AFRY Precision - Advanced Simulation and Optimisation for Mineral Processing
A powerful solution for optimising plant efficiency
To enhance plant efficiency, reduce design risks, and increase profitability, AFRY Precision modeling and optimisation service provides a powerful, targeted solution for mineral processing. Our consulting expertise empowers clients to design and optimise comminution circuits with precision, minimising costs and energy consumption.
Comminution is an essential part of mineral processing, separating valuable minerals from waste material. However, it is currently both energy-intensive and inefficient. This presents an opportunity to improve efficiency and achieve economic savings. By refining the comminution process, it's possible to encourage responsible resource consumption and reduce energy use.
In AFRY Precision service we are using JK SimMet, which is a software for analysing and simulating comminution and classification circuits in mineral processing operations. Ideal for both greenfield and brownfield projects, JK SimMet software is trusted worldwide globally by experts striving for excellence in mineral processing. AFRY has a strong experience in comminution, covering sustainable operating efficiency, throughput forecasting, minimising the overall costs and geometallurgical modeling.
Customised Flowsheet Design
- Development of graphic-based flowsheets for mineral processing plants, enabling precise modeling and visualisation of each comminution stage.
- Evaluation of various circuit configurations to identify the most efficient circuit, resulting in reduced design time and minimised risk.
Optimised Circuit Performance
- Improvement in the productivity and efficiency of existing mineral processing plants.
- Optimisation of output and reduction in energy consumption through adjustments to equipment parameters and flow rates.
Accurate Mass Balance Calculations and Model Fitting
- Execution of mass balance calculations to ensure effective resource allocation.
- Model fitting to specific site equipment, ensuring that simulations accurately reflect real-world conditions.
Operational Change Simulation
- Simulation of the impact of operational changes to predict product flow, size distributions, and performance metrics.
- Assessment of key metrics such as power consumption and optimal operating conditions to improve circuit efficiency.
Reduced Variability and Operational Stability
- Minimisation of performance fluctuations to stabilise processes and achieve consistent results.
- Identification and resolution of bottlenecks to improve availability, throughput, and recovery rates.
Site-based JK SimMet model for the comminution circuit
Efficient: A targeted solution for mineral processing that boosts plant efficiency, minimises design risks, and improves profitability through modeling and optimisation services.
Cutting costs: Our consulting expertise enables clients to precisely design and optimise comminution circuits, reducing costs and energy use.
Versatile: The JK SimMet software is widely adopted worldwide, incorporating cutting-edge, industry-standard functions and models for comminution processes.
Feedback from JKSimMet users in the industry:
Using JK SimMet allows us to identify bottlenecks and optimise the existing setup while maintaining the required grind size (P80). By implementing the optimised parameters, we achieved a 10% increase in annual throughput and reduced energy consumption per ton of processed material.
AFRY Precision services for global processes
Laboratory Metallurgical Testing Service
AFRY’s metallurgical testing service provides clients access to a full suite of required tests conducted by our trusted partners—leading metallurgical laboratories worldwide. These partners are fully licensed and equipped with certified technology, ensuring accurate, reliable results necessary for building precise models in JK SimMet. AFRY supports clients by developing tailored testing programs, coordinating directly with partner laboratories, managing sample logistics, and offering comprehensive technical support throughout the testing process. Laboratory testing and JK SimMet modeling are also vital for geometallurgical applications, enhancing ore body utilisation and optimising processing strategies.
Integration with Digitalisation Initiatives
AFRY provides a full suite of digitalisation services to support mineral processing facilities in achieving optimal efficiency. JK SimMet simulations seamlessly integrate into these efforts, combining simulation data with real-time operational insights on digital platforms. This integration enables the development of dynamic, responsive process control systems that support predictive maintenance, process optimisation, and continuous improvement, paving the way toward fully digital and highly efficient plant operations.
Geometallurgical Domain Identification and Modeling
Geometallurgical models are essential tools for predicting processing plant performance, managing risks in plant design, and optimising production planning in variable ore deposits. By integrating geological insights with metallurgical data, these models enable a comprehensive understanding of ore behaviour throughout the processing lifecycle. Metallurgical testing combined with JK SimMet modeling allows for the precise identification of primary geometallurgical domains and their impact on downstream processes and key performance indicators.
