Drill-to-Mill plant optimisation projects help improve productivity and reduce total mining costs.

During the past twenty years, some consultants and research centres have been involved in implementing a holistic methodology “Mine to Mill” to maximise the overall profitability of the operation rather than just optimising any individual process in a mining operation. These studies have shown that all the processes in the Mine to Mill value chain are inter-dependent and the results of the upstream mining processes have a significant impact on the efficiency of downstream milling processes such as crushing and grinding. Numerous Mine to Mill projects to date resulted in mill throughput increases of between 5 and 30 % depending on the ore strength and comminution properties.

In addition to the optimisation of existing mining and milling processes, this methodology has also been applied to greenfield studies and expansions. Our methodology requires intensive data collection – ore characterisation data, historical operating data, comprehensive drill&blast audits, surveys and benchmarking data. Site-specific mathematical models are developed for each process—blasting, crushing and grinding and flotation. By using these models, we can simulate a range of operating strategies for different types of ores in the mine and plant. EMC has worked in numerous Mine to Mill plant optimisation projects to date in which the mines achieved significant mill throughput increases (5 to 40%) and reductions (10 to 25%) in specific energy consumption. 

We use the same methodology for our heap leaching projects, namely Drill-to-Leach. Barrick Veladero Gold and Eldorado Kisladag Gold are good examples of such projects focusing on productivity improvements, cost and recovery.

Flotation surveys and simulations are carried out in some projects. EMC is experienced in flotation optimization studies.

Ore characterisation data and blast domain definitions are used to develop mill throughput forecasting models. Life of Mine plan as well as long-term strategic mine planning are coupled to our Drill-to-Mill plant optimisation projects in order to maximize the profitability of the operation in the long term.