development of an innovative copper flowsheet at …...phu kham flowsheet • 12.8 mt/a of...
TRANSCRIPT
Development of an Innovative
Copper Flowsheet at Phu Kham
M F Young and I Crnkovic
Phu Kham Location in Laos
Phu Kham Plant Layout
Plant Layout showing
• Primary Grinding• Rougher Flotation• IsaMill Regrinding
Phu Kham Flowsheet
PROCESSWATER
COARSE ORE STOCKPILE
ROUGHER FLOTATION CELLS
1st CLEANER FLOTATION CELLS
2nd CLEANER FLOTATION CELLS
3rd CLEANER FLOTATION CELLS
ISAMILL
GYRATORYCRUSHER SAG MILL
No.1 BALL MILL
TAILINGS DAM
CONCENTRATETHICKENER
CONCENTRATETANK
CONCENTRATEFILTER
CONCENTRATESTOCKPILE
MILL CYCLONES
ROUGHERCONCENTRATECYCLONES
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/t
of 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 to
make 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 Profile For Cu-Afternoon Test
0
10
20
30
40
20 40 60 80 100Cum Cu Recovery
Cum
Cu
Gra
de
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 flotation rate 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 of the cleaner circuit to increase cleaning capacity
• This new circuit allowed final concentrate to be produced from the IsaMill regrind product in one flotation cell and remove more than half the load from the existing cleaning circuit
New Phu Kham Flowsheet
PROCESSWATER
COARSE ORE STOCKPILE
ROUGHER FLOTATION CELLS
1st CLEANER FLOTATION CELLS
2nd CLEANER FLOTATION CELLS
3rd CLEANER FLOTATION CELLS
JAMESON CELL
ISAMILL
GYRATORYCRUSHER SAG MILL
No.1 BALL MILL
TAILINGS DAM
CONCENTRATETHICKENER
CONCENTRATETANK
CONCENTRATEFILTER
CONCENTRATESTOCKPILE
MILL CYCLONES
ROUGHERCONCENTRATECYCLONES
Layout of IsaMill and Jameson Cell
Jameson Cell Flotation at Phu Kham
• IsaMill Cyclone Overflow P80=20 microns• IsaMill Discharge P80=38 microns• Feed (Rougher Conc) Grade = 3-5% Cu
Phu Kham Jameson Cell Grade-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 (%)
Cu grade
(%)
Cyclone overflow only
Cyclone oveflow + IsaMilldischarge
Jameson Cell Size by Size Recovery on IsaMill 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
Rec
ove
ry %
Cu CYC OF 1 Cu CYC OF 2
New Cleaning Circuit Results
• Jameson Cell was initially commissioned on the regrind cyclone overflow
• 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 this
stream
• Jameson Cell then treated cyclone overflow plus IsaMill discharge• Jameson Cell still produced high grade copper concentrate at 26% to
29% 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-Recovery Curve-C1F
0
5
10
15
20
25
30
0 10 20 30 40 50 60 70 80 90 100Cu Recovery %
Cu
Gra
de %
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 Nozzle for high intensity
mass transfer
Failsafe In LineCheck Valve to
preventSlurry Spills
Spool Piece and High Pressure Seal for safeInsertion and
removal
Compact Ball Valve for Secure
Isolation
Solenoid Control Valve and flexible connection hose
Sturdy Barrel Union
Connection for rapid
maintenance
k La
Gas Flow
Low PressureRing sparge
High Pressuresparge
HyperSparge
HyperSparge installed in IsaMill Discharge line
Phu Kham – Effect of AerationPlant Surveys
Phu Kham Jameson Cell PerformanceBefore 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
Gra
de %
Cu
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
Rec
ove
ry %
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 final concentrate
• and regrinding 25 microns can produce +30% Cu in final concentrate
• Jameson Cell installation was an innovative flowsheet change to removed load from cleaning circuit and increased plant capacity and decrease 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 to improve the circuit performance.