Background

Mine-to-Mill project at Newmont Ahafo operation

initiated in early 2009 under direction of Metso PTI

PTIs methodology termed Process Integration & Optimisation (PIO)

primary objectives of this project were to

improve blast fragmentation to optimise mill throughput improve crushing & grinding practices to optimise circuit performance

higher mill throughput has raised the need to

improve grind in both the SAG & ball milling circuits investigate effect of tonnage, grind & % oxide on leach recovery

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Ahafo Grinding Circuit

54x75 Gyratory Crusher MMD Sizer

Primary Ore Oxide Ore

2 MP800s
Pebble Crushers Krebs gMax26 Cyclones to Leach Tanks

Stockpile

20 to 30% oxide

SAG Mill

Screen
Ball Mill

34x16.5 13MW
12% 125mm balls

16.5x30 13MW
26% 76mm balls

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Mill Throughput Optimisation Project

PIO Methodology
benchmarking
blasting, crushing & grinding practices (and outcomes) ore characterisation modelling/simulation studies ore tracking (where required)

project timeline
January 2009
blast audits, ore tracking & grinding circuit surveys

May 2009
implementation of recommendations

November 2009
validation trials

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Ore Characterisation
Subika vs. Apensu
initial focus was on Subika ore (SAG limited) shift to Apensu ore (ball mill limited) during project
Drop Weight Test A*b 22 to 28 Bond Ball Work Index, kWh/t 15 to 17 Circuit Limitation SAG mill

Ore Source Subika

Apensu
Amoma

33 to 38
26 to 57

15 to 22
11 to 21

ball mill
variable

Awonsu
Oxide
20 to 30% typical

36
76

18
10

ball mill

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Benchmarking Study
current practices audited

blast patterns
implementation, fragmentation size, energy levels & distribution

primary crushing
product sampling, operating setting/gap

grinding circuits
sampling surveys of all process streams sizing & ore characterisation

double-bench blasting practices

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Ore Tracking
benchmarking audits
need to ensure correct material is being processed when will it enter the mill?

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Blast Validation Trials

trial program
three adjacent patterns in same area of Apensu pit as benchmarked
3 patterns x 2 benches = 6 trials

trial results
Survey Flitch Feedrate, tph % Oxide SAG kWh/t

Grind P80, microns 156

177 161

Benchmark
Trial 1 Trial 2

Top
Top Top

971
1,167 1,187

23.8
21.9 21.7

10.3
8.4 8.5

Trial 3
Benchmark

Top
Bottom

1,132
1,051

13.8
22.0

8.2
10.8

148
125

Trial 4
Trial 5 Trial 6

Bottom
Bottom Bottom

1,117
1,180 1,149

12.3
17.9 11.9

8.7
8.1 9.0

214
221 221

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Blasting Energy Levels

Ahafo Post-PIO Blasting Domains

Ahafo Pre-PIO

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SAG Mill Specific Energy

Benchmark (Top Flitch)
Benchmark (Bottom Flitch)

Apensu Blasting Trials

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Throughput Improvements
Condition Before PIO Benchmark Period Oct 08 Jan 09 Jan 09 Primary tph 722 780 Oxide tph 294 231 Total tph 1,016 1,011 % -106m 75.7

Validation Trials
Ongoing % Change

Nov 09
Jan Mar 10

965
938 30%

191
163 -45%

1,156
1,101 8%

76.6
76.3

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Ongoing Improvements
PTIs recommendations implemented
maintain primary & pebble crusher settings increased SAG mill ball load grinding media size change in ball mill

Ahafo also implemented

Metso advanced control package
AudioMill, VisioRock & OCS expert system

additional cyclone capacity (for feed density control) higher ball mill media load (for higher power draw) resulting in improved plant stability and throughput

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Conclusions
Mine-to-Mill (PIO) project outcomes
recommendations to both blasting & grinding practices validation trials confirmed positive effect of finer blast fragmentation 8% overall increase in throughput
at significantly lower oxide additions (lessen demand on oxide sources)

18% reduction in SAG mill specific energy continued improvements being implemented by Ahafo
advanced control system monitoring of crusher settings, ball loads etc.

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