PROPOSAL FOR EFFICIENCY AND PROCESS IMPROVEMENTS

AT LUBAMBE COPPER CONCENTRATOR

It is proposed to conduct a two-day plant audit of the Lubambe concentrator and
draw up a road map for improvement. Without seeing the plant, the following
proposal is based on our experience of similar copper concentrators.
SAG MILL PERFORMANCE:
The biggest cost savings can be made in this area as milling constitutes one of the
most significant cost elements in a concentrator. Our approach has been:

Critically analysing slurry rheology with the aim of increasing mill throughput.
This constitutes a variable cost component. Our greatest achievement has
been a 15% increase in throughput, with 12% being our average. A typical
guide is shown in Table 1.

Table 1: Showing operating guidelines for increasing SAG mill throughput,

based on slurry rheology analysis, this circuit used HPGR also
No
1
2
3
4
5

MILL
LOAD
DOWN
DOWN
UP
UP
UP

POWER
DRAW
DOWN
DOWN
UP
UP
DOWN

HPGR
LOAD
UP
DOWN
UP
DOWN
DOWN

ACTION

INCREASE MILL DENSITY

INCREASE MILL FEED
DECREASE MILL FEED
DECREASE MILL DENSITY
DECREASE MILL DENSITY
(OVERLOADING/BOGGING IMMINENT)
6
DOWN
UP
UP
DECREASE MILL DENSITY
(FINES ARE BEING FLUSHED OUT)
A critical imperative in the operation of a SAG mill is the density at which the
mill operates. Often, mill operators run a SAG mill at the same density like
that of a ball mill. This is a fundamental error. Incorrect mill density is usually
detected by the heat generated in a SAG mill. This leads to the waste of
energy, and inefficient grinding. Figure 1 is an example of one of the plant
surveys we conducted.

Figure 1: The effect of regulating SAG mill density on power draw

Analyse the grinding media used in the milling section. Often, mill ball
breakage, Figure 2, leads to high balls consumption and reduced throughput,
as broken balls cannot perform useful work but sit in the mill and takes up
space while consuming energy!

Figure 2: Broken mill balls which could add to consumption, and reduce
throughput

In addition, broken mill balls add to iron ions in the pulp. Iron in flotation pulp
has been known to depress sulphide minerals flotation rate and copper
recovery.
The application of reagents suite on the flotation circuit affects both
concentrate grade and copper recovery. In addition, a stubborn and persistent
froth could lead to pump sumps overflowing and a dirty plant floor. Apart from
copper lock-up, a dirty floor could lead to accidents from slips and falls. Often,
our recommendations result in the type of flotation froth shown in Figure 3.

Figure 3: A sweet flotation froth, as evidenced by the clear patches, resulting

from the manipulation of existing plants reagents

Premature damage and failure of conveyor belts also adds to operating cost.
We have implemented methodology for attenuating risks that can cause
premature belt wear and failure.
Poor stockpile management is the bane of any mill operator. Our
recommendations ensure that the coarse ore stockpile is at its maximum
level, Figure 4, at the commencement of day shift. This allows the mandatory
day-shift maintenance to be carried out in the crushing plant without
interrupting mill production.

Figure 4: Coarse ore stockpile at the commencement of day shift

Should plant availability permit, we often recommend the treatment of low

grade resource in order to fill plant capacity? This usually involves a variable
cost component. The plant manager can have a financial model on his
computer which will aid in this decision making process. That model will
consider:
o The selling price of copper
o The grade of the low grade material
o Known processing cost, and
o Anticipated plant recovery, Figure 5

Figure 5: Grade/recovery relationship graph for the treatment of low grade

resource

By explaining the deport of sulphide minerals in a froth column, Figure 6, we

can get operators to judiciously skim the desirable minerals, thus improving
concentrate grade

Figure 6: Deportment of sulphide minerals in a froth column

Froth floating on the surface of a concentrator thickener and reporting to the

overflow launder contributes to copper loss. We have successfully installed
mechanisms for eradicating such problems, Figure 7

Figure 7: A means of trapping fugitive froth escaping from a concentrate

thickener