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A Secondary Source of Microcrystalline Magnesite GRECIAN MAGNESITE Case Study

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A Secondary Source of Microcrystalline Magnesite GRECIAN MAGNESITE Case Study 3rd Greek Raw Materials Community Dialogue Old Tailings – A secondary source of Microcrystalline Magnesite GRECIAN MAGNESITE case study. ATHANASIOS VALATSOS 4-12-2018 Company’s Profile Established in 1959 by Mr G. Portolos Privately owned company Head quarters in Athens - Mines and production facilities in Yerakini, Chalkidiki R&D center in Vassilika, Thessaloniki Primary business activity is the mining, beneficiation and calcination of magnesium carbonate for the production of CCM, DBM, and unshaped basic refractories as well as raw magnesite Annual production capacity of 150.000mt of calcined products - More than 60 different MgO grades Export activity with sales to more than 60 countries in all continents ISO 9001:2015 and GMP+ certificates 370 employees in Greece Yerakini Deposit Microcrystalline magnesite (MgCO3) White color (“lefkolithos”= white stone) “Stockwork type” of orebody Waste rock is mainly serpentine and dunite Main characteristics of Yerakini magnesite: - Low iron content - Very low levels of heavy metals, P, F, Cl Recovery from the ROM material is critical parameter since it affects •The sustainability of the operation •The economic benefit •The lifespan of the mine GM Site – Mining Activity • Total rehabilitated area (1995-2016):165 .000 m2 • Planted trees(1988-2016):122.866 GM Site – Calcination Plant Calcination MgCO3 MgO + CO2 3 rotary kilns - 1 shaft kiln – 1 double inclined shaft kiln CCM is calcined at 800-1.200oC depending on the quality grade DBM is calcined at 1600-1.900oC depending on the quality grade Final processing of CCM and DBM Production of refractory mixes. Mining Activity at Yerakini Mine Within the framework of the Raw Materials Initiative GM aims to : 1. Increase the Recovery of magnesite from ROM material 2. Utilize the old fine ROM material which is stockpiled (Secondary source of Magnesite) 3. Re-use some of the by-Products of the mine 4. Continuously prepare new exploration drilling campaigns Internal development projects and adoption of state of the art new technologies International collaborations in EU funded programs and other projects (MagWasteVal, Magfines) Only in the last decades the cost of investment in internal development projects amounted to almost 30 million € History of beneficiation process in Yerakini 1910 On-site hand-sorting – Small scale operation Estimated Recovery 30-40% from ROM 1959-2000 Hand-Sorting Installations (late 60’s) – (+40mm Recovered – 0-40mm ROM material stockpiled) Introduction of Dense – Media separation method (1973) Laser Sorters– 1st industrial worldwide use of optical sorters (1977) (+25mm Recovered – 0-25mm stockpiled) (1st phase) and (+18mm Recovered – 0-18mm stockpiled) (2nd phase) New crushing and screening installation (1994) Estimated Recovery 60% from ROM 2001-2018 •New magnetic separation Unit(2001) •New screening installation for the size fraction 4-10mm and 10- 18mm ROM material (Greco –Screens)(2001) New type of camera sorters and high intensity magnetic separators for the processing of 4-10mm and 10-18mm ROM material(2006-2010) (+4mm Recovered – 0-4mm ROM material stockpiled) Estimated Recovery 74% from ROM •Acquisition of 2 Mobile Screening Units for the Screening of the Old fine stockpiled material (2012-2018) Exploitation of Tailings – A secondary source of Microcrystalline Magnesite Projects for the recovery Tailings Stockpiled ROM material of magnesite from ROM Stockpile Size Fraction Tonnage Source Estimated Kiln fines date back from 1995 Feed (Magfines) Magnesite (tn) A1 4-18mm 1,000,000 Unprocessed 200,000 Sources of old tailings ROM A2 0-40mm 712,000 Reject of H/P 213,600 1. Rejects of the Hand- Β1 0-40mm 7,967,353 Reject of H/P 796,735 Sorting processing Β2 0-40mm 1,012,189 Reject of H/P 121,219 Β3 0-25mm 2,611,013 Unprocessed 261,101 of the past (0- ROM 40mm) Β4 0-25mm 6,274,173 Unprocessed 627,417 ROM 2. Unprocessed ROM Β5 0-18mm 22,360,480 Unprocessed 2,236,048 material (either 0- ROM 18mm or 0-25mm) Β6 0-40mm 816,846 Reject of H/P 81,684 TOTAL 42,754,054 4,537,805 Old Tailing stockpiles Stockpile of -40mm and -18mm at GM deposit for re-processing Based on production data approximately 10% Based on production data approximately 12% of this stockpile is recoverable as suitable Kiln of this stockpile is recoverable as suitable Kiln feed for CCM feed for CCM or DBM Beneficiation flowsheet of kiln feed magnesite from tailings •Annual Production Capacity around 90.000 tones of Kiln feed magnesite •Almost 25% of the total needs for Kiln feed magnesite •Production cost almost 45% lower compared to kiln feed magnesite from current ROM material. New applications for magnesite from tailings Clean Air Within the framework of LIFEPOSITIVE MgO MgO (CCM) from tailings is used as reagent for the absorption of SOX from flue gases in the newly constructed Flue Gas Desulphurization Pilot Plant Insulating material (Rockwool boards) Raw magnesite from tailings is used as a basic insulating material for the construction of rockwool boards. (Successful collaboration of 2 greek companies to valorize low grade-products) Work and Conclusions • Old tailings consist an important source of magnesite and other minerals • To maximize the utilization of raw materials from the old stock piles that will extend the life of the mine. • To further increase the recovery of Yerakini reserves with the adoption of new technologies • To maintain and improve the sustainability of the mining activity to meet EU’s policies on raw materials and circular economy • To emphasize on eco friendly products and applications of MgO • To further invest in Research and Development THANK YOU! .
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