flujo inovador de proceso mina cobre

8/9/2019 Flujo Inovador de Proceso Mina Cobre

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D ev e lo p m e n t o f a n I n n o v a t i v e

Co p p e r Fl o w s h e e t a t Ph u K h am

M F Yo u n g a n d I Cr n k o v i c



Phu Kham Location in Laos



Phu Kham Plant Layout

Plant Layout showing

• Primary Grinding

• Rougher Flotation

• IsaMill Regrinding



Phu Kham Flowsheet

PROCESS

WATER

COARSE ORE

STOCKPILE

ROUGHER FLOTATION CELLS

1st CLEANER FLOTATION CELLS

2nd CLEANER FLOTATION CELLS

3rd CLEANER FLOTATION CELLS

ISAMILL

GYRATORY

CRUSHER SAG MILL

No.1 BALL MILL

TAILINGS DAM

CONCENTRATE

THICKENER

CONCENTRATE

TANK

CONCENTRATE

FILTER

CONCENTRATE

STOCKPILE

MILL CYCLONES

ROUGHER

CONCENTRATE

CYCLONES



Phu Kham Flowsheet

• 12.8 Mt/a of copper-gold bearing ore from the open pit

• Plant Feed Grades are 0.75% Cu and 0.33g/t of Au and 3.8g/tof Ag

• Concentrate quality is +25% Cu, 7 g/t of Au and 60g/t of Ag

• Primary Grinding Circuit contains

– 34 ft × 18 ft (13MW) SAG mill– 24 ft × 39 ft (13 MW) ball mill

• Regrinding Circuit contains

– M10,000 (2.6MW) IsaMill

• Ore has fine locking of copper and gangue minerals

• Ore requires regrinding rougher concentrate to 38 microns tomake good quality final copper concentrate



• IsaMill currently grinds from 90 microns to 38 microns

• Cleaner feed performance at 38 microns and 25 microns

• Laboratory Flotation Tests

Cleaner Grade-Recovery Prof ile For Cu-Afternoon Test

0

10

20

30

40

20 40 60 80 100Cum Cu Recovery

C u m C u G r a d e

No Regrind (PM) With Regrind (PM)

Cleaner Feed Performance



New Phu Kham Flowsheet

• Cleaning Circuit was overloaded at times

• Fine grinding to improve concentrate quality, slowed flotationrate and increase frothing issues in the cleaner circuit,decreasing the performance of the cleaner circuit

• Jameson Cell with froth washing was installed at the head ofthe cleaner circuit to increase cleaning capacity

• This new circuit allowed final concentrate to be produced fromthe IsaMill regrind product in one flotation cell and removemore than half the load from the existing cleaning circuit



New Phu Kham Flowsheet

PROCESS

WATER

COARSE

ORE

STOCKPILE

ROUGHER FLOTATION CELLS

1st CLEANER FLOTATION CELLS

2nd CLEANER FLOTATION CELLS

3rd CLEANER FLOTATION CELLS

JAMESON CELL

ISAMILL

GYRATORY

CRUSHER SAG MILL

No.1 BALL MILL

TAILINGS

DAM

CONCENTRATE

THICKENER

CONCENTRATE

TANK

CONCENTRATE

FILTER

CONCENTRATE

STOCKPILE

MILL CYCLONES

ROUGHER

CONCENTRATE

CYCLONES



Layout of IsaMill and Jameson Cell



Jameson Cell Flotationat Phu Kham



• IsaMill Cyclone Overflow P80=20 microns

• IsaMill Discharge P80=38 microns

• Feed (Rougher Conc) Grade = 3-5% Cu

Phu Kham Jameson CellGrade-Recovery Curve Performance

20.00

21.00

22.00

23.00

24.00

25.00

26.00

27.00

28.00

29.00

30.00

50% 55% 60% 65% 70% 75% 80% 85% 90% 95%

Cu recovery (%)

C u g r a d e ( % )

Cyclone overflow only

Cyclone oveflow + IsaMill

discharge



Jameson Cell Size by Size Recovery onIsaMill Cyclone Overflow Stream

Phu Kham Jameson Cell Size-By-Size Recovery

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

0 10 20 30 40 50 60 70 80

Size Fraction

R e c o v e r y %

Cu CYC OF 1 Cu CYC OF 2



New Cleaning Circuit Results

• Jameson Cell was initially commissioned on the regrind cycloneoverflow

• Cyclone Overflow was fine (P80=20 microns) and well liberated

• Jameson Cell produced 25.5% to 27.5% Cu grade at 75% to 90%Cu recovery on this stream

• Jameson Cell produced high recovery in all size fractions for thisstream

• Jameson Cell then treated cyclone overflow plus IsaMill discharge

• Jameson Cell still produced high grade copper concentrate at 26% to29% Cu grade at 55% to 60% copper recovery

• The recovery of the coarser size fraction was lower due to the

locking and lower liberation in the size fractions



Redox Measurements in Plant

Low Eh reduces the copper mineral flotation performance



Impact of Inert Grinding - Chalcopyrite

The Effect of Eh – Mt Isa Cu Ore

The critical importance of the grinding environment on fine particle recoveryin flotation - Stephen Grano - 2009



Cu Grade-Recov ery Curve-C1F

0

5

10

15

20

25

30

0 10 20 30 40 50 60 70 80 90 100Cu Recovery %

C u G r a d

e %

C1F Without Aeration C1F With Aeration RCOF

Cleaner Feed Performance

The Effect of Aeration in Laboratory Float



Grade

Recovery

Curves

(Total

Cu)

IMD

0

5

10

15

20

25

50 60 70 80 90 100

IMD Without Aeration IMD With Aeration

IsaMill Discharge Performance

The Effect of Aeration in Laboratory Float



HYPERSPARGESupersonic Gas Injection

Fine Bubble GenerationAble to generate much finer bubbles

for fast gas transfer rates

Supersonic GasInjection Nozzlefor high intensity

mass transfer

Failsafe In LineCheck Valve to

preventSlurry Spills

Spool Piece andHigh PressureSeal for safeInsertion and

removal

Compact BallValve for Secure

Isolation

Solenoid ControlValve and flexibleconnection hose

Sturdy BarrelUnion

Connection forrapid

maintenance

k L

a

Gas Flow

Low PressureRing sparge

High Pressuresparge

HyperSparge



HyperSparge installed inIsaMill Discharge line



Phu Kham – Effect of AerationPlant Surveys

Phu Kham Jameson Cell Performance

Before and After Aeration

22.0

23.0

24.0

25.0

26.0

27.0

28.0

40% 45% 50% 55% 60% 65% 70% 75% 80%

Recovery % Cu

G r a d e % C u

Before Hypersparge After Hypersparge



Phu Kham Jameson Cell Size-By-Size Recovery

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

0 10 20 30 40 50 60 70 80

Size Fraction

R e c o v e r y %

Before HyperSparge After HyperSparge

Phu Kham – Effect of AerationPlant Surveys



Summary

• IsaMill regrinds rougher concentrate to 38 micron to improve thefinal copper concentrate quality

• Cleaner feed performance at 38 microns is 25-28% Cu in finalconcentrate

• and regrinding 25 microns can produce +30% Cu in final concentrate

• Jameson Cell installation was an innovative flowsheet change toremoved load from cleaning circuit and increased plant capacity anddecrease cleaner circuit frothing issues

• Aeration of Cleaner feed has improve performance and fines

recovery and selectivity

• Jameson Cell has allowed the IsaMill to operate at Increase power toimprove the circuit performance.

flujo inovador de proceso mina cobre

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