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D ev e lo p m e n t o f a n I n n o v a t i v e
Co p p e r Fl o w s h e e t a t Ph u K h am
M F Yo u n g a n d I Cr n k o v i c
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Phu Kham Location in Laos
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Phu Kham Plant Layout
Plant Layout showing
• Primary Grinding
• Rougher Flotation
• IsaMill Regrinding
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Phu Kham Flowsheet
PROCESS
WATER
COARSE ORE
STOCKPILE
ROUGHER FLOTATION CELLS
1st CLEANER FLOTATION CELLS
2nd CLEANER FLOTATION CELLS
3rd CLEANER FLOTATION CELLS
ISAMILL
GYRATORY
CRUSHER SAG MILL
No.1 BALL MILL
TAILINGS DAM
CONCENTRATE
THICKENER
CONCENTRATE
TANK
CONCENTRATE
FILTER
CONCENTRATE
STOCKPILE
MILL CYCLONES
ROUGHER
CONCENTRATE
CYCLONES
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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/tof 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 tomake good quality final copper concentrate
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• IsaMill currently grinds from 90 microns to 38 microns
• Cleaner feed performance at 38 microns and 25 microns
• Laboratory Flotation Tests
Cleaner Grade-Recovery Prof ile For Cu-Afternoon Test
0
10
20
30
40
20 40 60 80 100Cum Cu Recovery
C u m C u G r a d e
No Regrind (PM) With Regrind (PM)
Cleaner Feed Performance
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New Phu Kham Flowsheet
• Cleaning Circuit was overloaded at times
• Fine grinding to improve concentrate quality, slowed flotationrate 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 ofthe cleaner circuit to increase cleaning capacity
• This new circuit allowed final concentrate to be produced fromthe IsaMill regrind product in one flotation cell and removemore than half the load from the existing cleaning circuit
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New Phu Kham Flowsheet
PROCESS
WATER
COARSE
ORE
STOCKPILE
ROUGHER FLOTATION CELLS
1st CLEANER FLOTATION CELLS
2nd CLEANER FLOTATION CELLS
3rd CLEANER FLOTATION CELLS
JAMESON CELL
ISAMILL
GYRATORY
CRUSHER SAG MILL
No.1 BALL MILL
TAILINGS
DAM
CONCENTRATE
THICKENER
CONCENTRATE
TANK
CONCENTRATE
FILTER
CONCENTRATE
STOCKPILE
MILL CYCLONES
ROUGHER
CONCENTRATE
CYCLONES
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Layout of IsaMill and Jameson Cell
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Jameson Cell Flotationat Phu Kham
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• IsaMill Cyclone Overflow P80=20 microns
• IsaMill Discharge P80=38 microns
• Feed (Rougher Conc) Grade = 3-5% Cu
Phu Kham Jameson CellGrade-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 (%)
C u g r a d e ( % )
Cyclone overflow only
Cyclone oveflow + IsaMill
discharge
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Jameson Cell Size by Size Recovery onIsaMill 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
R e c o v e r y %
Cu CYC OF 1 Cu CYC OF 2
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New Cleaning Circuit Results
• Jameson Cell was initially commissioned on the regrind cycloneoverflow
• 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 thisstream
• Jameson Cell then treated cyclone overflow plus IsaMill discharge
• Jameson Cell still produced high grade copper concentrate at 26% to29% 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
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Redox Measurements in Plant
Low Eh reduces the copper mineral flotation performance
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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
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Cu Grade-Recov ery Curve-C1F
0
5
10
15
20
25
30
0 10 20 30 40 50 60 70 80 90 100Cu Recovery %
C u G r a d
e %
C1F Without Aeration C1F With Aeration RCOF
Cleaner Feed Performance
The Effect of Aeration in Laboratory Float
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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
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HYPERSPARGESupersonic Gas Injection
Fine Bubble GenerationAble to generate much finer bubbles
for fast gas transfer rates
Supersonic GasInjection Nozzlefor high intensity
mass transfer
Failsafe In LineCheck Valve to
preventSlurry Spills
Spool Piece andHigh PressureSeal for safeInsertion and
removal
Compact BallValve for Secure
Isolation
Solenoid ControlValve and flexibleconnection hose
Sturdy BarrelUnion
Connection forrapid
maintenance
k L
a
Gas Flow
Low PressureRing sparge
High Pressuresparge
HyperSparge
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HyperSparge installed inIsaMill Discharge line
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Phu Kham – Effect of AerationPlant Surveys
Phu Kham Jameson Cell Performance
Before 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
G r a d e % C u
Before Hypersparge After Hypersparge
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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
R e c o v e r y %
Before HyperSparge After HyperSparge
Phu Kham – Effect of AerationPlant Surveys
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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 finalconcentrate
• and regrinding 25 microns can produce +30% Cu in final concentrate
• Jameson Cell installation was an innovative flowsheet change toremoved load from cleaning circuit and increased plant capacity anddecrease 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 toimprove the circuit performance.
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