waste (predominantly waste rock and tailings), and
758,000 tonnes of non-mineral waste. Source: www.riotinto.com
The Generalised Minerals Value Chain: where is waste generated?
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© AMIRA International Limited
loga
rith
mic
sca
le
Exploration / DiscoveryMining
Closure / Reclamation
Exploration by prospectors and
companies leads to discoveries that could become
mines.
Discovery depends detailed field
surveys, technical studies and finally
drilling.
Includes pre-feasibility, feasibility
and engineering studies, raising
capital and construction.
1 - 5 years
Includes milling & processing /
metallurgy to produce
concentrate or metal
Reclamation of sites to productive use
begins during operation and continues after
closure
Processing
Includes extraction, haulage, and stock
piling
DevelopmentDesign/Construction
The Generalised Minerals Value Chain: where is waste generated?
Operations
1 - 10 years or more decade to perpetuity 2 - 100 years
TimeTota
l was
te g
ener
ate
d:
no
t to
sca
le
In 2011 Rio Tinto alone generated about 1,535 million tonnes of mineral waste (predominantly waste rock and tailings), and
758,000 tonnes of non-mineral waste. Source: www.riotinto.com
To put this into perspective according
to the World Bank the world generates
about 1,420 million tonnes of urban
waste a year (50% in OECD countries)
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The changing nature of mining and
implication for waste generation
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Key Trend Implication for waste generation
Average head grades are declining • More gangue to be mined for the same amount of metal, greater haulage required
• increasing energy intensity as more material will need to be processed for the same amount of metal
• more beneficiation waste will be generated
Mining Industry Trends: Implications for waste generation
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Key Trend Implication for waste generation
Average head grades are declining • More gangue to be mined for the same amount of metal, greater haulage required
• increasing energy intensity as more material will need to be processed for the same amount of metal
• more beneficiation waste will be generated
Ore is becoming more complex • Increasing use of chemicals and other consumables to process ore into concentrate or metal
Mining Industry Trends: Implications for waste generation
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Mining Industry Trends: Implications for waste generation
Key Trend Implication for waste generation
Average head grades are declining • More gangue to be mined for the same amount of metal, greater haulage required
• increasing energy intensity as more material will need to be processed for the same amount of metal
• more beneficiation waste will be generated
Ore is becoming more complex • Increasing use of chemicals and other consumables to process ore into concentrate or metal
A shift from open pit to underground operations
• Increasing haulage distances
• Also ore becomes generally harder with depth increasing the energy intensity in comminution
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Mining Industry Trends: Implications for waste generation
Key Trend Implication for waste generation
Average head grades are declining • More gangue to be mined for the same amount of metal, greater haulage required
• increasing energy intensity as more material will need to be processed for the same amount of metal
• more beneficiation waste will be generated
Ore is becoming more complex • Increasing use of chemicals and other consumables to process ore into concentrate or metal
A shift from open pit to underground operations
• Increasing haulage distances
• Also ore becomes generally harder with depth increasing the energy intensity in comminution
Social License to Operate increasingly being threatened
• Society and regulators want zero-footprint mines
• This means eliminating waste, minimising, and maximally reusing and recycling
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Reduce, reuse and recycle
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Reuse (repurpose) - the new use or application of the total mine waste in its original form for an identified purpose directly without any reprocessing
Recycling - extraction of new valuable resource ingredients, or uses the waste as feedstock and converts the entire mine waste into a new valuable product or application with some reprocessing
Reuse and Recycling of mine waste – not new concepts
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Reuse and Recycling of mine waste – not new concepts
Reuse (repurpose) - the new use or application of the total mine waste in its original form for an identified purpose directly without any reprocessing
Recycling - extraction of new valuable resource ingredients, or uses the waste as feedstock and converts the entire mine waste into a new valuable product or application with some reprocessing
WE MUST REFRAME OUR VIEW AND CONSIDER WASTE AS A RESOURCE
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Mining wastes Reuse and Recycling options
Waste rocks • Resource of minerals and metals
• Backfill for open voids
• Landscaping material
• Capping material for waste
repositories
• Substrate for revegetation at mine sites
• Aggregate in embankment, road, pavement,
foundation and building construction
• Asphalt component
• Feedstock for cement and concrete
• Sulfidic waste rock as soil additive to neutralize
infertile alkaline agricultural soils
Mine waters • Dust suppression and mineral
processing applications
• Potable water
• Industrial and agricultural use
• Coolant or heating agent
• Generation of electricity using fuel cell
technology
• Engineered solar ponds to capture heat for
electricity generation, heating, or desalination
and distillation of water
• Recovery of metals from AMD waters
Mine drainage
Sludges
• Flocculant/adsorbant to remove
phosphate from sewage and
agricultural effluents
• Extraction of hydrous ferric oxides for paint
pigments
• Extraction of Mn for pottery glaze
Reuse and Recycling options for mining, processing and
metallurgical wastes
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Reuse and Recycling options for mining, processing and
metallurgical wastes
Processing wastes Reuse and Recycling options
Tailings • Sand-rich tailings mixed with cement
used as backfill in underground mines
• Clay-rich tailings as an amendment to
sandy soils and for the manufacturing
of bricks, cement, floor tiles, sanitary
ware and porcelains
• Mn-rich tailings used in agro-forestry,
building and construction materials,
coatings, cast resin products, glass,
ceramics and glazes
• Bauxite tailings as sources of alum,
soda
• Cu-rich tailings as extenders for
paints
• Fe-rich tailings mixed with fly ash and
sewage sludge as lightweight
ceramics
• Phlogopite-rich tailings for sewage treatment
• Phosphate-rich tailings for the extraction of
phosphoric acid
• Ultramafic tailings for the production of glass
and rock wool
• Carbon dioxide sequestration in ultramafic
tailings and waste rocks
• Reprocessing to extract minerals and metals
• Energy recovery from compost–coal tailings
mixtures
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Metallurgical
wastes
Reuse and Recycling options
Bauxite red mud • Treatment of agricultural and
industrial effluents
• Raw material for glass, tiles, cements,
ceramics, aggregate, bricks and
proppants for hydrofracturing
• Treatment of AMD waters
• CO2 sequestration
Historical base
metal smelting
slags
• Production of concrete and cement
• Use as fi ll, ballast, abrasive and
aggregate
• Extraction of metals (e.g. Cu, Pb, Zn, Ag, Au)
Reuse and Recycling options for mining, processing and
metallurgical wastes
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The challenges abound
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Challenges abound
1. Despite much effort in reuse and recycling over the last few decades the majority of mining waste is stored in an unsustainable way-> Ultimately the aim must be waste prevention or minimisation, but how?
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Challenges abound
1. Despite much effort in reuse and recycling over the last few decades the majority of mining waste is stored in an unsustainable way-> Ultimately the aim must be waste prevention or minimisation, but how?
2. Many recycling and reuse options at scale are not economic -> Much remains to be done to develop more effective recycling and reuse options that are economic
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Challenges abound
1. Despite much effort in reuse and recycling over the last few decades the majority of mining waste is stored in an unsustainable way-> Ultimately the aim must be waste prevention or minimisation, but how?
2. Many recycling and reuse options at scale are not economic -> Much remains to be done to develop more effective recycling and reuse options that are economic
3. Not all waste is the same – one mine’s waste is different to another > More work needs to be done to characterise the waste streams – the quantification, distribution and nature of the chemistry / mineralogy. Is it possible to develop recycling and reuse solutions that are not mine specific?
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Challenges abound
4. Hard waste such tailings still contain valuable minerals -> We need to develop cost effective solutions to process ultra low grade waste and extract the valuable minerals
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Challenges abound
4. Hard waste such tailings still contain valuable minerals -> We need to develop cost effective solutions to process ultra low grade waste and extract the valuable minerals
5. Many waste streams contains chemicals toxic to humans, fauna and flora -> There is a need to develop cheap processes to extract toxic chemicals and turn them into benign materials
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Challenges abound
4. Hard waste such tailings still contain valuable minerals -> We need to develop cost effective solutions to process ultra low grade waste and extract the valuable minerals
5. Many waste streams contains chemicals toxic to humans, fauna and flora -> There is a need to develop cheap processes to extract toxic chemicals and turn them into benign materials
6. Designing mines to prevent and minimise waste -> We need to know more about our ore body at the feasibility stage to be able to predict the nature and volume of the expected waste to enable the mine design to be optimised to eliminate what can be eliminated or reduced to the absolute minimum what cannot?
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Challenges abound
7. Minimizing the space required to store mining waste -> We need cost-effective means of filtering and dry stacking of tailings
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Challenges abound
7. Minimizing the space required to store mining waste -> We need cost-effective means of filtering and dry stacking of tailings
8. Monitoring of exiting waste repositories-> We need to develop predictive tools and reliable, field-tested modelling of long-term waste behaviour
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Challenges abound
7. Minimizing the space required to store mining waste -> We need cost-effective means of filtering and dry stacking of tailings
8. Monitoring of exiting waste repositories-> We need to develop predictive tools and reliable, field-tested modelling of long-term waste behaviour
9. Maintaining social license to operate -> We must build fail-safe storage systems capable of withstanding once in a thousand year event . Companies are now under increasing pressure to “guarantee” that there will be no adverse affects to people, society and the environment during the life of the mine and post-closure
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Why collaborate?
Solving the waste problem is not a competitive issue - it’s a whole of industry risk issue and requires cooperation
Collaboration works because even though companies are competitors, there are always synergies and strengths that can be leveraged
In a globalised economy it is difficult for companies to achieve excellence and competitive advantage across a wide range of disciplines
Solutions are increasingly captured outside a company's immediate environment
With the boom over, R&D is now subject to availability of scarce financial resources, spurring the need for collaboration
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Towards a minimalist waste scenario
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The minimalist waste mine
Waste generation, disposal and management is a major business risk for the industry
Mining industry’s future will depend on its ability to evolve quickly as possible towards a zero-waste state .
This ideal final state is unlikely to be achieved however, until in-situ extraction becomes a reality, and even then the generation of waste will not be entirely eliminated
In the interim it is possible to make big strides in making mines as “clean” as possible by reducing or eliminating waste where possible, repurposing waste and sustainably manage what waste is produced?
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The minimalist waste mine: A roadmap?
Perhaps what we need is a global roadmapping initiative to layout a path to achieve a minimalist waste mine, a “Clean Mine”
This will involve the following elements:• An industry developed strategic vision of what a “Clean Mine” should look like
• A well defined set of goals required to achieve the vision
• Identification of the current status. To this end a review of the nature and volume of waste generated in mines and the strategies currently used to minimise, store, re-use or eliminate waste will be commissioned
• Identification of the technical and other risks, and knowledge/capability gaps
• An industry endorsed goal-based plan of R&D activities required to mitigate risks and fill gaps based on a consensus of key priorities
• A focus on pre-competitive collaborative partnerships between companies, suppliers, research organisations and government agencies
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AMIRA International: an overview
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AMIRA International: enabling collaboration
AMIRA International is a private sector, not-for-profit , member-based
organisation
We are a facilitator, broker and manager of collaborative projects designed
to address industry challenges and needs; both technical and non-technical
Our members include explorers, producers and equipment, technology and
service suppliers from around the world
We are independent which means we can engage with solution providers
throughout the world, but ensure that local partners are part of the team
We have global reach: currently have offices in the USA, Chile , South Africa
with head office in Australia
We have a 57 year history of success
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AMIRA International’s two pillars
SUPPORTING THE GLOBAL MINING INDUSTRY VIA OUR TWO
SERVICE-DELIVERY PILLARS
TECHNOLOGY-
CENTRED
COLLABORATIVE
RESEARCH
ENTERPRISE
DEVELOPMENT,
INNOVATION &
IMPLEMENTATION
PILLAR 1 PILLAR 2
WE BROKER, COORDINATE AND DELIVER A BROAD RANGE OF COLLABORATION-BASED
SOLUTIONS
FOR TECHNOLOGICAL CENTRED CHALLENGES & ENTERPRISE DEVELOPMENT INNOVATION
AND IMPLEMENTATION
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AMIRA International: our members
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AMIRA International’s collaborative models
Co-opetition Model(Collaboration with peers,
who could be direct
competitors)
Sponsor A
Sponsor B
Sponsor C
Researcher A
Researcher B
Researcher C
Sponsor A
Sponsor B
Sponsor C
Researcher A
Researcher B
Researcher C
Sponsor
Researcher A
Researcher B
Researcher C
Non-competitor
Collaborative Model(Collaboration with peers
who are not direct
competitors)
One-on-one
Collaborative Model (includes managing
existing proprietary
projects for our
members)
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The AMIRA Collaborative model in action: Example of Pillar 1
Example of the “co-opetition” collaborative model
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The AMIRA Collaborative model in action: Example of Pillar 1
Project: P9P - The Optimisation of Mineral Processes by Modeling & Simulation
Sponsors: Alcoa, Anglo American, AngloGold Ashanti, Barrick Gold, BHP Billiton, Glencore , Teck Resources, LKAB, Lonmin, Newmont, MMG, Newcrest, Rio Tinto, Vale,
COREM, FLSmidth Minerals, Magotteaux, Metso, Outotec, Polysius, Russell Mineral Equipment, Senmin, and Tenova Bateman
Researchers: University of Queensland (JKMRC), Chalmers University of Technology (Sweden), Hacettepe University (Turkey), Universidade Federal do Rio de Janeiro (Brazil), University of Cape Town (South Africa), and CRC ORE
Example of the “co-opetition” collaborative model
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Nature of AMIRA International's projects
Exploration Mining
Mineral
processing /
metallurgy
Sustainability
De
mo
nst
rati
on
an
d
Tech
nic
al D
e-r
iski
ng 7:
Implementation
Improvement
Proven technology.
Technology fully integrated into intended operation system.
The technology has successfully operated with acceptable
performance and reliability.
6:
Implementation
Support
Technology installed. Technology is ready for implementation
Full-scale prototype in intended environment has shown
acceptable performance and reliability over a period of time, and
may already be successfully operational in other operating
environments.
De
velo
pm
en
t
5: Scale-up,
Trial/Demo
Technology integration tested.
Full-scale prototype built and integrated into intended operating
system with full interface and functionally tests.
4: Pilot
Technology qualified for first use.
Full-scale prototype built and technology qualified through testing
in intended environment, simulated or actual.
New hardware/software is now ready for first use and testing.
3: Proof of
Concept
New technology tested.
Prototype built and functionality demonstrated through testing
over a limited range of operating conditions.
Re
sear
ch
2: Laboratory
Concept validated.
Concept design or novel features of design validated through
model or small scale testing in laboratory environment.
Evidence that technology can meet specified acceptance criteria
with additional testing.
1: Science
Concept demonstrated.
Basic functionality demonstrated by analysis.
Technology is likely to meet specified objectives with additional
testing.
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Exploration / DiscoveryMining
Closure / Reclamation
• New discovery technologies• Improved ore genesis models• Developing vectors to ore• Undertaking regional studies• New data compilations• Data Metallogenica
• Improving Comminution• Enhancing flotation recovery• Improving extraction selectivity• Towards maximising reagent and water
recovery• Increased revenue from improved product
quality & product recovery• Integration of mining & processing• Optimising resource characterisation for
optimal production & recovery
• Improved environmental management
Mineral Processing & Metallurgy
• Enhancing Productivity
• Mine Safety- zero deaths
• Reduced operating costs
DevelopmentDesign/Construction
-------Operations------
Sustainability: Licence to Operate; New management practices
Roadmaps:Alumina, Copper, Drilling, Exploration undercover, In-
situ extraction, Heap-leach
AMIRA International’s projects
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AMIRA International’s global reach
Countries with Research Providers
Countries with Sponsors/Members
AMIRA Offices
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AMIRA International is willing to partner
The majority of the big challenges that mining companies are facing are
global in scope and would benefit from a global approach
AMIRA International is a open to collaboration with government agencies
and industry associations to address the big challenges facing the mining
sector
We are well connected with broad networks in industry and academia and
have many years of experience on how to build collaborative partnerships
between industry , solution providers and government
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WITH COLLABORATIONGREAT THINGS
RESULT
Com a Colaboração, Grandes Coisas Resultado
CollaborerC’est Aller Vers le Succès
合作共赢
Con la ColaboraciónGrandes Cosas Resultan
Obrigado