Risk Management in Mineral Processing Plant Design: Key Strategies

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Billions of dollars are poured into mineral processing projects every year and a significant amount of this capital expenditure is on expansion. In fact, in the six months to April 2012 over $3.5billion was spent in Australia alone. It is no wonder then, that such great emphasis is being put on risk management in the initial phase of mineral processing plant design to reduce long-term costs. Mining IQ recently spoke with Mark Reed, Senior Manager of Risk at leading engineering and project management company, Ausenco, who highlighted the importance of taking a whole-life view of a project, even in early design phases.

Design Deficiencies

Like in many major construction projects, there is often a tendency to follow templates and directly replicate past successful projects. However, Mark points out that this can often cause major bottlenecks to be missed or obsolete equipment to be selected. The most common occurrences are for example, people replicating the difference between a ROM pad and a plant, the bottleneck being the feed into a plant and its ability to effectively respond to blockages in a ROM feed bin. Design teams will often prescribe an elevating conveyer when there are many other options that are far more effective and cost efficient.

There is a key assessment model that Ausenco use, with the acronym RAMBO, standing for Reliability, Accessibility, Maintainability, Buildability and Operability. This is done early feed, so that the design has not progressed too far. This requires going through the process flow diagram one section at a time and “analyse what could be done better in each section” enabling continuous improvement.

The Importance of Considering Risk Management

The importance of considering risk management, seems like common sense, however it is often something that companies will rush without realising how much money could have been saved long term to minimise costs. According to Mark, “assessing what can go wrong, how it can go wrong and what we can do to minimise effects”. In doing this there needs to be consideration of cost and ease of construction in the early design phases and also of future expansion. Increasing capacity further down the track can be difficult, costly and interrupt daily operations.

Diligence in the Design Review Process.

The general rule that Ausenco follow is carrying out risk assessment at 30% and 60% reviews and then a final sweep at 80%. According to Mark there are often fundamental, common-sense decisions that can be made early on, that are overlooked. He used the examples of using grated flooring rather than suspended concrete flooring and considering environment impacts specific to plants i.e. a plant may be more effective with one wall rather than four.

Original design needs to take into consideration future expansion. Increased capacity can be difficult, costly and interrupt operations.

Summary

The biggest consideration in risk management in mineral processing plant design is taking a holistic view. Mark has advised that the engagement of construction, commissioning and operational experience in the very early design stages is of utmost importance, it can make a real difference. As is taking a step back and looking at the bigger picture with a whole life focus. Finally think simplicity, don’t over complicate it!

Hear more from Mark Reed and many other high profile mineral processing experts at Mineral Processing Plant Design & Construction held in Brisbane from 3 - 15 November, 2012. This event will explore the latest strategies around mineral processing, plant planning, design and construction as well as the most up to date technological innovations in this arena. For more information visit http://www.mineralprocessingplant.com.au, email enquire@iqpc.com.auor call 02 9229 1000.