Mine Process Report PDF

MIDDLE EAST TECHNICAL UNIVERSITY
MINING ENGINEERING DEPARTMENT
MINE 427
PROCESS DESIGN PROJECT

FINAL REPORT
SUBMITTED BY
KBRA KAHRAMANOLU
DLAN DUMAN
ALP GEZER
DENZ DEMRCOLU
1
TABLE OF CONTENTS
ABSTRACT ............................................................................................................................................... 5
METHOD OF PROCESS ............................................................................................................................. 6
DESIGN CRITERIA ..................................................................................................................................... 7
INTRODUCTION ....................................................................................................................................... 9
FLOWHEET OF PROCESSING PLANT ...................................................................................................... 10
MATERIAL BALANCE .............................................................................................................................. 14
PROCESS EQUIPMENT LIST .................................................................................................................... 16
ENVIRONMENTAL CONSIDERATION ...................................................................................................... 18
CAPITAL COST ESTIMATES ..................................................................................................................... 19
OPERATING COST ESTIMATES ............................................................................................................... 20
ECONOMICAL ANALYSIS ........................................................................................................................ 22
CONCLUSION ......................................................................................................................................... 25
APPENDICES........................................................................................................................................... 25
1)
CRUSHING CIRCUIT ........................................................................................................................ 25

2.1) SELECTON OF PRMARY CRUSHERS .................................................................................................................... 25
2)
SCREEN SELECTION ........................................................................................................................ 27

3.1) SELECTON OF 2 MM SCREEN: ........................................................................................................................... 28
3)
GRINDING & CLASSIFICATION CIRCUIT.......................................................................................... 28

4.1) SAG MLL SELECTON ....................................................................................................................................... 28
4.2) BALL MLL SELECTON ....................................................................................................................................... 30
4.2.1) Ball Mill in First Grinding Process ........................................................................................ 30

4.2.2) Ball Mill Selection in Regrinding Circuit .............................................................................. 31
4.3) GRNDNG CRCUT CALCULATONS ..................................................................................................................... 32
4.3.1) Selection of Hydrocyclone for first grinding process .......................................................... 32

4.3.2) Selection of Hydrocyclone for regrinding process .............................................................. 35
4)
FLOTATION CIRCUIT....................................................................................................................... 39
4.1) MASS BALANCE CALCULATONS ......................................................................................................................... 39
4.1.1) First Flotation Process ......................................................................................................... 40

4.1.2) Second Flotation Process .................................................................................................... 41
4.2) FLOATATON TME CELL SELECTON .................................................................................................................... 42
4.2.1) First Flotation Process ......................................................................................................... 42

4.2.2) Second Flotation Process .................................................................................................... 44
4.3) Conditioner Tank Calculations ....................................................................................................... 45
2
4.3.1) FOR CONDTONNG TANK 1(FOR FRST FLOTATON PROCESS) ............................................................................... 45

4.3.2) FOR CONDTONNG TANK 2(FOR SECOND FLOTATON PROCESS) .......................................................................... 45
5) DEWATERING .................................................................................................................................... 46
5.1) THCKENER SELECTON ..................................................................................................................................... 46
5.1.1) Feed of Regrinding Process ................................................................................................. 46

5.1.2) Pyrite Thickener .................................................................................................................. 46
5.1.3) Chalcopyrite Thickener........................................................................................................ 46
5.2) FLTER SELECTON ........................................................................................................................................... 47
5.2.1) Chalcopyrite Filter .............................................................................................................. 47

5.2.1) Pyrite Filter ......................................................................................................................... 47
6) PUMP SELECTION .............................................................................................................................. 47
6.1) PUMP FROM SUMP TO HYDROCYCLONE N FRST GRNDNG PROCESS ........................................................................ 47
6.2) PUMP FROM SUMP TO HYDROCYCLONE N REGRNDNG PROCESS ............................................................................. 50
6.3) PUMP FROM WET SCREEN TO CYCLONE .............................................................................................................. 53
6.4) PUMP FOR OFLOW OF CYCLONE (BALL MLL TO PUMP) .......................................................................................... 53
6.5) PUMP FOR FROTH OF SCAVENGER ...................................................................................................................... 54
6.6) PUMP FOR FROTH OF CLEANER2........................................................................................................................ 54
6.7) PUMP FOR TALNG OF CLEANER2 ...................................................................................................................... 55
6.8) PUMP FOR FROTH OF CLEANER1........................................................................................................................ 55
6.9) PUMP FOR OFLOW OF CYCLONE ....................................................................................................................... 56
6.10) PUMP FOR FROTH OF SCAVENGER .................................................................................................................... 56
6.11) PUMP FOR TALNG OF SCAVENGER .................................................................................................................. 57
6.12)PUMP FOR TALNG OF CLEANER1 ..................................................................................................................... 58
6.13) PUMP FOR FROTH OF CLEANER1...................................................................................................................... 58
6.14) PUMP FOR FEED OF PYRTE FLTER ................................................................................................................... 59
6.15) PUMP FOR FEED OF CHALCOPYRTE FLTER......................................................................................................... 59
6.16) PUMP FOR FEED OF WATER DAM FROM REGRNDNG THCKENER .......................................................................... 60
6.17) PUMP FOR FEED OF WATER DAM FROM PYRTE THCKENER .................................................................................. 60
6.18) PUMP FOR FEED OF WATER DAM FROM CHALCOPYRTE THCKENER ....................................................................... 61
6.19) PUMP FOR TALNG DSPOSAL ......................................................................................................................... 61
7) TAILING .............................................................................................................................................. 62
8) SELECTION OF AUXILIARY FACILITIES AND EQUIPMENTS ................................................................. 62
8.1) SELECTON OF STATONARY GRZZLY AND HOPPER .................................................................................................. 62
8.2) SELECTON OF GRZZLY FEEDER ........................................................................................................................... 62
8.3) SELECTON OF BELT CONVEYOR ......................................................................................................................... 63
8.4) STOCKPLE CALCULATONS ................................................................................................................................ 64
REFERENCES .......................................................................................................................................... 65
TABLE OF FIGURES
Figure 1: Crushing Circuit........................................................................................................ 27
Figure 2: Particle Size vs. Cumulative Passing (Pourghahramani, 2012) ................................ 29
Figure 3 : Circulating Load of Ball Mill .................................................................................. 30
Figure 4: Ball Mill Product Particle Distribution (M.Irannajad, 2006) ................................... 31
Figure 5: Circulating Load Of Regrinding Proces ................................................................... 31
Figure 6: Hydrocyclone diameter vs. d50 (Hoten, ., 2010, p70).......................................... 34
Figure 7: Pressure Drop vs. Cyclone Capacity(Hoten, ., 2010, p69) ................................... 34
Figure 8: Hydrocyclone underflow flow rate ........................................................................... 35
Figure 9: Hydrocyclone diameter vs. d50 (Hoten, ., 2010, p70).......................................... 37
Figure 10: Pressure Drop vs. Cyclone Capacity(Hoten, ., 2010, p69) ................................. 38
Figure 11: Hydrocyclone underflow flow rate ......................................................................... 38
Figure 12: Selection of Pump (Metso Expect Results, 2012) .................................................. 49
Figure 13: Pump Characteristics (Metso Expect Results, 2010) .............................................. 50
Figure 14: Selection of Pump (Metso Expect Results, 2012) .................................................. 52
Figure 15: Pump Characteristics (Metso Expect Results, 2012) .............................................. 52
ABSTRACT
This report is prepared as a preliminary feasibility study of copper processing plant and
includind all steps of the circuits through the process.
Open pit mining is selected as mining method. The run of mine ore has 1% copper grade in
chalcopyrite and is associated with pyrite and quartz as waste minerals. Life time of the
mineral processing plant is 15 years.
The run of mine ore has lots of steps in terms of mineral processing. In this report, the basic
steps that should be applied to mineral for obtaining copper, are crushing with jaw crusher,
grinding with sag mill, flotation with tailing Quartz, regrinding with ball mill, and reflotation
with tailing pyrite, respectively. And finally, obtained chalcopyrite from second flotation is
sent to thickener, and after filter, the valuable mineral is achieved.
First of all, detailed of the plant, capital cost, and operating cost calculations are done. After
that, necessary environmental concentration is presented. Finally, economic analysis is made
in order to determine the feasibility of the project
METHOD OF PROCESS
The flow of the copper ore starts from drilling and blasting operations in the field. . After that,
loosened ore is transported to processing plant and fed to a jaw crusher using a grizzly. The
run of mine ore has lots of steps in terms of mineral processing. In this report, the basic steps
that should be applied to mineral for obtaining copper are crushing with jaw crusher, grinding
with sag mill, flotation with tailing Quartz, regrinding with ball mill, and re-flotation with
tailing pyrite, respectively. And finally, obtained chalcopyrite from second flotation is sent to
thickener, and after filtration, the valuable mineral is achieved.
Firstly, the size of run of mine is decreased to 185 mm from 1000 mm with jaw crusher as
primary crusher. Also, jaw crusher is fed with 300 tph run of mine. The selected type of jaw
crusher is Model C-145 from Metso Companys Equipment, and feed opening width is 1400
mm, feed opening depth is 1000 mm and power consumption is 200 kW. Then, bulk
concentrate is sent to the sag mill. 185 mm ore is grinded to 2 mm and sag mill is fed with
260 tph-concentrates. The selected sag mill has 7.32 m (24 ft) diameter and 3 m length and
required motor power is 1250 kW. After sag mill, bulk is sent to the 2 mm aperture-screen for
identifying the pieces that are not grinded by sag mill to 2 mm-size. Then, the concentration is
sent to the hydrocyclone. The pieces that are bigger than 149 micron (100 mesh) are sent to
ball mill after hydrocyclone and the pieces that are equal and less than 149 micron are sent to
conditioner tank. Secondly, the bulk concentration is sent to the flotation part. From first
flotation part, quartz is taken as tailing. The bulk is sent to regrind part. The size of bulk is
decreased to 74 micron (200 mesh) by ball mill. The reason of regrinding is that being found
in interlocking chalcopyrite and pyrite can separate easily when their size are decreased to 74
micron. Thirdly, ore is sent to the second flotation part. In second flotation, chalcopyrite and
pyrite separate from each other. Finally, chalcopyrite is sent to thickener and filtration part, so
the valuable mineral is obtained.
DESIGN CRITERIA
Primary crusher
Daily feed rate: 6,060 ton/day

Feed size:1000 mm
Product size:185mm
Daily working hour: 16hours
Stockpile
Capacity: 25250m3
Sag Mill
Daily feed rate: 4070.304 m3/day

Feed size: 185 mm
Product size: 2mm
Working grindability index: 13,5kwh/t
4mm-screen for classification
Feed size: 4 mm
Product size: 0,149mm
0.149mm, Hydrocyclone for classification
Ball Mill

Feed size: 0.149 mm
Product size: 0,74mm
0.74mm, Hydrocyclone for classification
Pulp-Solid rate: %40
Rougher Time (min) = 13 min
Scavenger Time (min) = 13 min
Cleaner1 Time (min) = 9.75 min
Cleaner2 Time (min) = 9.75 min
Flotation
Regrinding product size: 0,074 mm
Rougher Time (min) = 16 min
Scavenger Time (min) = 16 min
Cleaner1 Time (min) = 11 min
(Regrinding) Feed rate: 10.60 lt/sec
Feet Pulp-Solid rate: %40
Product Pulp-Solid rate: %60
48 m2/t/day settling unit area
Thickening Area 41.08 m2
Dewatering
(Pyrite) Feed rate: 4.41 lt/sec
48 m2/t/h settling unit area
(Chalcopyrite) Feed rate: 4.48 lt/sec

48 m2/t/day settling unit area
(Pyrite) Feed rate: 1.52 lt/sec
Filter cake moisture: %9
Unit Capacity: 24000 kg/m2/day
Filtering
(Chalcopyrite) Feed rate: 1.66 lt/sec

Filter cake moisture: %8
Unit Capacity: 12000 kg/m2/day
Tailing: 14367.6 ton/day
Pupl rate: 14883 m3/day
Tailing Disposal
INTRODUCTION
The main purpose of the project is the liberation of Chalcopyrite and Pyrite from the run of
mine ore which includes quartz as gangue minerals. The ore processing facility consists of
conventional crushing, grinding flotation, and filtration. The average feed grades are
approximately pyrite 6% and chalcopyrite 3%. Expected Cu grade in the final concentrate is
22% with 85% recovery and pyrite recovery is also 60%.
Properties of Run of Mine Ore
Ore Reserve: 30 Million tons, averaging 1% Cu, with 6% pyrite, 3% chalcopyrite,
90% quartz.
Ore Grindability Index; 13,5 kWh/ton
Open Pit Mining; 330 working days a year
Top size (assumed): 1000 mm
A) Theoretical Life of mine
By Taylors formula;
L= 0.2 x (Tonnage)0.25, L= 0.2 x (30,000,000)0.25=14.8~ 15 years
B) Daily Production
30,000,000/15= 2,000,000 ton/year
2,000,000/330= 6,060 ton/day
C) Hourly production of plant
6060/16=~ 380 tph hourly production for the primary crusher circuit
6060/24= ~ 260 tph hourly production for the rest of the plant
D) TrueDensiy of Block Material and Bulk Density
True Density of r.o.m ore:
Copper is attached with chalcopyrite and the missing 1% in the mineralogical analysis is some
minor gangue mineral component.
The volume of the in-situ material has 40% porosity and 60% solid when broken. Considering
the swelling factor, the bulk density will be equal to;
FLOWHEET OF PROCESSING PLANT

R.O.M.
1
1
Stationary
Grizzly
1
Hopper
1
3
Grizzly Feeder
1
1
Jaw Crusher
4
5 Belt Conveyor
Stockpile
5
5
10
5
6
Water
7
7
Sag Mill
7
8
Wet Screen
Water
10
12
9
Pump &Sump
11
13
12
Cy
Conditioner Tank
12
10
Hydrocyclone
11
BallMill
14
23
17
15
16
13
14
Rougher
17
Scavenger
18
19
22
15
17
20
Cleaner 1
21
16
Cleaner 2
23
22
24
11
Tailing Dam
24
Water
Thickener
(concentrate)
18
25
2
26
2
30
27
19
Ball Mill
27
28
Water
29
20 Pump &Sump
21
Hydrocyclone
29
31
30
0
Pyrite
22
Cy Conditioner Tank
44
31
30
Filter
31
34
34
37
32
33
23
Rougher
42
35
24
Scavenger
26 Thickener
36
37
25
Cleaner 1
40
38
12
38
40
28
Thickener
39
44
43
27
29
Filter
45
Chalcopyrite
13
Water Dam
41
MATERIAL BALANCE
Hourly Capacity
Ore
Water
(ton)
(ton)
Strea
m No.
Stream Name
1
2
Feed of Hopper
Undersize of
Grizzly Feeder
Feed of Jaw
Crusher
Feed of Belt
Conveyor
Feed of Stockpile
Sag mill Fresh
Feed
Water Inlet
Sag mill Product
Circulating Load
of Sag Mill
Product of Wet
Screen
380
80
380
80
Pulp
Solid
(%) by
Weigh
t
-
Total
(ton)
300
300
380
380
260
10
11
SG
Q
(lt/sec
)
Operatin
g Hour
(h)
16
16
380
24
380
260
24
24
279.56
19.56
65
69.89
4.89
69.89
349.45
24.45
80
80
2.06
2.06
47,11
3.30
24
24
24
260
65
325
80
2.06
204.91
24
Water Inlet
325
492.14
24
650
557.14
1207.14
54
1.53
219.25
24
650
557.14
1207.14
54
1.53
219.25
24
12
Total Feed of
Pump Sump
Total Feed of
Cyclone
Oflow of Cyclone
390
167.14
557.14
70
1.82
85.12
24
13
Uflow of Cyclone
260
390
650
40
1.35
134.13
24
14
260
390
650
40
1.35
134.13
24
15
Product of
Conditioner Tank
Feed of Rougher
271.54
407.31
678.85
40
1.35
140.08
24
16
Tailing of Rougher 248
372
620
40
1.35
127.94
24
17
Froth of Scavenger 8.54
12.81
21.35
40
1.35
4.41
24
18
Tailing of
Scavenger
239.46
359.19
598.65
40
1.35
123.53
24
19
Froth of Rougher
23.54
35.31
58.85
40
1.35
12.14
24
20
Feed of Cleaner1
24.24
36.36
60.6
40
1.35
12.50
24
21
Tailing of Cleaner1 3.7
5.55
9.25
40
1.35
1.91
24
22
Froth of Cleaner2
1.05
1.75
40
1.35
0.36
24
3
4
4
5
6
7
8
9
11
0.7
14
Hourly Capacity
Stream Stream Name
No.
Pulp
24
Froth of Cleaner1
20.54
30.81
51.35
Solid
SG
(%) by
Weight
40
1.35
25
Water Discharge
17.12
17.12
26
20.54
13.69
34.99
60
1.85
5.13
24
27
Product of
Thickener
Feed of Ball mill
51.34
26.89
78.23
66
2.01
10.79
24
28
Water Inlet
28.32
28.32
24
29
51.34
42.01
93.35
55
1.73
14.99
24
30
Feed of
Pump&Sump
Oflow of Cyclone
30.8
13.20
44.00
70
2.16
5.66
24
31
Uflow of Cyclone
20.54
27.23
47.77
42
1.49
8.89
24
32
Feed of Rougher
23.44
31.07
54.51
42
1.49
10.14
24
33
Tailing of Rougher 11.89
15.76
27.65
42
1.49
5.15
24
34
Froth of Scavenger 1.7
2.25
3.95
42
1.49
0.73
24
35
10.19
13.51
23.70
42
1.49
4.41
24
36
Tailing of
Scavenger
Froth of Rougher
11.55
15.31
26.86
42
1.49
5.00
24
37
Tailing of Cleaner1 1.2
1.59
2.79
42
1.49
0.52
24
38
Froth of Cleaner1
13.72
24.07
42
1.59
4.48
24
39
Water Discharge of Chalc. Thickener

Water Discharge of Pyrite Thickener
Feed of Water Dam -
10.27
10.27
24
10.11
10.11
24
20.38
20.38
24
Feed of Pyrite
Filter
Feed of Chalc.
Filter
Product
(Chalcopyrite)
Product (Pyrite)
10.19
3.4
13.59
75
2.48
1.52
24
10.35
3.45
13.8
75
2.31
1.66
24
10.35
10.35
10.19
10.19
40
41
42
43
44
45
Ore
(ton)
Water
(ton)
Total
(ton)
10.35
15
Q
Operating
(lt/sec) Hour (h)
10.60
24
24
PROCESS EQUIPMENT LIST

Equipme
nt
Number
Quantity
Motor
Power
(kW)
Equipment Description
2007Cost ($)
Grizzly
30000
Stationary Hopper, 50 m3
17000
7.6
VF561-2V Grizzly
Feeder(width=3000mm, length=6100
mm)
2981
223.8
C145 Jaw Crusher(Feed opening

depth=1100 mm, width=1400 mm)
539152
106
Belt Conveyor (Jaw Crusher to

Stockpile)(W=914 mm, L= 90 m)
204669
1250
Sag Mill (D=7.32 m, L=3m)
6204838
1.5
Wet Screen (2 mm, L = 2.5 W = 6.15 m)
23945
44
MR250 model Pump & Sump (250 mm

inlet 200 mm outlet diameter)
13509
10
Cyclone (cyclone Diameter=76 cm,

apex diameter=17 cm)
13714
11
710
Ball Mill (3.81x3.66 m)
961211
12
22
XB-3500 Model
Conditioner Tank (50 m3)
100000
13
1100
Standard Rougher Flotation Cells

(Wemco,15 cells in series with 6,98 m3)
1300000
14
600
Standard Scavenger Flotation Cells

(Wemco,14 cells in series with 7.13 m3)
850000
15
200
Standard Cleaner1 Cells

250000
Standard Cleaner2 Cells

250000
200
16
16
Equipment
Motor
Power
(kW)
Equipment Description
2007Cost ($)
Number
Quantity
18
Thickener (D = 7.2 m)
74214
19
6.74
MR-100 Model Pump&Sump (75 mm

inlet, 50 mm outlet diameter)
13509
20
Cyclone (cyclone Diameter=66 cm,

apex diameter=7 cm)
11209
21
108
Ball Mill (2.13 2.13).
604080
22
17
XB-2500 Model Conditioner Tank

(10 m3)
27019
23
1100
Standard Rougher Flotation Cells

(Denver, 16 cells in series with 0.61 m3)
900000
24
600

(Denver, 18 cells in series with 0.27 m3)
600000
25
200

(Denver, 12 cells in series with 0.28m3)
250000
26
1.5
Thickener (chalcopyrite)
(D = 5.13 m)
8006
28
1.5
Thickener (pyrite)
(D = 5.09 m)
7006
29
Denver Sala Filter (pyrite)

(D=3.0 m, L=3.0 m)
5503
30
Denver Sala Filter (chalcopyrite)

(D=1.8 m, L=3.0 m)
5503
Pipe (400 m)
950000
16
250
Pump&Sump
1200000
TOTAL
15352313
17
ENVIRONMENTAL CONSIDERATION
Copper can interrupt the activity in soils, as it negatively influences the activity of
microorganisms and earthworms. It is not decomposed by itself in nature, it
can accumulate in plants and animals. Copper is a trace element for human
beings. Although the human body can tolerate a high amount of copper, its
very excessive amounts can cause health problems. Because of this reasons a complete mine
planning and reclamation needs to be prepared at the beginning of the life of the copper
mines.
Tailing of the plant includes pyrite, FeS2, it can be oxidized producing SO2. It causes H2SO4
production when mixed into water, which is very dangerous for all livings. On the other hand
SO2 causes air pollution. Therefore a tailing dam shoul be constructed.
Acid rock drainage is the main problem in tailing dams.To control acid rock drainage can be
solved by neutralizing for example by adding finely crushed
limestone to the tailings,
sulphide removal and seperate storage in the latter stages of the mine.
The drained water in the tailing dam is recycled in a suitable way and used in a grinding
circuit and other processes where water is needed.
Since this is a surface mine activity, there will be a pit void in left after the mining activity. To
revitalize the mining environment the open pit must be reclaimed. To reclaim it, either the pit
void will be backfilled with the waste material, as long as it is not too expensive, or backfilled
with water to create an artificial lake.
Another problem is noise due to the crushing and grinding circuits. That noise is prevented by
the usage of personal hearing protection devices such as ear plugs, noise stopper, ear muffs.
Mining and mineral production are also sources of dust, which is generated at almost all
stages of operation, contributing to air pollution. Dust is produced by open pits and by
crushing and grinding operations. In crushing circuit, there are dust collectors and water
sprays. Green area around the pit favors the quality of air.
In conclusion, to prevent the hazards discussed above, necessary precautions are taken to
protect the environment.
18
CAPITAL COST ESTIMATES

First of all, the 2007 and 2012 Marshall and Swift Cost Indexes was found which are 1453, 2,
1598,76 respectively. The costs of equipment in matche.com are costs of year 2007.
Therefore, we converted prices to present values by using the formula:
Cost 2007
Cost 2012
M & S CostIndex 2007

M & S CostIndex 2012
Our equipment cost is 15352313$ in 2007

Our equipment cost is 16890079$ in 2012
Preliminary Cost Estimation

The calculations are successes according to Exponential Cost - Capacity Ratio
A
B
C
D
E
F
G
H
I
J
K
Types of Expenditure
Equipment
Installation
Process Piping
Instrumentation
Buildings and Site Development
Auxiliaries (Electricity, water, etc.)
Outside Lines
Total Physical Plant
Engineering and Construction
Contingencies
Size Factor
Total Cost
Formula
a
1,43xa
0,20xb
0,10xb
0,40xb
0,10xb
0,10xb
b+ c+ d+ e+ f+ g
0,40xh
0,30xh
0,05xh
h+ i+ j+ k
Exchange rate of the dollar to YTL (on 15.01.2013) = 1, 77 TL

The total capital cost is 72996410.24$ =130000000 TL
19
Cost ($)
15352313
21953807.59
4390761.518
2195380.759
8781523.036
2195380.759
2195380.759
41712234.42
16684893.77
12513670.33
2085611.721
72996410.24
OPERATING COST ESTIMATES

Annually operating cost calculations are done based on Murgul Copper Mine due to the
similarities of the flow of the process and equipment used. But, the annual production rates
differ for both of the companies. Costs are given as their TL equivalents.
Table 1: Personnel Details
Type of Personnel
Number of Personnel
General Manager
Assistant General Manager (Head Engineer)
Mining Engineer
Mechanical Engineer
Electrical Engineer
Chemical Engineer
Safety Engineer
Marketing and Sales Manager
Commercial & Financial personnel
Security
Secretary
Doctor
Labor
65
Total
89
20
Table 2: Salaries
A
General Manager
Assistant General Manager (Head
Engineer)
Mining Engineer
Mechanical Engineer
Electrical Engineer
Chemical Engineer
Safety Engineer
Commercial & Financial Manager
Marketing and Sales Manager
Security
Secretary
Doctor
Labor
Total
# of
A
Gross Salary
(TL/Month)
8,000
Total Gross
Salary
(TL/Month)
8,000
Annual
Gross Salary(TL)
96,000
1
1
6
1
1
1
1
3
2
3
3
1
65
89
5,000
3000
2,500
2,500
2,500
2,500
3,000
3,000
1,000
1,000
3,000
1,000
38,000
5,000
18,000
2,500
2,500
2,500
2,500
9,000
6,000
3,000
3,000
3,000
65,000
3,382,000
60,000
216,000
30,000
30,000
30,000
30,000
108,000
72,000
36,000
36,000
36,000
780,000
40,584,000
Total annual salary of employees is 40,584,000TL
Direct and Indirect costs

Electricity : 9694 kW * 0.21 kW/h * 24 h* 330 day = 14,657,328 TL
Cost of flotation reagents: 37530 kg is consumed per year * 2 ($/kg) = 75060 $ = 112,590 TL
Property taxes: 1-2 % of the capital cost anually.
Property taxes = (1.5/100) * 100,500,000 = 1,507,500 TL
Insurance : 1.25 % of the capital cost anually.
Insurance = (1.25/100) * 100,500,000 = 1,256,250 TL
Maintanence Cost : 4 % of the capital cost anually.
Maintanence Cost = (4/100) * 100,500,000 = 4,020,000 TL
Delivered cost = 18 TL/ton x 280800 = 5,054,400 TL
Total annual salary of employees = 1,428,000 TL
Annual Operating Cost of the Plant: 27,113,000 TL
Other Cost = 20,000,000 TL / year
Mining Cost = 37.5 TL/ton * 10000 ton/day* 300 days = 112,500,000 TL
Total Annual Cost = 160,537,000 TL
21
Total direct, indirect and fixed costs = 160,537,000 + 100,500,000 = 261,037,000 TL

Overhead Cost: 8 % of the total direct, indirect and fixed costs
Overhead Cost = (8/100) * 261,037,000 = 20,882,960 TL
Research: 5 % of the total direct, indirect and fixed costs
Research = (5/100) * 261,037,000 = 13,051,850 TL
Total Annual Cost = 294,971,810 TL
ECONOMICAL ANALYSIS
Final copper concentrate is 8,029.50$/ton (London Metal Exchange price at
15.01.2013) = 14212.22 TL/ton
Yearly Chalcopyrite Concentrate Production = 10.35 tph*24h*330day=81972 tpy
Annual Revenue = 14212.22 TL/ton * 81972 tpy = 1165004098 TL/year
Cash Flow Diagram:
1165004098 TL 1165004098 TL 1165004098 TL
n = 15 years
0
294,971,810 TL 294,971,810 TL 294,971,810 TL
130000000
IRR Estimation:
Initial cost: 130000000
Total annual cost: 294,971,810 TL
Annual revenue: 1165004098TL
Before Tax: 870032288 TL
22
For IRR = 166 %

PW = -130000000 - 294,971,810
2.66 15 1
2.66 15 1
+
28,424,430,000
1.66 x 2.66 15
1.66 x 2.66 15
PW = -130000000 - 177,693,786 + 279,108,316 = 912949.7TL

For IRR = 170 %
PW = -130000000 - 294,971,810
2.715 1
2.715 1
+
28,424,430,000
1.7 x 2.715
1.7 x 2.715
PW = -130000000 173,512,771 + 272,541,084 = -1477594.642TL
166
170
x
x
912949.7
1477594.6
x = 168,5
IRR = 169 %
Profit Estimation:
MARR = 15 %
Initial cost: 130000000 TL
Total annual cost: 294,971,810 TL
After cost analysis, the profit is obtained from this mineral processing. The applicability of
this plant is a profitable process. Net profit, after 15 years, is 19439523858 TL. According to
MARR that is 15%, net present value is 5663502043 TL.
23
24
Payback Period:
PBP =
130000000
1165004098 - 294971810
2 months
Payback period is nearly 2 months.
CONCLUSION
The main purpose of the project is to design a processing plant for an ore reserve that is
30000000 tons which consists of chalcopyrite, pyrite and quartz and to be operated in 15
years. Hence, the costs and number of equipments are optimized. As a result of the
calculations, it is found out that the payback period of the project is very short according to
real cases. Also, IRR of the project is very high. These results are because of the optimistic
attitudes to cost minimizations and profit maximizations. Besides those technical points it is
also learned planning in project management, working with deadlines and cooperating with
group members.
APPENDICES
1) CRUSHING CIRCUIT
2.1) Selection of Primary Crushers
Since the hourly capacity is 300 thp and it is less than 800 tph, the selection of a jaw crusher
is more suitable as a primary crusher.
The capacity of the crushing plant should be adapted for the interpretation of tables;
The specific gravity is given as 2.7 for the capacities and technical specifications chart of the
Metso Minerals C-Series Jaw Crushers.
= ~ 386 tph hourly production for primary crusher selection.
Since the top size of the r.o.m ore is 1000 mm, the required feed opening of the jaw crusher
should be at least;
1000mm/0.9= 1111 mm, min. feed opening depth mm
25
Table 3: Capacities and technical specifications of METSO C Series jaw crushers (Metso Expect
Results, 2012)
Model C-145
Feed Opening width; 1400mm
Feed Opening depth; 1100 mm
Capacity range; 325 to 445 mtph
Power Consumption; 200 kW (300HP)
Product Size; 0-185mm
Since our feed opening should be at least 1111 mm, and our product size should be at most
200 mm, it is convenient to select C-145 intersecting to 0-185 mm product size jaw crusher
equipment.
Reduction Ratio= 1000mm/185mm=5.40 It fits with the jaw crusher reduction ratio range.
26
Figure 1: Crushing Circuit
2) SCREEN SELECTION
The following formula from the text book (Hoten, 2010, p 40) is used while selecting the
screens.
A: Net screening area, m2

T: Total material fed to the screen, tph
C: Empirical unit capacity, t/ m2/ h
K1: Materials bunk density correction factor
27
K2: Screen overflow correction factor

K3: Correction factor for the particle smaller than the half of the screen aperture size
K4: Correction factor for wet screening
For determination of K1, K2 and K3 factor, graph 2.4 and graph 2.5 is used (Hoten, 2010, p
41-42).
3.1) Selection of 2 mm Screen:

The capacity of 2mm screen will be;
T =260 tph
C (for 2 mm aperture size); 9 t/ m2/ h
K1 (for 1.68 t/ m3 material bulk density):1.68/1.6=1.05
K2 (for 7% screen overflow):0.91
K3 (for 90% feed passing 2 mm aperture size): 2
2
A = 2.5 W2, W = 2.46 m, L = 2.5W = 6.15 m
3) GRINDING & CLASSIFICATION CIRCUIT

4.1) Sag Mill Selection
Top size:-185 mm
The hourly solid capacity: 260 ton/hour.
The desired product size of sag mill: 2 mm.
wi: 13.5 kwh/ton
The calculation of specific (required) power of sag mill:
W = 10 wi(
(required specific power for all grinding
process)
28
For ball mill:

Wball mill = 10 wi(
For sag mill, the specific power is:
-
=4.81 kwh/ton
Calculation of length and width of sag mill:

P=pKLD2.5
P = 4.81*260 = 1250, 6 kW
p = 2.4 (assumed)
K = 1.6 (from figure 2.7 p. 60, the critical speed is 75% and the load of mill 26% by volume)
1263.4=2.4*1.6*D/2.5*D2.5
D= 6.79 m L=2.72 m
We choose 7.32 m (24 ft) diameter and L=3 m.
We take percent of load 28%by volume, 8% of load ball and 20% of load pulp. Also 20% by
weight of pulp is water.
Water amount: (260 + mwater)*20/100= 65 tons water in pulp
Figure 2: Particle Size vs. Cumulative Passing (Pourghahramani, 2012)
The 90% of product of sag mill: -2000 micron

The 80% of product of sag mill: -149 micron
29
4.2) Ball mill selection

4.2.1) Ball Mill in First Grinding Process
Figure 3 : Circulating Load of Ball Mill
104+40X = 260
X=3.9 and 100x =390 which means that the hourly solid capacity of ball mill is 390 ton/hour
Top characteristic size: 2 mm
The desired product size of sag mill: 0.149 mm.
wi: 13.5 kwh/ton
Our feed to ball mill is 20 % of total hourly feed (The 80% of product of sag mill: -149
micron)
390 ton/hour * 0.2 = 78 tons
Wball mill = 10 wi(
Total Power = W * Capacity * 1.1
=8.04*78*1.1=690 kW
From table 2, 15 at .Hotens textbook;
There is a 710 kW commercially available ball mill (3.81x3.66m).
30
Figure 4: Ball Mill Product Particle Distribution (M.Irannajad, 2006)
The 40% of product of ball mill is under -149 micron from graph.
4.2.2) Ball Mill Selection in Regrinding Circuit
Figure 5: Circulating Load Of Regrinding Proces
Topfeed size: 0.149mm

Feed of ball mill is (fresh feed+ circulation load): 51.34 tph solid with 26.89 tph water,
31
Fresh solid feed, 20.54 tph chalcopyrite& pyrite

The desired product size of sag mill: 0.074 mm. (80%)
wi: 13.5 kwh/ton
Our feed to ball mill is 20.54 tons per hour of chalcopyrite and pyrite concentration and the
ore with 80% passing size is 0.149 mm.
Wball mill = 10 wi(1/74-1/149)=4.63 kwh/ ton
Total Power = W * Capacity * 1.1
=4.63*20.54*1.1= 104,7kW
From table 2, 15 at .Hotens textbook;
There is a 108 kW commercially available ball mill (2.13 2.13).
4.3) Grinding Circuit Calculations

4.3.1) Selection of Hydrocyclone for first grinding process
Separation size of the hydrocyclone is called d50. Because of our processing purpose, 149m
separation size is required. First of all, we need an empirical relation between the size
distribution of overflow and separation size. Using the following relation
can be found
with f = 1.25 for 80% of overflow is passing 149m (Hoten, ., 2010, p 66).
By using
value we can now reduce the application case to standard case by using the
following formula.
F1: Correction factor for solid % of pulp in application case by volume

F2: Correction factor for feeding pressure of cyclone
F3: Correction factor for specific gravity of solid particles
: Solid % by volume
Feeding pressure
32
Specific gravity of solid

Specific gravity of liquid
650 tph solid from pump and %46 water by weight

Volume of the solid = 650 / 2.8 = 232.14 m3/h
Volume of the water = 557.14 / 1 = 557.14 m3/h
Total volume of the feed = 232.14+ 557.14 = 789.28 m3/h = 219.2 lt/s
Cv = (232.14 /789.28) 100
Cv = 30%
For 30% solid by volume;
For 40 kPa feeding pressure (assumed);
For
and
Therefore,
Using the following chart, from
value, the cyclone diameter can be determined.
33
Figure 6: Hydrocyclone diameter vs. d50 (Hoten, ., 2010, p70)
The theoretical cyclone diameter from the chart is approximately 68 cm which is in between
66cm and 76 cm of commercial diameters. After the cyclone diameter is determined, capacity
can be determined by the following chart.
Figure 7: Pressure Drop vs. Cyclone Capacity(Hoten, ., 2010, p69)

34
Because of the high capacity values of 68 cm, our selection will be 76 cm diameter cyclone
for our low capacity classification operation.
From the chart, the capacity of the hydrocyloneis 120 lt/sec.
Total volume of the feed = 219.2 lt/s
Number of the hydrocyclone = 219.2 / 120 = 1, 83 = 2 hydrocyclone
So 2 hydrocyclone with 1 spare are used with 76 cm diameter.
To decide the apex diameter Chart 2.11 at p.70 in Hoten is used.
Flow rate for underflow = 131.52 lt/s for 2hydrocyclone
So flow rate for 1 hydrocyclone 65.8lt/s
Figure 8: Hydrocyclone underflow flow rate
From the chart, diameter of the apex is 17 cm.

Diameter of hydrocyclone: 76 cm
Diameter of apex: 17 cm
Capacity: 120lt/s
Number of hydrocyclone: 2 + 1(spare) = 3
4.3.2) Selection of Hydrocyclone for regrinding process
By using
value we can now reduce the application case to standard case by using the
following formula.
35
F1: Correction factor for solid % of pulp in application case by volume

F2: Correction factor for feeding pressure of cyclone
F3: Correction factor for specific gravity of solid particles
: Solid % by volume
Feeding pressure
Specific gravity of solid
Specific gravity of liquid
Total feed hydrocyclone; 51.34 tph solid + 42.01 tph water= 93.35 tph by 55% solid by
weight
Volume of the solid = 51.34/ 4,48 = 11.46m3/h

Volume of the water = 42.01 / 1 = 42.01 m3/h
Total volume of the feed = 11.46+42.01= 53.47 m3/h = 14.85lt/s
Cv = (11.46/53.47) 100
Cv = 21.4 %
For 21.4% solid by volume;
For 20kPa feeding pressure (assumed);
For
and
36
Therefore,
Using the following chart, from
value, the cyclone diameter can be determined.
Figure 9: Hydrocyclone diameter vs. d50 (Hoten, ., 2010, p70)
The theoretical cyclone diameter from the chart is approximately 66. After the cyclone
diameter is determined, capacity can be determined by the following chart.
37
Figure 10: Pressure Drop vs. Cyclone Capacity(Hoten, ., 2010, p69)
Our selection will be 66 cm diameter cyclone for our classification operation.

From the chart, the capacity of the hydrocyloneis 50lt/sec.
Total volume of the feed = 14,85lt/s
Number of the hydrocyclone = 14,85/ 50 = 0,3 = 1hydrocyclone
So 1hydrocyclone with 1 spare are used with 66 cm diameter.
To decide the apex diameter Chart 2.11 at p.70 in Hoten is used.
Flow rate for underflow =9.28lt/s for 1 hydrocyclone
Figure 11: Hydrocyclone underflow flow rate
From the chart, diameter of the apex is 7.1cm.

38
Diameter of hydrocyclone: 66 cm
Diameter of apex: 7.1 cm
Capacity: 50 lt/s
Number of hydrocyclone: 1+ 1(spare) = 2
4) FLOTATION CIRCUIT
4.1) Mass Balance Calculations
Formula weight of Cu is 63,546 g/mol
Formula weight of S is 32, 0655 g/mol
Formula weight of Fe is 55,845 g/mol
Formula weight of CuFeS2 is 183, 5225 g/mol
Formula weight of FeS2 is 119, 9762 g/mol
Fe percentage in bulk concentrate is 0,03*(
) +(
)*0,06 = 0,037 = 3,7%
Cu percentage in bulk concentrate is 0,03*(
) = 0,01 = 1%
S percentage in bulk concentrate is 0,03*(
) +(
)*0,06 = 0,043 = 4,3 %
Total chalcopyrite, pyrite and tailing amount in feed:

(260*1.03/100)= 2.68 tph Cu in Cu concentrate
With 2.35 tph Fe in Cu concentrate
With 2.72 tph S in Cu concentrate
(260*3.2/100)= 8.32 tph S in pyrite concentrate
With 7.26 tph Fe in pyrite concentrate
Total chalcopyrite concentrate in feed: 2.68+2.35+2.72= 7.8 tph
Total Pyrite concentrate in feed: 8.32+7.26= 15.6 tph
Tailing (quartz) concentrate in feed: 236.6 tph
Overall recovery of Cu is 85 % and Cu grade in final Cu concentrate is 22%. Overall pyrite
recovery is 60%. and final S grade in pyrite concentrate is 49%.
Total Cu, Fe, S amount in final Cu concentrate:
0.85 = (C1*0.22)/(260*0.01),
C1 = 10.35 tph total amount of final Cu concentration

39
(10.05 * 22/100)=2.28 tph: Amount of Cu in final Cu concentrate

With 2.00 tph of Fe in Cu concentration
With 2.3 tph of S in Cu concentration
Total chalcopyrite concentrate in final Cu concentrate: 2.28 +2.00 +2.3= 6.58 tph
Pyrite and tailing concentration in final Cu concentrate: 10.35 - 6.58= 3.77 tph
Total Fe, S amount in final Pyrite concentrate:

0.60= (C2*0.49)/(260*0.032)
C2=10.19 tph total amount of final pyrite concentration
(10.19*49/100)= 4.99 tph: Amount of S in final Pyrite concentrate

With 4.35 tph of Fe in final Pyrite concentration
Total pyrite concentrate in final pyrite concentrate: 4.99+4.35= 9.34 tph
Chalcopyrite and tailing concentration in final pyrite concentrate: 10.19-69.34= 0.85
tph
4.1.1) First Flotation Process

Pulp density => 40 % solid by weight
4.1.1.1) Feed of Rougher
Solid Amount = 271.54 tph
Water Amount = 407.31 tph
Amount of Pulp = 678.85 tph
Flow Rate of O/F = 8.4048 m3/min
4.1.1.2) Feed of Scavenger
Solid Amount = 248 tph
Water Amount = 372 tph
Amount of Pulp = 620 tph
Flow Rate of O/F = 7.6764 m3/min pulp
4.1.1.3) Feed of Cleaner1
40

4.1.2) Second Flotation Process

Pulp density =>42 % solid by weight
4.1.2.1) Feed of Rougher
4.1.2.2) Feed of Scavenger
41
4.2) Floatation Time Cell Selection

4.2.1) First Flotation Process
4.2.1.1) Cu Rougher;
Flotation (rougher) Time (min) = 13 min
Flotation Cells = 12-18
Thus the volume is 8.4048m3/min * 13 min = 109.2624 m3
Cell
Number
12
Unit Vol., 8,72

m3
13
14
15
16
17
18
8,05
7,475
6,98
6,54
6,16
5,81
So with 15 cells in series with 6,98 m3 unit cell volume ,it is convenient to choose
8,50 * 0,8 = 6,80 m3 nominal cell volume Wemco mechanic flotation machine with 6kW
motor power and 1,50 m3/min air flow rate, from the table 3.11 in the etinHotens
Principles of Mineral Processing Design Book.
4.2.1.2) Cu Scavenger;
Thus the volume is 7.6764 m3/min * 13 min = 99.7932 m3
Cell
Number
12
13
14
15
16
17
18
Unit
Vol.,m3
8.32
7.68
7.13
6.65
6.241
5.87
5.54
So with 14 cells in series with 7.13 m3 unit cell volume ,it is convenient to choose
8,50 * 0,8 = 6,80 m3 nominal cell volume Wemco mechanic flotation machine with 6kW
motor power and 1,50 m3/min air flow rate, from the table 3.11 in the etinHotens
Principles of Mineral Processing Design Book.
42
4.2.1.3) Cu Cleaner1;
Flow Rate of O/F = 0.75 pulp
Flotation (rougher) Time (min) = 13*0,75 min = 9.75 min
Thus the volume is 0.75 m3/min * 9.75 min = 7.3125 m3
Cell
Number
12
13
14
15
16
17
18
Unit Vol.,
m3
0.61
0.56
0.52
0.49
0.46
0.43
0.41
0.59 * 0,8 = 0.47 m3 nominal cell volume Wemco mechanic flotation machine with 23kW
motor power and 6 m3/min air flow rate, from the table 3.11 in the etinHotens Principles
of Mineral Processing Design Book.
Flow Rate of O/F = 0.1146 m3/min pulp.
Thus the volume is 0.1146 m3/min * 9.75 min = 1.11735 m3
Cell
Number
12
13
14
15
16
17
18
Unit Vol,
m3
0.09
0.09
0.08
0.07
0.07
0.07
0.06
0.31 * 0,8 = 0.248 m3 nominal cell volume Wemco mechanic flotation machine with 56kW
motor power and 12 m3/min air flow rate, from the table 3.11 in the etinHotens Principles
of Mineral Processing Design Book.
43
4.2.2) Second Flotation Process

4.2.2.1) Cu Rougher;
Cell
Number
12
13
14
15
16
17
18
Unit Vol,
m3
0.81
0.75
0.70
0.65
0.61
0.57
0.54
So with 16 cells in series with 0.61 m3 unit cell volume, it is convenient to choose
0.71 * 0,8 = 0.568 m3 nominal cell volume Denver mechanic flotation machine with
55m3/hmaximum pulp flow rate and 1,33 m3/min air flow rate, from the table 3.10 in the
etinHotens Principles of Mineral Processing Design Book.
4.2.2.2) Cu Scavenger;
Thus the volume is 0.309 m3/min * 16 min = 4.944m3
Cell
Number
12
13
14
15
16
17
18
Unit Vol,
m3
0.41
0.38
0.35
0.33
0.31
0.29
0.27
So with 18 cells in series with 0.27 m3 unit cell volume, it is convenient to choose
0.34 * 0,8 = 0.272 m3 nominal cell volume Denver mechanic flotation machine with 25m3/h
maximum pulp flow rate and 0.67 m3/min air flow rate, from the table 3.10 in the
44
Flotation (rougher) Time (min) = 16*0.75= 12 min
Cell
Number
12
13
14
15
16
17
18
Unit Vol,
m3
0.28
0.25
0.24
0.22
0.21
0.19
0.18
So with 12cells in series with 0.28m3 unit cell volume, it is convenient to choose
0.34 * 0,8 = 0.272 m3 nominal cell volume Denver mechanic flotation machine with 25m3/h
maximum pulp flow rate and 0.67 m3/min air flow rate, from the table 3.10 in the
4.3) Conditioner Tank Calculations

4.3.1) For Conditioning Tank 1(for first flotation process)
260 tph solid and 390 tph water
Volumetric Flow Rate of O/F =
= 482.86 m3/hr = 8.05 m3/min),
Required volume of conditioner = 12 min * 8.05 m3/min = 96.6 m3

We use two 50 m3conditioners for Quartz seperation. Reagents used in otation are sulfuric
acid (H2SO4) for adjusting pH to 5, 300 g/ton Xanthate as collector, 52,8 g/ton pine oil as
frother and sodium silicate (Na2SiO3) as a depressant. Conditioning time has been taken as
10-12 minutes.
4.3.2) For Conditioning Tank 2(For Second Flotation Process)

20.54 tph solid and 28.83 tph water
Volumetric Flow Rate of O/F =
= 31.81 m3/hr = 0.53 m3/min
Required volume of conditioner = 12 min * 0.53 m3/min = 6.36 m3

We use one 10 m3 conditioner for Chalcopyrite flotation. Reagents used in otation are lime
(CaO) for adjusting pH to 11, dithiophosphates as collector, 52,8 g/ton pine oil as frother.
Conditioning time is taken as 10-12 minutes.
45
5) DEWATERING
5.1) Thickener selection
5.1.1) Feed of Regrinding Process
Pulp is 40 % solid by weight; 20.54 tph solid + 30.81 tph water = 51.35 tph
Thickener product will be 60 % by weight; 20.54 tph solid and 20.54*40/60=13.69 tph water
Amount of water in thickener O/F = 30.81 13.69 = 17.12 tph water
Amount of pulp in product = 20.54 + 13.69 = 34.23 tph pulp
Assuming 2 m2/t/h settling unit area for chalcopyrite & pyrite concentrate:
Thickening Area = 2 m2/t/h x 20.54tph = 41.08 m2
, D = 7.2 m
Rake motor 3 HP, lift motor 1 HP Total Power 3 kW
5.1.2) Pyrite Thickener

Amount of water in thickener O/F = 13.51 3.4 =10.11 tph water
Amount of pulp in product = 10.19 + 3.4= 13.59tph pulp
Thickening Area = 2 m2/t/h x 10.19tph = 20.38m2
, D = 5.09 m
5.1.3) Chalcopyrite Thickener

Amount of water in thickener O/F = 13.72 3.45 = 10.27 tph water
Amount of pulp in product = 10.35 + 3.45 = 13.8 tph pulp
46
Thickening Area = 2 m2/t/h x 10.35tph = 20.7 m2

, D = 5.13 m
5.2) Filter Selection

5.2.1) Chalcopyrite Filter
Chalcopyrite concentrate (80 % -74 micron), 10350 kg/h
10350/500 = 20.7 m2
(From Denver Sala Basic, table: 4.8)
We choose; D=3.0 m, L=3.0 m, Effective filter area per meter=7.1 m2/m
3.0*7.1= 21.5 m2 Effective are of vacuum filter
Selected disc diameter: 2 m with 3.8 m2/disc ,
20.7/3.8= 5.45 => 6 discs selected.
5.2.1) Pyrite Filter

Pyrite concentrate (80 % -74 micron), 10190kg/h
10190/1000= 10.19 m2
(From Denver Sala Basic, table: 4.8)
We choose; D=1.8.0 m, L=3.0 m, Effective filter area per meter=4.2 m2/m
3.0*4.2= 12.6 m2 Effective are of vacuum filter
Selected disc diameter: 2 m with 3.8 m2/disc ,
10.19/3.8= 2.68 => 3 discs selected.
6) PUMP SELECTION
6.1) Pump from Sump to Hydrocyclone in first grinding process
(650 ton solid and 557.14 ton water 46% water 54% solid)
Solid feed: 260+390=650 ton
Water: 557.14 ton
Total=1207.14 ton
47
SGpulp=1.53 ton/m3
Qslurry=0.22 m3/s
The formulas are determined from etinHotens Book. Hz ,Hp , Hf, Hv are calculated according to
various parameters.
In pump calculations, used the formulas below:
Hz (m) = Assumption
Hp (m) =
Pr essure kPa
g SGPulp
100
Pipe Cons tan t
0.2083
Hf(ft/100 ft) =
H f ( ft )
Hf (ft) =
1,85
Qslurry (m 3 / s ) 15850 .2
Pipe.Diameter (inch)
4 ,8655
Pipe Lenght(m)
0,3046
100
Va 2
Hv (m) = 2 g
TDH (m) = (Hz + Hp + Hf+ Hv) x 1.1

R = 1-0.000385*(SGORE-1)(1+
Total Water Head (m) =
*(%solid by weight)*ln(
TDH (m)
R
Required Power (HP) = 1.341
sl
g Qslurry (m 3 / s ) TDH (m)

1000
Pipe Constant = 120 (Rubber)

Hz (m) = 9 (assumed)
Pressure = 40kPa (It is a design criteria)
Hp (m) =
= 2.67 m
48
1,85
f=
Hf (ft) =
Hv (m) =
= 7.2ft/100 ft
=25ft= 7.6 m
= 0.82 m
TDH (m) = (9 + 2.67 +7.6 + 0.82) x 1.1= 22 m (due to adding 10% safety factor)
R = 1-0.000385*(2.8-1)(1+
)*(35)*ln(
= 0.89
=24.7 m
By using TDH/R=24.7 m and 790 m3/hour pulp flow rate we found the pump with 250mm inlet
diameter and 200mm outlet diameter which is 250/200F model is suitable.
Figure 12: Selection of Pump (Metso Expect Results, 2012)
49
Figure 13: Pump Characteristics (Metso Expect Results, 2010)

sl

1000
= 97.4 HP
Required Power(HP)=1.341*
From Metso catalog

MR250 model horizontal slurry pump was selected.
6.2) Pump from Sump to Hydrocyclone in regrinding process

Solid Feed calculation of Sump& Pump
8.22 + 40X= 20.54, X= 0.308
Solid Fresh feed of pump &sump: 20.54 tph solid which consists of 10.35 tph Chalcopyrite
concentration and 10.19 tph Pyrite concentrations
Liquid Fresh feed of pump &sump:16.81 tph water
Circulating load: 100*0.308= 30.8 tph solid with 13.20 tph water (150%)
Total solid amount in feed of pump& sum: 51.34 solid, 51.34*45/55= 42.01 tph water
Total feed of Pump&Sump; 51.34 tph solid + 42.01 tph water= 93.35 tph by 55% solid by
weight.
50
1.75 ton/m3
SGpulp=
SGsolid= 4.48 ton/m3

Qslurry= 0,015 m3/s
Pipe Constant = 120 (Rubber)
Hz (m) = 9 (assumed)
Pressure = 50kPa (It is a design criteria)
Hp (m) =
=2,91 m
f=
Hf (ft) =
Hv (m) =
= 1.44ft/100 ft
= 5.01 m
= 0.82 m
TDH (m) = (9 + 2,91+5.01+ 0,82) x 1.1= 19.51m (due to adding 10% safety factor)
R = 1-0.000385*(4.48-1)(1+
)*(55)*ln(
= 0.84
=23,36 m
By using TDH/R= 19,51 m and 53,34m3/hour pulp flow rate we found the pump with 75mm inlet
diameter and 50mm outlet diameter which is 75/50 C model is suitable.
51
Figure 14: Selection of Pump (Metso Expect Results, 2012)
Figure 15: Pump Characteristics (Metso Expect Results, 2012)

sl

1000
=6.74 HP
Required PowerHP)=1.341*
52
From Metso catalog MR100 model horizontal slurry pump was selected.
6.3) Pump from Wet Screen to Cyclone

The stream number of this pump is 8, tonnage of passsing there is 19.56 tons ore and 4.89
tons water; totally 24.45 tons. The solid (%) by weight is 80 and the specific gravity is 2.06
gr/cm3. Therefore, the volumetric flow rate 3.3 lt /sec and operating hour is 24 hours.
Table 4: Properies of Pump
V (m/s)
Q (m^3/s)
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
2.341531136
0.004595255
C
f
Top. Efektif boru uzunluu
0.0019625
(ft)
0.05
Hf
50000
Hz
0.005433333
Hv
80
Hp
2.06
TDH
1.4
Power(kW)
1.719001844
R
1.414001844
Ss
4.89
Cw
19.56
d50(mikron)
60.61
efficiency
120
15.36142026
1969.69697
894.3969198
rpm
40
1.872864358
10
0.279447913
2.587626441
41.67743813
13.18992793
0.389033811
2.6
80
3000
0.280104344
6.4) Pump for Oflow of Cyclone (ball mill to pump)

The stream number of this pump is 12, tonnage of passsing there is 390 tons ore and 167,14
tons water; totally 557,14 tons. The solid (%) by weight is 70 and the specific gravity is 1,82
gr/cm3. Therefore, the volumetric flow rate 85,12 lt /sec and operating hour is 24 hours.
V (m/s)
5.990021045
Q (m^3/s)
0.128016484
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
0.021371625
0.165
50000
0.005433333
4.775857017
1.82
1.4
4.409099763
4.104099763
C
f
(ft)
Hf
Hz
Hv
Hp
TDH
Power(kW)
R
Ss
53
120
21.71555505
40
2.647560472
10
1.828764124
4.947044397
22.17448911
41.28866274
0.96352641
2.6
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
390
19.56
1.89
Cw
d50(mikron)
efficiency
4.775857017
3000
0.693739016
1030.27981
rpm
693.3376213
6.5) Pump for Froth of Scavenger

tons water; totally 21.35 tons. The solid (%) by weight is 40 and the specific gravity is 1,35
gr/cm3. Therefore, the volumetric flow rate 4,41 lt /sec and operating hour is 24 hours.
V (m/s)
1.843098097
Q (m^3/s)
0.006112865
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
120
7.266414101
0.003316625
0.065
50000
0.002372222
40
1.35
1.4
1.361268717
1.056268717
12.81
8.54
20.41
C
f
(ft)
Hf
Hz
Hv
Hp
TDH
Power(kW)
R
Ss
Cw
d50(mikron)
efficiency
1326.530612
rpm
541.5461295
40
0.885921207
10
0.173140193
3.8422332
23.60118801
3.748287338
0.694516905
2.6
40
3000
0.500052172
6.6) Pump for Froth of Cleaner2

The stream number of this pump is 22, tonnage of passsing there is 0,7 tons ore and 1,05 tons
water; totally 1,75 tons. The solid (%) by weight is 40 and the specific gravity is 1,35 gr/cm3.
Therefore, the volumetric flow rate 0,36 lt /sec and operating hour is 24 hours.
V (m/s)
1.021257634
Q (m^3/s)
0.000501055
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
C
120
f
7.423475538
0.000490625
(ft)
40
0.025
Hf
0.905070138
50000
Hz
10
0.000194444
Hv
0.053158367
40
Hp
3.8422332
54
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
1.35
1.4
0.711257199
0.406257199
1.05
0.7
20.41
TDH
Power(kW)
R
Ss
Cw
d50(mikron)
efficiency
23.44148536
0.305157682
0.694516905
2.6
40
3000
0.500052172
1326.530612
rpm
780.1815387
6.7) Pump for Tailing of Cleaner2

The stream number of this pump is 23, tonnage of passsing there is 3 tons ore and 4.5 tons
water; totally 7.5 tons. The solid (%) by weight is 40 and the specific gravity is 1,35 gr/cm3.
Therefore, the volumetric flow rate 1.55 lt /sec and operating hour is 24 hours.
V (m/s)
1.350869886
Q (m^3/s)
0.002147377
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
120
6.278007864
0.001589625
0.045
50000
0.000833333
40
1.35
1.4
1.036262958
0.731262958
4.5
3
20.41
C
f
(ft)
Hf
Hz
Hv
Hp
TDH
Power(kW)
R
Ss
Cw
d50(mikron)
efficiency
1326.530612
rpm
573.3256457
40
0.765414719
10
0.093009656
3.8422332
23.28341212
1.29899961
0.694516905
2.6
40
3000
0.500052172

tons water; totally 51.35 tons. The solid (%) by weight is 40 and the specific gravity is 1,35
V (m/s)
2.075250475
Q (m^3/s)
0.014702371
A (m^2)
C
120
f
5.814998821
0.007084625
(ft)
40
55
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
0.095
50000
0.005705556
40
1.35
1.4
1.848777355
1.543777355
30.81
20.54
20.41
Hf
Hz
Hv
Hp
TDH
Power(kW)
R
Ss
Cw
d50(mikron)
efficiency
0.708964656
10
0.219503799
3.8422332
23.39435037
8.936193613
0.694516905
2.6
40
3000
0.500052172
1326.530612
rpm
417.2028618
6.9) Pump for Oflow of Cyclone

tons water; totally 44 tons. The solid (%) by weight is 70 and the specific gravity is 2.16
V (m/s)
2.644769252
Q (m^3/s)
0.008771708
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
C
f
0.003316625
(ft)
0.065
Hf
50000
Hz
0.008555556
Hv
70
Hp
2.16
TDH
1.4
Power(kW)
2.22795619
R
1.92295619
Ss
13.2
Cw
30.8
d50(mikron)
47.30
efficiency
40
1.728016441
10
0.356513985
2.901278131
35.41948223
15.9524384
0.465404585
2.6
70
3000
0.335091301
1756.756757
777.0962131
rpm
120
14.1733632
6.10) Pump for Froth of Scavenger

The stream number of this pump is 34, tonnage of passsing there is 1.7 tons ore and 2.25tons
water; totally 3.95 tons. The solid (%) by weight is 42 and the specific gravity is 1.49 gr/cm3.
56

V (m/s)
1.126444108
Q (m^3/s)
0.001083217
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
C
f
0.000961625
(ft)
0.035
Hf
50000
Hz
0.000472222
Hv
43.03797468
Hp
1.49
TDH
1.4
Power(kW)
0.977966
R
0.672966
Ss
2.25
Cw
1.7
d50(mikron)
22.52
efficiency
120
6.012534345
1360.264901
614.6699271
rpm
40
0.733048187
10
0.064672596
3.746946611
23.83250554
0.711543649
0.671315658
2.6
43.03797468
3000
0.483347274
6.11) Pump for Tailing of Scavenger

The stream number of this pump is 35, tonnage of passsing there is 10.19 tons ore and
13.51tons water; totally 23.7 tons. The solid (%) by weight is 42 and the specific gravity is
1.49 gr/cm3. Therefore, the volumetric flow rate 4.41 lt /sec and operating hour is 24 hours.
V (m/s)
1.959929572
Q (m^3/s)
0.006500351
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
C
f
0.003316625
(ft)
0.065
Hf
50000
Hz
0.002830556
Hv
42.99578059
Hp
1.49
TDH
1.4
Power(kW)
1.554794
R
1.249794
Ss
13.51
Cw
10.19
d50(mikron)
22.49
efficiency
120
8.141423973
1359.784624
575.8740001
rpm
57
40
0.992602411
10
0.195786133
3.748270036
24.46306932
4.379277336
0.671637897
2.6
42.99578059
3000
0.483579286
6.12)Pump for Tailing of Cleaner1

The stream number of this pump is 37, tonnage of passsing there is 1.2tons ore and 1.59
V (m/s)
1.083067743
Q (m^3/s)
0.000765187
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
C
f
0.0007065
(ft)
0.03
Hf
50000
Hz
0.000333333
Hv
43.01075269
Hp
1.49
TDH
1.4
Power(kW)
0.881828
R
0.576828
Ss
1.59
Cw
1.2
d50(mikron)
22.50
efficiency
120
6.691663663
1359.955006
689.5007274
rpm
40
0.815847634
10
0.059787754
3.747800433
23.95415515
0.504930576
0.671523554
2.6
43.01075269
3000
0.483496959

V (m/s)
1.948420546
Q (m^3/s)
0.00646218
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
0.003316625
0.065
50000
0.002875
42.99958455
1.59
1.4
1.676407124
1.371407124
13.72
10.35
C
f
(ft)
Hf
Hz
Hv
Hp
TDH
Power(kW)
R
Ss
Cw
d50(mikron)
58
120
8.053200394
40
0.981846192
10
0.193493508
3.748150724
24.44255992
4.350238191
0.671608846
2.6
42.99958455
3000
%v/V
Sl. Dens.
(kg/m^3)
22.49
efficiency
0.483558369
1359.827908
rpm
572.4923741
6.14) Pump for Feed of Pyrite Filter

water; totally13.59 tons. The solid (%) by weight is 75 and the specific gravity is 2.48 gr/cm3.
V (m/s)
1.909766811
Q (m^3/s)
0.002398667
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
120
13.66528644
0.001256
0.04
50000
0.002830556
74.98160412
2.48
1.4
1.641650569
1.336650569
3.4
10.19
53.55
C
f
(ft)
Hf
Hz
Hv
Hp
TDH
Power(kW)
R
Ss
Cw
d50(mikron)
efficiency
1856.752496
rpm
911.8443521
40
1.666071723
10
0.18589242
2.745029276
37.57184684
5.326141768
0.427359688
2.6
74.98160412
3000
0.307698976
6.15) Pump for Feed of Chalcopyrite Filter

water; totally13.8 tons. The solid (%) by weight is 75 and the specific gravity is 2.31gr/cm3.
V (m/s)
2.01700668
Q (m^3/s)
0.00253336
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
0.001256
0.04
50000
0.002875
75
2.31
1.4
C
f
(ft)
Hf
Hz
Hv
Hp
TDH
Power(kW)
59
120
15.11867321
40
1.843268637
10
0.207355553
2.744452286
38.09422472
5.706507638
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
1.562542519
1.257542519
3.45
10.35
53.57
R
Ss
Cw
d50(mikron)
efficiency
0.427219198
2.6
75
3000
0.307597822
1857.142857
rpm
963.0474979
6.16) Pump for Feed of Water Dam from Regrinding Thickener

The stream number of this pump is 25, tonnage of passsing there is 17.12 tph water.
V (m/s)
Q (m^3/s)
1.421783
0.005469
0.003847
0.07
50000
2.78E-13
5.84E-09
1.33
1.4
1.409542
1.104542
17.12
1E-09
0.00
C
f
(ft)
Hf
Hz
Hv
Hp
TDH
Power(kW)
R
Ss
Cw
d50(mikron)
efficiency
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
120
4.12369
40
0.50276
10
0.103031
5.09684
17.27289
1.284943
1
2.6
5.84E-09
3000
0.72
1000
rpm
387.9142
6.17) Pump for Feed of Water Dam from Pyrite Thickener

V (m/s)
Q (m^3/s)
1.360039
0.00323
A (m^2)
D (m)
P (Pa)
Ms (tps)
0.002375
0.055
50000
2.78E-13
C
f
(ft)
Hf
Hz
Hv
60
120
5.031338
40
0.613421
10
0.094277
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
9.89E-09
1.33
1.4
1.172854
0.867854
10.11
1E-09
0.00
1000
Hp
TDH
Power(kW)
R
Ss
Cw
d50(mikron)
efficiency
5.09684
17.38499
0.763731
1
2.6
9.89E-09
3000
0.72
rpm
472.2687
6.18) Pump for Feed of Water Dam from Chalcopyrite Thickener

V (m/s)
Q (m^3/s)
A (m^2)
D (m)
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
1.381563
0.003281
0.002375
0.055
50000
2.78E-13
9.74E-09
1.33
1.4
1.172854
0.867854
10.27
1E-09
0.00
C
f
Top. Efektif boru uzunluu (ft)
Hf
Hz
Hv
Hp
TDH
Power(kW)
R
Ss
Cw
d50(mikron)
efficiency
120
5.179635
40
0.631501
10
0.097284
5.09684
17.40819
0.776853
1
2.6
9.74E-09
3000
0.72
1000
rpm
479.7427
6.19) Pump for Tailing Disposal

The stream number of this pump is 18, tonnage of passsing there is 239.46 tons ore and
359.19 tph water; totally 598.65 tons. The solid (%) by weight is 40 and the specific gravity
is 1.35 gr/cm3. Therefore, the volumetric flow rate 123.53 lt /sec .
V (m/s)
Q (m^3/s)
A (m^2)
4.14809
0.172256
0.041527
D (m)
0.23
C
f
(ft)
Hf
61
120
7.471905
200
0.910975
P (Pa)
Ms (tps)
Cw
Ss
F
Vc+0.305
Vc
Water(tph)
solid(tph)
%v/V
Sl. Dens.
(kg/m^3)
50000
0.066517
40
1.33
1.4
3.934208
3.629208
359.19
239.46
20.41
1326.531
Hz
Hv
Hp
TDH
Power(kW)
R
Ss
Cw
d50(mikron)
efficiency
rpm
10
0.876995
3.842233
24.75566
110.7904
0.694517
2.6
40
3000
0.500052
344.4456
7) TAILING
Total amount of Tailing ; 260 (C1 + C2) = 260 ( 10.35 + 10.19 ) = 239.46 tph
Chalcopyrite % in tailing =
Pyrite % in tailing =
* 100 = 0.51%
* 100 = 2.61 %
8) SELECTION OF AUXILIARY FACILITIES AND

EQUIPMENTS
8.1) Selection of stationary grizzly and hopper
Our daily production is 6060 tons, we use one jaw crusher for communition process.
The commercially available stationary grizzly and hopper that are suitable for our hourly
production, r.o.m particle size and max feed opening of crushing device are listed below.
Nordberg NW Series NW110
Feed hopper volume=50 m3
width = 4800 mm
Grizzly feeder VF561-2V
Length=6100 mm, width=1000 mm
8.2) Selection of grizzly feeder

The hourly feed should be 380tph according to calculations. Therefore, the feed of jaw
crusher is approximately 300 tph. The rest, 80tph is sent to the belt conveyor by grizzly
feeder.
The required feed to jaw crusher is 300 tph with a bulk density of 1.68 ton/m3.Then we can
estimate the speed of feeder with following formula.
62
Our coarse size materials are assumed to be 80-100 % and the coefficient of width of feeder
should be 3, so the coefficient of width opening of feeder should be 3.5 according to the table
6.2 (Nordberg Rexnord, 1984).
The width of feeder = 3*1000 mm = 3000 mm
The width opening of feeder = 3.5*1000 mm = 3500 mm
The selection of grizzly feeder should be done according to above sizes and the hourly feed
that is 380 tph.
Capacity (tph) = width*400*the coeff. of inclination
380=w*400*(5o=1.25)
W=0.76 m
According to table 6.4 (Hoten, 2010, p.163), the selected width is 0.76 m, the power of
feeder is 10-20 HP.
8.3) Selection of Belt Conveyor

Our daily production is 6060 tons, we use one jaw crusher for communition process. Our feed
of jaw crusher is 300 ton and characteristic feed size is 1000 mm. Our jaw crusher max feed
opening is 1111 mm.
The product of jaw crusher material has 185mm characteristic feed size for that reason the
lowest belt width which is 914 mm from table 6.6 (Hoten, 2010, p.165) .this type of belt
conveyor is chosen according to the coarsest particle size.
The belt speed of conveyor is calculated by the below.
In order to calculate the power consumption of the belt, following equation will be used.
Factor A and B is determined by use of table 6.7 (Hoten, 2010, p.166).

Factor C is determined by
Factor A is given as 0.97 kW for 914 mm belt width and 90 meters length.
63
For 90 m belt length
For 5 tph capacity and 24 m height
The power consumption of belt conveyor is;
8.4) Stockpile Calculations

Volume of stockpile:Actually, the amount of the stockpile should be equal to the amount of
production in a week.
m3
Volume of stockpile=
Although angle of repose of a stockpile changes according to material type, generally

can be used for preliminary studies. Therefore, the base diameter and height of
conical stockpile can be determined using following formulas (Hoten, 2010, p.155-156).
64
REFERENCES
Metso Expect Results. (2010). Retrieved December 2012, from The orion series of heavy & mining
duty horizontal slurry pumps:
http://www.metso.com/miningandconstruction/matobox7.nsf/docsbyid/aa7a41bb5acda403
42256af60048c82e/$file/orion_series.pdf
Metso Expect Results. (2012). Retrieved december 2012, from Nordberg C Series Jaw Crushers:
www.metso.com/miningandconstruction/MaTobox7.nsf/DocByID/
M.Irannajad, A. S. (2006, december). Minerals Engineering. Spreadsheed-based Simulation of Closed
Ball Mill Circuits, pp. 1495-1504.
Pourghahramani, P. (2012, May). Minerals Engineering. Effects of Ore Characteristic on Product
Shape Properties and Breakage Mechanisms in Industrial SAG Mills, pp. 30-37.
Wills , B.A. , Napier-Munn, T. (2006). Mineral Processing Technology, An Introduction to the
Practical Aspects of Ore Treatment and Mineral Recovery
Gupta, A. , Yan, D.S., Introduction to Mineral Processing Design and Operation
Froth Flotation Fundamental Principles:
http://www.chem.mtu.edu/chem_eng/faculty/kawatra/Flotation_Fundamentals.pdf
Park, C. , Jeon, H. (2010). The Eect of Sodium Silicate as pH Modier and Depressant in the Froth
Flotation of Molybdenite, Ores, Materials Transactions, Vol. 51, No. 7 pp. 1367 to 1369:
http://www.jim.or.jp/journal/e/pdf3/51/07/1367.pdf
Hoten, . (2010). Cevher Hazrlama ve Zenginletirme Temel lemlerinin Tasarm. "Orta Dou
Teknik niversitesi"
65

Mine Process Report PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mine Process Report PDF

Uploaded by

Copyright:

Available Formats

MIDDLE EAST TECHNICAL UNIVERSITY

MINING ENGINEERING DEPARTMENT

PROCESS DESIGN PROJECT

CRUSHING CIRCUIT ........................................................................................................................ 25

SCREEN SELECTION ........................................................................................................................ 27

GRINDING & CLASSIFICATION CIRCUIT.......................................................................................... 28

4.2.1) Ball Mill in First Grinding Process ........................................................................................ 30

4.3.1) Selection of Hydrocyclone for first grinding process .......................................................... 32

4.1.1) First Flotation Process ......................................................................................................... 40

4.2.1) First Flotation Process ......................................................................................................... 42

4.3.1) FOR CONDTONNG TANK 1(FOR FRST FLOTATON PROCESS) ............................................................................... 45

5.1.1) Feed of Regrinding Process ................................................................................................. 46

5.2.1) Chalcopyrite Filter .............................................................................................................. 47

Daily feed rate: 6,060 ton/day

Daily feed rate: 4070.304 m3/day

Daily feed rate: 932.256 m3/day

(Chalcopyrite) Feed rate: 4.48 lt/sec

(Chalcopyrite) Feed rate: 1.66 lt/sec

FLOWHEET OF PROCESSING PLANT

Tailing of Rougher 248

Froth of Scavenger 8.54

Tailing of Cleaner1 3.7

Tailing of Rougher 11.89

Froth of Scavenger 1.7

Tailing of Cleaner1 1.2

Water Discharge of Chalc. Thickener

PROCESS EQUIPMENT LIST

C145 Jaw Crusher(Feed opening

Belt Conveyor (Jaw Crusher to

Sag Mill (D=7.32 m, L=3m)

Wet Screen (2 mm, L = 2.5 W = 6.15 m)

MR250 model Pump & Sump (250 mm

Cyclone (cyclone Diameter=76 cm,

Ball Mill (3.81x3.66 m)

Standard Rougher Flotation Cells

Standard Scavenger Flotation Cells

Standard Cleaner1 Cells

Standard Cleaner2 Cells

MR-100 Model Pump&Sump (75 mm

Cyclone (cyclone Diameter=66 cm,

Ball Mill (2.13 2.13).

XB-2500 Model Conditioner Tank

Standard Rougher Flotation Cells

Standard Scavenger Flotation Cells

Standard Scavenger Flotation Cells

Denver Sala Filter (pyrite)

Denver Sala Filter (chalcopyrite)

limestone to the tailings,

CAPITAL COST ESTIMATES

M & S CostIndex 2007

Our equipment cost is 15352313$ in 2007

Preliminary Cost Estimation

Exchange rate of the dollar to YTL (on 15.01.2013) = 1, 77 TL

OPERATING COST ESTIMATES

Table 1: Personnel Details

Assistant General Manager (Head Engineer)

Marketing and Sales Manager

Commercial & Financial personnel

Total annual salary of employees is 40,584,000TL

Direct and Indirect costs

Total direct, indirect and fixed costs = 160,537,000 + 100,500,000 = 261,037,000 TL

Cash Flow Diagram: