XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 551
will be adjusted, and the Eject will be collected while the
Drop will be re-introduced after each cascade with a sensi-
tivity adjustment to the setting after each run. This method
(Cascade) allows for the creation of grade vs recovery vs
mass pull curves.
OBJECTIVE
Three different case studies are presented, to assess the
impact of pre-concentration through SBS using different
flowsheet scenarios to demonstrate the impact on energy
and water consumption and wet tailings generation.
CASE STUDIES
Case Study 1: Polymetalic Ore Pre-Concentration:
Effect on Grinding Circuit
A comprehensive study was conducted by Esteves, et al.
(2023) to evaluate the potential and impact of sensor-based
sorting (SBS)333 on the grinding circuit performance of
a polymetallic ore at the Aripuanã Project in Brazil. SBS
test work was performed using a Feasibility methodology,
which is presented in detail in the referenced paper, and
the resultant samples underwent destructive assays, Drop
Weight Test (DWT) and Bond Work Index (BWi) assess-
ments (Figure 3).
The study revealed significant differences in elemental
composition, breakage behaviour, and P80 values, achiev-
ing a 50% mass rejection with 98% recoveries for zinc and
lead. The pre-concentration process indicated that high-
grade material is relatively softer than gangue, and process
simulations using JKSimMet software demonstrated how
the addition of a pre-concentration stage could enhance
SAG and ball mill throughput while reducing energy
consumption.
Furthermore, the grinding tests, including Bond Work
Index (BWi) and Drop Weight Test (DWT), indicated sub-
stantial differences between pre-concentrated and non-con-
centrated samples. The pre-concentrated samples showed a
BWi value between 80% to 85% of the feed material and an
Axb value up to 1.30 times the feed Axb value (Figure 4).
These changes, combined with the particle size distribu-
tion (PSD) effects, resulted in a 10% increase of the SABC
circuit mill capacity from 235 t/h to 260 t/h. Additionally,
the pre-concentration process led to a 38% rejection of the
Run-of-Mine (ROM) feed material, significantly reducing
the energy and water required for downstream processing.
The increase on flotation grade also showed an effect on the
flotation recovery, thus generating an increase in the overall
plant metal recovery. In the optimal pre-concentration sce-
nario, water usage decreased by 44%, energy consumption
by 34%, and fine waste generation by 43%, illustrating the
substantial resource savings and efficiency improvements
achieved through SBS technology.
Case Study 2: Pre-Concentration of Copper Oxides:
Effect on Leaching
The utilization of acid leaching in the processing of
oxidized copper ore is a pivotal technique in the mining
industry. It’s a hydrometallurgical method that involves
the use of acidic solutions to dissolve and extract copper
from its oxidized mineral forms. Acid leaching offers sev-
eral advantages, including the ability to treat low-grade ores
and reduce energy consumption compared to traditional
pyrometallurgical processes. However, acid leaching also
presents several disadvantages. The process can generate sig-
nificant amounts of waste, leading to environmental con-
cerns related to acid mine drainage and soil contamination.
The handling and disposal of these acidic effluents require
stringent environmental controls and remediation mea-
sures, which can be costly. Additionally, the consumption of
large volumes of acid and the potential for equipment cor-
rosion necessitate careful management and maintenance,
further increasing operational costs (Jergensen, 1999).
Test work was performed to evaluate the impact of pre-
concentration on an oxidized copper ore, which presented
Figure 3. Flowsheet of the analysis (Esteves, 2023)
will be adjusted, and the Eject will be collected while the
Drop will be re-introduced after each cascade with a sensi-
tivity adjustment to the setting after each run. This method
(Cascade) allows for the creation of grade vs recovery vs
mass pull curves.
OBJECTIVE
Three different case studies are presented, to assess the
impact of pre-concentration through SBS using different
flowsheet scenarios to demonstrate the impact on energy
and water consumption and wet tailings generation.
CASE STUDIES
Case Study 1: Polymetalic Ore Pre-Concentration:
Effect on Grinding Circuit
A comprehensive study was conducted by Esteves, et al.
(2023) to evaluate the potential and impact of sensor-based
sorting (SBS)333 on the grinding circuit performance of
a polymetallic ore at the Aripuanã Project in Brazil. SBS
test work was performed using a Feasibility methodology,
which is presented in detail in the referenced paper, and
the resultant samples underwent destructive assays, Drop
Weight Test (DWT) and Bond Work Index (BWi) assess-
ments (Figure 3).
The study revealed significant differences in elemental
composition, breakage behaviour, and P80 values, achiev-
ing a 50% mass rejection with 98% recoveries for zinc and
lead. The pre-concentration process indicated that high-
grade material is relatively softer than gangue, and process
simulations using JKSimMet software demonstrated how
the addition of a pre-concentration stage could enhance
SAG and ball mill throughput while reducing energy
consumption.
Furthermore, the grinding tests, including Bond Work
Index (BWi) and Drop Weight Test (DWT), indicated sub-
stantial differences between pre-concentrated and non-con-
centrated samples. The pre-concentrated samples showed a
BWi value between 80% to 85% of the feed material and an
Axb value up to 1.30 times the feed Axb value (Figure 4).
These changes, combined with the particle size distribu-
tion (PSD) effects, resulted in a 10% increase of the SABC
circuit mill capacity from 235 t/h to 260 t/h. Additionally,
the pre-concentration process led to a 38% rejection of the
Run-of-Mine (ROM) feed material, significantly reducing
the energy and water required for downstream processing.
The increase on flotation grade also showed an effect on the
flotation recovery, thus generating an increase in the overall
plant metal recovery. In the optimal pre-concentration sce-
nario, water usage decreased by 44%, energy consumption
by 34%, and fine waste generation by 43%, illustrating the
substantial resource savings and efficiency improvements
achieved through SBS technology.
Case Study 2: Pre-Concentration of Copper Oxides:
Effect on Leaching
The utilization of acid leaching in the processing of
oxidized copper ore is a pivotal technique in the mining
industry. It’s a hydrometallurgical method that involves
the use of acidic solutions to dissolve and extract copper
from its oxidized mineral forms. Acid leaching offers sev-
eral advantages, including the ability to treat low-grade ores
and reduce energy consumption compared to traditional
pyrometallurgical processes. However, acid leaching also
presents several disadvantages. The process can generate sig-
nificant amounts of waste, leading to environmental con-
cerns related to acid mine drainage and soil contamination.
The handling and disposal of these acidic effluents require
stringent environmental controls and remediation mea-
sures, which can be costly. Additionally, the consumption of
large volumes of acid and the potential for equipment cor-
rosion necessitate careful management and maintenance,
further increasing operational costs (Jergensen, 1999).
Test work was performed to evaluate the impact of pre-
concentration on an oxidized copper ore, which presented
Figure 3. Flowsheet of the analysis (Esteves, 2023)