resumen extracto criterio diseño ogp-1

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Resumen Criterio de diseño Planta Concentradora

1.3 Design Basis

The process design criteria for the facilities are based on data supplied by BHPB/MEL. The data are

based mainly on experience derived from the existing Laguna Seca and Los Colorados concentrators.

Where design criteria were not available, criteria have been developed from reasonable assumptions

with BHPB/MEL concurrence. 1.4 Definition of Design Value Terms

The process criteria are listed as BALANCE and/or DESIGN conditions; they are site specific and the

following values apply only to the new OGP1 concentrator. The context in which these terms are used

is in accordance with the following definitions: Operating Days The number of plant operating days per year is 365 days. Availability The availability represents the electro - mechanical time factor; i.e., when the

equipment is able to run and depends on the operational requirements to do so. This project considers for the concentrator plant an average availability of 0.96.

Utilization The utilization represents the operational time factor; i.e., when the equipment is really running. This project considers for the concentrator plant an average

utilization of 0.99.

Run time: A run time factor of unity represents the capability of, and requirement for, any equipment or facility being on-line for 24 hours per day for all operating days in the year. A run time of less than unity reflects the combined effect of allowed availability for that facility and the utilization effect from the on-line time of

upstream or downstream equipment, or from other factors.

Run time = Availability x Utilization Run time = 0.96 x 0.99

= 0.95

Nominal capacity This is the plant name plate throughput value; in this case the nominal plant capacity is 152 000 tons per day and represents the yearly average throughput considering the respective availability and utilization. This value has been defined

by BHPB/MEL.

Hourly capacity Represents the plant throughput considering the run time. This is the Balance

condition.

t / h = nominal plant capacity

run time x 24

t / h = 152 000 or 6667 t/h

0.95 * 24

Annual Rate = Nominal capacity x Operating days = 152 000 t/d x 365 d /y

= 55 480 000 t/y

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All Balance mass and flow rates, together with the respective run time factors,

should be consistent with a single annual mass balance.

Design Value: The criteria values in this column provide the instantaneous process values that take account of flows that operate for less than 24 hours during one operating day, or where it is intended that the particular equipment will have an additional

capacity to allow for maintenance, catch-up capability or for variability in process parameters. The Design values are intended as attainable continuous rates and

do not include any additional design allowance(s), by engineer or vendor, to

ensure attainment. The combinations of Design values neither relate to the

annual productions defined nor integrate to represent a metallurgical balance.

The Design values are individual rates used for sizing equipment. 2 PROCESS SUMMARY

2.2 Process Description (152 000 t/d OGP 1 Concentrator)

Crushing Escondida has two open pit mines known as Escondida Pit and Escondida Norte Pit. In each facility

run-of-mine (ROM) ore is dumped from mine trucks into the dump pockets of existing primary gyratory

crushers. The crushed coarse ore will be transported by a new overland belt conveyor system from the

pits to a new concentrator covered coarse ore (c.o.) stockpile. The c.o. overland conveyor system has a

rated capacity of approximately 12 200 dry tons per hour. At the new OGP 1 concentrator, the stockpile will be located to the south of the existing Phase IV

stockpile with a storage capacity of 80 0001 tons of effective live load and a total capacity of 146 000

tons of live capacity. The stockpile will be fully covered to minimize dust emission. Grinding The coarse ore will be reclaimed from the extended stockpile by eight belt feeders and fed to a SAG mill feed conveyor. The grinding circuit will consist of a single line comprised of a 12.19 meter diameter

by 7.92 meter long (EGL) (40 foot diameter by 26 foot long) semi-autogenous grinding (SAG) mill, and

four 7.92 meter diameter by 12.95 meter long (EGL) (26 foot diameter by 42.5 foot long) ball mills. The SAG mill discharge will flow onto the mill trom mel and two vibrating screens (one operating and one

installed standby; there will be one screen spare stored in the warehouse). The combined trommel and screen undersize will be pumped with two pumps (one operating and one standby) to the ball mill circuit

via two distributors (one operating and one standby) for distribution to four ball mill sumps. The trommel

and screen undersize, together with the ball mill discharge, will be pumped to four cyclone clusters, each equipped with nineteen 838 mm (33 inch) diameter cyclones for classification. The cyclone

clusters will operate in closed circuit with the ball mills. The cyclone overflow, at a P80 product size of

145 micrometres, will be fed to the rougher flotation circuit. The cyclone underflow will return to the ball mills. The SAG mill screen oversize (pebbles) will be conveyed by a set of belt conveyors to two cone

crushers. The crusher product will be discharged back to the SAG mill feed conveyor and fed to the

SAG mill along with fresh feed from the c.o. stockpile. Flotation

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The final product from ball mill grinding lines will report to seven rows of rougher flotation cells via a

slurry distributor. The flotation circuit will consist of seven rows of rougher cells (300 m3) with seven

cells in each row, three (3) rows of scavenger cells (300 m3) with seven cells in each row, and twelve

second cleaner column cells (4.5 metres in diameter). The rougher concentrate, will be reground in three 3000 hp tower mills. The reground rougher will be cleaned in the Rougher cleaner flotation column circuit with either seven

or six column cells, the concentrate will report like final concentrate. The scavenger concentrate will be cleaned utilizing either five or six scavenger cleaner column cells.

The combined column cell concentrate will be the final copper concentrate while the column cell tailings

will be returned to the scavenger flotation cells, without regrinding. The rougher tailings, commingled

with the scavenger tailings (final mill tailings), will flow by gravity to tailings thickeners for dewatering

and disposal. Concentrate Thickening and Transport The final concentrate from the OGP 1 concentrator will be thickened in two new 42.7 meter (140 foot)

concentrate thickeners located adjacent, on the north side of the existing Laguna Seca concentrate

thickeners, and the underflow from the new and existing thickeners will be pumped to four new storage

tanks, similar in size to existing Laguna Seca storage tanks. A new distributor will be provided which will

permit feeding any of the new and existing concentrate storage tanks. The thickener overflows (from the two existing thickeners plus the two new ones) will be cleaned in a

new 42.7 meter (140 foot) diameter clarifier, located adjacent, by the new OGP1 concentrate

thickeners. The clarifier underflow will be pumped to the concentrate storage tanks and the overflow will

be sent to an existing water reclaim system for recycling at Laguna Seca concentrator. The existing and new concentrate storage tanks will be connected with the existing pipelines via a new

pump station located at Laguna Seca, and two pipelines. The tie-in connection will be near to main gate

pipeline, a distance of about 15.3 km from the new pump station at Laguna Seca. The concentrate from the new OGP1 concentrator, commingled with the concentrate from Laguna

Seca, will be pumped via two existing pipelines to the existing Coloso filter plant for dewatering.

Design Criteria for Process

25713-220-3DR-V01-00001-00A Tailings Disposal and Reclaim Water Flotation tailings will be thickened in three 125 metre (410 foot) diameter thickeners located south of the

existing Laguna Seca tailings thickeners. The flotation tailings collection box will have one (1) pump that

will permit pumping one third of the total flow to the existing Phase IV tailings thickeners. Thickened

tailings will flow by gravity to the existing impoundment system. Water reclaimed from the tailings thickeners and impoundment will be collected in two new thickener

overflow tanks, and pumped to a new process water reservoir (100 000 m3).

Fresh water will be received in a new 3400 m3 tank that will be linked to an existing fresh water tank. A

new fresh water distribution loop will provide fresh water to the new concentrator, to an expanded

reverse osmosis plant, and to an upgraded fire loop. Filter Plant at Coloso (Existing) In this facility the concentrate is received and dewatered to 9 percent moisture. The high density

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concentrate is pumped to existing filters; the concentrate (filter cake) is then discharged onto an

individual feeders which in turn discharge onto a belt conveyor that takes it to an existing concentrate

storage building. The filtrate is pumped to an existing clarifier for polishing. 2.3 Block Process Flow Diagram

The facilities to which these design criteria relate are presented in the attached simplified block process

flow diagram. Table 2-1 presents a Summary of Design Criteria for the process facilities.

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BLOCK FLOW DIAGRAM

Page 9 of 49

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Design Criteria for Process

25713-220-3DR-V01-00001-00A

TABLE 2-1 SUMMARY OF DESIGN CRITERIA ORGANIC GROWTH PROJECT 1

Production Summary Plant ore feed rate nominal Copper content

Copper recovery

Copper concentrate

Concentrate grade SAG Mill Number Diameter

Installed power SAG Mill Discharge Type of classification Number of screens Pebble Crushers Number Installed power Ball Mills Number Diameter

Installed power Primary Cyclones Number of clusters Cyclones per cluster

Product cyclones, 80% passing Rougher Flotation Cell size Number of rows

Cells per row Regrind Mills Number Installed power

Type

Unit 152 000 t/d

t/d 152 000 % 1.0 % 84.0 t/y 1 664 400

% Cu 28.0

no 1 ft 40

hp 32 200

SAG trommel/screen

N° 3 (1 op. + 1 stdby,1 spare)

N° 2

hp/ea. 1000

N° 4 ft 26

hp, ea. 21 000

N° 4 N° 19

μm 145

m3 300

N° 7

N° 7

N° 3 hp, ea. 3000

Vertical

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Cont. Table 2-1 Scavenger Flotation Cell size Number of rows

Cells per row Rougher Scavenger Flotation Number Diameter Scavenger Cleaner Flotation Number Diameter Concentrate Thickeners Number Diameter

Concentrate storage tanks Clarifier Number Diameter Tailings Thickeners Number Diameter

Unit 152 000 t/d

m3 300

N° 3

N° 7

Column Cell N° 7/6

m 4.5

Column Cell N° 5/6

m 4.5

N° 2 m 42.7

N° 4

N° 1

m 42.7

N° 3

m 125

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3 MEASUREMENT UNITS AND SYMBOLS

The Modernized Metric System of measurement used in this specification is in accordance with (USA) ASTM E380, Standard Practice for Use of the International System (SI) of Units. A period, not

comma, is used as the decimal marker. A small space (with no comma) is used to separate groups of three integers. The reference conditions for gas volume are 0C and 101 325 kPa, corresponding with a molar (ideal)

gas volume of 22 414 m3/ (kg⋅mol). This is shown as “m

3 (normal)” or abbreviated to (non-SI) “Nm

3.”

The unit “t” rather than Mg, is used for 1000 kg mass. SI Base Units: (dimensionally independent)

Measured Attribute Unit Symbol

Length metre m

Mass kilogram kg

Time second s

Electric current ampere A

Thermodynamic temperature Kelvin K

Amount of substance mole mol

Luminous intensity candela cd

Permitted Base Units:

Unit Symbol Definition

Measured Attribute

Time minute min 60 s

hour h 60 min

day d 24 h

(calendar) year y 365 d

Mass metric ton t 1000 kg

(Note: SI prefixes, as listed below, are used only with SI base units. It is incorrect to use these

prefixes with the “permitted base units”.)

SI Prefixes: (selected list only)

Multiplication Factor Prefix Symbol

1012 tera T 10

9 giga G

106 mega M

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Multiplication Factor Prefix Symbol

103 kilo k

102 hecto h

10 deka da

10-1 deci d

10-2 centi c 10

-3 milli m

10-6

micro µ 10

-9 nano n

10-12 pico p The prefixes and prefix symbols are used with the SI base units and derived units - with the exception of kg.

The base mass unit, kg, already has a prefix, and the SI prefixes are then applied to the unit gram (g). In this manner, the symbol for metric ton is Mg, however in this criteria the permitted alternate, t as

listed above, is used. The ASTM permitted form Wh is used rather than W⋅h.

Derived SI Units of Special Name:

Measured Attribute Unit Symbol Formula

Frequency (periodic) hertz Hz 1/s Force newton N kg⋅m/s

2

Pressure, stress pascal Pa N/m2

Energy, work, heat qty. joule J N⋅m Power, radiant flux watt W J/s Qty. of electricity coulomb C A⋅s Electric potential, emf volt V W/A Electric capacitance farad F C/V Electric resistance ohm Ω V/A Electric conductance siemens S A/V Magnetic flux weber Wb V⋅s

Magnetic flux density tesla T Wb/m2

Inductance henry H Wb/A Celsius temperature degree Celsius C K-273.15 Plane angle radian rad dimensionless Solid angle steradian sr dimensionless Luminous flux lumen lm cd⋅sr

Illuminence lux lx lm/m2

Activity (of a radionuclide) becquerel Bq 1/s Absorbed dose gray Gy J/kg

Dose equivalent sievert Sv J/kg

Units in Use:

Measured Attribute Unit Symbol Definition

Plane angle rad degree 1 = (π/180)

minute ' 1' = (1/60)o

second " 1" = (1/60)'

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Volume litre L 1 L = 10

-3 m

3

Area hectare ha 1 ha = 104 m

2

Energy (electrical) kilowatt-hour kWh 1kWh = .6MJ

Some Common Derived Units:

Measured Attribute Unit Symbol

Acceleration metre per second squared m/s2

Angular acceleration radian per second squared rad/s2

Angular velocity radian per second rad/s

Area square metre m2

Concentration mol per cubic metre mol/m3

Current density ampere per square metre A/m2

Density (mass) kilogram per cubic metre kg/m3

Electric flux density coulomb per square metre C/m2

Entropy joule per Kelvin J/K Heat capacity joule per Kelvin J/K

Heat flux density watt per square metre W/m2

Luminance candela per square metre cd/m2

Magnetic field strength ampere per metre A/m

Molar energy joule per mole J/mol

Molar entropy joule per mole Kelvin J/(mol⋅K)

Molar heat capacity joule per mole Kelvin J/(mol⋅K)

Moment of force newton metre N⋅m Permeability (magnetic) henry per metre H/m

Power density watt per square metre W/m2

Specific heat capacity joule per kilogram Kelvin J/(kg·K)

Specific energy joule per kilogram J/kg Specific entropy joule per kilogram Kelvin J/(kg⋅K)

Specific volume cubic metre per kilogram m3/kg

Surface tension newton per metre N/m Thermal conductivity watt per metre Kelvin W/(m⋅K)

Thermal conductance watt per square metre Kelvin W/(m2⋅K)

Velocity metre per second m/s Viscosity, dynamic pascal second Pa⋅s

Viscosity, kinematic square metre per second m2/s

Volume cubic metre m3

Abbreviations of Other Terms: Term Abbreviation alternating current ac barrel bbl boiling point bp cosine cos cotangent cot decibel dB diameter dia direct current dc electromotive force emf induced draft ID

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inside diameter i.dia maximum maxm minimum minm mole percent mol % molecular mass (weight) mol wt parts per billion ppb parts per million ppm parts per million by volume ppmv parts per million by mass (weight) ppmw power factor PF revolutions per minute rpm revolutions per second rps root mean square rms sine sin specific gravity Sp Gr tangent tan temperature temp ultra high frequency UHF very high frequency VHF volume vol volume percent vol % weight (mass) wt weight (mass) percent wt % 4 SITE DATA

For this section, see Specification Criteria for Site Condition 25599-230-3PS-G000-00001. 5 ENVIRONMENTAL CRITERIA

5.1 Applicable Regulations and Standards

The new 152 000 tons per day concentrator will maintain the current capacity of the existing mine and

concentrator facilities. An environment impact assessment (EIA) study will be prepared by a BHPB/MEL

subcontractor for building the new facilities and modifications to existing installations, required for the

OGP 1 concentrator. For additional information regarding the Environmental Criteria for the project facilities, see the

Environmental Design Criteria, Document No.25599-240-3DR-H01-00001. 5.2 Other Specified and Permit Requirements

Not applicable. 5.3 Summary of Interpretation to Process Design

The concentrator will be designed as a “zero discharge” facility with all process water reporting to the

tailings impoundment. The tailings from the concentrator flotation cells will flow to thickeners. The

thickener overflows will be returned to the process facilities. The thickened tailings, commingled with

tailings from the existing Laguna Seca concentrator, will flow by gravity to the existing tailings

impoundment at Laguna Seca. Process and reagent spills will be contained in detention areas. Reagents

spills will be mixed with the concentrator tailings.

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6 DESIGN CRITERIA REFERENCE DOCUMENTS

The following major documents were used to prepare the design criteria for the Phase V Escondida

Expansion Project. 6.1 BHPB Process Design Criteria, 25421-138-3DR-V01-00001 for Phase V, Rev. E, 24DEC08, 6.2 Kick Off Meeting, OGP 1, SPS, Presentation by BHPB/MEL 15APR10 6.3 Process Design Criteria Review, Letter BHPB/Bechtel, 20APR10, 6.4 Meeting Notes No. 01, 25599-220-G17-GEE-00001, OGP1 Design Criteria, 10APR10. 6.5 VIP’s summary works shops. 6.6 Process Design Criteria for selection phase study (SPS), 25594-230-3DR-V01-00001. 6.7 Meeting Notes No.11, 25599-230-G17-GEX-00011 6.8 Meeting Notes No.14, 25599-230-G17-GEX-00014 6.9 Meeting Notes No.14, 25599-230-G17-GEX-00033 “ Design Freeze”

Units Balance Design Code 7 PRODUCTION SUMMARY

7.1 Production Parameters

7.1.1 Annual Production

Plant feed – ore (152 000 x 365) t/y 55 480 000 E

Copper concentrate t/y 1 664 400 E

(55 480 000 x 0.01 x 0.84 ÷0.28)

Final tailings (by difference) t/y 53 815 600 E

Copper in concentrate t/y 466 032 E

(1 664 400 x 0.28)

7.1.2 Daily Production

Plant feed – ore t/d 152 000 A

Copper concentrate

(152 000 x 0.01 x 0.84 ÷ 0.28) t/d 4560 E

Final tailings (by difference) t/d 147 440 E

7.2 Concentrate Grade

Copper % 28 A

7.3 Recovery

Copper % 84 A

7.4 Operating Schedule

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Operating days per year d 365 A

Operating hours per year h 24 A

Availability % 96 A

Utilization % 99 A

Run time % 95

(0.96 x 0.99) A

Design Criteria for Procces

25713-240-3DR-V01-00001-00A

Units Balance Design Code

8 CHARACTERISTICS OF PROCCES MATERIALS

8.1 Introduction

The ore body contains chalcocite, covellite, chalcopyrite, copper oxides and several other ore types. The

predominant copper mineral is chalcocite.

Solids specific gravity

Mineral 1.0 % Cu Sp Gr. 2.8 2.8 A Concentrate 28.0 % Cu Sp Gr. 4.25 4.25 A

equation Sp Gr. = 0.0537*Ley Cu + 2.7463 E

8.2 Chemical Composition of ROM Ore

Copper content % 1.0 1.0 A

8.3 Physical Characteristics of ROM Ore

Maximum particle size m 1.2 A

Shape blocky A

Moisture % 3 3 A

ROM bulk density, wet: t/m

3 2.1 2.1 A

For weight purposes

For volume purposes t/m3 1.8 1.8 A

Ore hardness medium medium A

9 PRIMARY CRUSHING, TRANSPORT AND STORAGE

Operation Escondida has two open pit mines known as Escondida Pit and Escondida Norte Pit. In each

facility run-of-mine (ROM) ore is dumped from mine trucks into the dump pockets of primary gyratory

crushers. The crushed coarse ore will be conveyed from the pits to an extension of the existing Laguna

Seca concentrator covered coarse ore (c.o.) stockpile. The c.o. overland conveyor system has a rated

capacity of approximately 12 200 tons per hour.

9.1 Coarse Ore Stockpile

Live new capacity t 80 000 E Angle of repose degree 37.5 A

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Drawdown angle degree 70.0 A

Maximum particle size mm 356 E Units Balance Design Code

9.2 Coarse Ore Reclaim in. 14 E

Coarse ore reclaim t 6667 8667 E

Design factor 1.30 A

Feeders Number N° (6 op.+2 std by) 8 E

Capacity t/h, ea 1500 A

Drive adjustable speed

9.3 SAG Mill Feed

Conveyor Number N°

1

Capacity dry t/h 9534 E

Capacity wet t/h 9813 E

10GRINDING

10.1 Operating Time and Grinding Tonnage Rate

Operating days per year d 365 A Operating days per week d 7 A Operating shifts per day shifts/d 2 A Run time % 95 A Operating hours

(365 x 24 x 0.95) h/y 8322 E Feed rate t/h 6667 8667 E

(6667 x 1.3)

10.2 Grinding Power Requirement

10.2.1 SAG power

index

SPI Min 58 A

10.2.2 Work Index

Wi kWh/t 12.7 A

10.2.3 Mill Power

Specific power: SAG mill kWh/t 2.7 to 3.2 E


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Ball mill kWh/t 8.3 to 8.9 E

Shell installed power per line:

SAG mill kW, net 24 000 A

(hp), (32 200)

Ball Mill kW,net 4 x 15 700 A

Power consumption: (hp) (4 x 21 000)

SAG mill % 90 90 A

Ball mill % 95 95 A

10.3 SAG Mill

Mill N° 1 A

Installed motor power, net kW 24 000 A

Size of mill: (hp) (32 200)

diameter x length

(inside shell x length, EGL) ft 40 x 26 A

(m) 12.2 x 7.9

New feed rate per mill t/h 6667 8 667 A

(6667 x 1.3)

Feed size, 80% passing µm 85 000 A

Product size, 80% passing µm 8500 A

10.3.1 Design circulation load (pebbles)

Percentage of new feed (max.) % 10 15 A

Rate t/h 667 1000 E

Total dry feed to SAG mill t/h 7334 9534 E

(6667 +667) ((6667+667) x 1.3)

Mill discharge % solids % 75 70-75 A

Discharge trommel, % 60

Trommel

diameter x length m 6.2 x 4.8 A

aperture mm 25 x 60 A

SAG trommel undersize t/h 3734 4854 E

m3/h

(3734 x 1.3) E

Trommel wash water 300 600 A


Speed, % of critical % 78 0 to 82

Total loading, by volume % 25 30-35

Discharge type type slotted grate

Grate aperture mm 72

Size of grinding balls, mm 152

(in.) 6.0 A

Charge, by volume % 15 22 A

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Ball consumption kg/t ore 0.240 0.264 A

Liner consumption t/year 1580 1738 A

10.3.2 SAG Mill Discharge Screen

Design factor N° 1.3 A

Feed rate t/h 3600 E

Screen N° 3(1 op. + 1stdby + 1 warehouse A

spare)

Type double deck

Oversize t/h 667 1000 E

Percent Moisture % 6 A

Undersize t/h 36002 E

Percent solids incl. spray water % 67 67 E

Screen size, width x length m 3.7 x 7.33 D,A

Screen panels (bottom deck):

(ft) (12’ x 24’)

Aperture shape slotted

Aperture upper deck mm 35 x 60 A

Aperture lower deck mm 25 x 60 A

Material polyurethane

Screen wash water m3/h, ea 800 A

10.3.3 SAG Mill Screen Undersize Pumps


Pump N° 2(1 operating, 1 standby) A

Flow rate per pump t/h 6667 8667 A


Flow rate per pump m3/h 5288 8400 E

(5288 x 1.3)

Percent solids % 70 65 - 75 E

Specific gravity of pulp t/m3 1.81 1.81 E

Pump:

Type metal


10.3.4 SAG Mill Product Distributor


Number N° 2 (1 operating, 1 standby) A

Feed flow rate m

3/h 5288 8400 E

(screen undersize)

(5288 x 1.3)

Percent solids % 70 61-70 E


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10.3.5 Pebble Handling

Design factor, circuit N° 1.5

Pebble Crusher Protection Magnets

Magnets N° 3 (minimum) A

Location on pebble collection conveyor circuit & at transfer points

Metal detector N° 1

Location on crusher feed conveyor

Pebble Surge Bin

Feed:

Percent of SAG mill new feed wt % 10 15 A

Rate t/h 667 1000 E

Bin N° 2

Bin, design capacity t, ea. 500 E

h 0.5

Pebble Reclaim Conveyor (Crusher Feed)

Type type Belt


Drive type Adjustable speed

Feed rate, each t/h 667 1000 E

Pebble Crusher

Crusher N° 2 E

type: Cone A

Closed-size setting mm 12

Capacity per pebble crusher t/h, ea. 500

(@12 mm c.s.s.)

Type of crusher cavity fine

Circuit type open

10.4 Ball Mills

No. of mills N° 4 A

Installed power per mill, net kW, ea. 15 700 A

Size of mills: (hp), ea. (21 000)

diameter x length

(inside shell x length EGL) m 7.9 x 12.95

(ft) (26 x 42.5) A

New feed rate per mill t/h 1667 2200 E

(1667 x 1.3)

Feed size, 80% passing µm 8500 A

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Grinding circuit product size:

80 % passing µm 145

Circulating load % 350 450 A

Percent + 100 mesh % 20 A

Discharge rate per mill:

excluding safety screen recycle t/h 5833 7600 E

Discharge type type overflow

Mill discharge %solids % 75 A

Speed, % critical % 0 to 82 A

Ball charge, by vol., des., % 32 40 A, B

operating

Ball charge, by vol., struct. des. % 40 B

Liners material metal

Size of grinding balls mm 76.2

(in.) (3) A



Liner consumption t/year 1 380 1518 A

10.4.1 Primary Cyclone Feed Pumps

Design factor N° 1.3 Pump N° 6 (4 operating, 2 spare) A

Flow rate per pump m3/h 8512 11 000 E

Percent solids % 56 56 E


Pump type metal

Pump drive adjustable speed

10.4.2 Primary Cyclones

Number of clusters N° 4 A Cyclones locations/cluster N° 19 A Blanked for side discharge: N° 1

Operating N° 12 E Stand-by N° 7 E

Size mm 838 A (in.) (33)

Operating pressure psi 10 14 A

Feed per cluster:

Solids t/h 7500 10 000 E

Volume m3/h 8512 11 000 E


Overflow per cluster:

Solids t/h 1667 2167 E

Volume m3/h 4484 6000 E

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Percent solids % 30 30 A

Product size, P80 m 145 145 A

Underflow per cluster:


Volume m3/h 4028 5300 E


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11 FLOTATION AND REGRINDING

11.1 Rougher Flotation

11.1.1 Rougher Flotation Feed


Ore grade, copper % Cu 1.0 1.0 A

Feed rate t/h 6667 8667 E

(6667 x 1.3)

Solids specific gravity Sp Gr. 2.8 2.8 A


Pulp flow rate m3/h 17 937 23 300 E

Pulp specific gravity t/m3 1.24 E

pH 10 -10.5 A

11.1.2 Rougher Flotation Time and Cell Size

Required retention time min 38 A

Calculated retention time min 42 E

Effective cell volume factor % 85 D

Cell size m3 300 E

Number of cells N° 49 E

Number of rows N° 7 E

Number of cells per row N° 7 E

Distributor (7 way split) N° 1

11.1.3 Rougher Concentrate

Design factor 1.6 A, B

Copper content % Cu 7 7 A

Solids flow rate t/h 824 1300 E

Copper recovery % 86.5 87 A

Solids specific gravity Sp Gr. 3.12 3.12 E

Percent solids with no launder % 25 25 A

water m

3/h 2736 4400 E

Pulp flow

t/m3

(2736 x 1.6)

Pulp specific gravity 1.20 1.20 E


11.1.4 Rougher Tailings


Copper content %Cu 0.16 0.15 E




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pH

m3/h

10.5 10 to 10.5 A

Pulp flow 15 205 20 000 E

(15 205 x 1.3) E

11.1.5 Total plant tailings (solids)


Rougher tailings t/h 5843 7600 E

Scavenger tailings t/h 624 800 E

Total t/h 6467 8400 E

Flow rates m3/h 18 956 24 643 E

Pulp specific gravity

t/m3 1.23

(18 956 x 1.3) E

Solids % 28 28 E

11.2 Cleaner Flotation


Overall cleaner recovery % 97.1 97 A

Final cooper concentrate grade % 28 28 A

Cells type Column A

stages N° 2

Number of cells (Type N° 12 E

Microcells)

Diameter of column cell m 4.5 A

Height of column cell m 13.4 A

Air consumption, cm/s 2.4 3.0 E

Air consumption per cell m3/h 1373 1716 E

Bias % 2.5 E

Wash water - total m3/h 684 E


11.2.1 Rougher Cleaner Column Feed

Rougher cleaner feed: reground rougher concentrate Rougher cleaner feed pump N° 2(1 op. + 1 standby) A


Number of cells (Type N° 7/5

Microcells) t/ h/m

2

Conc. carrying rate 1.47 1.47

Copper content %Cu 7 7 E



Solids % 19.7 E

Pulp flow m3/h 3623 5797 E

t/m

3

(3623x1.6) E


Pump: Drive

adjustable speed

Control sump level

22 | P a g e

Type rubber lined

11.2.2 Rougher Cleaner Tailings


Copper content % Cu 4.34 4.34 E

Solids flow rate t/h 721 1 200 E


Percent solids % 17.1 17.1 E

pH m

3/h

11 11 A

Pulp flow 3733 6000 E

(3762 x 1.6)

11.2.3 Rougher Cleaner Concentrate (Final Flotation Concentrate)


Copper content % Cu 28.0 28.0 4A,E


Copper recovery , in stage % 50 50

Copper recovery, plant total % 84 84





(289 x1.6)

11.2.4 Scavenger Cleaner Column Feed


Conc. carrying rate t/ h/m2 1.47 1.47

Scavenger cleaner feed Scavenger concentrate

Copper content % Cu 7.45 7.45 A



Solids % 18.4 18.4 A


t/m

3

(3195 x 1.6) E


Scavenger cleaner feed pump 2 (1 operating, 1 standby)

Pump:


Control sump level

11.2.5 Scavenger Cleaner Column Concentrate (Final Flotation Concentrate)


Copper content % Cu 28 28 A


Copper recovery , in stage % 50 30 A

23 | P a g e




(272 x1.6)

11.2.6 Scavenger Cleaner Column Tailings





Percent solids % 17.4 17.4 E


(2926 x 1.6)


Pulp specific gravity t/m3 1.13 E

11.3 Scavenger Flotation

11.3.1 Scavenger Feed


Scavenger feed Rougher+ Scavenger Cleaner tailings




Solids % 17.3 17.3 E

Pulp flow m3/h 6654 10 650 E

t/m3

(6654 x 1.6)5 E


11.3.2 Scavenger Flotation Time and Cell Size

Required retention time min 45 A

Calculated retention time min 48.4 E

Effective cell volume factor % 85 D

Cell size m3 300 E

Number of cells N° 21 E

Number of rows N° 3 E

Number of cells per row N° 7 E

11.3.3 Scavenger Concentrate


Copper content % Cu 7.45 7.45 A


Copper recovery , in stage % 84 84 A


Percent solids % 20 A


t/m3 (2910x 1.6)

24 | P a g e


25 | P a g e


11.3.4 Scavenger Tailings


Copper content %Cu 0.27 0.27 E



Percent solids % 15 E


t/m3

(3745x 1.6)


11.4 Copper Concentrate Regrind

11.4.1 Copper Concentrate Regrind New Feed

Rougher concentrate t/h 824 1318 E

Total feed (solids) t/h 824 1318 E


Pulp specific gravity t/m3 1.20 1.20 E

11.4.2 Regrind Mill6

Mill type tower A

Mill N° 3 A

Specific power kWh/t 4.5 A

concentrate

Mill installed power (per mill) kW, ea 2242

(hp), ea (3000) A

Tower mill power draw % 82 A


Feed size, %-325 mesh 60 60

Product size, passing % -325 mesh 75 75 A

Ball size mm 25.4

(in.) 1.0


Mill circulating load % 150 200 A

Mill discharge, solids wt % 73 73 A


11.4.3 Regrind Cyclones

Number of clusters N° 3 A Operating N° 2 A

Stand – by N° 1 A

Cyclones/cluster N° 16 E

26 | P a g e

Operating N° 11 E

Stand – by N° 5 E

Size mm 508 (in.) 20 A

Operating pressure kPa 38

(psi) 21 A

Total Feed m3/h 4476 7162 E

% solids Wt% 35 35

Total Overflow



% solids wt% 19.7 19.7 E

Underflow per cluster



%solids wt% 73 73 A

11.4.4 Regrind Cyclone Feed Pumps

Pumps N° 3 (2 operating, 1 standby) A Pulp (per pump) m

3/h 2238 3580 E

Pulp specific gravity t/m3 1.31 1.31 E

Pump:


Control sump level Units Balance Design Code

12CONCENTRATE HANDLING

12.1 Concentrate Thickeners

Thickeners (both operating) N° 2 A

Total solids feed t/h 200 320 E


Total feed pulp flow m3/h 562 900 E

(562 x 1.6)

Feed percent solids % 28 28 E

Feed pulp specific gravity t/m3 1.27 1.27 E

Spray water m3/h, ea 200 400 E

Flocculant g/t 3.0 5.0 E

Flocculant dilution water m3/h, ea 22 43 E

Unit area m2/(t/d) 0.4 0.4 A

Thickener diameter m 42.7 A

(ft) (140)

Underflow, percent solids wt % 65 65 A

27 | P a g e

Pulp specific gravity t/m

3 1.99

Underflow flow rate m3/h, ea 77 125 E

(77 x 1.6)

Overflow, percent solids wt % 2.0 2.0 E

Overflow flow rate m3/h, ea 606 970 E

Pumps (per thickener) (426 x 1.6)

Number N° 2 (1 operating, 1 standby)

Flow rate m3/h, ea 77 125 E

Solids specific gravity Sp Gr. 4.25 (77 x 1.6)

A


Control underflow density

12.2 Clarifier

Number N° 1 A

Clarifier diameter m 42.7 E

(ft) 140

Total solids feed t/h 35 60 E

(35 x 1.6)


Total feed pulp flow m3/h 1715 2750 E

(1715 x 1.6)


Feed percent solids % 2.0 E

Feed pulp specific gravity t/m3 1.02 E

Underflow, percent solids wt % 65

Underflow flow rate m3/h 125 E

Overflow flow rate7 m

3/h 1570 2500 E

Flocculant g/t 1.0 2.0 E

Flocculant dilution water m3/h, ea 10 21 E

Pumps

Number N° 2 (1 operating, 1 standby)

Flow rate m3/h 145 230 E

(145 x 1.6)



Control Underflow density

12.3 Concentrate Storage Tanks

Storage tanks N° 4 E

Size of storage tank m 15 x 15.5 A

(diameter x height) m

3

2465 E

Effective volume per tank at

90% full m3

Effective volume total 9860 E

Feed flow rate (total) m3/h 158 253 E

Retention time h 60 (158 x 1.6)

28 | P a g e

Solids feed t/h 200 320 E

(200 x 1.6)


Feed percent solids % 65 A

Feed Pulp specific gravity t/m3 1.99 E

12.4 Feed to Concentrate Slurry Pumping and Pipeline

12.4.1 Pumping

Transfer of concentrate from storage tanks at Laguna Seca to existing pipelines near main gate, a distance approximately 15.3

km. Units Balance Design Code

Concentrate daily production t/d 4560 6000 (4560x1.3) E

Design factor N° 1.3 A Charge Pumps

Number N° 2(1 operating, 1 stand - by)

Type centrifugal

Speed variable

Pipeline Pumps

Number N° 2

Type positive displacement

Speed Adjustable

Solids feed t/h 200 260 E Solids specific gravity Sp Gr. 4.25 E

Flow rate m3/h 158 205 E

Percent Solids % 65 A

Slurry specific gravity t/m3 1.99 E

Concentrate size, passing 44 microns

(expected) % 75

(coarse) % 70

12.4.2 Pipeline

Pipeline, diameter, nominal (in.) 1-9 in. + 1- 7 in.

13 TAILINGS THICKENING AND DISPOSAL

13.1 Tailings Thickeners

Design factor N° 1.3 A Thickeners N° 3 A Total solids feed t/h 6467 8400 E (6467 x 1.3) Solids specific gravity Sp Gr. 2.76 2.76 E

Total feed pulp flow m3/h 19 389 25 200 E

(19 389 x 1.3) Feed percent solids % 27.5 27.5 E

29 | P a g e

Feed pulp specific gravity t/m3 1.23 1.23 E

Flocculant g/t 20 25 E Flocculant dilution water m

3/h, ea 148 185 E

Unit area m2/(t/d) 0.20 A

Thickener diameter m 125 A

(ft) (410) Units Balance Design Code

Underflow:

Underflow, percent solids wt % 51 51 A

Solid Feed rate t/h, ea 2156 E

Underflow flow rate m3/h, ea 2851 3706 E

t/m

3

(2851 x 1.3)

Pulp specific gravity 1.48 1.48 A

Overflow: m

3/h, ea

Overflow flow rate 3612 4700 E

m

3/h, total

(3612 x 1.3)

10 836 14 100 E

(10 836 x 1.3)

pH 9.5 to 11 A

13.2 Thickener Overflow Tanks and Pumps

Tailings thickener overflow m3/h 11 104 14 435 E

Concentrate thickener overflow m3/h 607 971 E

Tailings pond reclaim water8 m

3/h 2183 E

13.3 Laguna Seca Tailings Disposal System

Solids feed – Phase IV + 4th

BM t/h 6063 A

Solids feed – Phase OGP1 t/h 6467 A

Solids feed – Total system t/h 12 530 E

Slurry flow rate–Ph. IV + 4th

BM m3/h 8025 E

Slurry feed – Phase OGP1 m3/h 8553 E

Slurry flow rate – Total system m3/h 16 578 E

Slurry, percent solids wt % 51 A

Slurry, specific gravity Sp Gr. 1.48 E

Water in tailings m3/h 12 039 E

l/sec 3344 E

Units Balance Design Code 14 REAGENTS

14.1 Lime

30 | P a g e

14.1.1 Material Characteristics

Form Burnt lime

Typical consists

-100 % passing mm 19

Chemical formula t/m

3

CaO

Bulk density 0.9 to 1.0

Angle de repose degrees 50

Active CaO % 77.8

Specific heat at 37.8 ºC cal/g 0.19

Safety: Irritation and burned skin

Stability Degradable if storage wet

Storage life limitation None, if kept dry

Corrosion data no corrosive

14.1.2 Consumption

Per ton of mill feed k/t 1.6 2.0 A

Total consumption t/h 10.7 17.3 E

(1.6 x 6667/1000) (2.0 x 8667/1000)

t/d 256 416 E

14.1.3 Milk – of Lime Storage Tanks

Number of tanks grinding area N° 2

Number of tanks flotation area N° 2

Storage tank grinding area m 11 x 11

(diameter x height)

Storage tank grinding area m 5 x 5

(diameter x height)

14.2 Collector

D - 111 g/t 24 45 A

A 317 g/t 10 15 A

14.3 Frother

X 133 g/t 11 15 A


Pine oil g/t 5 10 A

14.4 Activator9

NaSH g/t

80 110 A

14.5 Flocculant10

14.5.1 Tailings TEC g/t 20 25 A

2050

g/t

2 5 A

14.5.2 Concent. TEC

2050

31 | P a g e

14.6 Anti-scalant

Mill sperce 8120 ppm 4.5 A

15 FILTER PLANT -By Others

resumen extracto criterio diseño ogp-1

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