Process Control Philosophy

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DOC No: 195-G-F-01 CLIENT: ENVIROGOLD (LAS LAGUNAS) LIMITED PROJECT: LAS LAGUNAS GOLD PROJECT SHEET: 1 of 36 TITLE: PROCESS DESIGN CRITERIA 1.0 Plant Site and Climatic Conditions 2.0 Operating Philosophy 3.0 Ore Characteristics 4.0 Area 10 - TSF Reclaim 5.0 Area 15 - Grinding 6.0 Area 20 - Flotation 7.0 Area 25 - Concentrate Regrind 8.0 Area 30 - Albion Leach 9.0 Area 40 - CIL 10.0 Area 42 - Elution 11.0 Area 44 - Electrowinning and Smelting 12.0 Area 46 - Carbon Regeneration 13.0 Area 50 - Cyanide Detoxification 14.0 Area 55 - Tailings Disposal 15.0 Area 60 / 62 / 66 - Water Services 16.0 Area 70 - Reagents 17.0 Area 80 / 85 - Air and Oxygen Services 1 Feasibility Study Data 2 Consultant Recommendation 3 Vendor Recommendation 4 Owner Recommendation - Las Lagunas Limited 5 Engineer Recommendation - Lycopodium Minerals Queensland 6 Calculated 7 Assumption 8 Testwork 2 23/01/12 Updated - Flowsheet Change LLL LLL LLL 1 04/01/10 Revised LLL LLL LLL 0 30/04/09 Issued For Construction LLL LLL LLL REV DATE REVISION DETAILS ORIG CHKD DES PROJ CLIENT DESIGN CRITERIA TABLE OF CONTENTS SOURCE REFERENCES L:\2204 - Las Lagunas Gold Project\30 - Engineering\LL01 Completion - Lycopodium\Process Deliverables\120123\195-G-F-01 Rev 2 120123

description

Las Lagunas Gold Tailings project

Transcript of Process Control Philosophy

  • DOC No: 195-G-F-01

    CLIENT: ENVIROGOLD (LAS LAGUNAS) LIMITED

    PROJECT: LAS LAGUNAS GOLD PROJECT SHEET: 1 of 36

    TITLE: PROCESS DESIGN CRITERIA

    1.0 Plant Site and Climatic Conditions2.0 Operating Philosophy3.0 Ore Characteristics4.0 Area 10 - TSF Reclaim5.0 Area 15 - Grinding6.0 Area 20 - Flotation7.0 Area 25 - Concentrate Regrind8.0 Area 30 - Albion Leach9.0 Area 40 - CIL

    10.0 Area 42 - Elution11.0 Area 44 - Electrowinning and Smelting12.0 Area 46 - Carbon Regeneration13.0 Area 50 - Cyanide Detoxification14.0 Area 55 - Tailings Disposal15.0 Area 60 / 62 / 66 - Water Services16.0 Area 70 - Reagents17.0 Area 80 / 85 - Air and Oxygen Services

    1 Feasibility Study Data2 Consultant Recommendation3 Vendor Recommendation4 Owner Recommendation - Las Lagunas Limited5 Engineer Recommendation - Lycopodium Minerals Queensland6 Calculated7 Assumption8 Testwork

    2 23/01/12 Updated - Flowsheet Change LLL LLL LLL1 04/01/10 Revised LLL LLL LLL0 30/04/09 Issued For Construction LLL LLL LLL

    REV DATE REVISION DETAILS ORIG CHKD DES PROJ CLIENT

    DESIGN CRITERIA

    TABLE OF CONTENTS

    SOURCE REFERENCES

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  • 1.0

    Description Value Unit Ref. Rev.

    1.1 Site locationLocation Sanchez Romirez 1 0Country Dominican Republic 1 0Plant site nominal coordinates

    Process Plant Site 1902' N 1 07009' W 1 0

    Elevation 125 m ASL 1 0

    1.2 Daily maximum 28 C 1 0

    Daily absolute maximum 35 C 1 0 Daily minimum 19 C 1 0

    Daily absolute minimum 17 C 1 0

    1.3 PrecipitationMonthly mean January 80 mm 1 0 February 97 mm 1 0 March 87 mm 1 0 April 125 mm 1 0 May 232 mm 1 0 June 161 mm 1 0 July 187 mm 1 0 August 185 mm 1 0 September 146 mm 1 0 October 144 mm 1 0 November 150 mm 1 0 December 125 mm 1 0Annual mean 1718 mm 1 0

    1.4

    Annual mean 1100 mm 1 0

    1.5 WindsPrevailing Wind Direction NNE - SSW 1 0

    1.6 Seismicity

    Seismic Zone Zone 4 UBC 1 0

    Ambient temperature

    PLANT SITE AND CLIMATIC CONDITIONS

    Evaporation

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  • 2.0 OPERATING PHILOSOPHY

    Description Value Unit Ref. Rev.

    2.1 800,000 t/a 1 0

    2.2 MiningOperating basis Weeks per year 52 weeks 6 0 Days per week 7 days 6 0 Shifts per day 3 4 0 Hours per shift 8 hours 6 0

    2.3 Tailings reclaiming Operating basis Days per year 365 days 6 0 Days per week 7 days 6 0 Hours per day 24 h 6 0 Shifts per day 3 4 0

    2.4 Process plant Operating basis Days per year 365 days 6 0 Days per week 7 days 6 0 Hours per day 24 h 6 0 Shifts per day 3 4 0

    Available hours 8,760 h/a 6 0Operating hours 8,000 h/a 1 0

    153 h/week 6 0Availability 91.3 % 6 0

    Process plant total nominal annual dry ore throughput

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  • 3.0 ORE CHARACTERISTICS

    Description Value Unit Ref. Rev.

    3.1 Density Tailings SG Design 2.69 1 0Tailings bulk density Design - dry 1.27 t/m3 4 0

    Design - wet 1.71 t/m3 4 0

    3.2 Moisture content Nominal 20 % 4 0Design 20 to 35 % 4 0

    3.3 Physical

    Bond ball mill index P80 44 m 19.3 kWh/t 1 0Size distribution

    D95 180 m 1 0D80 80 m 1 0D50 12.8 m 1 0D20 3.62 m 1 0

    3.4 Mineralogy Ore mineralogy

    Pyrophyllite Al2Si4O10(OH)2 1 0Pyrite FeS2 1 0Sphalerite ZnS 1 0Galena PbS 1 0Chalcopyrite CuFeS2 1 0Arsenopyrite FeAsS 1 0

    Ore head analysis Gold 3.76 ppm Au 1 0Silver 38.62 ppm Ag 1 0Sulphide 4.94 % S2- 1 0Iron 5.55 % Fe 1 0Zinc 0.38 % Zn 8 0Lead 0.07 % Pb 8 0Copper 0.05 % Cu 8 0Arsenic 0.04 % As 1 0Silica 72.29 % SiO2 1 0Aluminium oxide 8.83 % Al2O3 1 0Magnesium oxide 0.29 % MgO 1 0Calcium oxide 0.46 % CaO 1 0

    3.5 Plant performance Gold Flotation recovery Design - % Au in float feed 83.0 % 8 0 Leach extraction Design - % Au in leach feed 84.0 % 8 0 CIL recovery Design - % Au in leach feed 83.7 % 6 0 Total recovery Design - % Au in feed 69.5 % 6 0Silver Flotation recovery Design - % Ag in float feed 80.0 % 8 0 Leach extraction Design - % Ag in leach feed 78.0 % 8 0 CIL recovery Design - % Ag in leach feed 70.2 % 6 0 Total recovery Design - % Ag in feed 56.1 % 6 0

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  • 4.0 AREA 10 - TSF RECLAIM

    Description Value Unit Ref. Rev.

    4.1 Area design throughput Design - dry 800,000 t/a 1 0100 t/h 1 0

    Design - wet 125 t/h 6 0

    4.2 Feed details Moisture content Nominal 20 % 4 0

    Design 20 to 35 % 4 0Reclaim/feed method Dredge 4 2

    4.3 Product detailsSolids throughput rate 100 t/h 6 0% solids Nominal 40 % w/w 7 0

    Design 40 to 50 % w/w 7 0Slurry throughput 250 t/h 6 0Slurry flowrate 187 m/h 6 0

    4.4 Water return pumpType Vertical Spindle 5 0Arrangement Duty/Standby 4 0

    'The Tailings Storage Facility (TSF) Reclaim Area is to directly feed the Las Lagunas Process Plant. This Area consists of a diesel powered, piloted Dredge unit, complete with 3-D control.

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  • 5.0 AREA 15 - GRINDING

    Description Value Unit Ref. Rev.

    5.1 Area design solids throughput 800,000 t/a 1 0

    5.2 Circuit type Ball mill 1 0Classification type Cyclones 1 0

    5.3 Comminution feed parametersSolids feed rate 100 t/h 1 0

    F80 80 m 1 0

    5.4 Mill product tank Tank type Agitated, variable level, open 4 0Flowrate 187 m/h 6 0Number of tanks 1 1 0Residence time 72 min 6 0Tank volume 223 m 4 0Tank diameter 6.6 m 4 0Tank height (including freeboard) 7.1 m 4 0Tank freeboard 0.5 m 4 0

    5.5 Grinding feed pumpsType Centrifugal slurry 3 0Arrangement Duty 4 0Details Gland seal water requirements 35 L/min 3 0

    300 kPa 3 1

    5.6 Ball millType O/F trommel 4 0Operation Closed circuit 4 0Mill dimensions Diameter 3.05 m 3 0

    EGL 4.88 m 3 0Installed power 700 kW 3 0Specific energy requirements kW per tonne - new feed ex cyclone U/F 19.3 kWh/t 1 0Grinding media type Steel ball, 750 HB 7 0Grinding media consumption 1.0 kg/t 1 0Grinding media make-up size Diameter 40 mm 3 0Mill maximum grinding media charge 34 % v/v 3 0Mill drive Fixed - 3 0Mill speed 75 % Crit. 3 0

    18.1 RPM 6 0Mill Discharge % Solids Design 72 % w/w 7 0

    5.7 Mill discharge hopper design Design - residence time 1 min 7 0Design - volume 6.7 m 6 0

    5.8 Mill discharge pumpsType Centrifugal slurry 3 0Arrangement Duty 4 0Details Gland seal water requirements 48 L/min 3 0

    430 kPag 3 0

    5.9 ClassificationType Cyclone - Multotec VV100 3 0Solids feed rate 350.2 t/h 6 0Feed % solids Design 56.1 % w/w 6 0Slurry flowrate 403 m/h 6 0Feed pressure Design 150 kPag 3 0Cyclone diameter 100 mm 3 0Operating units 20 3 0Standby units 4 3 0Circulating load Design - % of new feed to underflow 250 % 1 0Overflow P80 38 m 8 0Underflow slurry percent solids 74.0 % w/w 1 0Overflow slurry percent solids 35.0 % w/w 1 0

    The reclaimed tailings is recieved by the Grinding Area as a slurry. This slurry reports to the agitated Mill Surge Tank. Slurry is pumped from here to the Mill Discharge Hopper. The milling circuit consists of a ball mill operating in closed circuit with classifying cyclones. The cyclone overflow reports to the Flotation Area. The Mill Discharge Hopper receives both the new slurry and the ball mill discharge stream. This material is pumped directly to the classification cyclones.

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  • 6.0 AREA 20 - FLOTATION

    Description Value Unit Ref. Rev.

    6.1 Area design solids throughput 800,000 t/a 1 0

    6.2 Trash screenType Upwards inclined vibrating 4 0Screen dimensions 1.53 x 4.88 m 3 0Trash screen aperture Slotted 0.63 x 8.8 mm 4 0Details Spray water requirements 20 m/h 3 0

    6.3 Flotation feed samplerType Primary cross cut / Secondary vezin 4 0Details Slurry capacity 245 m/h 6 2

    6.4 Flotation feed pumpsType Centrifugal slurry 3 0Arrangement Duty 4 0Details Gland seal water requirements 35 L/min 3 0

    341 kPa 3 1

    6.5 Flotation conditioning tank Tank type Agitated, overflow, open 4 0Number of tanks 2 1 0Residence time Each 10 min 6 0Tank volume Each 43.1 m 6 0Tank diameter 3.8 m 6 0Tank height 4.8 m 6 0Tank freeboard 1.0 m 4 0Height step between adjacent tanks 0.4 m 4 0

    6.6 Flotation cellsCell type Self aspirated 4 0Solids feed rate Design 100 t/h 1 0Slurry percent solids 32.5 % w/w 6 0Flowrate 247 m/h 6 0Average flowrate 200 m/h 6 0No. cells 5 3 0Tank volume Each 40.0 m 3 0Height step between adjacent cells 0.4 m 3 0Cell volume % air Design 15 % v/v 3 0

    6.7 Flotation dataScale-up Factor Design 2.3 4 0Flotation residence time Laboratory 23.0 min 1 0

    Continuous - Design 52.9 min 6 0Actual 60.0 min 6 0

    Mass pull to concentrate Design - % feed solids to conc. 28.0 % 1 0Design - solids to conc. 28.0 t/h 6 0

    Concentrate recovery Gold recovery Design - % Au in float feed 83.0 % 1 0 Silver recovery Design - % Ag in float feed 80.0 % 1 0 Sulphide recovery Design - % S2- in float feed 96.0 % 1 0Concentrate launder water flowrate 10.0 m/h 4 0Concentrate slurry percent solids - ex water addition 23.0 % w/w 6 0

    6.8 Flotation hopper design Flotation concentrate hopper Design - residence time 3 min 6 0

    Design - volume 10.5 m 7 0Flotation concentrate hopper Design - residence time 6 min 6 0

    Design - volume 10.5 m 7 0Flotation tails hopper Design - residence time 4 min 6 0

    Design - volume 10.5 m 7 0

    6.9 Flotation concentrate pumpType Centrifugal slurry 3 0Volumetric froth factor 2.5 7 0Arrangement Duty 4 0Details Gland seal water requirements 35 L/min 3 0

    420 kPag 3 0

    The Flotation Area receives cyclone overflow from the grinding area. This stream gravitates to the Mill Product Tank. This slurry is then fed via the duty operating Flotation Feed Pump to the first of two conditioning tanks. The flotation circuit consists of five flotation cells. A bulk concentrate is collected and reports to the Flotation Concentrate Hopper. This stream is then pumped to concentrate regrind. Conversely, the flotation tailings stream is pumped to the Final Tails Hopper.

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  • 6.0 AREA 20 - FLOTATION (CONTINUED)

    Description Value Unit Ref. Rev.

    6.10 Flotation tails pumpsType Centrifugal slurry 3 0No. stages 2 3 1Arrangement Duty / standby 4 0Details Gland seal water requirements - each 35 (1) and 35 (2) L/min 3 1

    590 (1) and 1090 (2) kPag 3 1

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  • 7.0 AREA 25 - CONCENTRATE REGRIND

    Description Value Unit Ref. Rev.

    7.1 Area design solids throughput 224,000 t/a 1 0

    7.2 Circuit type Ultrafine grinding mill 2 0Classification type Cyclones 2 0

    7.3 Concentrate regrind feed parametersSolids feed rate New solids - flotation concentrate 28.0 t/h 2 0

    7.4 Concentrate regrind surge tank Tank type Agitated, variable level 4 0Solids feed rate Design - total 84.0 t/h 6 0Flowrate 223 m/h 6 0Total residence time 60 min 6 0Tank volume Each 223 m 4 0Tank diameter 6.6 m 6 0Tank height (including freeboard) 7.1 m 6 0Tank freeboard 0.5 m 4 0

    7.5 Concentrate cyclone feed pumpType Centrifugal slurry 3 0Arrangement Duty 4 0Details Gland seal water requirements 35 L/min 3 0

    491 kPa 3 0

    7.6 ClassificationType Cyclone - Krebs gMAX 6 3 0Solids feed rate 84.0 t/h 6 0Feed % solids Design 30.0 % w/w 6 0Slurry flowrate 225 m/h 6 0Feed pressure Design 90 kPa 3 0Cyclone diameter 150 mm 3 0Vortex finder 50 mm 3 0Spigot 50 mm 5 0Operating units 7 3 0Standby units 1 3 0Circulating load Design 200 % 3 0Overflow P80 11.9 m 8 0Underflow density 45.0 % w/w 3 0Overflow density 18.0 % w/w 3 0

    7.7 Concentrate regrind feed hopper designHopper details Design - residence time 1 min 7 0

    Design - volume 3.0 m 6 0

    7.8 Concentrate regrind feed pumpType Centrifugal slurry 3 0Arrangement Duty 4 0Details Gland seal water requirements 28 L/min 3 0

    435 kPag 3 0

    7.9 Concentrate regrind mill - Ultrafine grinding millType IsaMill - M3000 2 0Operation Closed circuit 2 0Installed power 1,500 kW 3 0Specific energy requirements kW per tonne new feed 65 kWh/t 3 0Grinding media type Ceramic MT1 3 0Grinding media consumption g per kWh 15 g/kWh 3 0Grinding media make-up size Design - diameter 2.5 mm 3 2Mill grinding media charge Design - volume 70 % v/v 3 0Mill Discharge % Solids Design 45 % w/w 3 0Mill product sizing P80 11.9 m 2 0Maximum slurry temperature 65 C 3 0Details Gland seal water requirements 2.0 m/h 3 0

    600 kPa 3 0Flush water requirements 3.5 m/h 3 0

    600 kPag 3 0

    The concetrate regrind circuit consists of an IsaMill (Concetrate Regrind Mill) operating in closed circuit with classifying cyclones. The flotation froth concentrate slurry is pumped to the to the agitated Concentrate Regrind Surge Tank. This tank additionally receives the Concentrate Regrind Mill product. The slurry contents of this tank is then pumped to the Concentrate Cyclone Cluster for classification. The Concentrate Cyclone overflow stream reports to the Concentrate Thickener and the underflow stream gravitates into the Concentrate Regrind Feed Hopper. The latter stream is then pumped to the Concentrate Regrind Mill.

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  • 7.0 AREA 25 - CONCENTRATE REGRIND (CONTINUED)

    Description Value Unit Ref. Rev.

    7.10 Ground concentrate samplerType Primary cross cut / Secondary vezin 4 0Details Slurry capacity 138 m/h 6 0

    7.11 Concentrate thickener Type High rate thickener 3 0Solids feed rate 28.0 t/h 6 0Concentrate thickener feed percent solids 18.0 % w/w 6 0Concentrate thickener feed slurry density 1.13 t/m 6 0Nominal concentrate thickener feed flowrate 138 m/h 6 0Concentrate residue settling rate 0.25 t/m.h 8 0Thickener area reqirements 112 m 6 0Thickener diameter Calculated 11.9 m 6 0

    Actual 12 m 3 0Thickened underflow Percent solids - Maximum 49 % w/w 3 0

    Percent solids - Design 28 % w/w 3 0Thickener overflow percent solids 0.02 % w/w 7 0Thickener flocculant dosage 100 g/t 8 0

    7.12 Albion leach feed pumpType Centrifugal slurry 3 0Arrangement Duty 4 0Details Gland seal water requirements 28 L/min 3 0

    374 kPag 3 0

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  • 8.0 AREA 30 - ALBION LEACH

    Description Value Unit Ref. Rev.

    8.1 Albion leach feed characteristics Solids feed rate 28.0 t/h 6 0Feed slurry percent solids 27.5 % w/w 6 0Feed slurry density 1.22 t/m 6 0Feed slurry temperature 42 C 6 0Nominal slurry flowrate 83 m/h 6 0Nominal S2- grade 16.9 % 6 0

    8.2 Albion leach tanks Tank type Agitated, overflow, covered 4 0Total residence time Design 30 h 2 0No. tanks 5 2 0Assumed gas hold-up 5.0 % v/v 2 0Tank volume Average 599 m 2 0Tank diameter 8.8 m 2 0Tank aspect ratio Height : diameter 1.1 2 0Tank Height 11.0 m 2 0Tank freeboard Minimum 1.0 m 2 0Height step between adjacent tanks 0.3 m 4 0

    8.3 Albion leach parametersSlurry requirement Slurry percent solids Maximum - per tank 35 % w/w 2 0Oxygen requirement Design addition rate Design - utilisation, % stoichiometric 80 % 2 0

    Design - per tonne of leach feed 285 kg/t 6 0Design - specific addition rate 7,990 kg/h O2 6 0

    Oxygen supply stream details Oxygen stream purity 93 % O2 3 0 Oxygen supply stream throughput 8,591 kg/h 6 0 Oxygen supply stream temperature 40 C 3 0 Oxygen supply stream pressure 600 kPag 3 0 Oxygen supply stream flowrate 6,635 Nm/h 6 0

    1,003 Am/h 6 0Oxygen addition details 2 0 Oxygen stream addition per tank 1,718 kg/h 6 0

    1,327 Nm/h 6 0 Addition method / model Sparge / HPOS-650-7.5 2 1 Flowrate per point Design - Nm/h per sparger 147 Nm/h 2 0 Sparger Arrangement Total 60 2 1

    Duty - per tank 9 2 1Standby - per tank 3 2 1

    Limestone requirement Design addition rate Design - utilisation, % stoichiometric 85 % 2 0

    Design - per tonne of leach feed 409 kg/t 6 0Design - specific addition rate 11.5 t/h 6 0

    Limestone slurry percent solids 40 % w/w 4 0 Limestone slurry volume 21.2 m/h 6 0Off-gas details Gas water saturation Design 90 % 2 0

    8.4 Tank design operating details Tank 1 design - temperature, C / slurry pH >80 / 5.5 C / pH 2 0 Tank 2 design - temperature, C / slurry pH 97 / 5.5 C / pH 2 0 Tank 3 design - temperature, C / slurry pH 97 / 5.5 C / pH 2 0 Tank 4 design - temperature, C / slurry pH 97 / 5.5 C / pH 2 0 Tank 5 design - temperature, C / slurry pH 97 / 5.5 C / pH 2 0

    The Albion Leach Area comprises of 5 leach tanks. Each tank is sparged with oxygen and dosed with limestone slurry to control slurry pH. Each leach tank overflows into the next sequential tank, hence progressively gravitating through the leach train. The resultant oxidised slurry is cooled via slurry cooling towers before being pumped to the CIL Area for neutralisation.

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  • 8.0 AREA 30 - ALBION LEACH (CONTINUED)

    Description Value Unit Ref. Rev.

    8.5 Albion leach chemistry - Major species onlyPyrite oxidation: 4FeS2 + 15O2 + 2H2O = 2Fe2(SO4)3 + 2H2SO4 (1a) 2 0 4FeS2 + 3O2 + 6H2SO4 = 2Fe2(SO4)3 + 8S + 6H2O (1b) 2 0Oxidation of other sulphide minerals: ZnS + 2O2 = ZnSO4 (2a) 2 0 2ZnS + O2 + 2H2SO4 = 2ZnSO4 + 2S + 2H2O (2b) 2 0 PbS + 2O2 = PbSO4 (2c) 2 0 2PbS + O2 + 2H2SO4 = 2PbSO4 + 2S + 2H2O (2d) 2 0 CuFeS2 + 4O2 = FeSO4 + CuSO4 (2e) 2 0 CuFeS2 + O2 + 2H2SO4 = CuSO4 + FeSO4 + 2S + 2H2O (2f) 2 0 2FeAsS + 7O2 + H2SO4 + 2H2O = Fe2(SO4)3 + 2H3AsO4 (2g) 2 0 4FeAsS + 7O2 + 4H2SO4 + 2H2O = 4FeSO4 + 4S + 4H3AsO4 (2h) 2 0Subsequent oxidation of reaction products: 4FeSO4 + O2 + 2H2SO4 = 2Fe2(SO4)3 + 2H2O (3a) 2 0 Fe2(SO4)3 + 4H2O = 2FeOOH + 3H2SO4 (3b) 2 0 CuSO4 + CaCO3 = CuCO3 + CaSO4 (3c) 2 0 ZnSO4 + CaCO3 = ZnCO3 + CaSO4 (3d) 2 0Acid consumption - pH control: H2SO4 + CaCO3 + H2O = CaSO4 + 2H2O + CO2 (4a) 2 0 CaSO4 + 2H2O = CaSO4.2H2O (4b) 2 0

    8.6 Albion leach operating detailsExtent of overall Albion reactions- Sulphide species Total pyrite oxidation Design - % of Albion feed 77.0 % 2 0 Reaction - (1a) Design - % of Albion feed 75.4 % 2 0 Reaction - (1b) Design - % of Albion feed 1.6 % 2 0 Total sphalerite oxidation Design - % of Albion feed 20.0 % 2 0 Reaction - (2a) Design - % of ZnS in Albion feed 1.0 % 2 0 Reaction - (2b) Design - % of ZnS in Albion feed 19.0 % 2 0 Total galena oxidation Design - % of Albion feed 20.0 % 2 0 Reaction - (2c) Design - % of PbS in Albion feed 1.0 % 2 0 Reaction - (2d) Design - % of PbS in Albion feed 19.0 % 2 0 Total chalcopyrite oxidation Design - % of Albion feed 2.5 % 2 0 Reaction - (2e) Design - % of CuFeS2 in Albion feed 0.1 % 2 0 Reaction - (2f) Design - % of CuFeS2 in Albion feed 2.4 % 2 0 Total arsenopyrite oxidation Design - % of Albion feed 50.0 % 2 0 Reaction - (2g) Design - % of FeAsS in Albion feed 17.5 % 2 0 Reaction - (2h) Design - % of FeAsS in Albion feed 32.5 % 2 0- Other Reaction - (3a) Design - % conversion >99% % 2 0 Reaction - (3b) Design - % conversion >99% % 2 0 Reaction - (3c) Design - % conversion >99% % 2 0 Reaction - (3d) Design - % conversion >99% % 2 0 Reaction - (4a) Design - % conversion >99% % 2 0 Reaction - (4b) Design - % conversion >99% % 2 0

    8.7 Albion leach product characteristics Leach products solids throughput rate 45.4 t/h 6 0Leach product slurry percent solids 35.0 % w/w 6 0Leach product slurry density 1.24 t/m 6 0Nominal slurry flowrate 104.8 m/h 6 0Nominal Au grade 6.9 ppm Au 6 0Nominal Ag grade 68.0 ppm Ag 6 0

    8.8 Albion product tank Tank type Covered, variable level 2 0Tank diameter 1.50 m 4 0Tank aspect ratio Height : diameter 6 4 0Tank height 9.0 m 4 0Tank freeboard 0.9 m 4 0Tank volume 14 m 4 0Residence time Maximum 8 min 4 0

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  • 8.0 AREA 30 - ALBION LEACH (CONTINUED)

    Description Value Unit Ref. Rev.

    8.9 Cooling tower feed pumpsType Centrifugal slurry 3 0Arrangement Duty / standby 4 0Details Gland seal water requirements 35 L/min 3 0

    587 kPag 3 0

    8.10 Slurry cooling towersType Slurry spray tower 2 0Materials of construction Spray nozzles Ceramic 3 0

    Housing FRP 3 0Number of towers 1 3 0Slurry feed temperature Design 97 C 3 0

    Design 45 C 3 0Solids feed rate 45.4 t/h 6 0Feed percent solids 34.5 % w/w 6 0Feed slurry density 1.23 t/m 6 0Nominal feed flowrate 107 m/h 6 0Feed pressure Design 250 kPag 3 0Heat capacity of slurry 4,219 J/(kg.K) 8 0Feed solids size distribution

    D98 38 m 2 0D80 19 m 2 0D50 9 m 2 0

    Associated solution loss Nominal 7.4 t/h 2 0

    8.11 Cooling tower product hopper designHopper details Design - residence time 2.0 min 4 0

    Design - volume 3.2 m 6 0

    8.12 Neutralisation feed pumpsType Centrifugal slurry 3 0Arrangement Duty 4 0Details Gland seal water requirements 35 L/min 3 0

    331 kPag 3 0

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  • 9.0 AREA 40 - CARBON IN LEACH

    Description Value Unit Ref. Rev.

    9.1 Neutralisation parametersSolids feed rate 45.7 t/h 6 0Feed slurry percent solids 35.8 % w/w 6 0Feed slurry density 1.28 t/m 6 0Nominal flowrate 100 m/h 6 0Lime addition rate kg lime per tonne of feed solids 5.5 kg/t 8 0

    251 kg/h 6 0Lime slurry percent solids 20 % w/w 4 0Lime slurry volume flowrate 1.11 m/h 6 0Slurry pH Design 10.5 8 0

    9.2 Neutralisation tank Tank type Agitated, overflow, open 4 0Total residence time 5 h 1 0Number of tanks 1 1 0Tank volume 496 m 6 0Tank diameter 8.2 m 6 0Tank height 10.4 m 6 0Tank freeboard 1.0 m 4 0

    9.3 Carbon in leach tanks Tank type Agitated, overflow, open 4 0Total residence time 26 h 1 0Number of tanks 6 1 0Tank volume Average 441 m 6 0Tank diameter 8.2 m 6 0Tank height Average 8.4 m 6 0Tank freeboard Minimum 1.0 m 4 0Height step between adjacent tanks 0.3 m 4 0

    9.4 Carbon in leach parametersSolids feed rate 46.0 t/h 6 0Leach feed percent solids 35.2 % w/w 6 0Leach feed slurry density 1.27 t/m 6 0Nominal flowrate 102.4 m/h 6 0Nominal feed grade Gold Design 6.78 g/t 6 0 Silver Design 67.2 g/t 6 0Leach metal extraction Gold % of Au in CIL feed 84.0 % 8 0 Silver % of Ag in CIL feed 78.0 % 8 0CIL initial free NaCN concentration (CN- titratable) 500 ppm 8 0CIL maintained free NaCN concentration (CN- titratable) 300 ppm 8 0CIL NaCN consumption kg NaCN per tonne of CIL feed solids 1.28 kg/t 8 2Specific oxygen addition rate 83 kg/h O2 8 0Oxygen stream purity 93 % O2 3 0Oxygen stream throughput 89 kg/h 6 0Oxygen stream flowrate 69 Nm/h 6 0Oxygen stream entry pressure Approximate 600 kPag 3 0Oxygen stream flowrate Approximate 10 Am/h 6 0Method of oxygen addition Sparge 1 0

    9.5 CIL carbon parametersCIL carbon concentration 30 g/l 1 0Loaded carbon loadings Gold Design 910 g/t 6 0 Silver Design 7,112 g/t 6 0Stripped carbon loadings Gold Design 50 g/t 4 0 Silver Design 300 g/t 4 0

    The CIL Area comprises of one neutralisation tank and 6 Carbon-in-Leach (CIL) tanks. This area receives the cooled slurry product owing from the cooling towers. This slurry is raised to a slurry pH suitable for cyanide leaching through the addition of lime within the Neutralisation Tank. Cyanide solution is added to the first CIL Tank. Additionally, oxygen is sparged to each of the six CIL tanks. For the last five CIL tanks, carbon slurry is advanced by the use of airlifts in a flow pattern that is counter current to the main slurry flow. Conversely, loaded carbon is extracted from the first CIL tank and is screened and washed prior to proceeding to Elution Area.

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  • 9.0 AREA 40 - CARBON IN LEACH (CONTINUED)

    Description Value Unit Ref. Rev.

    9.6 Carbon handling Intertank carbon transfer - CIL tank No. 2 through No. 6 Transfer time Design 12.0 h/day 1 0 Intertank carbon transfer method Air lift 1 0 Carbon batch size 7,000 kg/strip 4 0 Nominal flowrate 19.4 m/h 6 0Loaded carbon recovery - CIL tank No. 1 Transfer time Design 2.0 h/day 4 0 Removal method Recessed impeller pump 4 0 Carbon batch size 7,000 kg/strip 4 0 Nominal flowrate 116.7 m/h 6 0

    9.7 Carbon recovery screenType Upwards inclined vibrating 4 0Screen dimensions 1.22 x 4.27 m 3 0Trash screen aperture Slotted 0.8 x 8.8 mm 4 0Details Spray water requirements 20 m/h 3 0

    9.8 Interstage carbon screensType Mechanically swept 4 0Screen area 6 m 3 0Trash screen aperture 0.8 mm 4 0

    9.9 CIL tailings propertiesSolids throughput 45.7 t/h 6 0Leach feed percent solids 33.8 % w/w 6 0Leach feed slurry density 1.26 t/m 6 0Nominal flowrate 107.4 m/h 6 0CIL residue grade Gold Design 1.09 g/t 6 0 Silver Design 14.9 g/t 6 0CIL solution loss Gold Design 0.01 ppm 4 0 Silver Extracted Ag adsorbed by carbon 90 % 4 0

    Design 2.7 ppm 6 0

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  • 10.0 AREA 42 - ELUTION

    Description Value Unit Ref. Rev.

    10.1 Elution circuit detailsMethod AARL 4 0Nominal mass of metal extracted Gold 6,021 g/strip 6 0 Silver 47,683 g/strip 6 0Carbon strip batch size 7,000 kg/strip 4 0Number of strips per week 7 strip/week 1 0Mass of carbon stripped per week 49 t/week 6 0Elution column carbon batch capacity 7 t 4 0Carbon bulk density Design 0.45 t/m 4 0

    10.2 Acid wash column detailsVessel construction Carbon steel, butyl rubber lined 4 0Acid wash column capacity requirements 15.6 m3 6 0Column aspect ratio Height : diameter 6.0 4 0Acid wash column dimensions Diameter Outer 1.524 m 6 0

    Inner 1.488 m 6 0 Height Total - end to end 9.859 m 6 0

    Inner - end to end 9.835 m 6 0Live - excluding freeboard 9.335 m 4 0

    Freeboard Design 0.500 m 4 0Column volume Total 16.5 m3 6 0 Live 15.6 m3 6 0

    10.3 Acid wash operating parametersBed volume (BV) 15.6 m3 4 0Treatment solution flow rate 2.0 BV/h 4 0

    31.1 m3/hr 4 0Superficial upflow velocity 47.8 mm/s 4 0

    10.4 AARL acid wash conditionsSolution flowrate 2.0 BV/h 4 0

    31.1 m3/hr 6 0Stage 1: Acid washAcid wash HCl concentration 3 % HCl 4 0Acid wash HCl solution density 1,013 kg/m 4 0Acid wash time 20 min 4 0Acid wash volume 10.4 m 6 0Acid wash temperature Ambient C 4 0Acid wash pressure Ambient kPa 4 0Acid HCl consumption (32% w/w HCl) 985 kg/strip 6 0

    850 L/strip 6 0Effluent solution destination Tailings 4 0Step 2: Water washWater wash time 120 min 4 0Water wash volume 62.22 m 6 0Water wash temperature Ambient C 4 0Water wash pressure Ambient kPa 4 0Effluent solution destination Tailings 4 0Step 3: Carbon transferApproximate transfer time 60 min 4 0Transfer water requirements 39.7 t 6 0

    39.7 t/h 6 039.7 m/h 6 0

    Carbon slurry % solids Average 15 % w/w 4 0Total acid wash time (excluding loading) 200 min 4 0

    3.3 h 4 0

    The elution circuit assumes a split AARL design.

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  • 10.0 AREA 42 - ELUTION (CONTINUED)

    Description Value Unit Ref. Rev.

    10.5 Elution column detailsVessel construction SS 316 4 0Elution column capacity requirements 15.6 m3 6 0Column aspect ratio Height : diameter 6.0 4 0Elution column dimensions Diameter Outer 1.524 m 6 0

    Inner 1.500 m 6 0 Height Total - end to end 9.717 m 6 0

    Inner - end to end 9.693 m 6 0Live - excluding freeboard 9.193 m 4 0

    Freeboard Design 0.500 m 4 0Column volume Total 16.5 m3 6 0 Live 15.6 m3 6 0

    10.6 Elution operating parametersBed volume (BV) 15.6 m3 4 0Treatment solution flow rate 2.0 BV/h 4 0

    31.1 m3/hr 4 0Superficial upflow velocity 48.2 mm/s 4 0Loaded carbon loadings Gold Design 910 g/t 6 0 Silver Design 7,112 g/t 6 0Stripped carbon loadings Gold Design 50 g/t 1 0 Silver Design 300 g/t 1 0

    10.7 Elution water tank Tank type Fixed level, open 4 0Tank volume 78.1 m 6 0Tank diameter 4.6 m 6 0Tank height (including freeboard) 5.1 m 6 0Tank freeboard 0.4 m 4 0

    10.8 Starter solution tank Tank type Variable level, covered 4 0Tank volume 21.2 m 6 0Tank diameter 3.0 m 6 0Tank height (including freeboard) 3.4 m 6 0Tank freeboard 0.4 m 4 0

    10.9 Weak electrolyte tank Tank type Variable level, covered 4 0Tank volume 78.1 m 6 0Tank diameter 4.6 m 6 0Tank height (including freeboard) 5.1 m 6 0Tank freeboard 0.4 m 4 0

    10.10 Elution heaterHeating method Indirect - thermal oil 4 0Number of units 1 4 0Fuel type Diesel 3 0Fuel consumption 605 L/strip 3 1Thermal output Maximum 2,500 kW 3 0

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  • 10.0 AREA 42 - ELUTION (CONTINUED)

    Description Value Unit Ref. Rev.

    10.11 AARL elution conditionsSolution flowrate 2.0 BV/h 4 0

    31.1 m3/hr 6 0Stage 1: Cold cyanide stripSolution NaCN concentration 3 % NaCN 4 0Solution density 1,014 kg/m 4 0Cold cyanide strip time 20 min 4 0Cold cyanide strip volume 10.4 m 6 0Cold cyanide strip temperature Ambient C 4 0Cold cyanide strip pressure Ambient kPa 4 0Cyanide consumption (NaCN solid) 315.4 kg/strip 6 0Cyanide consumption (20% w/w NaCN) 1,577 kg/strip 6 0

    1,451 L/strip 6 0Effluent solution destination Cyanide detoxification 4 0Step 2: Water rinseWater rinse time 60 min 4 0Water rinse volume 31.1 m 6 0Water rinse temperature Ambient C 4 0Water rinse pressure Ambient kPa 4 0Effluent rinse destination Cyanide detoxification 4 0Step 1: PresoakSolution NaOH concentration 3 % NaOH 4 0Solution NaCN concentration 3 % NaCN 4 0Solution density 1,046 kg/m 4 0Total solution requirements 14.0 m 6 0Hot elution cycle time Minimum 20 min 4 0

    Design 27 min 4 0Hot elution cycle volume Design 14.0 m 6 0Hot elution solution temperature >90 C 4 0Hot elution solution pressure 350 kPa 4 0Caustic consumption (50% w/w NaOH) 879 kg/strip 6 0

    575 L/strip 6 0Cyanide consumption (NaCN solid) 439.5 kg/strip 6 0Cyanide consumption (20% w/w NaCN) 2,197 kg/strip 6 0

    2,021 L/strip 6 0Antiscalant addition Design 15 mL/min 4 0Effluent solution destination Recirculates until 110C, then to Electrolyte Tank 4 0Step 4: Weak electrolyte elutionWeak electrolyte elution cycle time 110 min 4 0Weak electrolyte elution cycle volume 57.0 m 6 0Weak electrolyte elution solution temperature 130 C 4 0Weak electrolyte elution solution pressure 350 kPa 4 0Antiscalant addition Design 15 mL/min 4 0Effluent solution destination Electrolyte Tank 4 0Step 5: Water elutionWater elution cycle time 90 min 4 0Water elution cycle volume 46.67 m 6 0Water elution solution temperature 130 C 4 0Water elution solution pressure 350 kPa 4 0Antiscalant addition Design 15 mL/min 4 0Effluent solution destination Weak Electrolyte Tank 4 0Step 6: Cool downCool down elution cycle time 20 min 4 0Cool down elution cycle volume 10.4 m 6 0Cool down elution cycle final solution temperature Ambient C 4 0Cool down elution solution pressure 350 kPa 4 0Antiscalant addition Design 15 mL/min 4 0Effluent solution destination Weak Electrolyte TankStep 7: Carbon transferApproximate transfer time 60 min 4 0Transfer water requirements 39.7 t 6 0

    39.7 t/h 6 039.7 m/h 6 0

    Carbon slurry % solids Average 15 % w/w 4 0Total elution time (excludes time assoicated with loading and presoak recirc.) 6.5 h 4 0Total volume to cyanide detoxification tank 41.5 m 4 0Total presoak volume 14.0 m 4 0Total volume to eluate tank 71.0 m 4 0Total volume to weak electrolyte tank 57.0 m 4 0

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  • 11.0 AREA 44 - ELECTROWINNING AND SMELTING

    Description Value Unit Ref. Rev.

    11.1 Electrowinning design dataThroughput 71.0 m/strip 6 0

    71.6 t/strip 6 04.6 BV/strip 6 0

    No. batches treated per week 7.0 batch/week 1 0Pregnant eluate solution SG 1.01 6 0Pregnant eluate (or electrolyte) nominal metal concentration Gold Design 86 ppm 6 0 Silver Design 678 ppm 6 0Barren electrolyte nominal metal concentration Gold Design 5 ppm 3 0 Silver Design 10 ppm 3 0

    11.2 Electrolyte tank Tank type Agitated, variable level, covered 4 0Tank volume 100.1 m 6 0Tank diameter 5.0 m 6 0Tank height (including freeboard) 5.5 m 6 0Tank freeboard 0.4 m 4 0

    11.3 Electrolyte return tank Tank type Constant level, covered 4 0Tank volume 1.4 m 6 0Tank diameter 1.2 m 6 0Tank height (including freeboard) 1.6 m 6 0Tank freeboard 0.4 m 4 0

    11.4 Electrowinning cellsCell type Sludge 4 0Materials of Construction Polypropylene 3 0Number of electrowinning cells 4 3 0Cathode details Construction type SS stocking 3 0 Number per cell 12 3 0 Area Each 0.56 m 3 0Anode details Construction type SS 316 mesh 3 0 Number per cell 13 3 0 Area Each 0.56 m 3 0Flow rate per cell 18 m/h 3 0Total electrolyte solution circulation flowrate 72 m/h 6 0Electrolyte circulation time 20 h/strip 3 0Rectifier Capacity Each - per cell 0 - 10 V DC 3 0 0 - 1500 A 3 0

    11.5 Cathode treatmentType Wash / filter / retort / smelt 4 1Sludge contained metal Gold Design 5.8 kg/batch 6 0 Silver Design 47.8 kg/batch 6 0

    11.6 Mercury retortType Retort furnace / condensor / separator 3 1Details Electric fired, 41 kW 3 1Volume 0.2 m 3 1Requirements Chilled Water (< 21 deg. C.) 4.0 m/h 3 1

    11.7 Smeting dataQuantity of pours per week Design 3 per week 4 0Mould arrangement 5 x 1000 oz (Carousel)Flux requirements - Total 31.2 kg/pour 7 0Flux Recipe - Example Silica Flour 1 parts 7 0 Borax 2 parts 7 0 Sodium Nitrate 1 parts 7 0

    Pregnant eluate from each elution cycle is transferred to the Electrolyte Tank. This solution becomes theelectolyte to be circulated through the electrowinning cells for approximately 20 hours. At the completion ofelectrowinning the spent electrolyte solution is returned to the CIL circuit.

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  • 11.0 AREA 44 - ELECTROWINNING AND SMELTING (CONTINUED)

    Description Value Unit Ref. Rev.

    11.8 Smelting furnace . Type Crucible 3 0

    Number of units 1 3 0Capacity A300 (300 kg Brass) 3 0Fuel type Diesel 3 0Fuel consumption 20 l/h 3 0Thermal output Maximum 190 kW 3 0

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  • 12.0 AREA 46 - CARBON REGENERATION

    Description Value Unit Ref. Rev.

    12.1 Carbon movementCarbon strip batch size 7,000 kg/batch 1 0Number of batches per week Maximum 7 batch/week 1 0Mass of carbon stripped per week 49 t/week 1 0

    12.2 Carbon regeneration parametersCarbon feed rate Design - dry 450 kg/h 3 0Operating hours per day 15.6 h/batch 6 0Regeneration temperature 650 to 700 oC 4 0Residence time Design 20 min 4 0

    12.3 Regeneration kilnType of kiln Horizontal 4 0Number of units 1 4 0Feed method Variable speed screw feeder 3 0Fuel type Diesel 3 0Fuel consumption Design 52 l/h 3 0Thermal output Maximum 750 kW 3 0Details Cooling water requirements 1.0 m/h 3 0

    12.4 Carbon sizing screenType Vibrating 3 0Trash screen aperture 0.8 mm 3 0

    Eluted carbon from the elution column will be transferred to the carbon regeneration kiln for reactivation. Thecarbon will be passed over a dewatering screen to remove free moisture before progressing to the kiln feedhopper. The carbon will be fed by screw feeder into the diesel fired rotary horizontal kiln at a temperature of 650to 700 deg. C. The carbon will have a nominal residence time of 20 minutes at this elevated temperature. Thecarbon will then be discharged onto a a small vibrating screen for quenching and classification beforedischarging into the final CIL tank.

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  • 13.0 AREA 50 - CYANIDE DETOXIFICATION

    Description Value Unit Ref. Rev.

    13.1 Cyanide detoxification feed characteristics Solids feed rate 45.7 t/h 6 0Feed slurry percent solids 32.5 % w/w 6 0Feed slurry density 1.25 t/m 6 0Nominal flowrate 112.5 m/h 6 0Free NaCN concentration (titratable CN-) 25 CNFREE 8 2WAD cyanide concentration 200 CNWAD 8 2

    13.2 Cyanide detoxification tanks Tank type Agitated, overflow, open 4 0Number of tanks 1 4 0Slurry residence time Design 2.5 h 8 0Air hold-up volume Design 15 % v/v 4 0Tank volume Each 331 m 6 0Tank diameter 7.5 m 6 0Tank aspect ratio Height : diameter 1.0 4 0Tank height 8.6 m 6 0Tank freeboard 1.1 m 4 0

    13.3 Cyanide detoxification parametersMethod Air / SO2 8 0Slurry pH Design 8.0 8 0Lime addition rate kg Ca(OH)2 per kg of SO2 0.10 kg/kg 8 0

    kg Ca(OH)2 per kg of SMBS 0.07 kg/kg 8 0kg Ca(OH)2 per tonne of feed solids 0.2 kg/t 8 2kg Ca(OH)2 per hour 9 kg/h 8 2

    Lime slurry percent solids 20 % w/w 4 0Lime slurry volume flowrate 0.0 m/h 8 0Specific air addition rate Design - Nm/h per kg SMBS 9.00 8 2Air flowrate Design 3,000 Nm/h 6 0Air supply pressure 120 kPag 6 0Method of air addition Sparge ring 3 0Source of sulphur dioxide Sodium metabisulphite (SMBS) 1 0SMBS addition requirement Stoichiometry kg SMBS / kg CNWAD 3.7 8 0SMBS addition rate % of Stoichiometry 200 % 8 2

    kg SMBS per kg of CNWAD 7.300 8 2kg SMBS per hour 137 kg/h 6 2

    SMBS solution strength 20 % w/w 4 0SMBS solution dosage volume flowrate 0.6 m/h 6 2Copper sulphate addition rate g CuSO4 per tonne of feed solids 0.0 g/t 4 0

    0.0 kg/h 6 0Copper sulphate solution strength 20 % w/w 4 0Copper sulphate solution dosage volume flowrate 0.0 L/h 6 0

    13.4 Cyanide detoxification product characteristics Solids feed rate 45.7 t/h 6 0Feed slurry percent solids 32.3 % w/w 6 2Feed slurry density 1.24 t/m 6 2Nominal flowrate 114 m/h 6 2WAD cyanide concentration Design 2 CNWAD 8 0

    13.5 Carbon safety screenType Upwards inclined vibrating 4 0Screen dimensions 1.22 x 4.27 m 3 0Trash screen aperture Slotted 0.63 x 8.8 mm 4 0Details Spray water requirements 20 m/h 3 0

    13.6 Cold cyanide effluent tank Tank type Variable level, closed 4 0Tank volume 60 m 6 0Tank diameter 4.2 m 6 0Tank height (including freeboard) 4.7 m 6 0Tank freeboard 0.4 m 4 0

    The CIL discharge stream gravitates to the Cyanide Detoxification Area. The cyanide detoxification processutlilised for Las Lagunas is the air / SO2 process. Sodium metabisulphite solution (source of SO2), along with acatalyst solution of copper sulphate is added to the first reaction vessel. Additionally, lime slurry is dosed into thesystem to control slurry pH. Air is sparged into each of the reaction vessels.

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  • 13.0 AREA 50 - CYANIDE DETOXIFICATION (CONTINUED)

    Description Value Unit Ref. Rev.

    13.7 Cyanide detoxification product samplerType Primary cross cut / Secondary vezin 4 0Details Slurry capacity 114 m/h 6 2

    13.8 Final tails hopper Hopper Details Design - residence time 5 min 4 0

    Design - volume 10.5 m 6 0

    13.9 Tailings pumpsType Centrifugal slurry 3 0No. stages 2 3 1Arrangement Duty / standby 4 0Details Gland seal water requirements - each 35 (1) and 35 (2) L/min 3 1

    580 (1) and 1040 (2) kPag 3 1

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  • 14.0 AREA 55 - TAILINGS DISPOSAL

    Description Value Unit Ref. Rev.

    14.1 Area design solids throughput 946,400 t/a 1 0Solids feed rate Nominal total 118 t/h 6 0

    14.2 Flotation tailings samplerType Primary cross cut / Secondary vezin 4 0Details Slurry capacity 158 m/h 6 0

    14.3 Tailings cyclone feed pumpType Centrifugal slurry 3 0Arrangement Duty 4 0Details Gland seal water requirements 35 L/min 3 1

    460 kPa 3 1

    14.4 Classification - flotation tailingsType Cyclone - Multotec VV165 3 0Solids feed rate 72.6 t/h 6 0Feed % solids Design 35.6 % w/w 6 0Slurry flowrate 160 m/h 6 0Feed pressure Design 150 kPag 3 0Cyclone diameter 165 mm 3 0Operating units 8 3 0Standby units 2 3 0Percent of feed to underflow Design 35 % 8 0Overflow P80 13 m 8 0Underflow slurry percent solids 58 % w/w 8 1Overflow slurry percent solids 29 % w/w 8 1

    14.5 Tailings thickener Type High Rate Thickener 3 0Solids feed rate 92.7 t/h 6 2Concentrate thickener feed percent solids 26.4 % w/w 6 2Concentrate thickener feed slurry density 1.19 t/m 6 2Nominal concentrate thickener feed flowrate 295 m/h 6 2Thickener diameter Actual 27 m 3 0Thickened underflow Percent solids - Maximum 54 % w/w 3 0

    Percent solids - Design 53 % w/w 3 0Thickener overflow percent solids 0.05 % w/w 4 0Thickener flocculant dosage 60 g/t 8 0

    14.6 Rheological properties of thickened slurry Solids Content Range 54 % w/w 8 0 Yield stress 11 Pa 8 0Solids Content Range 53 % w/w 8 0 Yield stress 8 Pa 8 0

    14.7 Tailings disposal pumpsType Centrifugal slurry 3 0Arrangement Duty / standby 4 0Details Gland seal water requirements - each 28 L/min 3 1

    790 kPag 3 1

    14.8 Tailings dam wall feed pumpsType Centrifugal slurry 3 0Arrangement Duty / standby 4 0Details Gland seal water requirements - each 20 L/min 3 1

    540 kPag 3 1

    14.9 Tailings disposal hopper design Tailings cyclone feed hopper Design - residence time 4 min 4 0

    Design - volume 10.5 m 6 0Tailings dam wall feed hopper Design - residence time 7 min 4 2

    Design - volume 3.2 m 6 0

    The flotation tailings stream and the cyanide detoxification discharge stream are pumped seperately to the Tailings Disposal Area. The Flotation Tailings slurry is classified to obtain a coarse underflow stream. This slurry material is pumped used for building tailings dam containment (or wall) material. The cyclone overflow stream together with the the cyanide detoxification discharge stream is dewatered within a high rate thickener. The thickened slurry is then disposed of within a designated section (confined cell) of the tailings dam.

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  • 14.0 AREA 55 - TAILINGS DISPOSAL (CONTINUED)

    Description Value Unit Ref. Rev.

    14.10 Tailings thickener overflow tank designTank type Variable level 4 0Residence time 21 min 4 0Tank volume 52 m 6 0Tank diameter 4.0 m 6 0Tank height (including freeboard) 4.5 m 6 0Tank freeboard 0.4 m 4 0

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  • 15.0 AREA 60 / 62 / 66 - WATER SERVICES

    Description Value Unit Ref. Rev.

    AREA 60 - RAW WATER / GLAND SEAL WATER 15.1 Raw water - Supply

    Water source Magnetite pit - 4 2Supply Raw water supply pump 4 0Nominal withdrawal flowrate Raw water supply pump 76 m3/h 6 0Nominal operating time 16 h/d 4 2Availability 74 % 6 2

    15.2 Raw water detailsGeneral water quality parameters pH 7.5 8 0 Conductivity 1,467 S/cm 8 0 TDS (total dissolved solids) 652 mg/L 8 0 TSS (total suspended solids) 4 mg/L 8 0 Turbidity 6 FTU 8 0Major ion concentration - Anion SO4

    2- 595 mg/L 8 0 Cl- 21 mg/L 8 0 NO3

    - Not detected mg/L 8 0Major ion concentration - Cation Ca2+ 177 mg/L 8 0 Na+ 14 mg/L 8 0Alkalinity Total alkalinity as CaCO3 197 mg/L 8 0Bacterial analysis Fecal coliform

  • 15.0 AREA 60 / 62 / 66 - WATER SERVICES (CONTINUED)

    Description Value Unit Ref. Rev.

    AREA 62 - POTABLE WATER 15.9 Potable water - Supply

    Water source Rain water - 1 0

    15.10 Potable water - TreatmentType None 1 2Treatment rate Maximum 0 m3/h 6 0

    15.11 Potable water - Storage Potable water tankTank type Fixed level, covered 4 0

    15.12 Potable water - Distribution Water source Potable water tank 1 0Potable water pump detailsType Vertical multistage centrifugal 3 0Arrangement Duty 4 0Flowrate Maximum 10 m/h 6 0

    Nominal 2 m3/h 6 0

    15.13 Emergency water header tank Tank type Fixed level, covered 4 0Tank volume 3.0 m 4 0Tank diameter 1.5 m 6 0Tank height 2.0 m 6 0Tank freeboard 0.3 m 4 0

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  • 15.0 AREA 60 / 62 / 66 - WATER SERVICES (CONTINUED)

    Description Value Unit Ref. Rev.

    AREA 66 - PROCESS WATER 15.14 Process water - Supply

    Water type Recycled water 1 0Supply source During operation Numerous - see below 1 0

    Make-up Raw water supply pump 1 0Supply flowrate Concentrate thickener O/F - Nominal 67 m3/h 6 1

    Tails thickener excess O/F - Nominal 84 m3/h 6 2TSF decant water recovery - Nominal 53 m3/h 6 2TSF run-off water - Design 45 m3/h 6 2Plant Site run-off - Design 4 m3/h 6 1Raw water make-up - Nominal 0 m3/h 6 1

    Excess flowrate Process water pond O/F - Nominal 48 m3/h 6 1

    15.15 Process water - Storage Process water pondDetails Process water pond / Environmental dam 4 1

    15.16 Process water - Distribution Water source Process water pump 1 0Process water pump detailsType Centrifugal 3 0Arrangement Duty 4 0Flowrate Nominal 154 m/h 6 2

    15.17 Fire water - Supply Water source Process water - 1 0Supply Process water pond / Environmental dam 1 1

    15.18 Emergency water - Distribution Water source Process water pump or fire water pump 1 0Number of fire hydrants 9 5 1

    15.19 Fire water - Fire pumpFire pump detailsType Diesel centrifugal 4 0Flowrate Design 136 m/h 5 1

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  • 16.0 AREA 70 - REAGENT MIXING, STORAGE AND DOSING Description Value Unit Ref. Rev.

    16.1 Ball mill grinding mediaSize 40 mm 3 0Grinding media type Steel ball, 750 HB 4 0Consumption 1.0 kg/t 1 0Packaging Drums 4 0Net weight 1 t 4 0

    16.2 Activator reagent Reagent details Consumption - Flotation g PbNO3 per tonne of float feed 0 g/t 4 0 Total consumption Design 0.0 kg/h 6 0 Packaging Bulk bag 4 0 Net weight 1,000 kg 4 0 Physical form Powder - 4 0 Mixing strength Solution PbNO3 concentration 20.0 % w/w 4 0 Mixed solution SG 1.33 4 0 Mix batch size PbNO3 solid 1,000 kg 4 0 Mix batch volume 3.8 m3 4 0 Storage tank volume Live 8.7 m3 4 0Lead nitrate mixing tank details Tank type Agitated, variable level, covered 4 0 Tank residence time Operating hours N/A h 6 0 Tank volume 4.6 m 6 0 Tank diameter 1.8 m 6 0 Tank height 2.2 m 6 0 Tank freeboard 0.4 m 4 0Lead nitrate storage tank details Tank type Variable level, open 4 0 Tank residence time Operating hours N/A h 6 0 Tank volume 8.7 m 6 0 Tank diameter 2.2 m 6 0 Tank height 2.7 m 6 0 Tank freeboard 0.4 m 4 0Lead nitrate ringmain pump Pump type Helical rotor 3 0 Arrangement Duty 4 0 Details Design ringmain flow 1.6 m/h 6 0

    Design dosage flow - Flotation 0 L/h 6 0

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  • 16.0 AREA 70 - REAGENT MIXING, STORAGE AND DOSING (CONTINUED)

    Description Value Unit Ref. Rev.

    16.3 Xanthate collector reagent - Potassium amyl xanthate (PAX) Reagent details Design consumption g PAX per tonne of float feed 140.0 g/t 1 0 Total consumption 14.0 kg/h 6 0 Packaging Bag 4 0 Net weight 250 kg 1 2 Physical form Powder - 4 0 Mixing strength Solution PAX concentration 10.0 % w/w 4 0 Mixed solution SG 1.07 4 0 Mix batch size PAX solid 250 kg 4 2 Mix batch volume 2.3 m3 4 0 Storage tank volume Live 4.8 m3 4 0Xanthate mixing tank details Tank type Agitated, variable level, covered 4 0 Tank residence time Operating hours 18 h 6 0 Tank volume 2.3 m 6 0 Tank diameter 1.4 m 6 0 Tank height 1.9 m 6 0 Tank freeboard 0.4 m 4 0Xanthate storage tank details Tank type Variable level, open 4 0 Tank residence time Operating hours 37 h 6 0 Tank volume 4.8 m 6 0 Tank diameter 1.8 m 6 0 Tank height 2.3 m 6 0 Tank freeboard 0.4 m 4 0Xanthate dosing pump Pump type Diaphragm 3 0 Arrangement Duty 4 0 Details Design solution dosage flow 131 L/h 6 0

    16.4 Frother reagent - Cytec F549 Reagent details Design consumption g frother per tonne of float feed 60.0 g/t 1 0 Total consumption 6.0 kg/h 6 0 Packaging Tote (1,050 litre) 1 2 Net weight 1,029 kg 1 2 Physical form Solution - 4 0 Mixing strength Solution frother concentration 100.0 % w/w 4 0 Mixed solution SG 0.98 4 0 Storage tank size Frother solution 394 kg 4 0 Storage tank volume Live 0.40 m3 4 0Frother storage tank details Tank type Variable level, covered 4 0 Tank residence time Operating hours 66 h 6 0 Tank volume 0.4 m 6 0 Tank diameter 0.8 m 6 0 Tank height 1.2 m 6 0 Tank freeboard 0.4 m 4 0Frother dosing pump Pump type Diaphragm 3 0 Arrangement Duty 4 0 Details Design dosage flow 6.1 L/h 6 0

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  • 16.0 AREA 70 - REAGENT MIXING, STORAGE AND DOSING (CONTINUED) Description Value Unit Ref. Rev.

    16.5 Dithiophosphate collector reagent - Aero 407 Reagent details Design consumption g Aero 407 per tonne of float feed 140.0 g/t 1 0 Total consumption 14.0 kg/h 6 0 Packaging Tote (1,050 litre) 1 2 Net weight 1,223 kg 1 2 Physical form Solution - 4 0 Mixing strength Solution Aero 407 concentration 100.0 % w/w 4 0 Mixed solution SG 1.17 4 0 Storage tank size Aero 407 solution 468 kg 4 0 Storage tank volume Live 0.4 m3 4 0Dithiophosphate storage tank details Tank type Variable level, covered 4 0 Tank residence time Operating hours 33 h 6 0 Tank volume Each 0.4 m 6 0 Tank diameter 0.8 m 6 0 Tank height 1.2 m 6 0 Tank freeboard 0.4 m 4 0Dithiophosphate dosing pump Pump type Diaphragm 3 0 Arrangement Duty 4 0 Details Design dosage flow 12.0 L/h 6 0

    16.6 Concentrate regrind mill grinding mediaGrinding media type Ceramic MT1 1 0Grinding media consumption Design - g per IsaMill kWh 15.0 g/kWh 3 0

    kg per hour 18.20 kg/h 6 0kg per tonne of new mill feed 0.98 kg/t 6 0

    Grinding media make-up size Design - diameter 2.5 mm 3 2Grinding media SG 3.82 3 0Grinding media bulk density 2.3 t/m 3 0Packaging Bulk bag 3 0Net weight 1 t 1 0

    16.7 Flocculant - Concentrate Thickener Reagent details Type Ciba MagnaFloc 10 8 0 Design consumption g flocc. per tonne of thickener feed 100 g/t 3 0 Total consumption 2.8 kg/h 6 0 Packaging Bag 4 0 Net weight 25 kg 4 2 Physical form Powder - 4 0 Mixing strength Flocc concentration 0.25 % w/w 4 0 Mixed solution SG 1.00 4 0Flocculant mixing tank details Tank type Agitated, variable level, covered 3 1Flocculant dosing tank details Tank type Variable level, covered 3 1Flocculant dosing pump Pump type Helical rotor 3 0 Arrangement Duty / standby 3 0 Details Design dosage flow 1.12 m/h 6 0Flocculant dosing details Dosing strength Flocc concentration 0.025 % w/w 4 0 Dilution water requirements 10.1 m/h 6 0

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  • 16.0 AREA 70 - REAGENT MIXING, STORAGE AND DOSING (CONTINUED) Description Value Unit Ref. Rev.

    16.8 Flocculant - Tailings Thickener Reagent details Type Ciba MagnaFloc 10 8 0 Design consumption g flocc. per tonne of thickener feed 60 g/t 8 0 Total consumption 5.6 kg/h 6 2 Packaging Bag 4 0 Net weight 25 kg 4 2 Physical form Powder - 4 0 Mixing strength Flocc concentration 0.25 % w/w 4 0 Mixed solution SG 1.00 4 0Flocculant mixing tank details Tank type Agitated, variable level, covered 3 1Flocculant dosing tank details Tank type Variable level, covered 3 1Flocculant dosing pump Pump type Helical rotor 3 0 Arrangement Duty / standby 3 0 Details Design dosage flow 2.22 m/h 6 2Flocculant dosing details Dosing strength Flocc concentration 0.025 % w/w 4 0 Dilution water requirements 20.0 m/h 6 2

    16.9 Sodium cyanide Reagent details Consumption - CIL kg NaCN per tonne of CIL feed 1.28 kg/t 8 2 58.9 kg/h 6 2 Consumption - Elution kg NaCN per Cu wash strip 315.4 kg/strip 6 2 kg NaCN per elution strip 439.5 kg/strip 6 0 Total consumption Operating day - assumes 21.92 h/d 1606.0 kg/d 6 2 Packaging Box 4 0 Net weight 1,000 kg 4 0 Physical form Pillows or briquettes - 4 0 Mixing strength Solution NaCN concentration 20.0 % w/w 4 0 Mixed solution SG 1.087 4 0 Mix batch size NaCN solid 1,000 kg 4 0 Mix batch volume 4.6 m3 4 0 Total Storage tank volume Live 14.8 m3 4 0Sodium cyanide mixing and storage tank details Tank type Agitated, variable level, covered 4 0 Tank residence time Operating hours 44 h 6 2 Tank volume Each 14.8 m 6 0 Tank diameter 2.8 m 6 0 Tank height 2.8 m 6 0 Tank freeboard 0.4 m 4 0Sodium cyanide dosing pump Pump type Vertical multistage centrifugal 3 0 Arrangement Duty 4 0 Details Design ringmain flow 10.5 m/h 6 0

    Design dosage flow - CIL 0.3 m/h 6 2Design dosage flow - Elution 2.9 m/h 6 0

    16.10 Activated carbon Consumption Design 40 g/t 7 0Packaging Bulk bag - 4 0Net weight 1,000 kg 4 2Physical form Granules - 4 0Dosing method Manual, by hand - 4 0

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  • 16.0 AREA 70 - REAGENT MIXING, STORAGE AND DOSING (CONTINUED) Description Value Unit Ref. Rev.

    16.11 Hydrated Lime Reagent details Consumption - CIL kg lime per tonne of CIL feed 5.5 kg/t 8 0 251 kg/h 6 0 Consumption - Detox kg lime per tonne of Detox feed 0.2 kg/t 8 2 9.2 kg/h 6 2 Total consumption 260.6 kg/h 6 2 Packaging Bag 4 0 Net weight 1,000 kg 4 0 Physical form Powder 4 0 Solids SG 2.65 4 0 Solids bulk density 1.00 t/m 4 0 Available lime (CaO) Design 76 % CaO 4 0 Sizing F95 180 m 4 0

    F80 80 m 4 0F50 6.7 m 4 0

    Mixing strength Slurry lime concentration 20.0 % w/w 4 0 Mixed slurry SG 1.13 4 0 Mix batch size lime solid 1,000 kg 4 0 Mix batch volume 4.4 m3 4 0 Total Storage tank volume Live 10.6 m3 4 0Lime mixing and storage tank details Tank type Agitated, variable level, covered 4 0 Tank residence time Operating hours 202 h 6 2 Tank volume Each 10.6 m 6 0 Tank diameter 2.4 m 6 0 Tank height 2.8 m 6 0 Tank freeboard 0.4 m 4 0Lime ringmain pump Pump type Peristaltic 3 0 Arrangement Duty / standby 4 0 Details Design ringmain flow 5.8 m/h 6 0

    Design dosage flow - CIL 1.1 m/h 6 0Design dosage flow - Detox 0.0 m/h 6 2

    16.12 Hydrochloric acid

    Reagent details Consumption Elution 985 kg/strip 6 0

    850 L/strip 6 0 Supply concentration 32 % w/w 4 0 Packaging Tote (1,050 litre) - 4 0 Net weight 1,217 t 4 0 Supply solution SG 1.16 - 4 0Acid storage tank details Tank type Variable level, covered 4 0 Tank residence time No Strips 3.3 d 6 0 Tank volume 2.8 m 6 0 Tank diameter 1.5 m 4 0 Tank height 2.0 m 4 0 Tank freeboard 0.4 m 4 0Acid dosing pump Pump type Magnetic drive centrifugal 3 0 Arrangement Duty 4 0 Details Design dosage flow 2.5 m/h 6 0

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  • 16.0 AREA 70 - REAGENT MIXING, STORAGE AND DOSING (CONTINUED) Description Value Unit Ref. Rev.

    16.13 Sodium hydroxide Reagent details Consumption Elution 879 kg/strip 6 0

    575 L/strip 6 0 Supply concentration 50 % w/w 4 0 Packaging Tote (1,050 litre) - 4 0 Net weight 1,607 t 4 0 Supply solution SG 1.53 - 4 0Sodium hydroxide storage tank details Tank type Variable level, covered 4 0 Tank residence time No Strips 4.9 d 6 0 Tank volume 2.8 m 6 0 Tank diameter 1.5 m 4 0 Tank height 2.0 m 4 0 Tank freeboard 0.4 m 4 0Sodium hydroxide dosing pump Pump type Helical rotor 3 0 Arrangement Duty / standby 4 0 Details Design dosage flow 3.4 m/h 6 0

    16.14 Sodium metabisulphite (SMBS)

    Reagent details Design consumption kg SMBS per tonne of detox feed 3.0 kg/t 8 2 Total consumption 137 kg/h 6 2 Packaging Bulk bag 4 0 Net weight 1,000 kg 4 0 Physical form Powder - 4 0 Mixing strength Solution SMBS concentration 20.0 % w/w 4 0 Mixed solution SG 1.15 4 0 Mix batch size SMBS solid 2,000 kg 4 0 Mix batch volume 8.7 m3 4 0 Total Storage tank volume Live 23.4 m3 4 0SMBS mixing and storage tank details Tank type Agitated, variable level, covered 4 0 Tank residence time Operating hours 39.2 h 6 2 Tank volume Each 23.4 m 6 0 Tank diameter 3.1 m 6 0 Tank height 3.5 m 6 0 Tank freeboard 0.4 m 4 0SMBS dosing pump Pump type Helical rotor 3 0 Arrangement Duty 4 0 Details Design dosage flow 0.6 m/h 6 2

    16.15 Diesel Fuel details Supply Tanker truck 4 0 Supply solution SG 0.85 - 4 0Process diesel storage tank details Tank type Variable level, covered 4 0 Tank residence time 7.6 d 6 0 Tank volume 10.9 m 6 0 Tank diameter 2.4 m 4 0 Tank height 2.8 m 4 0 Tank freeboard 0.4 m 4 0Diesel pump Pump type Centrifugal 3 0 Arrangement Duty 4 0 Details Design ringmain flow 6.1 m/h 6 1

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  • 16.0 AREA 70 - REAGENT MIXING, STORAGE AND DOSING (CONTINUED) Description Value Unit Ref. Rev.

    16.16 Limestone Limestone parameters Packaging Bulk loose 4 0 Physical form Rock 4 0 Solids SG 2.93 4 0 Solids bulk density 1.00 t/m 4 0 Moisture content Nominal 10 % 4 0

    Design 5 to 25 % 4 0 Purity Percent limestone 95 % CaCO3 8 0 Sizing F95 12.50 mm 8 0

    F80 10.00 mm 8 0F50 2.75 mm 8 0

    Bond ball mill index P80 106 m 9.8 kWh/t 8 0Limestone operation details Mill design solids throughput - dry 95,712 t/a 3 0

    17.2 t/h 6 0 Operating hours 5,550 h/a 6 0

    107 h/week 6 0Availability 63.4 % 6 0

    Circuit type Ball mill 4 0Limestone ball mill O/F trommel 4 0 Operation Closed circuit - cyclones 4 0 Mill dimensions Diameter 2.2 m 3 0

    EGL 4.4 m 3 0 Installed power 260 kW 3 0 Mill grinding media charge - Maximum 37 % v/v 3 0 Mill speed 75 % Crit. 3 0

    21.4 RPM 3 0 Mill Discharge % Solids Design 72 % w/w 7 0Limestone mill discharge pump Arrangement Duty 4 0 Details Gland seal water requirements 28 L/min 3 0

    477 kPag 3 0Limestone cyclones Type Cyclone - Multotec VV250 3 0 Operating units 1 3 0 Standby units 1 3 0 Circulating load Design - % of new feed to undeflow 250 % 1 0 Feed % solids Design 59.5 % w/w 6 0 Feed pressure Design 90 kPag 3 0 Cyclone diameter 375 mm 3 0 Overflow P80 106 m 8 0 Underflow slurry percent solids 74.0 % w/w 3 0 Overflow slurry percent solids 40.0 % w/w 3 0Limestone slurry details Consumption - Flotation kg lime per tonne of Flotation feed 5.0 kg/t 8 0 Flotation 500 kg/h 6 0 Consumption - Albion kg lime per tonne of Albion feed 409 kg/t 8 0 Albion leach 11464 kg/h 6 0 Total consumption 11964 kg/h 6 0 Mixing strength Slurry limestone concentration 40.0 % w/w 4 0 Mixed slurry SG 1.35 4 0Limestone slurry storage tank details Tank type Agitated, variable level, open 4 0 Tank residence time Operating hours 12.0 h 6 0 Tank volume 281 m 6 0 Tank diameter 7.1 m 6 0 Tank height 7.6 m 6 0 Tank freeboard 0.5 m 4 0Limestone ringmain pump Arrangement Duty / standby 4 0 Details Design ringmain flow 199.0 m/h 4 1

    Design dosage flow - Flotation 0.9 m/h 6 0Design dosage flow - Albion 21.2 m/h 6 0

    16.17 Limestone mill grinding mediaGrinding media type Steel ball, 750 HB 7 0Size 65 mm 3 2Consumption 1.2 kg/t 1 0Packaging Drums 4 0Net weight 1 t 1 0

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  • 17.0 AREA 80 / 85 - AIR AND OXYGEN SERVICES

    Description Value Unit Ref. Rev.

    17.1 Service air Number of compressors 2 4 0Type Rotary screw 4 0Arrangement Lead / lag 4 0Capacity, each 450 Nm/h 1,3,6 0

    53 Am/h 6 0Operating pressure 750 kPag 4 0

    17.2 Process oxygen Type VPSA 3 0Number of units 1 3 0Product oxygen purity % oxygen 93 % 3 0Total Oxygen requirement Total O2 - pure 8.1 t/h 4 0

    Product throughput 8.7 t/h 6 0Product flowrate 6,704 Nm3/hr 6 0Product flowrate 1,014 Am3/hr 6 0

    Product temperature 40 C 3 0 Product pressure 600 kPag 3 0Albion leach Oxygen requirement Total O2 - pure 8.0 t/h 4 0

    Product throughput 8.59 t/h 6 0Product throughput 6,635 Nm3/hr 6 0Product flowrate 1,003 Am3/hr 6 0

    Stream temperature 40 C 3 0 Stream pressure 600 kPag 3 0CIL Oxygen requirement Total O2 - pure 0.08 t/h 4 0

    Product throughput 0.09 t/h 6 0Total @ output purity 69 Nm3/hr 6 0Total @ output purity 10 Am3/hr 6 0

    Stream temperature 40 C 3 0 Stream pressure 600 kPag 3 0

    17.3 Cyanide detoxification air Type 3 0Number of units 2 3 0Arrangement Duty / standby 4 0Air requirement Total air 3.5 t/h 4 0

    Total air 3,000 Nm3/hr 6 0Total air 1,519 Am3/hr 6 0

    Required operating pressure 80 kPag 6 0Actual operating pressure 120 kPag 3 0

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