Sociedad Min era Cerro Cerro Verde Verde S.A.A.
Prima rim ary Sulfide ulf ide Proj Proje ect Project No. PSP108
Process ro cess De Design si gn Criteri Cri teria a Docu Doc u m ent No. C-DCC-DC-25 25-0 -001 01 Rev. 1 27 January Januar y 2006 2006
F:\103\109 ENGDOC\109.3 CRIT_DC\PROCESS CRIT_DC\PROCESS\C-DC-25-001\C-DC-25 \C-DC-25-001\C-DC-25-001_PROCDESC -001_PROCDESCRIT_REV1.DOC RIT_REV1.DOC
Client Name: Project Name: Name: Proj ect Numb er:
Socied ad Minera Cerro Verde S.A.A. Primary Sulfide Project PSP108 PSP108
Docu ment C-DC-25-00 C-DC-25-001 1 Page 1 of 64 Rev. 1
FLUOR
Mining & Minerals
PROCESS DESIGN CRITERIA
This document has been revised as indicated below. Changes after revision 0 are identified by vertical bars at the right side of the page, with additions being underlined. Please replace all pages of this document and destroy the superceded copies. Rev No. C 0 1
Originator (name/initials) Ken Wood Ken Wood Ken Wood
Rev Date 24Nov04 11Feb05 27Jan06
Revision Revision Descripti Descripti on Issued for Approval Issued for Design Issued for Design
New Issue
APPROVAL S
Entire Document Re-issued
ORIGINAL SIGNED BY FLUOR
DATE
CLIENT
DATE
Brad Matthews
04Feb06
Jim Vanderbeek
04Feb06
Area Project Engineer:
Ken Wood
04Feb06
Lead Discipline Engineer:
Ken Wood
04Feb06
Project Manager: Engineering Manager:
Process Approval:
F:\103\109 ENGDOC\109.3 CRIT_DC\PROCESS CRIT_DC\PROCESS\C-DC-25-001\C-DC-25-0 \C-DC-25-001\C-DC-25-001_PROCDESC 01_PROCDESCRIT_REV1.DOC RIT_REV1.DOC
PROCESS
Client Name: Project Name: Name: Proj ect Numb er:
Socied ad Minera Cerro Verde S.A.A. Primary Sulfide Project PSP108 PSP108
Docu ment C-DC-25-00 C-DC-25-001 1 Page 1 of 64 Rev. 1
FLUOR
Mining & Minerals
PROCESS DESIGN CRITERIA
This document has been revised as indicated below. Changes after revision 0 are identified by vertical bars at the right side of the page, with additions being underlined. Please replace all pages of this document and destroy the superceded copies. Rev No. C 0 1
Originator (name/initials) Ken Wood Ken Wood Ken Wood
Rev Date 24Nov04 11Feb05 27Jan06
Revision Revision Descripti Descripti on Issued for Approval Issued for Design Issued for Design
New Issue
APPROVAL S
Entire Document Re-issued
ORIGINAL SIGNED BY FLUOR
DATE
CLIENT
DATE
Brad Matthews
04Feb06
Jim Vanderbeek
04Feb06
Area Project Engineer:
Ken Wood
04Feb06
Lead Discipline Engineer:
Ken Wood
04Feb06
Project Manager: Engineering Manager:
Process Approval:
F:\103\109 ENGDOC\109.3 CRIT_DC\PROCESS CRIT_DC\PROCESS\C-DC-25-001\C-DC-25-0 \C-DC-25-001\C-DC-25-001_PROCDESC 01_PROCDESCRIT_REV1.DOC RIT_REV1.DOC
PROCESS
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
0.01 PROCESS DESIGN CRITERIA- INDEX Se c t i o n
WB S No .
0.01
3000
0.02
Des c r i p t i o n
Rev
By
Dat e
In d ex
1
PR
27-J an -06
3000
Un i t s an d A b b r ev i at i o n s
1
PR
27-J an -06
0.03
3000
So u r c e Co d es
1
PR
27-J an -06
0.04
3000
Pr o c es s Des i g n B as i s
1
PR
27-J an -06
0.05
3000
Si t e Co n d i t i o n s
1
PR
27-J an -06
0.06
3000
Gen er al
1
PR
27-J an -06
0.07
3000
Or e Var i ab i l i t y
1
PR
27-J an -06
0.08
3000
B l o c k Fl o w Di ag r am
1
PR
27-J an -06
1.01
3110
Pr i m ar y Cr u s h i n g
1
PR
27-J an -06
1.02
3120
Co ar s e Or e St o c k p i l e
1
PR
27-J an -06
1.03
3210
St o c k p i l e Rec l ai m Feed er s
1
PR
27-J an -06
2.01
3220
Sec o n d ar y Cr u s h i n g an d Sc r een i n g
1
PR
27-J an -06
2.02
3230
Ter t i ar y Cr u s h i n g an d Sc r een i n g
1
PR
27-J an -06
2.05
3300
B al l Mi l l i n g
1
PR
27-J an -06
2.06
3320
B al l Mal l B al l Han d l i n g Fac i l i t y
1
PR
27-J an -06
2.07
3330
B al l Mi l l Di s c h ar g e Pu m p /Su m p
1
PR
27-J an -06
2.08
3330
Pr i m ar y Mi l l i n g Cl as s i f i c at i o n
1
PR
27-J an -06
4.01
3410
Ro u g h er Fl o t at i o n
1
PR
27-J an -06
4.02
3410
Sc av en g er Fl o t at i o n
1
PR
27-J an -06
4.03
3420
Ro u g h er Co n c en t r at e Po l i s h i n g
1
PR
27-J an -06
4.04
3420
Sc av en g er Co n c en t r at e Reg r i n d
1
PR
27-J an -06
4.05
3420
Reg r i n d Ci r c u i t Cl as s i f i c at i o n
1
PR
27-J an -06
4.06
3440
Cl ean er Fl o t at i o n - Fi r s t Cl ean er Cel l s
1
PR
27-J an -06
4.07
3440
Cl ean er Fl o t at i o n - Cl ean er /Sc av en g er Cel l s
1
PR
27-J an -06
4.08
3430
Cl ean er Fl o t at i o n - Fi n al Co l u m n Cel l s
1
PR
27-J an -06
4.09
3510
Co p p er Mo l y Co n c en t r at e Th i c k en i n g
1
PR
27-J an -06
5.01
3520
Mo l y Ro u g h er -Sc av Fl o t at i o n
1
PR
27-J an -06
5.02
3520
Mo l y Cl ean er Fl o t at i o n
1
PR
27-J an -06
5.03
3530
Mo l y Th i c k en i n g /Dew at er i n g & Dr y i n g
1
PR
27-J an -06
5.04
3540
Reagents - Lime / NaHS / Nitrogen
1
PR
27-J an -06
5.05
3540
Reag en t s - Mo l y Pl an t
1
PR
27-J an -06
6.01
3610
Co p p er Co n c en t r at e Th i c k en i n g
1
PR
27-J an -06
6.02
3620
Co n c en t r at e Sl u r r y St o r ag e an d Dew at er i n g
1
PR
27-J an -06
6.03
3630
Co n c en t r at e Dr y St o r ag e an d L o ad i n g
1
PR
27-J an -06
7.01
3700
Tai l i n g Th i c k en i n g
1
PR
27-J an -06
8.01
3800
Tai l i n g Co l l ec t i o n an d Di s p o s al
1
AG
27-J an -06
8.02
4000
Tai l i n g Dam & Seep ag e Co l l ec t i o n
1
AG
27-J an -06
9.01
3910
Reag en t s - Co l l ec t o r
1
PR
27-J an -06
9.02
3910
Reag en t s - Fr o t h er / Mo l y Co l l ec t o r
1
PR
27-J an -06
9.03
3910
Reag en t s - Fl o c c u l an t s
1
PR
27-J an -06
9.04
3910
Reag en t s - L i m e
1
KW
27-J an -06
9.04 9.05
3900/5100
Pr o c es s / Fr es h Wat er Sy s t em s
1
AG
27-J an -06
9.06
3930/3960
Reag en t s - Wat er Tr eat m en t
1
KW
27-Jan-06
9.07
5100
Fr es h Wat er Tr eat m en t
1
KW
27-Jan-06
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Co m m en t s
|
| | | |
2 of 64
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
0.02 Units and Abbreviations
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Ab br evi ati on s:
Abbreviation °C o
' " . a A Bq C cd d D80 dB F F80 g/t Gy h H Hz J K kg kW L lm lx m M min µm mo mol MW N N/A O/F P80 Pa rad s
Meaning degree Celsius degree of arc minute of arc second of arc decimal separator thousands separator (space, not comma) year ampere 1 s-1 becquerel 1 Bq = coulomb 1C = 1 A.s candela day Size which 80% of the material passes a square mesh screen of the same opening decibels farad 1F = 1 C/V Feed size of which 80% passes a square mesh screen of the same opening grams per metric tonne, = parts per million (weight) gray 1 Gy = 1 J / kg hour henry 1H = 1 V.s/A (or Wb/A) 1 s-1 hertz 1 Hz = joule 1J kelvin kilogram kilowatt liter lumen 1 lm lux 1 lx meter 6 Prefix for 10 , or million
=
1 N.m
= =
1 cd.sr 1 lm/m2
Note 2: Note 2:
minute micron (micrometer) month mole Megawatt newton 1N = 1 kg.m/s2 not applicable Overflow Product size of which 80% passes a square mesh screen of the same opening pascal 1 Pa = 1 N/m2 radian second
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Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
0.02 Units and Abbreviations
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Ab br evi ati on s:
Abbreviation S sr Sv t T T80 TBA, TBD U/F V VSD W Wb (Omega)
Meaning siemens 1S = 1 A/V steradian sievert 1 Sv = J / kg metric tonne 1 t = 1000 kg tesla 1T = 1 Wb/m2 Transfer product size of which 80% passes a square mesh screen of the same opening To be announced, to be determined Underflow volt 1V = 1 W/A Variable speed drive watt 1W = 1 J/s weber 1 Wb = 1 V.s 1 ohm = 1 V/A
N/A oz troy ounce 1 oz = 31.1035 g lb pound (avoirdupois) = 453.59 g Note 2: It is preferable that the words lumen and lux be spelled out.
(for use with metal prices only)
Definition o f design value terms:
Annual rate Operating days Availability Nominal capacity
Flowsheet balance
Design values
Flow rate per 365 calendar days Number of plant operating days per year is 365 days The time actually operated as a percentage of total available time For the grinding and flotation sections of the plant, availability is 93% The overall average capacity of the plant is 108,000 t/d. On an hourly basis the nominal flow includes the availability, for example: 108,000 t/d = 4,839 t/h 24 h/d x 93% availability This is the same mass rate as shown on the flowsheets/mass balance The values in the flowsheet balance represent the steady state average rate during the design utilization time (availability) per operating day for any facility or equipment as calculated above. Design values are the nominal hourly or average (flowsheet ) flows multiplied by the appropriate design factors for the specific process section or equipment. They include availability Design values are the instantaneous values that take into account variability in process parameters, f lows that operate for less than 24 h in an operating day, or where additional capacity is required to allow for maintenance or catch-up capability. Design values do not relate to annual production nor are they cumulative to represent a metallurgical balance. Design values are individual rates used to size equipment While actual flows might be forced to exceed the design values, performance would be degraded. For example grind could be coarser, recovery reduced, etc.
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Soci edad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
0.03 Source Codes
Initial Revision *
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
CODE
DESCRIPTION
A
Basic design criteria set by and/or agreed with SMCV
B
Primary Sulfide Prefeasibility Study
C
Derived from SMCV testwork program data
D
Derived from design calculations
E
Engineering handbook data
F
Fluor data based on experience from other projects
G
Normal industry practice
H
Assumed values--represents best estimate from available data
I
Manufacturer/Vendor-originated data
J
Criteria from Technology supplier
K
Preliminary information --requires further evaluation and confirmation
L
Data from existing operation
REV
*Note: Current design criteria Revision A is taken as Revision D of specification C-DC-25-901 HPGR.
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Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
0.04 Process Design Basis
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revisio n
P.Rosario
Date:
27-Jan-06
Rev
1
•
•
•
•
•
• •
•
•
Sociedad Minera Cerro Verde S.A.A. (SMCV) currently operates a mining/leaching SX/EW facility which produces copper cathodes. It is located near the city of Arequipa in Southern Peru, at an elevation approaching 2,800 m. The climate is generally temperate and dry, but with limited precipitation in January through March. Minimum temperatures are above freezing. The current project involves the installation of a new concentrator to treat primary sulfide ores which are becoming available as the existing oxide ore is removed from the Cerro Verde and Santa Rosa open pit mines. The primary product will be a copper sulfide concentrate of approximately 28% Cu grade, as well as a limited amount of byproduct molybdenum concentrate. Concentrate will nominally be shipped overseas through the Pacific Ocean port of Matarani, Peru, approximately 95 km from the mine site. The mineral resource is relatively low grade at an average of 0.64% Cu for the first ten years. The project viability is enhanced by the low mine waste stripping requirements as a result of oxide mining activities. The nominal treatment rate will be 108,000 t/d. There will be no provision made for future expansion and mine life will be in excess of 25 years. The approach to design of the facilities will be to design for low capital cost while still aiming at an operating cost limit of $0.60/lb copper or less. Design plant capacity will be as close as practicable to nameplate capacity to help limit capital costs. Operating schedule will be 24 h/d, 365 days per year The plant will be designed for safe and efficient operation and maintenance but with as compact a layout as is compatible with safety and efficiency. Overall plant design will be on the basis of complying with current North American standards of health, safety and environmental control, specifically OSHA, MSHA and EPA standards. Peruvian standards will be met where they are more stringent than the North American ones. The basic circuit will include: single primary gyratory crusher, with overland conveyor to a coarse ore stockpile. a secondary crushing circuit consisting of cone crushers operating in closed circuit with screens. a tertiary crushing circuit consisting of high pressure grinding rolls (HPGR) operating in closed circuit with ball mill feed screens. four grinding lines each consisting of a feed bin, two ball mill feed screens, a ball mill, and a cyclone classification system. flotation of a bulk Cu-Mo concentrate in one row of cells per ball mill; concentrate regrind in vertical stirred mills followed by upgrading in a combination of mechanical and column flotation cells. concentrate thickening. molybdenum separation, dewatering and packaging. copper concentrate dewatering by thickening and pressure filtration. Tailing will be thickened at the concentrator site, with overflow water recycled to the process water system. Tailing will be diluted and cycloned at or near the tailing embankment to provide sand for construction of the embankment itself, beyond the engineered starter dam. Specific equipment sizes, quantities and details will be developed in the Equipment List. Copper concentrate will be transported off site to the port of Matarani. Molybdenum concentrate will be packaged in drums or bulk bags for shipping to destination. • • •
•
• •
• • • •
| |
•
• •
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6 of 64
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
0.04 Process Design Basis
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revisio n
P.Rosario
Date:
27-Jan-06
Rev
1
•
Intermediate storage will be provided at several points in the process to accommodate different operating availabilities for different areas. Limited storage will be provided by the mine for stockpiling run of mine ore ahead of the primary crusher. This material will require rehandling by front end loader. Coarse ore stockpile will provide 10 h live storage and nominally 4-5 d total storage with bulldozing. This will provide adequate capacity to allow primary crusher maintenance without disrupting downstream operations. Approximately ½ h surge capacity will be provided ahead of HPGRs while over 2 h storage will be provided between the HPGR and ball mill circuits. Concentrate slurry storage for 24 h operation will be provided ahead of the filtration system to allow for a lower availability in the filter operation. Filtered concentrate storage will be provided for a total of 10 d operation, to allow for possible disruptions or delays to concentrate transport to the port. Storage will consist of 24 h capacity for direct loading, with the balance on an emergency storage pad. Concentrate loading and moving will be by front end loader. Storage for 30 d concentrate production will be provided at the port to allow for accumulation of shipload lots of concentrate as well as having capacity to accommodate delays in ship arrivals. Plant layout will be such as to maximize gravity flow of the major process streams, consistent with capital constraints of site preparation costs. Tailing flow to the tailing impoundment area will be by gravity. Spares will largely be uninstalled to constrain capital costs and to simplify installation and operation. The plant will have an advanced level of automation to help in achieving the target grinding circuit availability of 93% and the key metallurgical targets of 28% copper concentrate at 90% recovery. Design factors used in equipment sizing will be kept as low as practicable while still being able to achieve the design throughput and metallurgical performance on a yearly basis. They will be stated clearly and will be specific for each section of the process rather than applied overall. There will be no discipline design factors applied on top of the process design factors, other than required safety factors. Design Factors: For primary crushing and coarse ore conveying, a design factor of 1.111 will be used. This will meet the grinding circuit feed requirements while also allowing a reasonable margin to replenish the stockpile after crusher shutdowns. Catch-up capacity will be provided by operating at greater than the design availability on a short term basis. From coarse ore reclaim through crushing, grinding, bulk rougher-scavenger flotation, and final plant tailing, design flow will be 111.1% of nominal or balance flow, on a mass basis. This is to compensate for variability in the grindability of the ore, to ensure that over the course of a year, the daily average production can be achieved. From rougher-scavenger concentrate through regrind and cleaner circuits the design will allow for a maximum head grade of 1% Cu at nominal throughput, or 0.8% Cu head grade at the maximum throughput. This factor allows the equipment to be sized to handle the tonnage variations expected from the grinding circuit as well as the range of concentrate production resulting from variability of the copper head grade. These design factors do not relate to the defined annual production nor do they add up to result in a metallurgical or mass balance. They are used for sizing equipment. •
•
•
•
•
•
•
• •
•
•
•
•
•
•
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Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
0.04 Process Design Basis
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revisio n
P.Rosario
Date:
27-Jan-06
Rev
1
•
The design froth factors are as follows: Copper rougher concentrates froth factor - 1.5 Copper cleaner concentrates froth factor - 3.0 Molybdenum rougher and rougher/scavenger concentrates froth factor – 3.0 Molybdenum 1st cleaner concentrates – 3.0 Molybdenum 2nd and 3rd cleaner concentrates – 3.5 Molybdenum 4th, 5th, and 6th cleaner concentrates – 4.0 These froth factors are used for sizing equipment as follows: For gravity lines (Rougher/Scavenger/Polishing/Regrind/Final Cleaners/Moly) the flow will equal the design maximum slurry flow multiplied by the froth factor. The pipes or launders will be assumed to be 50% full. For pump boxes, the live volume will equal the design maximum slurry flow multiplied by the froth factor, divided by the retention time. The retention time will be a minimum of 1 minute, as limited by available space. The freeboard above the overflow centerline will be 0.5 m and the freeboard below the overflow centerline and operating level will also be 0.5 m, leading to an operating level of 1 m below the top of the pump box. For sumps, the live volume will equal the slurry drain flow multiplied by the froth factor divided by the retention time. The volume will be determined by fl oor area and sump slopes. Floor area is a function of layout and segregation of spillage products by process characteristics. Low level will be determined by the minimum operating level of the sump pump. High level, or the sump floor high point and the sump pump base plate elevation will be 150 mm below the top of the sump opening. Sumps will have a retention time of 5 minutes, space permitting. Pumps process flow will equal the design maximum slurry flow multiplied by the froth factor. The pump vendor flow will equal the design maximum slurry flow multiplied by the adjusted froth factor by pump vendor. Pressure lines flow will equal the design maximum slurry flow. Distributor boxes live volume will equal the design maximum slurry flow multiplied by the froth factor divided by the retention time. Retention times will be a minimum of 30 seconds as limited by available space. The operating level will equal the driving head required through dart valves (if applicable), nozzle, elbow (if applicable) at the design maximum slurry flow. The freeboard above the overflow centerline will be 0.5 m and the freeboard below the overflow centerline and the operating level will be 0.5 m. The flow through samplers will equal the design maximum slurry flow multiplied by the froth factor.
• • • • • • •
•
•
•
•
• •
|
•
• •
All reagent storage facilities will require secondary containment facilities as necessary. The study will use SI (International System of Units) metric units, except for piping, which will be in Imperial units.
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8 of 64
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
0.05 Site Conditions
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revisio n
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Data
Source Rev
Reference
1. Project Location
Mine location Project elevation: Project latitude: Project longitude:
masl deg/min deg/min
16 km ESE of Arequipa, Peru 2,700 m (8,860 ft) 16° 32’ south 71° 37’ west
L L L
A A A A
Spec C-DC-10-002 Spec C-DC-10-002 Spec C-DC-10-002
L L L L
A A A A
Spec C-DC-10-002 Spec C-DC-10-002 Spec C-DC-10-002 Spec C-DC-10-002
L L L H H
A A A A A
Spec C-DC-10-002 Spec C-DC-10-002 Spec C-DC-10-002 Spec C-DC-10-002 Spec C-DC-10-002
H L L
A A
Spec C-DC-10-002 Spec C-DC-10-002
L H
0 0
Spec C-DC-10-002 Spec C-DC-10-002
L
A
Spec C-DC-10-002
L L
0 A
Spec C-DC-10-002 2000-2002 data
L L
A A
2000-2002 data 2000-2002 data
L L
0 A
EIS data 2000-2002 data
2. Site Acc ess
Road distances to: Arequipa Pacific port of Matarani Lima, the country’s capital San Jose, railway access
km km km km
26 100 1,100 12
3. Climatic Conditi ons
A. Air Temperatures Average annual maximum °C 24.7 Average annual minimum °C 3.7 Average daily variation °C 16.6 Design maximum °C 30 Design minimum °C 0 (Short occurrences only) B. Wind Maximum gust km/h 100 Prevailing winds direction Southwesterly Winds are frequently laden with fine volcanic ash. C. Precipitation Average annual precipitation mm/a 40.7 Maximum 24 hour rainfall mm 81.5 D. Evaporation Average daily evaporation mm/d 6.1 E. Solar Radiation Average daily radiation W/m2 6,270 Range W/m2 4,230-7,850 F. Barometric Pressure Average annual mm Hg 555 Range mm Hg 551-559 G. Relative Humidity Average annual % 56.1 Range 8-100
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9 of 64
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
0.06
General
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev. Reference
*If different than the nominal Ore type Ore specific gravity Ore moisture content Ore moisture content
nominal range
Nominal annual capacity Concentrator availability Instantaneous surge factor, throughput Concentrator treatment rate Concentrator treatment rate Operating schedule
% % t/a %
Porphyry Copper 2.75 1.7 1-5
B A L
A A
A D B D A A A A A
A
B-p.183
A
t/h t/d d/a h/d shifts/d h/shift
39,420,000 93.0 1.111 4,839 108,000 365 24 3 8
Ore head grade, years 1-10 Cu, average Mo, average Ag, average
% % g/t
0.64 0.019 1.54
B C C
1 A A
|
Metal recoveries, years 1-10 Cu, average Ag, average, to copper conc Mo, average, to Cu-Mo concentrate Mo, average, Mo concentrator
% % % %
91.4 61 71.6 90
C,D C C,H C,H
1 A 1 2
|
Concentrate grades, years 1-10 Cu, average Ag, average, in Cu concentrate Mo, average, in Cu-Mo concentrate Mo, average, in Mo concentrate
% g/t % %
29.4 47 0.677 55
C,D C,D C,D C,D
1 1 1 1
| | | |
C,D D
1 1
Des. Calc @ max feed rate & max gra
| |
C,D C,D C,D
1 1 1
Calc @ ave feed rate & ave grade
| | |
Copper concentrate production rate (dry), years 1-10 Average t/d Yearly production (nominal) t/a
2,149 784,000
Metal production, years 1-10 Cu, average Cu, maximum Mo, average
231,000 266,000 4,800
t/a t/a t/a
5,376 120,000
2,812
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
C C A C
Dynamic simulation
A A A A
| |
Calc @ ave feed rate & max grade Calc @ ave feed rate & ave grade
10 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
0.07 Ore Variability
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-03
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Ore Variability by Year 108,000 t/d
Variable SPI BWI Production rate Grind size P80 Ball mill specific power Head grade Copper Head grade Molybdenum Recovery of copper Concentrate grade Concentrate grade Concentrate production
Units min. kWh/t t/h µm kWh/t % Cu % Mo % % Mo % Cu t/d
Sou rc e Rev Reference Years 1-10 Years 11-29 Average Minimum Maximum Average Minimum Maximum 146 122 160 141 121 159 15.2 14.4 15.6 15.1 14.4 15.7 4,839 5,376 4,839 5,376 125 125 8.25 7.90 8.48 8.22 7.82 8.49 0.64 0.54 0.74 0.49 0.37 0.69 0.019 0.016 0.026 0.012 0.001 0.022 91.4 90.9 91.7 90.0 85.0 91.0 55.0 55.0 29.4 27.9 30.1 27.7 27.3 31.3 2,149 2,812 1,719 2,503
Ore Lithology and Alteration Characteristics on page 2 of 3 of this spec. JK Drop Test and breakage data on page 2 of 3 of this spec. Metallurgical parameters by lithology and alteration type on page 2 of 3 of this spec. and flotation model. SPI and BWI distribution curves for LOM orebody on page 3 of 3 of this spec.
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
C
C
C,D C,D C,D C,D C,D C,D C,D C,D C,D C,D C,D
A A C A A A A 1 1 1 1
C C C
A A 1
C
A
Mine Plan VO2 Rev10
From material balance.
| | | | | | | | | | |
| |
11 of 64
ORE VARIABILITY BY LITHOLOGY / ALTERATION TYP
GN1- Gneiss YGD 2- Yarabamba Granodiorite
Lithology Codes
DMP 4- Dacite Monzonite Porphyry SBx 6-Silica Breccia
QTBX 8YGDBx 1 YGD Breccia DMPBx 9- DMP Breccia Document C-DC-25-001_Rev 1
Cerro Verde Sulfide Project Metallurgical Test Program Ore Type Distribution and Proposed Ore Variation Ass essment Sampling Requirements
Model 10A Al ter ati on Type Al ter ati on Al ter ati on Code Code %
Propylitic External Argillic Phyllic Potassic Silicic Propylitic (Sil) Silicic Propylitic (QS) Quartz Sericite
PE 1 A 2 PHY 3 K-S 4 SIL 5 PI-SIL 6 PI-QS 7
7.48 0.76 37.62 19.65 9.18 18.92 6.37 99.98
Totals
GN 1 % Samples
0.00 0.00 0.61 2.53 0.85 4.35 1.74 10.08
0 0 1 3 2 6 3 15
YGD 2 % Samples
6.76 0.74 27.08 8.93 4.33 8.79 2.50 59.13
9 2 37 12 6 12 3 81
Lithology SBx 6 % Samples
DMP 4 % Samples
0.71 0.02 7.60 8.01 2.86 4.56 1.79 25.55
2 0 10 11 4 6 3 36
0.01 0.00 0.21 0.01 0.18 0.39 0.18 0.98
QTBX 8 % Samples
0 0 0 0 0 0 0 0
0.00 0.00 0.92 0.06 0.36 0.32 0.00 1.66
% Samples
0 0 1 0 0 0 0 1
0.00 0.10 0.03 0.33 0.30 0.05 0.81
0 0 0 0 0 0 0 0
YGDBx 10 % Samples
0.00 0.00 1.10 0.08 0.27 0.21 0.11 1.77
0 0 2 0 0 0 0 2
Cerro Verde Drop Test Summary Lithology Code
Alteration Hazen Code Number
2 2 4 2 4 2 4 1 2 4
3 3 3 4 4 5 5 6 6 6
1 2 3 4 5 6 7 8 9 10
A
Drop Test Parameters b Axb
66.25 60.10 57.79 57.90 63.96 62.00 62.34 73.52 69.66 53.57
0.82 1.23 0.75 0.62 0.44 0.81 0.91 0.42 0.53 1.16
54.33 73.92 43.34 35.90 28.14 50.22 56.73 30.88 36.92 62.14
SPI/BWI Data Ta
0.52 0.89 0.41 0.52 0.21 0.53 0.52 0.40 0.42 0.80
SG
2.85 2.86 2.87 2.92 2.86 2.79 2.84 2.86 2.86 2.89
No. SPI/BWI
SPI Ave
37 37 10 12 11 6 4 6 12 6
101 101 104 173 180 97 107 164 149 179
Min
Max
44 44 58 83 127 48 33 98 95 154
SD
161 161 186 242 232 146 152 297 192 233
Ave
34 34 50 52 32 39 49 69 26 32
14.9 14.9 14.0 15.4 16.2 12.9 15.4 15.6 15.4 15.3
BWI (kwh/mt) Min Max
13.2 13.2 12.5 12.8 13.4 10.8 13.7 13.4 12.7 14.5
SD
16.5 16.5 16.0 17.3 18.2 15.0 17.2 17.5 19.7 16.3
Distrib ution of Metallurgi cal Ore Type Parameter (MET01) From L OM Plan Lithology Alteration MET01 Number % of Cu Mo Cu Conc of B loc ks Tot al Rec ov er y Recov er y Grade 51 1-4-6-8-9-10 1-2-7 13,121 19.0 90.1 51.4 28.4 52 2 1 3,960 5.7 82.8 51.4 26.1 53 2 2 488 0.7 90.1 53.1 28.4 54 2 3 18,037 26.1 85.0 49.1 24.8 55 2 4 6,600 9.5 88.1 51.6 30.9 56 2 5 3,078 4.5 90.0 50.1 27.4 57 2 6 5,634 8.2 91.4 56.2 29.1 58 2 7 1,509 2.2 88.7 53.8 25.5 59 4 3 5,388 7.8 88.0 48.0 30.1 60 4 4 5,770 8.3 92.7 52.9 29.8 61 4 5-6 5,171 7.5 93.2 55.3 29.8 0 365 0.5
Total
69,121
100.0
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
12 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001 Rev 0
Process Design Criteria Section:
0.07 Ore Variability
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-03
Rev A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
So ur ce Rev Reference C
Cerro Verde SAG Performance Index Distribution 100% 90% 80% 70%
%
60%
A
2.4 2.4 1.2 1.4 1.5 1.7 1.9 1.5 1.9 0.7
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001 Rev 0
Process Design Criteria Section:
0.07 Ore Variability
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-03
Rev A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
So ur ce Rev Reference C
A
C
A
Cerro Verde SAG Performance Index Distribution 100% 90% 80% 70%
% e 60% v i t a 50% l u m 40% u C 30% 20% 10% 0% 0
25
50
75
100
125
150
175
200
225
250
275
300
SAG Performance Index (minu tes)
Cerro Verde Bond Work Index Distributi on 100% 90% t 80% n e 70% c r e P 60% e v 50% i t a 40% l u m 30% u C 20% 10% 0% 10
11
12
13
14
15
16
17
18
19
20
Bond Work Index (kWh/t)
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
13 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
0.08 Block Flow Diagram
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-03
Rev A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
Units
Data
1
Source Rev Reference
108,000 t/d HPGR case:
See drawing no. PSP108-C-0000-25I-001 Rev 4
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
C
1
|
14 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
1.01
Primary Crushing
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
Units
Nominal
Size (mm) 2,000 1,200 600 200 100 50 25 12 6 mm t/a t/h t/h t/h mm mm days/year shifts/day hours/shift % h/d 3 t/m
Cum % passing 100 99 95 70 50 30 25 15 8 380 39,420,000 6,429 6,429 6,540 200 165 365 3 8 70% 16.8 1.6
Design*
Source
1 Rev
Reference
* If different than the nominal Run of mine feed size: Top size
Nominal run of mine 80%passing Crusher annual production (dry) Crushing rate (dry) Disch. conveyor capacity average Coarse ore conveyor capacity (wet) Open side setting recommended Product size 80% passing Operating schedule
Availability (crusher & disch. conv.) Bulk density (dry) vol. calcs - design Bulk density (dry) wt. calcs - design Abrasion index, average/range Crushing work index (low energy) av/range Ore UCS, Average/max Crusher type No of crushers Crusher size Crusher dump pocket capacity Crusher surge pocket capacity Truck dump points Dust suppression method Moisture content, nominal/range Dump pocket cleanout method Mine haul truck capacity, design Maximum conveyor inclination Maximum inclination at loading point Minimum chute slopes Dynamic surcharge angle of material on belt Angle of repose Angle of withdrawal
3
t/m Bond kWh/t MPa _ in t t units % t degrees degrees degrees degrees degrees degrees
7,200 7,200 7,300
1.92 0.24/0.2 to 0.3 13/7-19 140/250 Gyratory 1 60-113 500 500 2 Water spray and ADS spray 1.7/1-5 Backhoe 238 15 10 70 25 max 37 65
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
H H H H H H H H H H A D D D I I A A A G G H
A A A A A A A A A A C C C C A A A A A A A A
H H C H A,G D I G G A G H G A F F F F B E
A A C A A A C A A A 0 A A A A A A A A A
Maximum Maximum
Dawson tests
15 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
1.02 Coarse Ore Stockpile
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
Units
Stockpile live capacity (dry) Stockpile live capacity (dry) Stockpile diameter Stockpile height Stockpile capacity total without pushing Stockpile capacity total with bulldozing Stockpile capacity total Material angle of repose Draw down angle Moisture content Bulk density (dry) vol. calcs - design Bulk density (dry) wt. calcs - design
t h m m t t d degrees degrees % 3 t/m 3 t/m
Nominal
Design*
50,000 10 115 44 250,000 400,000 4 37 65 1-5 1.6 1.92
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
Source
F D C C F A F A F L F F
1 Rev
Reference
* If different than the nominal C-7606-3100-59-SK102 A C A A A A A A A A A A
16 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
1.03
Stockpile Reclaim Feeders
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
Units 3
t/m Bulk density (dry) vol. calcs - design 3 t/m Bulk density (dry) wt. calcs - design Nominal feed top size mm Number of lines Feed moisture, nominal % Total feed rate, nominal (dry), design (wet) t/h Number of feeders Normal no. feeders operating Feed rate/feeder (dry) - nominal, (wet) - max t/h Feeder type Feeder control VSD/Fixed Feeder drive type Coarse ore reclaim conveyor capacity wet t/h width mm Coarse ore reclaim dust control Coarse ore surge bin capacity time min tonnage, per line t Availability %
Nominal
Design*
1.6 1.92 280 1 2.4 5,056 4 3 1,685 Apron VSD VFD 11,500 2,400 ADS sprays 17 800 89
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
6,000
2,000
Source
A A E A L D F F D F G G D D G K D G
1 Rev
Reference
* If different than the nominal A A A A 0 C A A C A A A 0 A A A A 1
|
17 of 64
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
2.01 Secondary Crushing & Screening
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev 1
Units
Nominal
Design* Source Rev Reference
* If different than the nominal Coarse ore screens
Purpose Number of screens Feed to screening section New feed, nominal (dry), design (wet) Recirculated, nominal, design (wet) Total, nominal (dry), design (wet) Feed rate per screen, nominal (dry), design (wet) Screen feed size 100 % passing 80% passing % passing 75 mm % passing 40 mm % passing 20 mm Screen size and type To deck o enin Efficiency Bottom deck opening Efficiency Screen oversize (combined TD + BD) per screen Screen undersize product (-40 mm) per screen
Ref. Bruno CVHPGR24r
G D
A C
A D D D L D D D D D D D D D D A
1 1 0 C 0 C C C C 0 C C C C 1 1
4 750 45 70 74 Closed, C.O. Screens type ADS 40 t/10 t overhead crane % 85
D I D I D I,A G F G
A A A A A A A A 1
t/h
D
0
Scalp secondary crusher feed 4 t/h t/h t/h t/h mm mm % % % m mm % mm % t/h t/h
5,056 5,800 5,056 6,300 10,112 11,500 2,528 3,200 280 103 73 46 24 3.66 x 7.93 DD Banana 76 90 49 90 1,264 1,700 1,264 1,500
Utilization 89% ** *
| | |
*** ***
| |
Secondary crushin g
Number of crushers Crusher size Closed side setting Product percent passing css Product percent passing 47 mm Open or closed circuit Secondary crushing & screening dust control Secondary crushing maintenance crane Crusher Normal Operating Loading Factor
No. kW mm % %
|
Crusher Feed
Screen oversize (combined TD + BD)
1,264
1,700
|
CVHPGR 24n
| | |
*Maximum new feed rate and maximum recirculation do not coincide **Design value calculated assuming 2 crushers@100% load and 2@normal 85% load ***Design value calculated with crusher@85% load
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
18 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
2.02 Tertiary Crushing & Screening
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Rev
Reference
Units
Nominal
Design*
Source
* If different than the nominal Tertiary crushi ng
Surge bin capacity, per unit Number of crushers Section availability Crusher type, size Installed power per unit Specific throughput rate Specific energy Specific press force Feed topsize Circulating load Feed rate per crusher, dry Feed moisture Product size P80 Tertiary product bulk density Tertiary product bulk density Expected wear rate Expected roll life Tertiary crushing dust control
time tonnage installed operating
range range range range range range % -5 mm Flake Loose range
min t
31 1,200 4 4 % 91% HPGR 24/17-8 kW 2 x2,500 ts/hm3 200-256 256 kWh/t 1.7-2.0 2.0 N/mm2 3.5-4 4.0 mm 46 50 % 20-75 75 t/h 2,349 2,630 % 3-6% 5% mm 4-10.8 10.8 % 65 t/m3 2.3 t/m3 1.4 g/t ore 0.75 h 5,700-6,700 6,000 Dust collection, wet scrubber
Ball mill screening
Total feed rate to screens Section availability Surge bin capacity, per unit
t/h % h t
9,396 93% time 2.1 tonnage 5,000 Number of screens 8 Feed rate per screen t/h 1,149 Number of feeders per screen 1 Capacity per feeder t/h 1,149 2,100 Wet or dry screening Wet Screen feed arrangement Pulping box ahead of screen; water sprays both decks Screen size, type m 3 X 7.3 DD Banana 12 Top deck opening mm Efficiency % 88 Bottom deck opening mm 6 Efficiency % 91 Oversize product moisture range % 5-10% 10% Circulating load to HPGR circ, total dry t/h 4,355 wet t/h 4,839 range % 20-90 75 Undersize product, total dry t/h 4,840 Undersize product, size P80 mm 2.8 3.5
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
F D I,A I A I I I I I I I D H I I C C C I G
C A A A C 0 0 A A A C A A C A A C 1 A A A
G D A D D D D F D A,G F D D D D D H D D I D D
A 0 C 0 A C C C C A A 0 C C C C A C C C C 1
Dynamic Simulation Dynamic Simulation
1.6 is used for bin sizing Krupp-Polysius "
|
Ref Bruno CVHPGR25
Ref. Sim HPGR PSDs
19 of 64
|
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
2.05 Ball Mill Grinding
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Rev
Reference
Units
Nominal
Design*
Source
* If different than the nominal Ball Milling
Section availability Number of mills Feed rate per mill - dry Feed rate total - dry Solids S.G. design basis Feed size - T80 Product size P80 - range
% t/h t/h _ µm µm
93% 4 1,211 4,843 2.75 2,800 115-150
1,350 5,400
125
A D D D C D C
C A 1 1 A C C
C C C,A
A A A
C,D
A A C
C,D C,D C,D
C C C
F
A
| |
Mill feed characteristics
Reduction in ball mill feed work index "soft" % 11.9 "hard" % 6.3 Assumed for design % 10 * Open circuit test. Reduction expected to be less for closed circuit product test. Work Index, maximum annual average (reduced basi metric 14.1 metric Work Index, annual average range (reduced) 13.0 - 14.1 Nominal New feed size distribution Size Cumulative mm % Passing 5.6 99.7 5 98.7 2.8 80.0 1 57.0 0.5 44.0 0.31 37.0 0.2 32.0 0.125 27.0 0.09 24.0 D99 mm 5.6 New feed D80 mm 2.8 D50 mm 0.7 Circuit configuration
Screen undersize product discharges to ball mill discharge/cyclone feed sump and is cycloned before reaching ball mill feed
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
Krupp Krupp Krupp
20 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
2.05 Ball Mill Grinding
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Rev
Reference
Units
Mill drive type Mill motor Design factor for grinding and downstream Ball mill operating point Ball load (nominal) Charge volume Percent of critical speed Ball mill drive design conditions Ball load (drive design point) Charge volume Percent of critical speed Ball mill structural design point Ball load Total charge Mill diameter inside shell Mill effective grinding length Critical speed Operating speed, nominal Mill rotation direction Trommel installed Liner material Liner wear rate Maximum ball size Estimated ball consumption Slurry percent solids by mass Lime addition Pulp pH Circulating load - design basis (UF:OF)
type kW
Nominal
Gearless 12 000 1.11
Design*
Source
* If different than the nominal B 0 B 0 C
% by vol % by vol %
35 35 75
B F B
C A C
% by vol % by vol %
38 38 75
B I B
A A C
% by vol 40 % by vol 40 m (ft) 7.300 (24) m (ft) 11.000 (36) rpm 15.9 % critical 75
F I B B D B
A 0 0 C C
Clockwise, viewed from feed end Yes/no No type Steel g/t ore 22 mm 75 kg/t ore 0.35 % 72 yes/no yes pH 9.5-10 % 250
I F G B B B A C B G
0 A A A A A A A A A
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
21 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
2.06 Ball Mill Ball Handling
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units Ball delivery method Ball delivery mass per load Ball size, normal Ball specification Ball consumption rate Ball consumption Ball storage capacity Ball storage capacity, total mass Ball loading to long term storage Ball recovery method from feed hopper
Ball feeding/metering system Manual/automatic/continuous operation Feeders Ball feed rate Feeder operating time, design Ball transfer to ball feeding conveyor Feed selection to specific ball mill Ball addition measurement method Emergency ball addition method Emergency ball addition point Emergency ball bucket capacity
t mm kg/t ore t/d d t
Nominal
Design*
Truck 35 75 Forged 0.35 38 31 1,200 Rear dump truck Gravity fed chute
53
Metering feeder to ball conveyor Automatic number 1 t/h 6.6 16.8 h/d 24 High angle conveyor Diverter gates on ball distribution conveyor Belt weightometer Ball bucket by crane Feed point on each ball mill feed chute t 4
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
Source Rev Reference * If different than the nominal G A K A B A G A B A D 1 A 1 D A G A G A
F A G A A F F F F F F
| |
A A A A A A A 0 A A A
22 of 64
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
2.07 Ball Mill Discharge Sump/Pump
Initial Revisio n
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revisio n
P.Rosario
Date:
27-Jan-06
Rev
1
Units Per Ball Mill Grinding Line
New feed mass, design maximum Ball mill circulating load (UF:OF) Total cyclone feed, including circulating load Solids specific gravity Cyclone feed density Cyclone feed slurry specific gravity Number of cyclone clusters per ball mill Feed volume per cyclone cluster Number of operating pumps, total Number of installed standby pumps Number of uninstalled standby pumps Pressure drop across cyclones Pump type Pump size Pump liner material Pump impeller material Pump drive Sump retention time, minimum Sump volume Sump shape
Nominal Design* Source Rev Reference
* If different than the nominal 1,211 1,350 A 1 250% G A 4,238 4,700 D 1 2.75 B A % wt. 50% 60% K A 1.46 1.6 D A 1 G A m /h 5,832 6500 D 1 Design value calc @ 50% wt. mm 1 A A 0 A A 1 A A per 2 operating pumps kPa 69 I 0 Horizontal centrifugal slurry pump G A 28x26 D A Metal G A Metal G A VFD A C min 1.95 1.75 G 1 m 190 D 1 Sides sloped at 60 deg from horiz.(lower part) A t/h % t/h
Estimated cycl one feed size distributi on
100 % passing size F100 80% passing size F80 % passing 75 µm
µm µm
%
6,000 550 28-35
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
H H H
C C C
23 of 64
| | |
|
| |
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No. PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
2.08 Primary Milling Classification
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revisio n
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal Design* Source Rev Reference
Total Grinding Circuit:
* If different than the nominal 5,400 A 1 G A 18,900 D 1 60% G A A A
Total new feed mass t/h 4,843 Ball mill circulating load (U/F:O/F) % 250% Total classification feed t/h 16,951 Cyclone feed density % wt. 50% Number of cyclone clusters (1 per ball mill) 4 Per ball mill/cyclone cluster m3/h Feed volume per cyclone cluster 5,832 6,500 m µ Split size D50 Overflow: Product solids mass t/h 1,211 1,350 µm Product P80 size 125 125-149 Product density, weight % solids % wt. 28% m3/h Product slurry volume 3,554 3,950 Underflow Product solids, mass t/h 3,027 3,370 µm Product D80 size 2,000 Product density, weight % solids % wt. 72% Product specific gravity 1.85 m3/h Product slurry volume, nominal 2,278 2,540 Cyclone Clusters Cyclone size mm 840 Cyclone type High efficiency design Number of operating cyclones per cluster 6 Total number of cyclones per cluster 8 Vortex finder diameter mm 350 Vortex finder material ceramic Apex diameter 163 Apex fixed/adjustable fixed Apex material ceramic Pressure drop across cyclones kPa 69 Distributor type Bottom feed radial manifold Cyclone installation angle, degrees from vertical degrees 11 Cyclone isolation Full flow knife gate valves w/rubber sealing Cyclone valve operation Automated, air actuated Feed manifold lining Rubber Underflow launder lining Rubber Overflow launder lining Rubber Estimated size distributions Size Feed (nom) Underflow Overflow Cum % Cum % Cum % passing passing passing µm 12,500 100.0 100.0 100.0 9,500 99.7 94.6 100.0 4,750 97.8 88.2 100.0 3,350 96.6 84.7 100.0 2,000 92.7 79.8 100.0 850 86.2 70.5 100.0 600 81.7 64.5 99.9 300 66.1 44.9 96.9 212 57.1 35.2 90.7 150 47.5 25.7 83.0 106 38.6 17.4 75.3 75 32.9 15.0 68.0 F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
| |
D
1 A
|
D A C D
1 C A 1
|
D D A D D
1 A A A 1
|
I G I I D G D G G I G I G G G G G
0 A 0 0 0 A 0 A A 0 A 0 A A A A 0
I
A
|
|
|
Candelaria
24 of 64
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
Initial Revision Last Revision
4:01
Rougher Flotation
C-DC-25-901 HPGR Rev. D P.Rosario
Date:
15-Mar-04
Rev
A
Date:
27-Jan-06
Rev
1
Units
Nominal
minutes t/h t/h m3/h m3/h % % Yes/No
0 4,843 4,480 14,215 13,120 28 25 - 32 Yes 10-11 125
Design*
Source
Rev
F
1 0 C 0 C A A A 1 A
Reference * If different than the nominal
Conditioning time Feed rate Feed rate - Minimum Pulp flow rate Pulp flow rate - Minimum % Solids by mass % Solids by mass - Range Lime addition Slurry pH P80 feed Cell type Cell Volume Effective Cell volume No of rows of cells No. of cells/row Residence time basis Effective Volume Air Holdup Pulp residence time - 1st cell Pulp residence time - 2nd cell Concentrate collection lip length Lip loading factor - 1st cell Lip loading factor - 2nd cell Froth factor for concentrate design Flotation air Air volume/cell Air pressure Air temperature Feed grade Stage recovery - 1st cell Stage recovery - 2 cells combined Tailing grade - 1st cell Tailing grade - 2nd cell Conc grade - 1st cell Conc grade - 2nd cell Weight floated % of plant feed - 1st cell Weight floated % of plant feed - 2nd cell Concentrate rate - solids only - 1st cell Concentrate % solids - 1st cell Concentrate P80 microns Concentrate solids S.G. - 1st cell
µm
5,400 15,800
C,G B
Mechanical 160 m /cell 136 m3 /cell _ 4 _ 2 ave flow@ave density@effective cell volume % (100-% Air Holdup) % 15 minutes 2.30 minutes 2.33 m/cell 60.0 t/m/h 1.05 1.43 t/m/h 0.78 1.01 _ 1.5 forced/induced Induced Not Applicable m3/h kPa Not Applicable degrees C Not Applicable 3
% Cu % % % Cu % Cu % Cu % Cu % % t/h % µm _
0.64 55.57 78.81 0.290 0.140 17.18 11.33 2.07 1.31 100.2 39.8 110 3.65
D D D D B F
0.50-1.00 51.96-58.23 75.71-80.93 0.213-0.457 0.221 15.48-19.59 13.68 2.84 1.70 84-138 30.0 - 42.0 125 3.53-3.83
B D B,D B,D
F D D I D D G I I I
A B C/D C B/D C/D C/D C/D C/D C/D D,G C C/D
A A 1 1 1 A A C C A C C C 0 0 0 0
| |
Ball mill cyclone operating range Lime added to one line
|
| | | Industry standard
Vendor specification
A C C 1 C 1 1 1 1 1 1 1 B
| | | | | | | |
Concentrate Product Destination
A. Normal B. Alternate C. Alternate
Polishing mill Regrind mills Column Cells
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
F F
Normally - 1st cell feeding polishing mill
25 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
4:02
Scavenger Flotatio n
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Feed rate Pulp flow rate % Solids by mass Lime addition Slurry pH
t/h m3/h % Yes/No
4,675 13,882 27.8 No 10-11
5,200 15,400 27.6-27.8
B/D B/D B/D A,G C
0 1 C 1 1
Cell type Cell Volume Effective Cell volume No of rows of cells No. of cells/row Residence time basis Effective Volume Air Holdup Pulp residence time Concentrate collection lip length Lip loading factor Froth factor for concentrate design
Mechanical 160 m3 /cell 136 m3 /cell _ 4 _ 8 ave flow@ave density@effective cell volume % (100-% AIR HOLDUP) % 15 minutes 19.30 m/cell 60 t/m/h 0.51 _ 1.5
B I B/D B/D D I D I D C
A A 1 1 1 A A C A 1 A
I I I
0 0 0
Reference * If different than the nominal
Flotation air Air volume/cell Air pressure
forced/induced m3/h kPa
Induced Not Applicable Not Applicable
Feed grade Stage recovery Tailing grade Conc grade
% Cu % % Cu % Cu
0.140 76.4 0.035 4.76
0.098-0.221 73.7-79.3 0.027-0.055 3.68-6.31
B/D B/D B/D B/D
C C C C
Weight floated % of plant feed Weight floated % of plant feed Concentrate rate - solids only Slurry flow rate Concentrate % solids Concentrate P80 microns Concentrate solids S.G.
% % t/h m3/h % µm _
3.98 5.29 256.3 992.3 21.96 125 3.17
4.53 5.00-6.24 223.8-303.6 868-1164 21.93-22.52 115-150 3.07-3.35
C/D C/D C/D C/D C/F C C
C 1 C 1 1 A C
| As per Float model, lime added @Regr.
Vendor recommendation
| | |
Vendor recommendation Vendor recommendation
Vendor specification Vendor specification
|
4 stages average
Vendor recommendation Vendor recommendation
Includes Rougher # 2 cons Excludes #2 Rougher cons Includes #2 Rougher cons Includes #2 Rougher cons Includes #2 Rougher cons Includes #2 Rougher cons
| | | |
Concentrate Product Destination
A. Normal B. Alternate
Regrind mills None
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
| |
26 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
Initial Revision Last Revision
4:03
Rougher Concentrate Polishing
C-DC-25-901 HPGR Rev. D P.Rosario
Date:
15-Mar-04
Rev
A
Date:
27-Jan-06
Rev
1
Units
Nominal
no.of % type kW -
2 93 SMD 355 355 Top
% of plant feed % of plant feed t/h t/h % µm µm % Load t/h mm kg/t ore conc _ pH
2.07 3.38 100 164 39.5 110 40 26 4.5 3 0.335 3.65 10.5
kWh/t _ type mm/kt ore
Design*
Source
Rev
I G K
0 C 0 C 0
Reference * If different than the nominal
No. of Mills Availability Mill type Mill motor Mill Feed Location New feed rate total New feed rate total New feed rate total New feed rate total Pulp percent solid Feed size - P80 Product size - P80 - (Minimum) Media Ball load average Normal operating charge Maximum media ball size Estimated media ball consumption Solids S.G. Pulp pH Specific power consumption Sizing basis Liner material Liner wear rate
Based on Rougher cons from 1 st cell
K
1 1 0 0 1 C A 1 1 1 1 C A
5 Power Requirement
C G
1 A
METSO
magnetic rubber 0.14
I H
1 1
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
2.84 4.54 140 224 39.8 50
B/D C B/D C B/D C C I I C C
3.83
Based on Rougher cons from 1 st 2 cells
| |
Based Rougher cons from 1 st cell Based Rougher cons from 1 st 2 cells
| DML LC test report Sep04
| | | |
METSO METSO METSO METSO
METSO recommendation
| |
METSO
| |
27 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
4:04
Scavenger Concentrate Regrind
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
_ % type kW -
3
Design*
Source
Rev
Reference * If different than the nominal
No. of Mills Availability Mill type Mill motor Mill Feed Location
I G K
C C C C A
35
B/D B/D F/D C C I I I I H B I
1 1 1 C 1 1 1 1 1 1 C A
pH
10.5-11.0
C
A
Specific power consumption Sizing basis
kWh/t _
12.2
I C
1 C
Liner material Liner wear rate (screw only)
type kg/t ore
I I
A 1
New feed rate to cyclone total % of plant feed New feed rate total t/h Mill feed percent solids by mass % Feed size - P80 µm Product size - P80 µm Ball load average % Load Normal operating charge t Recommended ball size mm Maximum ball size mm Estimated ball consumption kg/t feed Solids S.G. _ % Vertical mill grinding efficiency improvement Pulp pH
93 VTM 1500
1119 Bottom 5.29
5.00-6.24
256
224-304
64.5
64-65
125
168
30
30-35
26 128 12.5 31 0.25 3.17
3.07-3.35
Power requirement magnetic 0.0014
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
Does not include any portion of Clean. Scav. Conc.
| | |
NB New circuit feed not cyclone underflow NB Circuit product from regrind cyclones
| | | | | |
Basis: Metso/DML test report #63383, Sept04
|
|
28 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
Initial Revision Last Revision
4:05
Regrind Circuit Classification
C-DC-25-901 HPGR Rev. D P.Rosario
Units
Date:
15-Mar-04
Rev
A
Date:
27-Jan-06
Rev
1
Nominal
Design*
Source
Rev
Reference * If different than the nominal
No. cyclone clusters per pump No. installed cyclones per cluster No. cyclones operating Cyclone size, type Vortex finder diameter Apex diameter Cyclone feed rate Cyclone feed rate - Minimum Cyclone feed rate (solids)
m3/h m3/h t/h
Cyclone feed pulp density Cyclone feed % Solids by mass Cyclone feed D80 Cyclone feed D50
t/m3 % µm µm
1.34 36.8 85 35
Cyclone underflow pulp density Cyclone underflow % Solids by mass Cyclone u/f D50 Cyclone overflow pulp density Cyclone overflow % solids by mass Cyclone O/F rate, dry Cyclone o/f P80 Cyclone o/f P50
t/m3 % t/m3 % t/h µm µm
1.80 65 70 1.17 21.7 258 30 14
_
3.17
kPa
125
%
160
Solids S.G. Cyclone inlet pressure Circulating load
_ _ _ mm mm mm
µm
1 14 12 380, high efficiency 113 75 1,367 1,610 1,190 671 810
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
34 - 38
60 - 70
18 - 22 310 25 - 35
3.07 - 3.35
140 - 180
I I I I I I B/D C C
A 1 0 A 0 0 1 C 1
B/D B/D C C
1 1 A A
| |
B/D B/D C B/D B/D
| |
C C
1 1 A 1 1 1 A A
C
C
I
A
I
1
|
Includes lime addition
|
Includes lime addition
|
| | |
|
Initial Estimate -
29 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
4:06
Cleaner Flotatio n - 1st Cleaner Cells
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Conditioning time Feed rate Pulp flow rate % Solids by mass Lime addition Slurry pH
minutes t/h m3/h % Yes/No
0 461 1,849 21.4 No 10.0 - 11.0
F C,D C,D C C C
1 1 1 C A A
Cell type Cell Volume Effective Cell volume No of rows of cells No. of cells/row Residence time basis Effective Volume Air Holdup Pulp residence time Concentrate collection lip length Lip loading factor Froth factor for concentrate design
mechanical 160 C/B m /cell 136 C/B m3 /cell _ 1 C _ 6 C ave flow@ave density@effective residence time % (100-% Air holdup) % 15 I minutes 26.48 C/B/D m/cell 60 I t/m/h 1.74 I _ 3 F
Reference * If different than the nominal
586 2,253 21.1 - 22.1
3
Flotation air Air volume/cell Air pressure
forced/induced m3/h kPa
Induced air Not Applicable Not Applicable
Feed grade Stage recovery Tails grade Conc grade
% Cu % % Cu % Cu
4.82 94.66 0.45 10.53
Weight floated % of plant feed Concentrate rate - solids only Concentrate % solids Concentrate P80 microns Concentrate solids S.G. Concentrate slurry flow rate
% t/h % µm _ m3/h
4.12 200 23.9 30 3.64 692
A A A A A A A A 1 A C A
| | |
Industry standard
| Vendorspecification
A I I
0 0 0
3.72 - 6.74 91.1 - 94.9 0.32 - 0.76 8.71 - 13.16
C,D C,D C C,D
1 1 C 1
| |
3.55 - 5.79 158 - 280 18 - 26
C,D C,D C,D C C,D C,D
1 1 1 A 1 1
| | |
3.49 - 3.87 959
|
| |
Including water addition
Concentrate Product Destination
A. Normal B. Alternate
Column cells Regrind circuit
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
30 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
4:07
Cleaner Flotatio n - Cleaner Scavengers Cells
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Conditioning time Feed rate Pulp flow rate % Solids by mass Lime addition Slurry pH
minutes t/h m3/h % Yes/No
0 261 1,163 19.6 No 10.0 - 11.0
F C C,D C,D C C
1 C 1 1 A A
Cell type Cell Volume Effective Cell volume No of rows of cells No. of cells/row Residence time basis Effective Volume Air Holdup Pulp residence time Concentrate collection lip length Lip loading factor Froth factor for concentrate design
mechanical 160 C/B m3 /cell 3 136 C m /cell _ 1 C _ 4 C ave flow@ave density@effective residence time % (100-% AIR HOLDUP) % 15 I minutes 28.1 C,D m/cell 60 I t/m/h 0.02 I _ 1.5 F
A A A A A A A A 1 A C A
Flotation air Air volume/cell Air pressure
forced/induced m3/h kPa
Induced Not Applicable Not Applicable
Feed grade Stage recovery Tails grade Conc grade
% Cu % % Cu % Cu
0.45 6.3 0.43 5.02
% t/h % % µm µm
0.03 1.5 22 18-24 30 25-35 3.34 10.7
Weight floated % of plant feed Concentrate rate - solids only Concentrate % solids Concentrate % solids - range Concentrate P80 microns Concentrate P80 microns - range Concentrate solids S.G. Concentrate slurry flow rate
3
m /h
302 1,293 19.3 - 20.5
A I I
0 0 0
0.32 - 0.76 2.7 - 14.6 0.31 - 0.66 3.37 - 7.81
C C,D C C,D
C 1 C 1
0.01 - 0.09 0.5 - 4.3
C C,D C C C C C C,D
C 1 C A A A C 1
3.18 - 3.63 16.4
| | |
Industry standard
| Vendor specification
| | | |
3
Including wash water (5.0 m /h)
Concentrate Product Destination
A. Normal B. Alternate
Regrind circuit columns
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
31 of 64
|
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
4:08
Cleaner Flotation - Final Column Cells
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Conditioning time Feed rate Pulp flow rate % Solids by mass Lime addition Slurry pH
minutes t/h
Column diameter Column height No. of Columns
m m _
5.0 12.0 4
type
drip pans 180 +ve
m3/h % Yes/No
0 300 882 27.3 No 10.0 - 11.0
420 1220 27.0 - 27.6
F C C,D C,D C C
1 0 1 1 A A
|
C/I C/I C/I
1 1 1
| | |
C J
A A
|
C G F
0 A A
I I C
0 0 A
| |
Wash water addition method Wash water volume Wash water bias
m3/h
Carrying Capacity - Nominal Limiting Carrying Capacity Froth factor for concentrate design
t/h/m2 t/h/m2 _
1.2 1.50 3
Air supply pressure Air volume per column Air Superficial Velocity
kPag Nm /h cm/sec/m2
580 703 1.0
% Cu % % Cu % Cu
12.75 74.1 4.89 29.09
11.06 - 15.28 69.0 - 76.4 3.77 - 7.18 27.43 - 30.92
B/D B/D B/D B/D
1 1 1 1
| | | |
% t/h % µm _
2.01 97 31.9 30 4.01 235
1.67 - 2.94 74 - 143 28-34 25-35 3.93 - 4.10 339
B/D B/D B/D C B/D B/D
1 1 1 A 1 1
| | |
Feed grade Stage recovery Tails grade Conc grade Weight floated % of plant feed Concentrate rate - solids only Concentrate % solids Concentrate P80 microns Concentrate solids S.G. Final Concentrate slurry flow rate
3
m3/h
325
1.8
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
Industry standard
Vendor is 4
| |
Including all water additions
32 of 64
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
4:09
Copper Moly Concentrate Thickening
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Feed Thickenin g
No. of thickeners Thickener diameter Thickener type Thickener feed rate
Fresh feed Overall Thickener feed rate - Minimum Fresh feed Overall Flocculant addition Diluted feed % Solids Diluted feed % Solids - Range Underflow % Solids Underflow % Solids - Range Specific Area (design)
m type t/h t/h t/h t/h g/t Conc % % % % 2 m /t solids/day
1 30.0 conventional 97 129 74 98 0 22.2 40 0.15
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
143 191
21.0 - 26.0 50 35 - 50
B B D D D D D A D D F F D
A C C 0 1 0 1 1 1 1 1 1 1
Fresh feed only Overall Fresh feed only Overall
| | | | | | | |
33 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
5:01
Moly Ro-Scav Flotation
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Flotation
Conditioning Tank volume Conditioning time Fresh Feed rate Feed rate (Combined) Pulp flow rate (Combined) % Solids by mass % Solids by mass - range Lime addition Slurry pH P80 feed
3
D C,D D D/F D/I D F,D D/F C C
1 1 1 1 1 1 1 1 1 1
Cell type Tank Mechanical 3 Cell Volume 30 m /cell 3 Effective Cell volume 25.5 m /cell No of rows of cells _ 1 No. of cells/row _ 6 No. of Rougher cells _ 4 No. of Rougher/Scavenger cells _ 2 Pulp residence time minutes 28.2 Froth factor for concentrate design _ 3.0 Air supply (O 2 depleted) Induced air, recirculated within closed cells and tanks
C,D I I F,D F,D F,D F,D F,D F I
1 1 1 1 1 1 1 1 1 1
Feed grade
C/D C/D C/D C/D C/D C/D C/D C/D C/D
1 1 1 1 1 1 1 1 1
D D F,D C F,D
1 1 1 1 1
| | | | |
D D F,D C
1 1 1 A
| | |
Tails grade Rougher Concentrate grade Final concentrate grade Mo Recovery (final)
m minutes t/h t/h 3 m /h % % Yes/No µm
56.5 15 97 127 224 39.7
74 - 143 98 - 191 326 37.0 - 42.0
No 11 30
% Mo % Cu % Mo % Cu % Mo % Cu % Mo % Cu %
0.677 29.1 0.068 29.4 3.60 12.00 55.0 0.5 90.0
% t/h % µm _
23.8 23.2 25.0 30 4.06
% t/h % µm
7.4 7.2 25.0 30
0.5-0.9 23 - 30
Nominal Fresh feed only Cu-Mo Conc/1st Cleaner Tail/Ro-Scav Con Combined Combined
| | | | | | | | | | | | | | | | | | | |
B,D B,D
Fresh feed (Cu-Mo Concentrate) Fresh feed (Cu-Mo Concentrate)
Mo. Rougher Flot. Only (4 cells) Mo. Rougher Flot. Only (4 cells)
| | | | | | | | |
Rougher
Weight floated % of moly plant feed Concentrate rate - solids only Concentrate % solids Concentrate P80 microns Concentrate solids S.G.
17 - 35 23 - 30 30 - 50
Rougher/Scavenger
Weight floated % of moly plant feed Concentrate rate - solids only Concentrate % solids Concentrate P80 microns
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
5.6 - 10.6 23 - 30 30 - 50
34 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
5:02
Moly Cleaner Flotation
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
st
1 Cleaner
Conditioning Tank volume Conditioning time Feed rate Feed rate - Minimum Pulp flow rate Pulp flow rate - Minimum % Solids by mass Lime addition Slurry pH D80 feed Cell type Air supply (O 2 depleted)
3
56.5 21 32 23 3 160 m /h 3 115 m /h % 17.2 Yes/No No 11 30 µm Mechanical Induced air, recirculated within closed cells and tanks Cell Volume 8.5 m3 /cell 3 Effective Cell volume 7.2 m /cell No of rows of cells 1 No. of cells/row 7 Pulp residence time min 19 Froth factor for concentrate design 3.0 Conc grade Weight floated % of moly plant feed Weight floated % of moly plant feed - range Concentrate rate - solids only Concentrate % solids Concentrate P80 microns Concentrate solids S.G.
m min t/h t/h
% Mo % Cu % % t/h % µm -
7.00 3.50 9.7 7-13 9.5 25.0 30 4.10
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
48 242 16 - 21
7.0 - 14.4 22.0 - 27.0 30 - 50
D C,D D D D D D/F D/F F C C,D I I I D/F D/F D/F F
1 1 1 1 1 1 1 1 1 1 1 1 C 1 1 1 0 1
C/D C/D D D D F,D C F/D
1 1 1 0 1 1 A C
| | | | | | | | | | | |
Nominal
| | | | |
Nominal
| | | | | | | |
35 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
5:02
Moly Cleaner Flotation
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
nd
2 Cleaner
Conditioning time Feed rate Feed rate - Minimum Pulp flow rate Pulp flow rate - Minimum % Solids by mass Lime addition Slurry pH D80 feed Column Diameter Column Height Column Effective Volume No. of Columns Wash water addition method Wash water volume Pulp residence time Carrying Capacity Air Volume - Normal Pressure - Normal Temperature - Normal Conc grade
Weight floated % of moly plant feed Concentrate rate - solids only Concentrate % solids Concentrate D80 microns Concentrate solids S.G.
min t/h t/h
µm
0 17.0 12.5 86 58 17.2 No 11 30
m m
2.6 10.0
3
m /h 3 m /h % Yes/No
m -
3
26.0 128 16 - 20
39.8 1
F D D D D D/F D/F F C
C 1 1 1 1 1 1 1 1
| | | | | | | |
I I D/I D/I
1 1 1 1
| | | |
drip pans 18.9
20.0
I D
1 1
| |
28 1.3
19 2.1
D D/I
1 1
| |
C
190 580 20
I I F
0 0 A
% Mo % Cu
12.96 2.20
C/D C/D
1 1
| |
% t/h % µm -
7.3 7.1 25.0 30 4.43
D D D/F C F/D
1 1 1 A C
| | |
type 3
m /h min 2
t/h/m /cell
3
Nm /h kPag o
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
4.8 - 9.6 5.3 - 10.9 23 - 27 30 - 50
36 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
5:02
Moly Cleaner Flotation
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
rd
3 Cleaner
Conditioning time Feed rate Feed rate - Minimum Pulp flow rate Pulp flow rate - Minimum % Solids by mass Lime addition Slurry pH D80 feed Column Diameter Column Height Column Effective Volume No. of Columns Wash water addition method Wash water volume Pulp residence time Carrying Capacity Air Volume - Normal Pressure - Normal Temperature - Normal Conc grade
Weight floated % of moly plant feed Concentrate rate - solids only Concentrate % solids Concentrate D80 microns Concentrate solids S.G.
min t/h t/h
µm
0 10.3 7.6 57 38 15.8 No 11 30
F D D D D D/F D/F F C
C 1 1 1 1 1 1 1 1
| | | | | | | |
m m
2.0 10.0 23.6 1
I I D/I D/I
1 1 1 1
| | | |
drip pans 17.6
20.0
I D
1 1
| |
25 1.3
16 2.0
D D/I
1 1
| |
C
113 580 20
I I F
0 0 A
% Mo % Cu
22.24 1.62
C/D C/D
1 1
| |
% t/h % µm -
4.3 4.2 25.0 30 4.46
D D D/F C F/D
1 1 1 A C
| | | | |
3
m /h 3 m /h % Yes/No
m -
3
type 3
m /h min 2
t/h/m /cell
3
Nm /h kPag o
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
15.7 87 15.0 - 18.5
3.5 - 5.5 3.1 - 6.4 23 - 27 30 - 50
37 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
5:02
Moly Cleaner Flotation
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
th
4 Cleaner
Conditioning time Feed rate Feed rate - Minimum Pulp flow rate Pulp flow rate - Minimum % Solids by mass Lime addition Slurry pH D80 feed Column Diameter Column Height Column Effective Volume No. of Columns Wash water addition method Wash water volume Pulp residence time Carrying Capacity Air Volume - Normal Pressure - Normal Temperature - Normal Conc grade
Weight floated % of moly plant feed Concentrate rate - solids only Concentrate % solids Concentrate D80 microns Concentrate solids S.G.
min t/h t/h
µm
0 5.8 4.3 32 21 15.9 No 11 30
F D D D D D/F D/F F C
C 1 1 1 1 1 1 1 1
| | | | | | | |
m m
1.6 10.0 15.1 1
I I D/I D/I
1 1 1 1
| | | |
drip pans 9.3
12.0
I D
1 1
| |
28 1.3
19 2.0
D D/I
1 1
| |
C
72 580 20
I I F
0 0 A
% Mo % Cu
32.90 1.16
C/D C/D
1 1
| |
% t/h % µm -
2.7 2.7 25.0 30 4.58
D D D/F C F/D
1 1 1 A C
| | |
3
m /h 3 m /h % Yes/No
m -
3
type 3
m /h min 2
t/h/m /cell
3
Nm /h kPag o
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
8.9 47 15.0 - 17.3
1.8 - 3.3 2.0 - 4.1 23 - 27 30 - 50
38 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
5:02
Moly Cleaner Flotation
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
th
5 Cleaner
Conditioning time Feed rate Feed rate - Minimum Pulp flow rate Pulp flow rate - Minimum % Solids by mass Lime addition Slurry pH D80 feed Column Diameter Column Height Column Effective Volume No. of Columns Wash water addition method Wash water volume Pulp residence time Carrying Capacity Air Volume - Normal Pressure - Normal Temperature - Normal Conc grade
Weight floated % of moly plant feed Concentrate rate - solids only Concentrate % solids Concentrate D80 microns Concentrate solids S.G.
min t/h t/h
µm
0 3.9 2.9 23 16 15.2 No 11 30
F D D D D D/F D/F F C
C 1 1 1 1 1 1 1 1
| | | | | | | |
m m
1.6 10.0 15.1 1
I I D/I D/I
1 1 1 1
| | | |
drip pans 2.0
12.0
I D
1 1
| |
40 1.2
25 1.8
D D/I
1 1
| |
C
72 580 20
I I F
0 0 A
% Mo % Cu
36.10 0.88
C/D C/D
1 1
| |
% t/h % µm -
2.4 2.3 25.0 30 4.58
D D D/F C F/D
1 1 1 A C
| | |
3
m /h 3 m /h % Yes/No
m -
3
type 3
m /h min 2
t/h/m /cell
3
Nm /h kPag o
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
6.0 36 14.0 - 18.0
1.4 - 3.0 1.7 - 3.6 23 - 27 30 - 50
39 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
5:02
Moly Cleaner Flotation
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
th
6 Cleaner
Conditioning time Feed rate Feed rate - Minimum Pulp flow rate Pulp flow rate - Minimum % Solids by mass Lime addition Slurry pH D80 feed Column Diameter Column Height Column Effective Volume No. of Columns Wash water addition method Wash water volume Pulp residence time Carrying Capacity Air Volume - Normal Pressure - Normal Temperature - Normal Conc grade
Weight floated % of moly plant feed Concentrate rate - solids only Concentrate % solids Concentrate D80 microns Concentrate solids S.G.
min t/h t/h
µm
0 2.3 1.7 9 6 22.0 No 11 30
F D D D D D/F D/F F C
C 1 1 1 1 1 1 1 1
| | | | | | | |
m m
1.0 10.0 5.9 1
I I D/I D/I
1 1 1 1
| | | |
drip pans 7.6
12.0
I D
1 1
| |
40 1.4
31 2.0
D D/I
1 1
| |
C
28 580 20
I I F
0 0 A
% Mo % Cu
55.00 0.50
C/D C/D
1 1
| |
% t/h % µm -
1.1 1.1 25.0 30 4.60
D D D/F C F/D
1 1 1 C C
| | | | |
3
m /h 3 m /h % Yes/No
m -
3
type 3
m /h min 2
t/h/m /cell
3
Nm /h kPag o
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
3.6 12 21 - 25
0.8 - 1.3 0.8 - 1.6 23 - 27 30 - 50
40 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
5:02
Moly Cleaner Flotation
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Cleaner-Scavenger
Conditioning time Feed rate Feed rate - Minimum Pulp flow rate Pulp flow rate - Minimum % Solids by mass Lime addition Slurry pH D80 feed Cell type Cell Volume Effective Cell volume No of rows of cells No. of cells/row Pulp residence time Froth factor for concentrate design Conc grade
Weight floated % of moly plant feed Concentrate rate - solids only Concentrate % solids Concentrate P80 microns Concentrate solids S.G.
min t/h t/h
F D D D D D/F D/F F C
A 1 1 1 1 1 1 1 1
| | | | | | | |
m /cell 3 m /cell min -
Mechanical 4.25 3.61 1 7 18 2.8
C,D D/I D/I D/F D/F D/F F
1 1 1 1 1 1 1
| | | | | | |
% Mo % Cu
2.00 4.00
C/D C/D
1 1
| |
% t/h % µm _
1.5 1.5 20 30 4.08
D D F,D C F/D
1 1 1 A C
| | |
3
m /h 3 m /h % Yes/No µm
3
0 9.9 7.3 83 55 10.9 No 11 30
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
15.1 124 9.5 - 13.5
0.8 - 2.3 1.1 - 2.3 18 - 22 30 - 50
Nominal
41 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
5:02
Moly Cleaner Flotation
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
st
Thickening - 1 Cleaner Concentrate
No. of thickeners Thickener diameter Thickener feed rate Thickener feed rate - Minimum Diluted feed % Solids Underflow % Solids Specific Area (design) Regrind
No. of Mills Availability Mill type Mill motor Mill Feed Location
m t/h t/h % %
1 15.0 10.9 8.1 14.5 35.0
m2/t solids/day
0.44
A F 16.7
D D D F D
For Future
_ % type kW -
New feed rate total % of plant feed New feed rate total t/h Pulp percent solids by mass % Feed size - P80 µm Product size - P80 µm Ball load average % Load Maximum ball size mm Estimated ball consumption kg/t ore Solids S.G. _ % Vertical mill grinding efficiency improvement
1
I G K
93 vertical stirred media mill TBD
Bottom
C A C 1 1 1 1 1
TBD
1 1 1 1 1 A A A 1 A
pH
10.5-11.0
C
A
Specific power consumption Sizing basis
kWh/t _
TBD Power requirement
C K
C A
Liner material Liner wear rate
type kg/t ore
I H
C C
Pulp pH
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD TBD TBD TBD
magnetic TBD
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
TBD
Depending on vendor information
| | | | |
0 A C C C A
B/D B/D F C C I I H B I
TBD
Position in circuit changed from Feas Study
NB New circuit feed not cyclone underflow NB Circuit product from regrind cyclones
| | | | |
Depending on vendor information Depending on vendor information Depending on vendor information
|
Depending on vendor information
42 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
5:02
Moly Cleaner Flotation
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Regrinding Mo Circuit Classificati on
For Future
No. cyclone clusters per pump No. installed cyclones per cluster No. cyclones operating Cyclone size, type Cyclone feed rate Cyclone feed rate - Minimum Cyclone feed rate (solids)
m /h 3 m /h t/h
1 TBD TBD TBD TBD TBD TBD
Cyclone feed pulp density Cyclone feed % Solids by mass Cyclone feed D80
t/m3 % µm
TBD TBD TBD
Cyclone underflow pulp density Cyclone underflow % Solids by mass Cyclone overflow pulp density Cyclone overflow % solids by mass Cyclone O/F rate Cyclone o/f P80
t/m %
3
t/m % t/h µm
TBD TBD TBD TBD TBD TBD
_
TBD
kPa
TBD
%
TBD
Solids S.G. Cyclone inlet pressure - Nominal Circulating load Nominal
_ _ _ mm 3
3
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
TBD TBD TBD
TBD
TBD TBD TBD TBD TBD
TBD
I I I I C C C C C C
0 A 1 1 C 1 1 1 1 1 1 1
| | | | | | | | |
C
1 1 1 1 1 1
| | | | | |
C
1
|
I
1
|
I
1
|
C C C C
43 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
5:03
Moly Thickening, Dewatering & Drying
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Thickening
No. of thickeners
-
0
A
A
m
Pressure Filter 8 12.6
F/I D/I I
1 1 1 1
| | | |
Filter
Type Number of chamber Nominal Size Sizing basis Filtration rate Solids feed rate Solids SG Filter feed flow rate % Solids % Solids - range Moisture in filter cake
2
kg/h/m
2
t/h 3 m /h % % %
130
200
D/I
1
|
1.1 4.60 3.8 23.4
1.6
D D D D F/D F/D
1 1 1 1 1 1
| | | | | |
7
5.3 22 - 28 7-8
Dryer
Type Number Area Scrubber Required Type Solids feed rate Moisture in dried product
m Yes/No _
Holo-Flite 1 19 Yes Wet
kg/h %
1077 max
2
F/I D D/I D D 1640 3.0
D A
|
1 A 1 Area to be determined A A
|
|
1 0
1 Denver-Sala Handbook 1 1 1
| | | | |
1
| |
Concentrate Storage
Moly concentrate bulk density Storage volume Storage capacity Discharge control
3
t/m 3 m h
1.92 15.0 26.0 rotary valve
2.0 18
E D D I
Concentrate Packaging
Container type
drums or bulk bags
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
G
44 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
Initial Revision Last Revision
5:04
|
Reagents - NaHS
C-DC-25-901 HPGR Rev. D K. Wood
Units
Date:
15-Mar-04
Rev
A
Date:
27-Jan-06
Rev
1
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Sodium Hydros ulfid e NaHS
Total Addition Consumption Mo Conditioning Tank st Mo 1 Cleaner Conditioning Tank Final Cleaner Flotation Annual (Dry Basis) Distribution Strength Density @ 40% Flow rate to process Mo Conditioning Tank st Mo 1 Cleaner Conditionin Final Cleaner Flotation Total Type 1 Shipping container Shipping Size Storage type Tank Storage Volume Number of Trucks - Storage Volume Equivalent Storage capacity Storage requirements Concentrated NaHS storage Operating temperature Min/Max temperature
g/t Conc g/t Conc g/t Conc g/t Conc t % 3
t/m L/min L/min L/min L/min
C/A D D D D I D D D D D
C 1 1 1 1 1 1 1 1 1 1
D/A D/A I D D D D G
1 1 1 1 1 1 1 1
| | | | | | | |
I I
1 1
| | |
1 1 1 1 1 1 1 1
1.3 1556 490
D/A I I D D D D D D D D D
1 1 1 1
| | | | | | | | | | | |
15
D D
1 1
| |
7,900 4,700 2,400 800 6,262 20 1.28 34 17 6 57
9,203
50 25 8 83
Solution @ 40% Strength type Tanker Truck 3 23 m type Tank 3 120 260 m # 11 d 8 5 Secondary containment o
25-35 C 20-49 C o Note: Minimum temperature increases to 30 C for solution concentration of 45%
Type 2 NaHS Concentration Flake Bag Size Solution produced per bag Mix tank (2.0 x 2.5 m) Bags to fill tank Bags per batch NaHS solution produced per batch Water addition per batch Retention Time Consumption for 14 days NaHS Flakes storage for 14 days Distribution Tank Capacity (4.7 x 4.7 m) Distribution Tank Retention Time
o
% t m3 m3 bags bags m3 m3 h m3 t m3 h
Flakes 72 1 3.3 7 2.0 2 6.60 5.2 1.9 1069
73 21
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
| | | | | | | | | |
Dry basis
45 of 64
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
Initial Revision Last Revision
5:05
Reagents - Moly Plant
C-DC-25-901 HPGR Rev. D P.Rosario
Units Defoamer
Density Flow rate to Mo Conditioning Tank st Flow rate to Mo 1 Cleaner Conditioning Tank Total flow rate Shipping container Tank storage volume Number of isotainers - storage vol. equivalent Diluted storage capacity Storage requirements
15-Mar-04
Rev
A
Date:
27-Jan-06
Rev
1
Nominal
Design*
Source
g/t g/t g/t t % t/m3 L/min L/min L/min type 3
m # d
TBA 95 61 156 124 Liquid 100 0.85 0.18 0.12 0.30
Rev
1
FUTURE
Type Addition to Mo Conditioning Tank st Addition to Mo 1 Cleaner Conditioning Tank Total Addition Annual Appearance Distribution Strength
Date:
K C/K C/K 180
0.26 0.17 0.43
Isotainer 3.5 3 9
D G G I/K D/K D/K
Reference * If different than the nominal
|
C C C
C C C C
H/K
6
D/K
Secondary containment
G
cst cc/min type
MOLYFLO 2.5 2.0 Liquid 100 0.92 4.58 4.10 Drums
A C/D D G G I I D I
d m3 #
34 0.2 1
C 0
Moly Collector
Type st Addition to Mo 1 Cleaner Conditioning Tank Total annual addition Appearance Distribution Strength Density Viscosity @ 21 oC st Flow rate to Mo 1 Cleaner Conditioning Tank Shipping container Storage capacity Tank Storage Volume Number of drums - storage vol. equivalent Storage requirements
g/t t %
Flow rate to Mo Conditioning Tank st Flow rate to Mo 1 Cleaner Conditioning Tank Total flow rate Tank storage volume Number of trucks - storage vol. equivalent Storage capacity Storage requirements
6.0 23
Secondary containment
Sodium Sili cate (Na2SiO 3)
Type st Addition to Mo 1 Cleaner Conditioning Tank nd th Addition to Mo 2 to 6 Cleaner Columns Total Addition Annual Appearance Density Distribution Strength
2.9
D D D G
FUTURE
g/t g/t g/t t t/m3 % L/min L/min L/min m3 # d
TBD 900 700 1600 1269 Liquid 1.40 20 6.88 5.35 12.24 34 1.5
K C/K C/K 1851
10 8 18
13 9 Secondary containment
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
D G I/K G D/K D/K D/K H/K D/K G
1 1 1 A A 1 1 1 1 1 1 1 0
| | |
1
|
| | | | | | |
C C C C C C C C C C C C 0
46 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
6:01
Copper Concentrate Thickening
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Concentrate production rate Concentrate production rate - Minimum Concentrate % Solids Thickener feed % Solids Pulp flow rate Slurry pH Solids less than 100µm Solids size P80% passing Solids size P50% passing Solids SG No. of thickeners Thickener type Thickener diameter Rake Drive type Rake lift type Final U/F conc. % solids Specific area Hydraulic loading Concentrate flocculant addition
t/h t/h % % m3/h
96 74 43.7 32.5 224 10.0 - 11.0
% µm µm
99 30 15 4.0
_ _ type m type type % m2/t solids/day m3/m2/h g/t
142
31 - 35 150 - 300
3.9 - 4.1
1 high capacity 20 center Automatic/Hydraulic 64 60 - 70 0.099 0.67 9.6
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
|
C/D C C/D C/D C/D C
1 C 1 1 1 A
C C C B/D
A A A 1
|
B G C
A C C A A A 1 1 1
| | |
B C D C
| | |
Includes filtrate return
47 of 64
Sociedad Min era Cerr o Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
6:02
Concentrate Slurry Stor age and Dewatering
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Concentrate slurry storage
Concentrate percent solids by mass Concentrate pulp density Solids SG Storage tank diameter Storage tank height No. of tanks Volume (total live capacity) Capacity (total) Capacity (total) - minimum Storage tank agitation intensity
% t/m3 m m 3
m h h 3 kW/m
63.2 1.90 4.00 11.0 11.0 2 1,900 24 16 Full solids suspension
D D D D D B D D G
1 1 1 A A A A 1 C A
F D B I I C I B F
A C C 1 1 A 1 A A
F F F F
TBC TBC TBC TBC TBC TBC TBC TBC TBC
| | | | | | | | | | |
TBC
|
| | |
| Maximum slurry flow, 115 m3/h
Filter
Type Total filtration capacity required Solids feed rate (average) Solids feed rate--(instantaneous) Slurry feed pressure Solids size P80% passing Membrane press required pressure Moisture in filter cake Number of filters Sizing basis @ 600 690 kPa feed pressure Cake thickness Filtration area per filter Number of filter plates per filter Cake volume per filter Filter cloth type Cake form time Pressing time Air blow time Total cycle time Cloth Washwater requirements Filter feed flow rate maximum
Pressure, Horizontal plate t/d solids t/h t/h kPag µm
kPag %
mm m2 # 3 m type min min min min m3/cycle/filter 3
m /h
2,150 96 600 30 1400 9 2
3,200 141 238
48 144 24 6.5 polypropylene 2 1 2.5 10.5 0.61
D/F I D/F D/F I
1 1 1 1 1 1 1 1 1 1
522
I
1
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
To be confirmed whether vertical or horizontal
|
| | |
48 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
6:03
Concentrate Dry Storage and Loading
Initial Revision
C-DC-25-901 HPGR Rev. D
Dat e:
15-Mar-04
Rev
A
Last Revision
P Rosario
Dat e:
27-Jan-06
Rev
1
Un i t s
Concentrate production rate Concentrate production rate Concentrate production rate Concentrate pr production ra rate - Annual
No m i n al
Ref er en c e * If different than the nominal Design based on peak production
| | | |
1 .8 2 .2
C C
A A
% % %
8 9 10 4.00
G K K
A A A C
Angle of repose
degrees
37
G
A
Chute reclaim angle
degrees
60
G
A
t t
3,600 20,000
D D
1 1
| |
G
1
|
Each load, before leaving site Each load, before leaving site
G G
A A
t /h
500
K
A
%
TBD
%
10.00
Covered Concentrate stockpile capacity Working capacity, covered Secondary handling, uncovered Concentrate handling method
t/m3 t/m3
Front end loader, conveyor to pots on tru
Shipment sampling required Shipment weighing required Reclaim rate - instantaneous Flow Moisture (FM) Average Transportable Moisture (FM x 90%) Maximum
142 2,812 3,100
Rev
1 1 1 1
Moisture content Minimum Average Maximum Solids S.G.
96 2,148 2,360 784,000
So u r c e
D D D D
Bulk density (wet) volume calcs Bulk density (wet) wt calcs
t/h dry t/d wet t/d dry t/t/a
Des i g n *
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
Years 1-10 average Years 1-10 average Years 1-10 average J&J tests
Depends on FM
7 min/truck loading rate
A K
1
Assumed
49 of 64
Sociedad Minera Cerro Verde S.A.A. S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
7:01
Tailing Thickening
Initial Revision
C-DC-25-901 C-DC-25-901 HPGR Rev. D
Dat e:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Dat e:
27-Jan-06
Rev
1
Un i t s
No m i n al
Des i g n *
So u r c e
Rev
Ref er en c e * If different than the nominal
Tailing production rate Tailing production rate - Minimum % Solids Pulp flow rate Slurry pH
t /h t /h % 3
m /h
Solids less than 100 µm Solids size P80% passing Solids size P50% passing Solids SG
% µm µm _
No. of thickeners Thickener diameter
_ m
Rake Drive type Rake lift type Thickener feed rate Final U/F % solids Thickener type Specific area (design) Hydraulic loading (design) Tailing flocculant addition
type type t/h % 2
m /t solids/day m3/m2/h g/t
4,746 3,300 27.1 14,532 10.0 73 119 53 2.73
5,250 26-30 16,040
2.74
2 75 center Automatic/Hydraulic Automatic/Hydraulic Cable 2,373 2,630 55 50 - 60 High Capacity 0.072 1.1 15.6
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
D C D D C
1 C 1 1 A
C C C B/D
C C C 1
B D/I
A 1 A 1 1 A C C C
D B G C D C/D
| Minimum rate, 1 mill line down.
| |
DML LC testing, Sep04 DML LC testing, Sep04 DML LC testing, Sep04
|
Basis max feed rate, specific area
|
Per unit
| |
Vendor settling test results
|
1
50 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
Initial Revision Last Revision
8:01
Tailing Collection & Disposal
C-DC-25-901 HPGR Rev. D A Gun so n
Un i t s
Dat e:
15-Mar-04
Rev
A
Dat e:
27-Jan-06
Rev
1
No m i n al
Des i g n *
So u r c e
Rev
Ref er en c e * If different than the nominal
Tailing Transport specification
Tailing production rate Tailing production rate - Minimum Solids SG % Solids Pulp Density Pulp density - Minimum Pulp flow rate Pulp flow rate - Minimum Slurry pH Solids less than 100 µm* Solids size P80% passing* Solids % passing 150 µm (100 #)* Solids % passing 75 µm (200 #)* Solids % passing 38 µm (400 #)*
t/h
% 3
t/m t/m3 3 m /h 3 m /h
4,746 4,400 2.73 55 1.53 1.46 5,630 5,210 9.0-10.5
5,250
50 - 60 1.61 6,220
% µm % % %
74 134 82.5 67.5 52.9
3
3,518
3,910
1.33 39.0 875
37 - 41 1,100
D D D D D D D D C
1 1 1 1 1 1 1 1 1
C C C C C
1 1 1 1 1
D D D
1 1 1
C C
1 1
D D
1 1 1
Design based on Max tons & Ave % solids Minimum based on Min tons & Ave % solid
| | | | | | | | | | | | | |
Dawson/URS Dawson/URS Dawson/URS Dawson/URS Dawson/URS
1st Stage Tailing Cycloning Specification
Cyclone feed dilution volume Cyclone feed pulp density - average Cyclone feed % Solids by mass Cyclowash volume Cyclone feed D80 Cyclone feed D50 Cyclone feed rate Cyclone feed rate - minimum Cyclone Feed Pressure
m /h t/m3 % 3 m /h µm µm 3
m /h 3 m /h kPa
119 53 9,148 8,480 200
10,160
| | | | | | Nott inc No inclu lude ded d cy cycl clow owas ash h vo volu lume me
|
*Size distribution data is from the URS tailing dam feasibility report.
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
| | |
51 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Feasibility Study Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
Initial Revision Last Revision
8:01
Tailing Collection & Disposal
C-DC-25-901 HPGR Rev. D A Gun so n
Units
Date:
15-Mar-04
Rev
A
Date:
27-Jan-06
Rev
1
Nominal
Design*
Source
Rev * If different than the nominal
2nd Stage Tailing Cyclo ning Specifi cation
Cyclone feed dilution volume Cyclone feed pulp density - average Cyclone feed % Solids by mass Cyclone feed rate Cyclone feed rate - minimum Cyclone Feed Pressure
3
m /h 3 t/m % m3/h 3 m /h kPa
3,474
% % % t/m3 % % µm % %
33.8 90 33.8 1.80 70.0 65-72 275 48.3 12
1.24 30 5,033 4,660 124
3,860 28-32 5,590
D D D D D D
1 1 1 1 1 1
I/D J J B/D I C J J J
1 1 1 1 1 A 0 0 1
| | | | | |
2nd Stage Cyclone underflow (desired product)
Mass recovery to underflow, % of 1st Stage Feed Assumed cyclone station utilization Required recovery to underflow, net Cyclone underflow pulp density Cyclone underflow % Solids by mass - Design Cyclone underflow % Solids by mass - range Solids size P80 % passing Solids % passing 150 microns (100 #) Solids % passing 75 microns (200 #)
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
90 34
<=15
Krebs 137&138-Nom MWH Design Criteria MWH Design Criteria 18Nov04 Telecon
Krebs Krebs MWH Design Criteria URS Final feasibility
52 of 64
| | | |
| | |
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section: Initial Revision Last Revision
8:02
|
Tailing Embankment Dam & Seepage Collection
C-DC-25-901 HPGR Rev. D A.Gun so n
Units
Date:
15-Mar-04
Date:
27-Jan-06
Nominal
Design*
Rev
A
Rev
1
Source
Rev
Reference
* If different than the nominal
Tailing starter embankment dam
Base elevation Crest elevation Crest width Water storage volume for start-up
| m m m m3
2,400 2,480 15 1,000,000
J J J J
A 0 0 1
2,400 2,660 50 2,500 1.30 1.58
J J J J J J
A A 0 0 1 1
J/D J J J/D
1 A A 1
J/D J/D
1 1
Subject to Review Board Approval
Basis MWH water bal.
|
MWH Vol. 5 Fig 2-1
| |
Tailing dam embankment
Base elevation Final crest elevation Final crest width Final crest length Consolidated tails tailing bulk density - dry basis Compacted dry density of underflow
m m m m t/m3 t/m3
MWH Design Criteria
Tailing seepage collection and pu mping
Seepage volume design Seepage pond volume Seepage pond residence time Seepage pond return pump capacity
m3/h m3 day 3
m /h
810 100,000 5.1 810
870 4.8 1,305
| | | |
Tailing water collection and pumpin g
Tailing pond reclaim water Tailing pond water pump capacity Number of pumps Reclaim distribution water to concentrator Number of pumps Central pond barge pump capacity
3
m /h m3/h m3/h m3/h
8,280 10,935 5 1222 3 4140
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
10,935
3000 7290
A
3op/2sb/1fut
| | |
D D D
1 1 1
| | |
Includes cyclone dilution
53 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
9:01
Reagents - Collector
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Primary Collector
Type Points of addition Grinding/Ball Mill Feed Scavenger flotation 1st Cleaner flotation Final Cleaner flotation Total Annual Appearance Density Make-up concentration Flow rate to process Grinding/Ball Mill Feed Scavenger flotation 1st Cleaner flotation Final Cleaner flotation Total Shipping and handling shipping container shipping volume Storage capacity Tank Storage Volume Storage requirements Number of Trucks - Storage Vol.Equivalent
C
1
C C C C
1 1 1 1
D I I D
C 1 1 1
0.78 0.29 TBD TBD 1.072
D D D D D
1 1 1 1 1
32
G G/D D
1 1 1 C 0 C
thionocarbamate g/t g/t g/t g/t g/t t t/m3 %
8.8 3.3 TBD TBD 12.1 477 Liquid 1.01 100
L/min L/min L/min L/min L/min
0.704 0.264 TBD TBD 0.97
type
Tanker Truck 23 36
3
m d
3
m
#
530
48 Secondary containment 2
D G
Primary collector is Cytec 5415
|
FUTURE FUTURE
| | | |
| | | | | | | | | | | |
FUTURE FUTURE
Secondary Collector
Type Points of addition Grinding/Ball Mill Feed Scavenger flotation 1st Cleaner flotation Final Cleaner flotation Total Annual Appearance Density Make-up concentration Flow rate to process Grinding/Ball Mill Feed Scavenger flotation 1st Cleaner flotation Final Cleaner flotation Total Shipping and handling Shipping container Shipping Mass Storage capacity, solution Storage type Storage requirements
Sodium isopropyl xanthate g/t g/t g/t g/t g/t
t/m3 %
2.80 1.30 0.30 TBD 4.40 173 Dry 1.35 10.0
L/min L/min L/min L/min L/min
2.20 1.02 0.24 TBD 3.456
type kg d
Bulk Bags 750 15
type
Tank Secondary containment
t -
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
TBD 193
2.44 1.14 0.26 TBD 3.84
13
C
1
D D D D
1 1 1 1
D I I D
C 1 1 1
| | |
D D D D D
1 1 1 1 1
| | | | |
G G/D D D
1 1 1 A 0
G
|
Aero343
| | | |
FUTURE
FUTURE
| | |
54 of 64
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
Initial Revision Last Revision
9:02
Reagents - Froth er / Moly Collector
C-DC-25-901 HPGR Rev. D P.Rosario
Units
Date:
15-Mar-04
Rev
A
Date:
27-Jan-06
Rev
1
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Frother
Type Points of addition Rougher Flotation Feed Scavenger Flotation Feed 1st Cleaner Flotation Final cleaner Flotation Total Annual Appearance Make-up concentration Density Flow rate to process Rougher Flotation Feed 1st Cleaner Flotation Final cleaner Flotation Total Shipping and handling shipping container shipping volume Storage capacity Tank Storage Volume Storage requirements Number of Trucks - Storage Vol.Equivalent
Methyl isobutyl carbinol 85%/glycol 15% g/t g/t g/t g/t g/t t % t/m3
6.9 TBD 1.5 1.5 9.9 390 Liquid 100 0.81
L/min L/min L/min L/min
0.69 0.15 0.15 0.99
type
Tanker Truck 23 53
C
1
C/D D C/D C/D C/D D I I/D I
1 1 1 1 1 1 1 1 1
0.76 0.17 0.17 1.10
D D D D
1 1 1 1
| | | |
48
G G/D D
| | |
434
|
Aero70
| | | | | | | | |
FUTURE
70 Secondary containment 3
D G
1 1 1 C 0
MOLYFLO
C
1
|
g/t g/t g/t g/t g/t t % t/m3 cst
18.80 7.20 1.50 TBD 27.50 1084 Liquid 100 0.92
D D D D
1 1 1 1
| | | |
D G G/D I I
1 A 1 1 1
|
L/min L/min L/min L/min
1.65 0.63 0.13 2.41
1.83 0.70 0.15 2.68
D D D D
1 1 1 1
| | | |
type
Tanker Truck 23 21.4
19.2
G G/D D
1 1 1 C 0 C
| | |
3
m d
3
m
#
Moly Collector
Type Points of addition Grinding/Ball Mill Feed Scavenger Flotation 1st Cleaner Flotation Final Cleaner Flotation Total Annual Appearance Make-up concentration Density Viscosity @ 21 oC Flow rate to process Grinding/Ball Mill Feed Scavenger Flotation 1st Cleaner Flotation Total Shipping and handling shipping container shipping volume Storage capacity Tank Storage Volume Storage requirements Number of Trucks - Storage Vol.Equivalent
3
m d
3
1205
4.58
m
70 Secondary containment
#
3
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
D G
FUTURE
| | |
55 of 64
Sociedad Min era Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
9:03
Reagents - Floccu lants
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
P.Rosario
Date:
27-Jan-06
Rev
1
Units
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Flocculant - Concentrate
Type Point of addition Cu Concentrate thickener Annual Appearance Make-up concentration Bulk density Solution S.G. Flow rate to process Cu Concentrate thickener Shipping and handling Shipping container Container Size Storage capacity, live Storage requirements
Anionic
K
0
g/t Conc t
9.6 8
C D
1 1
%
Dry Powder 0.5 0.85 1.0
F D I D
A 1 1 1
| | |
D
1
|
3
t/m
11
Design based on peak production
| |
m3/h
0.18
kg h
Bags 25 4 Secondary containment
H/K H/K D/K G
A A A 0
Anionic
K
A
15.6 603
C D
1 1
| |
F D I D
A 1 1 1
| | |
D
1
H/K H/K G D/K
A A 0
0.27
Flocculant - Tailing
Type Point of addition Nominal total addition rate Nominal Annual Appearance Make-up concentration Bulk density Solution S.G. Flow rate to process, design Shipping and handling shipping container Container Size Storage requirements Storage capacity, live
g/t Tailing t
% 3
t/m
m3/h
kg h
670
Dry Powder 0.5 0.85 1.0 7.4
8.2
Bulk Bags 750 Secondary containment 8
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
|
per thickener
A
56 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
9:04
C-DC-25-901 HPGR Rev. D
Initial Revision
K. Wood
Last Revision
|
Reagents - Lime
Units
Date:
15-Mar-04
Rev
A
Date:
27-Jan-06
Rev
1
Nominal
Design*
Source
Rev
Reference * If different than the nominal
Quicklime
Quality (min. CaO) Bulk density Solids S.G. Top Size Delivery method Total dry storage capacity Total dry storage capacity Consumption Total Ball Mill Grinding Flotation Daily Daily Daily Daily Annual Make-up pulp density Slurry S.G. Flow rate to process Ball Mill Grinding Flotation Slaking system Preparation schedule Total slaked lime storage capacity Total slaked lime storage capacity Storage requirements
% 3
t/m
mm
80 0.85 3.15 15 Pneumatic tanker
d
5.5
t
500
g/t g/t g/t t
1,000 910 90 108
t t t t % solids
120
128.4 142.7 82 91 102.2 113.5 37,294 41,438 15 1.1 3 31.9 35.4 m /h 3 3.1 3.5 m /h h/d 18 24 h 10 416 m3 Secondary containment
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
|
L/I K K K D D D C/A C/D C/D
1 A A A 1 1 1 C 1 1
CaO Ca(OH)2 Ca(OH)2 Ca(OH)2
D
1
Ca(OH)2
D D D D F D D D G D D G
1
Ca(OH)2 + CaO(NR)
1 1 1
CaO CaO at 80% CaO at 80%
| | |
A A 1 1 1 1 1 0
| | | | | | |
| | | | |
57 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
9:05
|
Process/Fresh Water Systems
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Last Revision
A.Gunson
Date:
27-Jan-06
Units
Nominal
Design*
A
Rev Rev
1
Source
Rev * If different than the nominal
A - Ri o Chi li Pumping Sys tem
A.1 Existing Rio Chili Intake system (Pump station No.1 A) Flow rate Number of pumps
360 3
792
1 A
m³/h m
2,880 5 40.5
3,600
1 1 1
m³/h -
3,017 2
3,600
1 A
m³/h m
3,050 3 32
3,600
1 1
m³/h -
3,048 13
3,600
m³/h -
Tested max capacity of 220 l/s
| |
A.2 New Rio Chili Intake system (Pump station No.1) Flow rate Number of pumps Discharge head, design
5 operating, 1 future
| | |
Existing settling basins feed filter banks
|
2 operating / 1 standby
| | |
A.3 Existing Rio Chili settling basins Flow rate Number of basins
A.4 Rio Chili filter system pumps Flow rate Number of pumps Discharge head, design
A.5 Rio Chili filter system Flow rate Number of filters
A.6 Existing Rio Chili 1st stage booster system (Pump station No.2) Flow rate Number of pumps Revised discharge point
m³/h -
1 1
| | |
13 operating
Change discharge point to new stage 3 feed tank
360 360 3 New pump station 3 A feed tank
|
1 A A
|
A.7 New Rio Chili 1st stage booster system (Pump station No.2 A) Flow rate Number of pumps Discharge head, design
m³/h m
2,688 5 395.5
3,240
1 1 1
| | | |
5 operating
A.8 Existing Rio Chili 2nd stage booster system (Pump station No.3) - to be dismantled Flow rate Number of pumps Future status
0 360 m³/h 3 Decommission after new system operational
|
1 A A
A.9 New Rio Chili 2nd stage booster system (Pump station No.3 A) Flow rate Number of pumps Discharge head, design
m³/h m
3,048 5 396.5
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
3,600
1 1 1
| | | |
5 operating
58 of 64
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
9.05
|
Process/Fresh Water Systems
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
A.Gunson
Date:
27-Jan-06
Rev
1
Source
Rev
Units
Nominal
Design*
Reference
* If different than the nominal
B - Site Water Storage & Treatment
B.1 Process Water Storage Tank Number of tanks Tank capacity, live Tank dimensions Retention time
m³ m dia. x m h h
2 7,500 25 x 17 1.3
0.9
A A A 1
|
(both tanks)
B.2 Fresh and Fire Water Storage Tank Number of tanks Tank capacity, live Tank dimensions Fire water reserve volume, minimum Fire water reserve time, minimum Fresh water volume, live Fresh water demand, nominal Retention time, nominal
m³ m dia. x m m³ min m³ m³/h h
1 8,500 25 x 19 680 120 7,820 3,048 2.6
m³/h m³/h m³/h
2 0/1 340 340 0
m³/d
23.1 1 8 3.12
A 1 1 0 0 1 1 1
| |
Including existing water
| | |
B.3 Fire Water Pumping System Number of pumps Number of pumps operating Capacity per pump Maximum supply Average demand
+ 1 jockey pump
A A A 0 A
B.4 Domestic Water Treatment Plant Plant capacity, per unit No of plants installed Average run time Peak supply, total
h/d m³/h
F:\103\109 EngDoc\109.3 CRIT_DC\Process\C-DC-25-001\C-DC-25-001_ProcDesCrit_Rev1.xls
1 1 1 1
Supply sulfide project only
Vendor
59 of 64
| | | | |
Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
9.05
|
Process/Fresh Water Systems
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
A.Gunson
Date:
27-Jan-06
Rev
1
Source
Rev
Units
Nominal
Design*
C - Fresh Water Users
Reference
* If different than the nominal
C.1 - General Distribution C.1.1 - Hose stations Number operating Demand per station Average total hose demand
m³/h m³/h
1 20 20
C.1.2. - Maintenance shop Demand
m³/h
15
C.1.3. - Miscellaneous Demand
m³/h
Total Nominal fresh water demand (General)
H H
A A A
15
K
A
46
46
D
0
|
m³/h
81
81
D
0
|
m³/h m³/h
4 45.3 181
50.4 201
I I
A 1 1
| |
m³/h
56
91
1
| |
C.2.4 Gland Seal Water and High Pressure Pumping Demand m³/h Number of pumps Number of pumps operating High pressure flow rate m³/h
120 2 1 82
252
169
D/I D D D
1 A A 1
| | | Assumed gravity flow to lower bench |
C.2.5 Reagents and Lime Preparation Demand
m³/h
49
178
I
1
Does not include moly plant
C.2.6 Process Make-up Water Nominal demand
m³/h
1,139
1,800
D
1
Primary Crushing
m³/h
29
42
D/I
1
C.O. Reclaim
m³/h
3
3
D/I
1
@ 89% availability
Secondary and Tertiary Crushing
m³/h
317
354
D/I
1
@ 89% availability
Total Demand
m³/h
349
399
D/I
1
@ mixed availability
m³/h
586
654
I
1
|
m³/h
2.9
3.0
I
1
|
m³/h
360
360
A
1
|
m³/h
123
137
I
1
|
m³/h
3,047
3,600
C.2. Process Consumption C.2.1 - Final Column Wash Water Number of columns Demand per column Total wash water demand
C.2.3. - Molybdenum plant, NaHS, and sodium silicate fresh water Total Demand
| |
C.2.7 Crushing Area Water
| | | |
@ 70% availability
C.2.8 Grinding Water Nominal demand C.2.9 Regrind/Polishing Water Nominal demand C.2.10 Existing SX/EW Operation Nominal demand C.2.11 Plant Air Compressors Nominal demand Total fresh water demand (Process)
1
| |
Adjusted for availability. Design flows not additive
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Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
9:05
|
Process/Fresh Water Systems
Initial Revision
C-DC-25-901 HPGR Rev. D
Date:
15-Mar-04
Rev
A
Last Revision
A.Gunson
Date:
27-Jan-06
Rev
1
Source
Rev
Units
Nominal
Design*
Reference
* If different than the nominal
D - Process Water Users
D.1 - Crushing and Grinding Circuit D.1.1 Tertiary Scrubbers Total Demand
m³/h
295
340
D
1
|
D.1.2 Ball Mill screen feed dilution Total Demand
m³/h
8,605
9,600
D
1
|
D.1.3 Ball Mill Grinding Total Demand
m³/h
2,385
13,600
D
1
|
D.2 - Flotation and Tailings Circuit D.2.1 Rougher cells feed Demand dilution/startup Demand concentrate wash water Total demand (All 4 lines)
m³/h m³/h m³/h
0 1.5 6
500 14.5 1,000
A 1 1
| |
D.2.2 Cleaner/Regrind/Column areas Total Demand
m³/h
10
500
1
|
D.2.3 Tailings Area Flushing/Startup Tailing Flocculant Dilution Tailing Thickener Area Total Demand
m³/h m³/h m³/h
0 0 0
65 1,000 1,000
A A A
D.2.4 Concentrate Area flushing/startup Total Demand
m³/h
0
250
A
D.2.5 Moly Plant Circuit process water Total Demand
m³/h
28
150
1
Including NaHS
|
Total process water demand
m³/h
11,322
17,000
1
Adjusted for availability Design flows not additive
|
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Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
9.05
|
Process/Fresh Water Systems
Initial Revision
C-DC-25-901 HPGR Rev. D
Last Revision
A.Gunson
Date: Date:
Units
Nominal
15-Mar-04 27-Jan-06
Design*
Rev
A
Rev
1
Source
Rev
Reference
* If different than the nominal
E - Net Water con sumers
E.1 Concentrator E.1.1 Final Concentrate Total consumption
m³/h
9.6
14
0
E.1.2 Domestic water consumption Total consumption
m³/h
1.00
2.3
1
|
Total consumption
m³/h
10.6
16
1
|
E.2 Tailing Embankment / Impoundment Dam E.2.1 Evaporative losses Total consumption (net)
E.2.2. Seepage Losses Total recovery flow consumption
m³/h
m³/h
E.2.3. Embankment Dam building entrained water recovery Total flow consumption m³/h
413
413
|
Includes Moly Conc.
| MWH TO CONFIRM ALL | 1 60,00 per month X 1.08 + increase | URS+MWH due to 2 pond impoundment Volume 6, scenario 1, Avg. year 3 evaporation
| |
290
290
MWH
1
Recycled to tailing pond - not lost
|
520
580
MWH
1
Design = Nominal + 11% 15% & 95% Avail
| | |
Recycled with seepage E.2.4. Stored Tailing tailings contained water + foundation losses Total consumption
See note 1
| | | |
Ref. Section D.1
|
m³/h
2,261
2,817
D
1
Design = Nominal + 15% & 95% Avail
m³/h
2,674
3,230
MWH
1
NB. Excludes initial foundation losses
By difference overall - evaporation Total overall tailing consumption
E.3 Other Users Total fresh water demand (General)
m³/h
81
81
D
1
Existing leach - SX/EW
m³/h
360
360
L
Overall consumption
m³/h
3,131
3,693
D
1
Less ore feed moisture Make up water required
m³/h m³/h
84 3,048
93 3,600
D D
1 1
|
1
E.4 Overall
| | Adjusted for availability | Not accounted in MWH water balanc | | Design flows not additive
Note 1: Basis MWH final water balance scenario 1, adjusted from 108,00 t/d to tailing tonnage 105,957 t/d and adjusted for 93% pumping availability on make-up water
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| |
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Sociedad Minera Cerro Verde S.A.A. Primary Sulfide Project Project No PSP108
Document C-DC-25-001_Rev 1
Process Design Criteria Section:
Initial Revision Last Revision
9:06
Reagents - Water Treatment
AJ Gu ns on K. Wood
Units
Date:
25-Oct-05
Rev
A
Date:
27-Jan-06
Rev
1
Nominal
Design*
Source
Rev
G
1
J D J D
1 1 1 1
D
1
J J D
Reference * If different than the nominal
An ti -Scal ant
Type Points of addition Recycle water to process water tank Storage capacity
ppm L/h m3 d
Delivery form Annual Consumption
m3
Millsperse 815-5 100% Concentration 1 5 8.9 50 3
2 x 10 m 100 18 Liquid in Isotainers 73 407
| | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
Corrosion Inhibitor
Drewgard 120
Type Addition points Secondary/Tertiary crushing cooling water Addition rate Total Consumption Tank Storage Volume Plant air compressor cooling water Addition rate Total Consumption Tank Storage Volume
ppm L/h L/d m3 d ppm L/h L/d 3
100% Concentration 1 5 0.30 1.80 7.1 40 5 700 1 0.1 22
m d
2.5 113
ppm kg/d
Solid 50 1.3
125 5 0.7 19
D D D
130
D D
1 1 1 1 1 1 1 1 1 1
100 11.6
J J J
1 1 1
J J J J
1 1 1 1
J J J
1 1 1
D
Domestic Water Treatment
Aluminum Sulfate type A Form Dosage Consumption Flocculant polymer Form Dosage Consumption Sodium Hypochlorite Form Dosage Consumption
Nalco8173 HMW Cationic polymer dry solid 1 4.5 ppm kg/d 0.03 0.1
13% concentration solution ppm L/d
7
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