david seaman
TRANSCRIPT
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Separation efficiency improvementof a low grade copper-gold flotation
circuit
Newcrest Mining LimitedDavid Seaman, Peter Manton & Paul Griffin
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Contents Process Overview Mineralogy Circuit Modification Installation Details
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Telfer Flotation Overview Dual train (underground and open pit) ~ 23Mtpa Typical head grades 0.1-0.2 % Cu; 1-2g/t Au; 1-5% Sulphur Gold distribution free gold/copper minerals/Pyrite (~5g/t) Copper minerals Predominantly Chalcopyrite and Chalcocite Copper concentrate produced - ~16% Copper
Tailings
Cu Ro
Cleaner Cleaner Scav
ReCleaner
Copper Con
Grindingcircuit
FFCC
Py Rougher
Cleaner Cleaner Scav
CIL
Copper Circuit
Pyrite Circuit
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Copper Concentrate MineralogyFinal Copper Concentrate Mass Distribution
0%
10%
20%
30%
40%
50%60%
70%
80%
90%
100%
Telfer - T1 Telfer - T2 Cadia Ridgeway BulkSulphide*
NSG
Other SulphidePyriteOther CuOther Cu SulphidesCpy
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Copper Concentrate Mineralogy Significant quantity of liberated
NSG diluting copper concentrate Copper minerals well liberated Opportunity to replace NSG withPyrite
improve gold recovery Increase copper concentrate grade0
10
20
30
40
50
60
70
80
90
100
T1-FFC T2-FFC T1-CuRon T1 Cu ReCl T2 Cu ReCl
other
Pyrite
Ch
Cpy
NSG
Cu Con Liberation (Cu) - Q1
0102030
405060708090
100
T1 FFC T2 FFC T1 Cu RoCon
T1 ReClCon
T2 ReClCon
Total Ternary (%)
Total Binary (%)
Liberated (%)
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Gangue Characteristics Size Predominantly fine and well liberated
Mostly Quartz & Feldspars
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Mechanism of Gangue Dilution Dilute Hot Flotation tests - ~5% solids
0
20
40
60
80
100
0 20 40 60 80 100
Mass Recovery (%)
G o
l d R e c o v e r y
( % )
T1 Ro Con A (May) T1 Cu Con
T1 ReCl Con (May) T1 ReCl Con
T1 Ro Con B
0
10
20
30
40
50
60
70
80
90
100
0 20 40 60 80 100
Mass Recovery (%)
G
o l d R e c o v e r y
( % )
T2 Cl Con T2 Cu Ro Con
20% of Mass (NSG) can be rejected by further cleaning with negligible change to overallrecovery
NSG is not being recovered by true flotation
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Cleaning Circuit limitations Cleaner cells heavily loaded Cells have insufficient launder capacity Residence time constraints do not allow for
further dilution in cleaners to reduce entrainment
%solids (min)Cu Ro 34.3 15.0Cu Cl 10.5 13.6Cu Cl Scav 9.2 14.4
Cu ReCl 10.1 20.7
Cu Recleaner Cells
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Reconfiguration of the Cleaning Circuit Simplified AMIRA P9 model:
Various reconfigurations simulated using Monte-Carlo Minor improvements could be made using existing equipment:
open-circuiting the Cl Scav Con (to Recleaners) diluting the Cl/Cl Scav bank to reduce Rw
Additional capacity required to make a significant improvement Jameson cell chosen as new capacity
published performance data (>50% stage recovery at high grades) ability to reject entrainment by froth washing Incorporated in model using the dilute batch float selectivity
wwij
wwijij R ENT Rk
R ENT Rk R
)1)(1()1(
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Modified Cleaner Flowsheet Installation of one Jameson cell per Train fed by Cu Ro Con
Similar approach to recent installations at Phu Kam and Prominent Hill Open circuit Cl Scav Con to allow additional dilution of Cleaners Modelled improvement consistent with mineralogical characterisation
RoA Ro B
Cleaner Cleaner Scav
ReCleaner
Ro Con A
Final Con
COF
Grinding circuit
FFCC
12
13
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21
22
-6 -4 -2 0 2 4 6
R e c l e a n e r
C o n c e n t r a t e
G r a
d e -
% C u
Copper Recovery from Cyclone Overflow (diff erence) % Cu
Baseline Jameson Cell Installation
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Jameson Cell Technology
The Downcomer
Slurry is pumped through a slurry lens orifice athigh pressure (150kPa)
Air is entrained into the downcomer
Mixing zone is formed in the downcomer where
particles and bubbles contact
Internal recycle of cell content allowing the use of
a fixed speed pump, designed for approximately
2:1 (downcomer flowrate: fresh feed)
Cells are fitted with wash-water trays to allow
effective froth washing to reduce entrainment
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Telfer Jameson Cell Installation
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Installation Details 2 x E3432/8 Jameson Cells Designed to treat up to 60tph fresh feed each (350m 3/h slurry) Concentrate and tailings flow by gravity Each cell driven by a 75kW Warman 10/8 pump (700m 3/h) Wash water utilisation ~ 30-100m 3/h Major equipment direct purchased by Newcrest, installation carried
out under a lump sump EPC - reduced project delivery time Timing
Oct 2010 Project initiated to address NSG in concentrate May 2011 Order placed for major equipment November 2011 New cleaning circuit commissioned
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Jameson Cell Actual vs Predicted
Similar selectivity observed to date, high stage recoveries achieved (>80%)for Cu and Au
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