628 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
The consequence would have been a reduction in addi-
tional overall water consumption that is proportional to the
reduction of tonnage of wet ore processed.
Similarly, for energy consumption, the future flowsheet
resulted in a 30% energy reduction per tonne of wet ore
processed and a 48% energy reduction on a per tonne of
copper produced basis. If energy reduction was the primary
focus, rejection of the particle sorting fines would have
avoided HPGR and stirred mill comminution of 7,950
tpd, further increasing the potential energy savings.
While reducing water and energy consumption, the
future flowsheet also increased the copper production from
128.3 tpd to162.1tpd, a 26% increase in metal produc-
tion. The alternative scenario where particle sorting fines
are rejected would have reduced the amount of copper pro-
duced to 152 tpd, still a 16% increase over the base case. A
more detailed trade-off study would need to be conducted
to evaluate this alternative option.
CONCLUSIONS AND
RECOMMENDATIONS
Efforts to improve sustainable practices in mining include
priorities such as reducing water and energy consump-
tion and improving resource utilization. Reducing water
Table 7. Future flowsheet—mass, water and energy balances
Mass and Water Balance Metal balance Energy Balance
Dry
Solids,
t/h
%Solids,
%
Water,
t/h
Cu,
%
Cu,
t/d
Specific
Energy,
kWh/t
Load,
kW
Annual
Consumption,
MWh
Crushing and Sorting Circuit 1.05 1,832 12,034
Bulk Ore Sorting Feed 8,333 97 258 ///
Margin Ore to Crushing and POS 883 97 27 0.14 21.5 1.1
High-grade Ore to Crushing 1,752 97 54 0.45 143.4 1.0
Combined Feed to HPGR 2,635 97 82 0.40 189.6 1.05
HPGR Circuit 5 10,742 86,569
HPGR Screen Undersize 2,148 65 1,157 0.40 189.6
Coarse Stirred Mill Circuit 8 17,187 138,510
Primary Cyclone Feed 2,148 55 1,758 0.40 189.6
Primary Cyclone Overflow 430 35 798 0.40 37.9
Coarse Stirred Mill Feed 1,719 55 1,406 0.40 151.7
Coarse Particle Flotation Circuit 1 2,148 17,314
CPF Cyclone Feed 2,148 49 2,204 0.40 189.6
CPF Cyclone Overflow 322 25 967 0.40 28.4
CPF Feed 1,826 60 1,237 0.40 161.2
CPF Concentrate 457 30 1,065 1.41 142.2
CPF Tailings 1,370 55 1,139 0.05 19.0
Fine Stirred Mill Regrind Circuit 20 15,575 125,525
Regrind Cyclone Feed 779 28 2,032 0.99 170.7
Regrind Cyclone Overflow 156 10 1,402 0.99 34.1
Fine Stirred Mill Feed 623 50 630 0.99 136.5
Cleaner Flotation Circuit 2.5 1,947 15,691
Cleaner Feed 779 28 2,032 0.99 170.7
Cleaner Concentrate 31 10 280 23.57 162.1
Cleaner Tailings 748 30 1,752 0.04 8.5
Concentrate Dewatering 20 623 5,021
Concentrate Thickener Feed 31 10 280 23.57 162.1
Filter Product 31 90 3.5 23.57 162.1
Tailings Dewatering 2 4,234 34,125
Final Tailings (wet) 2,117 42 2,891 0.05 27.5
Final Tailings (dry stack) 2,117 85 373.6
Water Loss (Fresh Water Demand) 433.6
*Compared to base case, energy increased by 0.05kWh/t as a result of particle sorters installation.
The consequence would have been a reduction in addi-
tional overall water consumption that is proportional to the
reduction of tonnage of wet ore processed.
Similarly, for energy consumption, the future flowsheet
resulted in a 30% energy reduction per tonne of wet ore
processed and a 48% energy reduction on a per tonne of
copper produced basis. If energy reduction was the primary
focus, rejection of the particle sorting fines would have
avoided HPGR and stirred mill comminution of 7,950
tpd, further increasing the potential energy savings.
While reducing water and energy consumption, the
future flowsheet also increased the copper production from
128.3 tpd to162.1tpd, a 26% increase in metal produc-
tion. The alternative scenario where particle sorting fines
are rejected would have reduced the amount of copper pro-
duced to 152 tpd, still a 16% increase over the base case. A
more detailed trade-off study would need to be conducted
to evaluate this alternative option.
CONCLUSIONS AND
RECOMMENDATIONS
Efforts to improve sustainable practices in mining include
priorities such as reducing water and energy consump-
tion and improving resource utilization. Reducing water
Table 7. Future flowsheet—mass, water and energy balances
Mass and Water Balance Metal balance Energy Balance
Dry
Solids,
t/h
%Solids,
%
Water,
t/h
Cu,
%
Cu,
t/d
Specific
Energy,
kWh/t
Load,
kW
Annual
Consumption,
MWh
Crushing and Sorting Circuit 1.05 1,832 12,034
Bulk Ore Sorting Feed 8,333 97 258 ///
Margin Ore to Crushing and POS 883 97 27 0.14 21.5 1.1
High-grade Ore to Crushing 1,752 97 54 0.45 143.4 1.0
Combined Feed to HPGR 2,635 97 82 0.40 189.6 1.05
HPGR Circuit 5 10,742 86,569
HPGR Screen Undersize 2,148 65 1,157 0.40 189.6
Coarse Stirred Mill Circuit 8 17,187 138,510
Primary Cyclone Feed 2,148 55 1,758 0.40 189.6
Primary Cyclone Overflow 430 35 798 0.40 37.9
Coarse Stirred Mill Feed 1,719 55 1,406 0.40 151.7
Coarse Particle Flotation Circuit 1 2,148 17,314
CPF Cyclone Feed 2,148 49 2,204 0.40 189.6
CPF Cyclone Overflow 322 25 967 0.40 28.4
CPF Feed 1,826 60 1,237 0.40 161.2
CPF Concentrate 457 30 1,065 1.41 142.2
CPF Tailings 1,370 55 1,139 0.05 19.0
Fine Stirred Mill Regrind Circuit 20 15,575 125,525
Regrind Cyclone Feed 779 28 2,032 0.99 170.7
Regrind Cyclone Overflow 156 10 1,402 0.99 34.1
Fine Stirred Mill Feed 623 50 630 0.99 136.5
Cleaner Flotation Circuit 2.5 1,947 15,691
Cleaner Feed 779 28 2,032 0.99 170.7
Cleaner Concentrate 31 10 280 23.57 162.1
Cleaner Tailings 748 30 1,752 0.04 8.5
Concentrate Dewatering 20 623 5,021
Concentrate Thickener Feed 31 10 280 23.57 162.1
Filter Product 31 90 3.5 23.57 162.1
Tailings Dewatering 2 4,234 34,125
Final Tailings (wet) 2,117 42 2,891 0.05 27.5
Final Tailings (dry stack) 2,117 85 373.6
Water Loss (Fresh Water Demand) 433.6
*Compared to base case, energy increased by 0.05kWh/t as a result of particle sorters installation.