410 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
published material exists for case studies where technolo-
gies have been trialled and proven in the field.
Purpose
The purpose of this paper is to provide technical details for
a case study of successful BOS implementation undertaken
at the Kansanshi Mine, starting in 2020. This case is under-
stood to be the highest throughput implementation of sen-
sor based bulk ore sorting publicly reported to date.
The paper will describe:
• BOS system design, including:
– Selection and placement of equipment
– Sensing technology and
– Installation, commissioning, and operations.
• Verification methods and
• Sorting separation results
Kansanshi Mine
The Kansanshi mine (100% First Quantum Minerals
“FQM”) is located in the North-Western Province of
Zambia. Kansanshi has an extended history of operation,
with the modern mine being established by FQM in the
early 2000s.
Mining
Mining at Kansanshi is by conventional open pit min-
ing using shovel and truck mining techniques. Ore types,
corresponding to independent processing streams in the
Kansanshi mineral processing plant, are categorized as
sulphide, oxide and mixed. The metallurgical processing
system is designed to operate with a high degree of flexibil-
ity to suit the various ore types received. As a result, there
are three main processing routes, with independent dump
stations and crushers, which feed corresponding process-
ing circuits. The flexible design of the process plant allows
ores to be treated through any of the three circuits which
allows balancing of tonnages as each circuit has different
capacities.
Geology and Mineralogy
Copper mineralisation at Kansanshi occurs as three depos-
its (Main, North West and South East). The deposits are
located within domal structures along the crest of a regional
antiform. Deposit mineralisation is closely associated with
these domes.
Three styles of primary sulphide mineralisation are
associated with these deposits:
• disseminated stratabound mineralisation
• sub-vertically dipping, quartz-carbonate-sulphide
veins crosscutting the stratigraphy
• localised breccia mineralisation
Weathering influences mineralisation as follows:
• near surface weathering in the saprolitic zone
• around vertical veins, with oxide copper mineralisa-
tion predominantly evident as malachite, tenorite
and chrysocolla
• mixed primary and secondary sulphide copper min-
eral assemblages in transitional zones between weath-
ering zones
• pervasive shallow to deep weathering located along
geological structures
Primary sulphide copper mineralisation is mostly chalco-
pyrite, with minor bornite. Oxide mineralisation is mostly
chrysocolla with malachite. The transition zone contains
mixed oxide, primary sulphide, secondary chalcocite and
minor native copper and tenorite. Minor copper is hosted
in clay and mica minerals, and is classified as refractory.
Gold is associated with copper mineralisation.
(Gray, Lawlor, &Briggs, 2020)
BULK SORTING EQUIPMENT
CONFIGURATION
In 2019, Kansanshi Mineral Processing and First Quantum
Minerals corporate personnel began discussion for the use
of sensor-based BOS using an MRA to address the miner-
alogical complexity associated with the primary sulphide
ore. Shown in Figure 3, The BOS equipment would be ret-
rofitted to the existing primary sulphide crushing circuit,
comprising of primary gyratory crusher and secondary
cone crusher feeding to the coarse ore feed stockpile for the
sulphide circuit, along with associated feeders, conveyors,
and transfer chutes. The BOS equipment to be retrofitted
would include:
• MRA configured for chalcopyrite grade measure-
ment, and
• Reject conveyor belt discharging to stockpile.
Modifications of existing equipment would include:
• Addition of hydraulically actuated rock box diverter
to a chute.
Retrofitting to Existing Crushing Circuit
The existing layout of the KMP primary sulphide crush-
ing circuit presented a favourable opportunity for retrofit-
ting of BOS system. CV-1201 receives primary crushed ore
from a gyratory crusher and discharges to a tower fitted
published material exists for case studies where technolo-
gies have been trialled and proven in the field.
Purpose
The purpose of this paper is to provide technical details for
a case study of successful BOS implementation undertaken
at the Kansanshi Mine, starting in 2020. This case is under-
stood to be the highest throughput implementation of sen-
sor based bulk ore sorting publicly reported to date.
The paper will describe:
• BOS system design, including:
– Selection and placement of equipment
– Sensing technology and
– Installation, commissioning, and operations.
• Verification methods and
• Sorting separation results
Kansanshi Mine
The Kansanshi mine (100% First Quantum Minerals
“FQM”) is located in the North-Western Province of
Zambia. Kansanshi has an extended history of operation,
with the modern mine being established by FQM in the
early 2000s.
Mining
Mining at Kansanshi is by conventional open pit min-
ing using shovel and truck mining techniques. Ore types,
corresponding to independent processing streams in the
Kansanshi mineral processing plant, are categorized as
sulphide, oxide and mixed. The metallurgical processing
system is designed to operate with a high degree of flexibil-
ity to suit the various ore types received. As a result, there
are three main processing routes, with independent dump
stations and crushers, which feed corresponding process-
ing circuits. The flexible design of the process plant allows
ores to be treated through any of the three circuits which
allows balancing of tonnages as each circuit has different
capacities.
Geology and Mineralogy
Copper mineralisation at Kansanshi occurs as three depos-
its (Main, North West and South East). The deposits are
located within domal structures along the crest of a regional
antiform. Deposit mineralisation is closely associated with
these domes.
Three styles of primary sulphide mineralisation are
associated with these deposits:
• disseminated stratabound mineralisation
• sub-vertically dipping, quartz-carbonate-sulphide
veins crosscutting the stratigraphy
• localised breccia mineralisation
Weathering influences mineralisation as follows:
• near surface weathering in the saprolitic zone
• around vertical veins, with oxide copper mineralisa-
tion predominantly evident as malachite, tenorite
and chrysocolla
• mixed primary and secondary sulphide copper min-
eral assemblages in transitional zones between weath-
ering zones
• pervasive shallow to deep weathering located along
geological structures
Primary sulphide copper mineralisation is mostly chalco-
pyrite, with minor bornite. Oxide mineralisation is mostly
chrysocolla with malachite. The transition zone contains
mixed oxide, primary sulphide, secondary chalcocite and
minor native copper and tenorite. Minor copper is hosted
in clay and mica minerals, and is classified as refractory.
Gold is associated with copper mineralisation.
(Gray, Lawlor, &Briggs, 2020)
BULK SORTING EQUIPMENT
CONFIGURATION
In 2019, Kansanshi Mineral Processing and First Quantum
Minerals corporate personnel began discussion for the use
of sensor-based BOS using an MRA to address the miner-
alogical complexity associated with the primary sulphide
ore. Shown in Figure 3, The BOS equipment would be ret-
rofitted to the existing primary sulphide crushing circuit,
comprising of primary gyratory crusher and secondary
cone crusher feeding to the coarse ore feed stockpile for the
sulphide circuit, along with associated feeders, conveyors,
and transfer chutes. The BOS equipment to be retrofitted
would include:
• MRA configured for chalcopyrite grade measure-
ment, and
• Reject conveyor belt discharging to stockpile.
Modifications of existing equipment would include:
• Addition of hydraulically actuated rock box diverter
to a chute.
Retrofitting to Existing Crushing Circuit
The existing layout of the KMP primary sulphide crush-
ing circuit presented a favourable opportunity for retrofit-
ting of BOS system. CV-1201 receives primary crushed ore
from a gyratory crusher and discharges to a tower fitted