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过程控制和优化解决方案帮助New Gold公司实现产量提升 2%。
当前，各地的采矿企业都面临着提高生产力的挑战。精简运营流程并优化自动化与控制过程，为采矿企业在当前市场竞争中开辟了一条达成生产目标的道路。
New Gold公司的 Peak Gold 矿场位于澳大利亚新南威尔士州中西部科矿区，对地下的金矿和铜矿进行开采作业。该矿场所产金银合质金主要销往珀斯铸币厂，铜精矿则销往亚洲市场。矿场拥有五座商用现役矿山和一家铜金矿加工厂。Peak Gold 矿场十分重视性、生产率及环境保护，对于技术的投资可谓不遗余力。
为优化 Peak Gold 选矿厂的生产率和过程控制，Peak Gold 采用了罗克韦尔自动化及矿物加工解决方案提供商 Manta Controls 的解决方案，成功提高了生产率，实现了成本节约同时改善了环保效果。
升级提升机驱动与控制系统
在改造选矿厂之前，罗克韦尔自动化系统和解决方案业务团队先升级了 Peak Gold 矿场的提升机驱动与控制系统。
Peak Gold 采用 814kW 提升机运输员工和物料，所以，确保提升机的性与可靠性至关重要。
据罗克韦尔自动化的解决方案顾问 Michael Gres 称，“基于罗克韦尔自动化非常成熟的矿井提升机的、控制和驱动系统，们为Peak Gold打造了一套定制化的矿井提升机驱动控制解决方案。该工程解决方案由们位于新南威尔士州 (NSW)兰科夫的当地驱动系统工程与生产团队与 Peak Gold 携手完成，方案的各方面都按客户的需求进行了精心设计。”
升级提升机可确保其符合的标准，此外，还可使用通用的控制与通信平台简化维护作业。项目的下一个阶段是通过优化 Peak Gold 选矿厂来提高矿场的生产率。
半自磨机(SAG)控制
半自磨机(SAG)是选矿作业中的关键组件，同时，也是非常难以控制的过程。这种过程中存在大量的可变因素，而主要目标则是程度地提高产量。据 Peak Gold 矿场经理 Vivian Beehan 介绍，“为改善生产率和过程控制，们开始着手优化 Peak Gold 选矿工厂。”
从 Peak、Perseverance 和 N e w Occidental 矿体中出产的矿石均在地下进行破碎，再吊升至地面矿堆并终输往半自磨机给料传送带。而从 New Cobar 和 Chesney 出产的矿石则拖运至 Peak，并在那里通过单独的料斗将其送入半自磨机给料传送带。
“现成的标准控制系统并不足以有效地改善选矿厂的产量和控制，”罗克韦尔自动化新南威尔士州销售经理 Sean Smith 表示。们提供的解决方案采用罗克韦尔自动化 ControlLogix® 的先进控制与编程功能，并集成了 Manta Controls® 的先进控制系统Manta Cube®。
“们花了 18 年的时间来完善 ‘Manta Cube’，现在，们能够提供一套绝妙的控制系统，这种控制系统可充分利用 ControlLogix 平台的先进过程控制功能，从而使过程控制再上一个台阶，”Manta Controls 总经理 John Karageorgos 表示。
采用先进控制与过程优化解决方案后，Peak Gold 的产量已提高两个百分点。这相当于每年增产 18,000 吨，即每年增产 2000 盎司黄金。
“该解决方案延长了磨机衬里的使用寿命，有助于提高磨机产量。同时延长了更换衬里的时间间隔，现在们每年只需更换三次衬里，而原来则需要更换四次，节省了大量的成本。”
减少消耗
矿石经过半自磨机加工后，在尼尔森选矿机的重力选矿回路中对金银进行回收，再于强化浸出反应器中进一步汰选，后在燃气炉中熔炼电解沉积物和矿浆，从而产出合质金锭。还可以采用第三种方法来回收金银，即在槽浸回路中化浸出。产生的矿浆即可熔炼为合质金锭。
为缩减成本并改善环境影响，们将Manta的“Cyanide Leach Cube”引入了 ControlLogix 控制系统，以此优化浸出在 Peak Gold 现场尾矿浓密机上装配了智能驱动器。
回路中化系统的相关控制。由此实现了浸出回路的先进过程控制，并显著减少了的用量。 “从 2013 年 1 月初到 2013 年 12 月 ， 加工每吨矿石所用的 ，已从 1.8 千克左右减少至 1.45 千克左右，”Beehan 表示。
“鉴于每吨的成本高达 4000 美元左右，减少的用量可以节省大量成本。此外，由于用量减少，浸出回路中的黄金回收量也额外增加了 1800 盎司。”
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