Taivaljärvi Concentrator Pekka Mörsky, Raimo Tahvanainen - PDF

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Geological Survey of Finland 1 Mineral Processing C/MT/2007/28 Outokumpu Taivaljärvi Concentrator Pekka Mörsky, Raimo Tahvanainen Geological Survey of Finland Mineral Processing 2 Contents 1 GENERAL 3

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Geological Survey of Finland 1 Mineral Processing C/MT/2007/28 Outokumpu Taivaljärvi Concentrator Pekka Mörsky, Raimo Tahvanainen Geological Survey of Finland Mineral Processing 2 Contents 1 GENERAL 3 2 FLOW SHEET 3 3 EQUIPMENT LIST 4 4 LAY OUT OF PLANT 5 5 INVESTING COSTS ESTIMATION 5 6 OPERATING COSTS ESTIMATION 6 7 TOTAL COSTS ESTIMATION 6 8 RECOMMENDATIONS 7 Geological Survey of Finland Mineral Processing 3 1 GENERAL This report is describing the basic engineering of Taivaljärvi ore concentrator for two new alternative versions, namely no.1) tpa version and no.2) tpa version. This revision design work is based on Outokumpu company's design report for tpa version by Raimo Frimodig from 1991 and the laboratory test reports on Taivaljärvi ore beneficiation by VTT. Reports are MIN 58 from , MIN 921 from and MIN 104/90 from Outokumpu s version was designed as mobile concentrator mainly using second hand equipment from old existing concentrator plant. The plant was divided in modules for each processing stages. The Outokumpu version and also this new design work were based on aforementioned laboratory tests and are missing any pilot plant data for more detailed design work. The flow sheets and the equipment lists for both new alternative versions are presented, and investing and operating costs of the concentrator plant are estimated. The investing costs are calculated on the up dated offers of chosen equipment manufacturers, which are indicated on cost estimations. 2 FLOW SHEET The design limits are ROM ore to the crushing plant and the concentrate storage. The first versions flow sheet is designed for tpa capacity, 33 t/h average feed capacity with 7800 active working hours per annum. The crushing plant consists of two stages, namely firstly open jaw crushing and secondly closed gyratory crushing with screening. The ore is crushed down to 100 % - 25 mm. The grinding circuit has two stages, primary rod mill in open circuit and secondary ball mill in closed circuit with hydrocyclone classifiers. The circulation load is estimated to be totally 100 % and the desired grind size is 80 % - 74 µm The classification cyclone overflow is floated in two flotation circuits, primary for lead (galena) and secondary for zinc (sphalerite), both consisting of rougher and scavenger stages and cleaning stages (two) of scavenger rougher concentrate. Thickeners and a drum filters are used in dewatering of the flotation concentrates. The flow sheet for tpa version is shown in Appendix 1. Geological Survey of Finland Mineral Processing 4 The feed flow is estimated to be 33 t/h and the concentrate flows are 1.4 % (0.462 t/h) of Pb-concentrate (having grade of 60 % Pb and recovery of 85 %) and 2.1 % (0.693 t/h) of Zn-concentrate (having grade of 52 % Zn and recovery of 85 %). The head grade is 0.93 % Pb and 2.45 % Zn and 275 g/t Ag and 1.5 g/t Au. The second version is designed for tpa, 58 t/h average feed capacity with 7800 active working hours per annum. The flow sheet is similar to the version no. 1, only the equipment sizes are checked and up-scaled. Concentrate flows are t/h of Pb-concentrate and t/h of Znconcentrate. The flow sheet for version no. 2 is shown in Appendix 2. 3 EQUIPMENT LIST The lists of the primary equipment for the designed concentrator versions are shown in Appendices 3 and 4. The lists comprise the technical description of the individual equipment, their source and cost estimation (Device position refers to the corresponding one in flow sheet). The offers are shown Appendix 7. Crushing The main equipments for crushing plant are from Sandvik except the iron scrap separator which is from IFE Technik. Grinding The mills for concentrator are from Outotec. For the version no. 1 the rod mill is Ø 2.2 x 3.8 m with nominal power of 175 kw and the ball mill Ø 2.7 x 4.8 m with nominal power of 450 kw. For the version no. 2 the rod mill is Ø 2.7 x 4.0 m with nominal power of 300 kw and the ball mill Ø 2.7 x 4.8 m with nominal power of 750 kw. Conveyors The conveyors and the feeders are from Sandvik. Pumps and classifiers The pumps and the cyclone classifiers for grinding circuit are from Weir Warman. Flotation The flotation equipments are Outotec 20 m 3, 10 m 3 and 5 m 3 Tank cells. For version no.1 there are three OK-TC-R-10 cells for roughing and scavenging stages in Pb-flotation and for two OK-TC-R-5 cells for Pb-cleaning. In Zn-flotation three OK-TC- Geological Survey of Finland Mineral Processing 5 R-10 cells are used for roughing and scavenging stages and two OK-TC-R-5 for Zncleaning. For version no. 2 there are three OK-TC-R-20 cells for Pb-roughing and scavenging stages, and two OK-TC-R-10 cells for Pb-cleaning. For Zn-flotation there are three OK- TC-R-20 cells for roughing and scavenging stages, and two OK-TC-R-5 cells for cleaning. The flotation circuit pumps are from Weir Warman. Thickeners The thickeners are Supaflo Ø 2 x 2 m type for version 1 and Supaflo Ø 3 x 2 m for version 2 There are separate units for both Pb and Zn circuits. The equipments are manufactured by Outotec. Filters The filters are drum vacuum filters from Metso, TF 1812, 6.8 m 2, same type for both versions, and one unit for each flotation concentrate. Reagent pumps Reagent dosing pumps are from Grundfos and water pumps from Sulzer. 4 LAY OUT OF PLANT The lay out drawings are described in Appendix 5 and 6. In Appendix 5 are crushing plant layouts. In Appendix 6 are layouts for concentrator. 5 INVESTING COSTS ESTIMATION The total investing cost estimations for both versions are calculated in the equipment lists in Appendices 2 and 3. The investing cost for version no. 1 ( tpa) is totally The corresponding one for version no. 2 ( tpa) is totally Geological Survey of Finland Mineral Processing 6 6 OPERATING COSTS ESTIMATION For operating costs of the plant are calculated all other costs than maintenance and analyzing costs. The maintenance task and analyzing activities are recommended to keep as outsourcing service. The maintenance cost estimation is up to /a and analyzing cost estimation up to /a. The exact services costs estimation needs to call for bids. The fixed personnel costs when having a plant superintendent, a foreman, two shift operators (totally 10) and two daily operators are estimated to be /a, are for version no.1 3 /t and for version no /t. Reagent and other bulk supplies costs are estimated to be 3.5 /t. Power cost for version no.1 is 2.49 /t (installed power 1714 kw, consumed 1371 kw = kwh/t; totally x = kwh ) and for version no.2 is 2.00 /t (installed power 2417 kw, consumed 1934 kw = kwh/t; totally x = kwh). Consumed power is 80 % of installed and estimated price is 0.06 /kwh. Total operating cost estimations (personnel + reagent and other bulk supplies + power) are: version no tpa 8.99 /t and version no tpa 7.1 /t 7 TOTAL COSTS ESTIMATION Investing and operating cost estimation for the two alternatives are shown in the following table. The table excludes the costs of laboratory and maintenance services t/a t/a /t /t Investing Costs Operating Costs Maintenance+Lab* ( ) (1.6) ( ) (0.89) Personnel Costs Reagents+Supplies , ,5 Power Total * not included Geological Survey of Finland Mineral Processing 7 8 RECOMMENDATIONS This revision report of Taivaljärvi concentrator plant design is based on those reports of the laboratory test work made at VTT and the first design plan of Outokumpu, and no pilot plant data are available. To get more accurate data for design basis, a pilot plant information should be needed. The piloting should give for example more exact process flows, figures for reagent consumptions, grade and recovery levels, which could be achieved in continuous process. It should be noted that the delivery time of some new equipments is approximately 24 months now and the prices are heightening about 20 % per year from this point of time. Outokumpu Kauko Ingerttilä Laboratory Manager Pekka Mörsky Senior Metallurgist Distribution: Silver Resources Oy, GTK Archive Appendices Crushing 101. Receiving hopper & feeder 102. Jaw crusher 103. Belt conveyor 104. Iron separator 201. Vibrating screen 202. Gyratory crusher 203. Belt conveyor 204. Belt conveyor 205. Belt conveyor 206. Belt conveyor 207. Ore stockpile, capacity 6000 t Grinding 301. Belt feeder, 4 Feeders 302. Belt conveyor 303. Rod mill D 2,2x3,8m 304. Slurry pump, 2 pumps 305. Pump tank 306. Ball mill D 2,7x4,0m 307. Hydrocyclone classifier, 2 cyclones CRUSHING Ore Feed Capacity: t/a m3/h GRINDING Flotation 401. Conditioner,10 m Flotation machine, 10 m Flotation machine, 10 m Flotation machine, 10 m Slurry pump 406. Slurry pump 407. Slurry pump 408. Flotation machine, 5 m Flotation machine, 5m Slurry pump 411. Slurry pump 412. Slurry pump 413. Slurry pump 421. Conditioner 10 m Flotation machine, 10 m Flotation machine, 10 m Flotation machine, 10 m Slurry pump 426. Slurry pump 427. Slurry pump, 2 pumps 428. Flotation machine, 5 m Flotation machine, 5m Slurry pump 431. Slurry pump 432. Slurry pump 433. Slurry pump Dewatering 501. Thickener D 2x2 m 502. Peristaltic pump 503. Drum Vacuum Filter 6,8m Belt conveyor 505. Pb- concentrate storage 521. Thickener D 2x2 m 522. Peristaltic pump 523. Drum Vacuum Filter 6,8m Belt conveyor 525. Zn- concentrate storage 525 DEWATERING DEWATERING APPENDIX 1. Pb-Flotation Zn-Flotation PPM/RTT Crushing 101. Receiving hopper & feeder 102. Jaw crusher 103. Belt conveyor 104. Iron separator 201. Vibrating screen 202. Gyratory crusher 203. Belt conveyor 204. Belt conveyor 205. Belt conveyor 206. Belt conveyor 207. Ore stockpile, capacity 6000 t Grinding 301. Belt feeder, 8 Feeders 302. Belt conveyor 303. Rod mill D 2,7x4,0m 304. Slurry pump, 2 pumps 305. Pump tank 306. Ball mill D 3,2x5,5m 307. Hydrocyclone classifier, 2 cyclones Ore Feed Capacity: t/a CRUSHING m3/h GRINDING Flotation 401. Conditioner 20 m Flotation machine, 20 m Flotation machine, 20 m Flotation machine, 20 m Slurry pump 406. Slurry pump 407. Slurry pump 408. Flotation machine, 10 m Flotation machine, 10m Slurry pump 411. Slurry pump 412. Slurry pump 413. Slurry pump 421. Conditioner 10 m Flotation machine, 20 m Flotation machine, 20 m Flotation machine, 20 m Slurry pump 426. Slurry pump 427. Slurry pump, 2 pumps 428. Flotation machine, 10 m Flotation machine, 10m Slurry pump 431. Slurry pump 432. Slurry pump 433. Slurry pump Dewatering 501. Thickener D 3x2 m 502. Peristaltic pump 503. Drum Vacuum Filter 6,8m Belt conveyor 505. Pb- concentrate storage 521. Thickener D 3x2 m 522. Peristaltic pump 523. Drum Vacuum Filter 6,8m Belt conveyor 525. Zn- concentrate storage 525 DEWATERING DEWATERING APPENDIX 2. Pb-Flotation Zn-Flotation PPM/RTT
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