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AGAA Presentation on Data from Sunrise Dam Gold Mine (SDGM). Context The Sunrise Dam Operation The Processing Circuit Data Collection Data analysis and evaluating opportunities using the SCADA system. Context - AGAA participation in EEO.
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AGAA Presentation on Data from Sunrise Dam Gold Mine (SDGM) • Context • The Sunrise Dam Operation • The Processing Circuit • Data Collection • Data analysis and evaluating opportunities using the SCADA system
Context - AGAA participation in EEO • March 2006 – Energy Scoping Study conducted by Renewable Energy Systems on the Processing Plant & Accommodation Village. • July 2007 – Energy Management Study conducted by Environ for the entire site. • AGAA registered for EEO participation in 2007 based on 2005/06 trigger year data of 2.4 pJ. • Consultant participation from Energetics with the EEO process.
The Processing Circuit • SDGM employs gravity/carbon-in-leach (CIL) technology to recover gold through processing up to a maximum licensed rate of 3.7Mtpa. • The circuit essentially consists of: • ROM Pad. • Crushing circuit – Jaw Crusher, Secondary Crusher + 2 x Tertiary Crushers. • Collection of Fine Ore after crushing, including a weightometer. • Milling (fixed drive) – Primary Ball Mill (80 mm steel balls) & 2 x Secondary Ball Mills (40 mm high chrome density balls). • Recovery Circuit - CIL
Data Collection • The Processing Plant uses a centralised SCADA (supervisory control and data acquisition) system to monitor and control the entire processing circuit – in other words, data collection. • The system encompasses the transfer of data between a SCADA central host computer in the Control Room and a number of Remote Terminal Units (RTUs) and Programmable Logic Controllers (PLCs) that are located at strategic points in the circuit – the crushers, the mills, conveyors, pumps, etc. • Data acquisition begins at the RTU & PLC level and includes meter readings and equipment status reports that are reported to SCADA as required. • Most control actions are performed automatically by the RTUs & PLCs but data in the SCADA system (in the Control Room) is compiled and formatted in such a way that a Control Room Operator can make supervisory decisions to adjust or override normal RTU(PLC) controls. • Data from the SCADA system may also be used for trending and other types of analytical auditing, depending on additional software packages.
Results • Improved Crusher Operation - A program has been introduced to improve crusher operation on site. This involves operating the machine such that it is controlled within a power band, as defined by the ore being fed to the ROM. This mode of operation has decreased energy consumption through the crushing circuit by reducing the amount of recirculating load in the circuit. In the past, variability in the recirculating load has meant that energy is wasted “crushing out”, where the circuit is run with no fresh feed being added. This project has also resulted in a steadier operation of the crushing circuit, which allows optimization to be completed in downstream unit operations. The estimated energy savings for this project have been approximately 50 GJ/year for 2010/11. • Mill Optimization - There is currently a project underway to increase the efficiency of the milling circuit through improved process control. Grind surveys are being conducted regularly to ensure the mill is operating effectively. The overall aim of the improved control is to reduce incidences where a grind out is required. This situation occurs when the mill is overloaded and must be operated with no fresh feed being added to remove some of the load from inside the mill. Savings have been realized through the development and implementation of a list of normal operating parameters and operating bands for the plant. The plant operators now work to keep the plant within the specified envelope and energy savings are achieved as a result.
