SAMPLING , ANALYSIS AND LAB ASSAY
SPA awareness
As a major mineral processing OEM , FLSmidth is aware of the need for a comprehensive sampling , preparation and analysis ( SPA ) process to take place across the flowsheet – hopefully in tandem with the processing equipment selection .
An effective SPA plan can result in positive effects for mining customers , such as optimum productivity and increased profitability .
IM put some questions to the company to find out more .
IM : How is FLSmidth helping clients with their sampling and analysis processes ? How far do you go in outlining sampling procedures ( size of samples , preparation , representativeness , etc ) throughout the process plant ? FLSmidth : The starting point of an efficient metal accounting system is a precise understanding of the process operations . It should rely on an accurate sampling and measuring system . This involves consultation to determine the type of minerals being processed , the desired outcomes of analysis and any specific challenges that are being faced by the clients .
FLSmidth ’ s SPA team includes experienced engineers , metallurgists and chemists with advanced process and laboratory flow knowledge , ensuring well thought through , technologically advanced solutions are offered that are tailored to each customer ’ s specific needs .
In addition to being a world leader in the supply of sampling & sample transport equipment , and manual & automated laboratories , FLSmidth also offers sampling and laboratory audits to assist with standard compliance and best practices .
FLSmidth further supports clients with engineering studies varying in detail depending on the clients ’ requirements . These typically vary from conceptual design , feasibility , pre-engineering and detail design studies , each catering for different levels of detail as required by the project phase . A detail engineering design study will supply the client with all the relevant details and designs to submit the sampling and / or laboratory design for construction as the overall system configuration , sample flow diagrams and layouts of the equipment / systems are established .
IM : Would you say certain clients / commodities are investing more in sampling processes ? Are , for example , gold clients that much more aware of the need to improve the accuracy of their sampling processes than others in , say , copper ? FLSmidth : As ore grades deplete and mineral processing cost increase , FLS has seen an increase in gold process plants investments in new and / or replacement fit-for-purpose sampling systems in an effort to improve operation productivity in comparison with base metal operations .
Many metallurgists understand the importance of taking quality samples to be analysed by on-stream analysers , assay and metallurgical laboratories to have a sound basis for making process decisions , allowing for better quality products with improved process efficiencies and profitability .
The increase in interest in battery minerals also requires significant investment in sampling and analysis processes due to the complexity of the minerals , and also the required accuracy of the analysis .
For other commodities , such as copper , where clients are expanding their capacity , the capacity of the sampling and analysis also increases and in many cases necessitates the upgrading of existing manual systems to semi-automated or fully-automated systems .
IM : Are you seeing more mining companies invest in automated sampling and analysis processes of late ? Is this also a reflection of the increased awareness of sample prep conditions , human errors and the amount of metal / mineral lost with inaccurate processes ?
The starting point of an efficient metal accounting system is a precise understanding of the process operations , FLSmidth says
FLSmidth : Yes , there has been an increase in the implementation of automation of sampling and laboratories over the last two-to-three years , particularly in regions where the market adoption of these automated technologies has been slow .
Properly selected and installed automated sampling systems that adhere to the Theory of Sampling are imperatives for unbiased accurate sample collection ; it is physically impossible for a human to consistently collect unbiased samples from the usually large process flow streams in modern processing plants .
Once the samples are collected , consistent proper sample preparation is essential for maintaining the representativeness of any sample collected from a process stream . Automated sample collection and automated sample preparation laboratories deliver consistently more reliable samples and dependable sample preparation , which in turn provides reliable data for assessing plant performance and optimisation strategies . Furthermore , automated-sampling , -sample transport and - laboratory preparation and analysis often lead to large improvements in the total processing times of samples compared with their manual counterparts , allowing faster data-driven decisions , which allows for improved process control .
However , it is not just the awareness of the effects of improvements in data quality and data availability that plays a role in driving clients towards sampling and laboratory automation . Factors such as reduced operating expenses – often due to reduced labour costs associated with automation – and safety of employees play significant roles in the decision-making process .
IM : What percentage of your clients are investing in sampling tools and platforms when they acquire processing equipment ? FLSmidth : All our clients are doing sampling in some form or another , with the majority of our large mining clients also having on-site manual , semi-automated or fully-automated laboratories , designed for their specific geochemistry and mineralogy analysis . There is a continued push by our clients to increase the recovery of their product , and , as technology advances , better sampling and more accurate analysis can assist with this , especially where the analysis outcomes are used to optimise the plant process control .
However , not all clients are proactive with including correct samplers at the time of acquisition of new processing equipment – often preferring to address this at a later date – leading to some poor outcomes when height and available space is not considered at the design stage , leaving the installation not suitable for placement of correct samplers . Wherever possible the capital processing equipment and the SPA activity needs to be considered holistically .
22 International Mining | FEBRUARY 2024