Previous work that was conducted on a large low-gradeGrade CopperCopper Project suggested that a conventional method featuring a crush-grind-float and saleSales of copper concentrateCopper concentrate method was not economically feasible due to the hardness and low gradeLow Grade of the copper oreCopper ore, which would require a significant amount of energy for grindingGrinding and therefore a high capital and operating costOperating Cost. For large low gradeLow Grade copperCopper projects, the conventional crush-grind-float is not financially viable even at currentCurrent copperCopper prices. However new technologyTechnology such as ore sorting, high pressure grindingGrinding rolls (HPGR) and coarse particle flotation (CPFCoarse Particle Flotation (CPF)) can reduce energy costs significantly, making these resources technically and commercially viable. Energy is usually the largest cost for such projects, so reducingReducing the energy costs to process low gradeLow Grade ores is critical. As an example, CPFCoarse Particle Flotation (CPF) can achieve 80% recoveryRecovery at 500 microns, significantly reducingReducing energy costs. If the main mineralised hosts in the copperCopper deposit are coarse grained the process is more amenable than for fine grained disseminated ores. Similarly, sensor-based ore sorting is a mineral pre-concentration technologyTechnology in which particles of material are separated based on some physical or chemical property as measured or inferred by a sensor. It is used to upgrade the process feed by identifying and rejecting waste material early in the miningMining process. Sensor-based ore sorting results in the pre-concentration of valuable materials into a lower gross volume. For disseminated copper oresCopper ore the results can improve gradesGrade dramatically. Heap leachingHeap leaching is another option due to the vast scale of these orebodies and the low-gradeGrade nature of the ores. New innovations using catalysed chemistry have changed process options for heap leachingHeap leaching, particularly using HPGR which allows finer crush sizes. Bacterial leachingBacterial leaching at 60 centigrade overcomes the passivationPassivation of chalcopyriteChalcopyrite and pyritePyrite causing the ore to generate acid for leachingLeaching. The costs associated with heap leachingHeap leaching compared to a whole ore floatation circuit are considerably lower. In addition, the removal of fines and flotationFlotation of a pyritePyrite copper concentrateCopper concentrate can be used to feed a roasterRoasters to produce acid on site reducingReducing operating costsOperating Cost for the heap leachHeap leach.

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Options for Large Low Grade Copper Projects

  • D. Connelly

摘要

Previous work that was conducted on a large low-gradeGrade CopperCopper Project suggested that a conventional method featuring a crush-grind-float and saleSales of copper concentrateCopper concentrate method was not economically feasible due to the hardness and low gradeLow Grade of the copper oreCopper ore, which would require a significant amount of energy for grindingGrinding and therefore a high capital and operating costOperating Cost. For large low gradeLow Grade copperCopper projects, the conventional crush-grind-float is not financially viable even at currentCurrent copperCopper prices. However new technologyTechnology such as ore sorting, high pressure grindingGrinding rolls (HPGR) and coarse particle flotation (CPFCoarse Particle Flotation (CPF)) can reduce energy costs significantly, making these resources technically and commercially viable. Energy is usually the largest cost for such projects, so reducingReducing the energy costs to process low gradeLow Grade ores is critical. As an example, CPFCoarse Particle Flotation (CPF) can achieve 80% recoveryRecovery at 500 microns, significantly reducingReducing energy costs. If the main mineralised hosts in the copperCopper deposit are coarse grained the process is more amenable than for fine grained disseminated ores. Similarly, sensor-based ore sorting is a mineral pre-concentration technologyTechnology in which particles of material are separated based on some physical or chemical property as measured or inferred by a sensor. It is used to upgrade the process feed by identifying and rejecting waste material early in the miningMining process. Sensor-based ore sorting results in the pre-concentration of valuable materials into a lower gross volume. For disseminated copper oresCopper ore the results can improve gradesGrade dramatically. Heap leachingHeap leaching is another option due to the vast scale of these orebodies and the low-gradeGrade nature of the ores. New innovations using catalysed chemistry have changed process options for heap leachingHeap leaching, particularly using HPGR which allows finer crush sizes. Bacterial leachingBacterial leaching at 60 centigrade overcomes the passivationPassivation of chalcopyriteChalcopyrite and pyritePyrite causing the ore to generate acid for leachingLeaching. The costs associated with heap leachingHeap leaching compared to a whole ore floatation circuit are considerably lower. In addition, the removal of fines and flotationFlotation of a pyritePyrite copper concentrateCopper concentrate can be used to feed a roasterRoasters to produce acid on site reducingReducing operating costsOperating Cost for the heap leachHeap leach.