COMPAÑÍA MINERA CASALE PROJECT Nº 159742 CERRO CASALE PROJECT PRE-FEASIBILITY/FEASIBILITY STUDY
TRADE-OFF STUDY REPORT Nº 159742-N-RE-32 FOR !"PR #S$ SA" ECONOMIC COMPARISON Prepared by
AMEC I%&'(%)&*+%), C.*,' S$A . Approved by Discipline Lead/Manager Project Engineer Engineering Manager Project Manager &lient
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&lient1s &omments2
(PL) (!M) (! M) ("A) ($%) (M!)
Pi e erre Lacombe Ian Orord "ober o t o Ab#rto Pa#l Mc"ae Mi'e !elson
I' +( Internal revie Iss#ed or #se
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TABLE OF CONTENT PA"E 1$
SUMMARY$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 3
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LIST OF ABBRE#IATIONS AND UNITS$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 4
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INTRODUCTION$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 5
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STUDY OBJECTI#ES SCOPE AND DELI#ERABLES$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 8 5. Objectives .............................................................................................................. * 5. %cope and
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TEC!NICAL DESCRIPTION$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 7 3. :ec=nical $%imMet %im#lations and Mass balance calc#lations .......................................
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CAPITAL COST ESTIMATE $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$12
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OPERATIN" COST ESTIMATE $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 13
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NET PRESENT #ALUE AND PAYBAC: ANALYSIS$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 15
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CONCLUSIONS AND RECOMMENDATIONS $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 17
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REFERENCES$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 1
APPENDICES Appendi? A E@#ipment Lists Appendi? < &apital &ost Estimates Appendi? & Operating &ost Estimates Appendi? D Draings Appendi? E &alc#lations Appendi? Mass
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TABLE OF CONTENT PA"E 1$
SUMMARY$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 3
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LIST OF ABBRE#IATIONS AND UNITS$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 4
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INTRODUCTION$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 5
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STUDY OBJECTI#ES SCOPE AND DELI#ERABLES$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 8 5. Objectives .............................................................................................................. * 5. %cope and
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TEC!NICAL DESCRIPTION$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 7 3. :ec=nical $%imMet %im#lations and Mass balance calc#lations .......................................
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CAPITAL COST ESTIMATE $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$12
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OPERATIN" COST ESTIMATE $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 13
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NET PRESENT #ALUE AND PAYBAC: ANALYSIS$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 15
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CONCLUSIONS AND RECOMMENDATIONS $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 17
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REFERENCES$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 1
APPENDICES Appendi? A E@#ipment Lists Appendi? < &apital &ost Estimates Appendi? & Operating &ost Estimates Appendi? D Draings Appendi? E &alc#lations Appendi? Mass
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SUMMARY :=is report presents t=e res#lts o an #pdated trade6o st#dy cond#cted by AME& Americas Ltd to compare t=e relative merits o a %A9 mill6based (t=e alternative) vers#s a 8P9"6based (t=e base case) grinding circ#it conig#ration or t=e &erro &asale project. :=e project considers t=e treatment o ore+ at a rate o *,+,,, tpd+ t=ro#g= a processing plant recovering gold and copper val#es. :=e 8P9" base case =as been developed at easibility (%) level+ it= t=e incl#sion o some o t=e major material =andling capital cost red#ction items identiied in t=e %6 stage b#t prior to considering t=e eect o t=e grind siBe target red#ction later implemented. implemented. :=e related design deliverables deliverables orm t=e basis o t=e operating and capital cost estimates presented in t=is report. or t=e %A9 alternative+ t=e siBing o t=e commin#tion e@#ipment as revised rom t=e earlier preeasibility (P%) stage assessment to relect adj#stment made since t=en to t=e poer re@#irement.
T);,' 1$1 E<+%+=* << A% ), ** C+=6)(* %> %> !P"R-B)' 0$ SA"-B)' C*(<*&
!PC Disco#nted , (FM) !PC Disco#nted 3 (FM) %imple Paybac' (years) I"" () 2
4,.4 77., 5.4 .0
:=e positive o#tcome o t=e inancial analysis+ avo#ring t=e 8P9"6based circ#it+ is bro#g=t by an e?pected red#ction o t=e overall commin#tion section operating costs by F,.0,3/t+ or F5*.3M per year+ set against t=e additional capital e?pendit#re o F.-M. 9rinding media and liners cons#mption dierences acco#nt or appro?imately F,.35/t o t=is red#ction =ile poer savings acco#nt or an additional F,.34/t. :=ese savings are partially oset by smaller increases in labo#r (F,.,7/t)+ liners (F,.7/t) and maintenance materials and spares costs (F,.3/t). Additional conveyors+ eeders and associated civil or's acco#nt or t=e b#l' o t=e capital cost dierence beteen t=e to commin#tion circ#it conig#rations. :=e ris's ris's associ associate ated d it= it= t=e adoptio adoption n o a 8P9"6b 8P9"6base ased d commin commin#tio #tion n circ#i circ#itt are deemed as manageable and+ to some e?tent+ less da#nting t=an or a circ#it it= %A9 mills. Most o t=e ris's associated it= t=e 8P9" circ#it relates to potential materials
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=andling iss#es and d#st prod#ction. :=ese can be mitigated t=ro#g= ade@#ate design eat#res. %c=ed#le delays d#e to casting problems+ long lead and installation times+ and saety iss#es d#ring maintenance are some o t=e 'non ris's associated it= a %A96based circ#it t=at o#ld be eliminated by t=e selection o t=e 8P9 " ro#te. :=e 8P9" circ#it is t=ereore reconirmed by t=e c#rrent st#dy #pdate as t=e preerred approac= or t=e commin#tion circ#it design at &erro &asale.
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LIST OF ABBRE#IATIONS AND UNITS %A9 8P9" !PC I"" P% % % t/d F 'G= 'G=/t M OPEH &APEH &%% %A<&6< P0, :0, mm micron c/ / O/ /% O/% v/v / g/t
%emi6A#togeno#s 9rinding 8ig= Press#re 9rinding "olls !et Present Cal#e Internal "ate o "et#rn Preeasibility %t#dy easibility %t#dy easibility %t#dy pdate Dry metric tonnes per day nited %tates o America Dollar $iloatt =o#r $iloatt =o#r per tonne Million Operating e?pendit#re &apital e?pendit#re &losed side setting %A9 mill+ open6circ#ited pebble cr#s=ing and ball mill conig#ration %creen apert#re siBe t=ro#g= =ic= 0, o t=e material passes :ranser siBe (0, passing t=is siBe) millimetre One t=o#sandt= o a millimetre complete it= nderlo Overlo ndersiBe OversiBe vol#me per vol#me proportion eig=t per eig=t proportion grams per tonne
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!/m/m ts/m7/=
3$
!eton orce per s@#are meter per meter lengt= o 8P9" roll tonnes second per c#bic meter per =o#r (speciic t=ro#g=p#t or 8P9")
INTRODUCTION AME& as irst re@#ested at t=e concl#sion o t=e P%+ by t=e &ompania Minera &asale (&M&)+ to perorm a trade6o st#dy comparing t=e relative merits o t=ese alternative grinding circ#it conig#rations+ it= a vie to select t=e most appropriate conig#ration or incl#sion in t=e los=eet o t=e proposed &erro &asale Mill at t=e % stage. :=e concl#sions o t=is earlier st#dy (doc#ment 3-456!6"E6,7) =aving indicated t=at a 8P9"6based circ#it o#ld be t=e most economical option to p#rs#e+ it as implemented or detailing in t=e s#bse@#ent %6stage o t=e st#dy. At t=e end o t=e P%+ t=e dierential capital cost as estimated at some F4*M+ avo#ring t=e %A96 based circ#it+ b#t an OPEH savings o F.,0/t as alloing a ast paybac'. :=e P%6 level %A9 circ#it &APEH and OPEH ere #sed or t=e base case =ile scoping6level estimates ere prepared to establis= t=e 8P9"6based relevant costs. Git= t=e establis=ed 8P9" circ#it OPEH and &APEH+ at %6level+ &M& e?pressed a re@#irement to revisit t=e earlier concl#sion by incorporating t=e act#aliBed costs or t=e major inp#ts and consider t=e details made available at %+ vers#s t=e #pdated val#es pegged or t=e %A96based option+ earlier developed at P%6level. :=is report presents t=e res#lts o t=is act#aliBed trade6o st#dy and orms part o t=e &erro &asale easibility %t#dy. !o additional relevant data as provided rom t=e ,,- testor' campaigns or siBing t=e %A9 mill circ#it+ besides a conirmation t=at t=e earlier *.- 'G=/t or
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Appendices or details)+ as part o t=e % deliverables pac'age. %#c= deliverables+ or t=e %A9 alternative ere #pdated rom t=e earlier P% level. :=e comparison is based on t=e re@#irements to deliver a lotation eed prod#ct at a P0, o 3, Km and a nominal rate o *, 't/d it= t=e design ore deined as representative o t=e Jear 63 ore type mi?t#re. :=e 3, Km #sed earlier as retained or t=is #pdate+ despite t=e selection o a iner target o , Km late in t=e ,,- easibility %t#dy stage+ since s#c= a selection as applied to t=e %A96based option o#ld =ave called or a o#rt= %A9 mill to be added+ and a revision o t=e n#mber+ and a possible conig#ration rearrangement+ o t=e accompanying pebble cr#s=ing and ball milling circ#its. :=is in t#rn o#ld =ave re@#ired a complete reassessment o t=e e?pected &APEH cost or t=is option. :=e aorementioned inormation as #sed to estimate and compare t=e dierential inancial indicators or t=e to alternative los=eets (see %ection 0).
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STUDY OBJECTI#ES SCOPE AND DELI#ERABLES 4$1
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:=e primary objective o t=is st#dy #pdate as to present a balanced and #nbiased comparison o t=e relative merits o a 8P9"6based grinding circ#it+ as developed to %6level+ vers#s t=e alternate scenario developed earlier or t=e P% involving a conventional %A<&6< circ#it. :=is comparison is meant to provide conirmation+ it= t=e additional design and costing details and acc#racy provided at t=e concl#sion o t=e %+ to allo decision ma'ers to gain #ll conidence in t=e earlier selection o t=e grinding circ#it or &erro &asale+ calling or t=e incl#sion o 8P9".
4$2
S<+6' )% B)&&'( L*=*&
:=e scope o t=e st#dy as to generate s#icient design data to allo a basic comparison o t=e economics o t=e to los=eets. :=e list o deliverables belo s#mmariBes t=e scope assigned to AME&. :=e battery limits or t=is trade6o st#dy are2 •
•
pstream 2 &oarse ore stoc'pile eed conveyor Donstream 2
:=e "OM cr#s=ing operation is identical or bot= t=e %A<&6< and 8P9" los=eets+ it= t=e e?ception o a ider coarse ore stoc'pile stac'ing conveyor+ as re@#ired or t=e 8P9"6based circ#it to deal it= sporadic bypassing o a tertiary cr#s=ing circ#it stream. %imilarly t=e lotation los=eets are identical+ it= bot= grinding circ#its re@#ested to generate a prod#ct it= a P0, o 3, microns+ at a similar sl#rry density reac=ing t=e ro#g=ing lotation section+ and at t=e same nominal t=ro#g=p#t capability
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o *,+,,, t/d. In t=e case o t=e %A96based circ#it+ t=e #tiliBation o t=e available ball mill poer contingency e?isting #nder t=e 8P9"6based option+ is #sed #p to permit a coarsening o t=e transer siBe rom t=e %A9 mills and limit t=eir poer demand.
4$3
D',*0'();,' :rade6O %t#dy deliverables are2 •
•
•
•
•
•
•
•
•
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Earlier :rade6O st#dy report (doc#ment 3-456!6"E6,7) % Design &riteria (doc#ment 3-456!6D&63) % Process lo Diagrams it= mass balance data %coping PD or %A96based circ#it Dierential e@#ipment list c/ indicated siBing o all main e@#ipment Operating cost estimate &apital cost estimate inancial analysis :rade6O st#dy report (t=is doc#ment 3-456!6"E67,)
TEC!NICAL DESCRIPTION 5$1
T'<.%*<), B)<@>(+% ig#re 3.6 belo s=os a concept#al bloc' diagram or t=e %A<&6< and 8P9" based grinding circ#its considered or t=e &erro &asale Mill.
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F*>(' 5$1-1 C+%<'6&), B,+<@ D*)>()= +( "(* %*%> C* (<*& A,&'(%)&*0' SABC-B C*(<*&
!P"R C*(<*&
&oarse Ore %toc'pile
&oarse Ore %toc'pile
%A9 Mill
Dry %creen O/%iBe
%econdary &r#s=er
/%iBe
%creen
O/%iBe
Pebble cr#s=er
8P9"
/%iBe O/%iBe /%iBe
%creen
Get %creen
O/%iBe
/%iBe
&yclones /lo
O/lo to lotation
&yclones
/lo
O/lo to lotation
In t=e %A<&6< conig#ration+ t=e added pebble cr#s=ing step complements t=e %A9 mill grinding poer in providing compression cr#s=ing o t=e so6 called critical siBe material+ =ic= o#ld ot=erise b#ild #p in t=e %A9 mill. :=e cr#s=ed pebble stream does not ret#rn to t=e %A9 mill b#t instead proceeds to a screening stage to allo or recycling o t=e coarse raction o t=e pebble stream. :=e ine raction proceeds to t=e ball milling circ#it. :=is arrangement allos or a coarser transer siBe to be obtained+ despite a possble tendency or t=e ore to generate a limited @#antity o inis=ed prod#ct t=ro#g= %A9 milling only.
5$2
D'*>% B)* :=e detailed design criteria doc#ments or bot= grinding alternatives =ave been p#blis=ed separately (3-456!6D&6,, or t=e base case %A<&6< circ#it+ and 3-456!6D&6, or t=e 8P9" alternative). :able 3.6 s#mmariBes and compares t=e 'ey design ass#mptions and data or bot= scenarios.
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T);,' 5$2-1 :' D'*>% C(*&'(*) D'*>% E,'='%& :=ro#g=p#t Primary cr#s=ing circ#it prod#ct Primary cr#s=ing circ#it prod#ct top siBe Design ore blend Overall circ#it grinding #tiliBation %econdary cr#s=er circ#it #tiliBation >$:ec= A?b ore =ardness parameter >$:ec= ta abrasiveness parameter Estimated
t/d P0, (mm)
SABC-B O6&*+% *,+,,, 3,
B)' C)' !P"R *,+,,, 3,
mm
5,
5,
U%*&
Jear63 composite - - na
03
-.
na
,.7
,.7
'G=/t
*.-5
*.,-
'G=/t
5.*
5.*
microns /
-, 3, 75
-, 3, 75
!ote2 . :=e initial base case sim#lations made #se o t=e 0, mm primary cr#s=er prod#ct. Later iterations it= t=e retained 8P9" circ#it in % adopted 3, mm b#t no comparable sim#lation data or t=e %A<&6< circ#it ere generated.
:=e secondary cr#s=ing circ#it or t=e alternative+ as per t=e pebble cr#s=ing circ#it #nder t=e base case+ is e?pected to r#n only 03 o t=e time. :o compensate or t=is loer #tiliBation+ compared to t=e rest o t=ese respective circ#it1s components+ an additional pebble cr#s=er+ s=ared by all t=ree %A9 grinding lines+ =as been incl#ded in t=e %A<&6< design =ile an intermediate cr#s=ed ore stoc'pile =as been incl#ded in t=e 8P9" circ#it design. Per :able 3.6+ t=e ball mill or' inde? or t=e 8P9" circ#it is e?pected to be 3 loer t=an t=at o t=e %A9 mill6based circ#it+ per t=e testor' cond#cted by Polysi#s =ic= s=oed val#es o #p to - (beore adj#stment or dierential 0, and P0, beteen tests). :=is red#ction is attrib#ted to t=e so6called micro crac'ing eect+ res#lting rom t=e =ig= stresses imparted on t=e material passing t=ro#g= t=e 8P9" rolls.
5$3
A0)*,);,' I%+(=)&*+% All inormation pertaining to t=e %A<&6<+ as t=e base case carried in t=e Preeasibility %t#dy+ is available in separate doc#ments not d#plicated in t=is report. G=ere relevant+ t=e %A<&6< data is s=on to allo direct comparison it= t=e relevant alternate case #nder st#dy. or t=e 8P9" option+ t=e deliverables prepared #p to t=e point =ere t=e decision as made to decrease t=e lotation eed P0,+ rom t=e prior 3, Km to t=e revised , Km val#e+ ere t=e basis or t=e estimates.
5$4
!P"R T'&+(@ )% S*=,)&*+% R',& Drill core samples ere provided to Polysi#s to test t=e amenity o t=e ore to 8P9" cr#s=ing. :=e samples tested by Polysi#s incl#ded a Jear to 3 blend composite sample as ell as an additional si? individ#al ore type samples. :=e objectives o t=e tests ere to generate data re@#ired or e@#ipment siBing+ cost estimates and to assess ris's pertaining to t=e variability o t=e orebody N. %ome o t=e 'ey metrics and indings rom t=ese tests are2 •
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Liner ear rates increase it= an increase in eed moist#re content. :=e implication is t=at t=e los=eet design and e@#ipment siBing s=o#ld aim at minimiBing 8P9" eed moist#re+ e.g. t=ro#g= longer et screens to ens#re better drainage. At a 5 moist#re content t=e A:GAL abrasion test yielded a ear rate o * g/t or t=e composite sample. :=is is classiied by Polysi#s as a lo to medi#m abrasiveness ore response. Meas#red ear rates ere all in t=e medi#m abrasiveness range it= minimal variability beteen t=e individ#al ore types. :=e speciic energy inp#t at t=e optim#m gri nding orce as .0 'G=/t A speciic t=ro#g=p#t (m6dot) o , ts/m 7/= as meas#red at t=e optim#m grinding conditions. Loc'ed cycle cr#s=ing tests s=oed t=at t=ere o#ld be no b#ild6#p o a =arder component in closed circ#it operation d#e to preerential cr#s=ing o soter constit#ents. %creening tests cond#cted it= t=e "E9"O prod#ct revealed t=at t=e compacted ca'es disagglomerate easily d#ring et screening.
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AME& adopted 3 as a reasonably conservative estimate or t=e e?pected poer red#ction. :ests cond#cted on t=e seven samples indicated only minor dierences in process parameters.
Polysi#s cond#cted sim#lations based on t=eir testing o t=e composites and on proprietary scale6#p actors. %ome o t=e 'ey sim#lation o#tp#ts are2 •
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5$5
A tertiary 8P9" circ#it prod#ct o 6* mm can be prod#ced #sing eit=er ive large .* ? .43 m rolls or si? .5 ? .4 m rolls. &ost and ease o operation dictate t=e latter+ i.e. to parallel #nits or eac= o t=e t=ree identical grinding lines+ it= one 8P9" dedicated to eeding eac= one o t=e si? ball mills. At a nominal rolls speed o .53 m/s t=is conig#ration ill r#n at appro?imately -, o t=e ma?im#m speed providing an estimated * contingency on t=ro#g=p#t. At a -, 8P9" #tiliBation and an estimated average circ#lating load o 3 #sing a c#t siBe on t=e et screen o , mm+ t=e nominal eed to eac= 8P9" ill be +0*5 t/=+ re@#iring 7+37, 'G o motor poer+ incl#ding mec=anical losses. :=e #se o to +43, 'G variable speed drives per 8P9" #nit ill allo or minor variability in bot= t=ro#g=p#t and ore =ardness.
J:S*=M'& S*=,)&*+% )% M) ;),)%<' <),<,)&*+% :able 3.36 compares 'ey parameters obtained rom sim#lations+ it= an adj#stment or t=e revised *, 't/d t=ro#g=p#t. G=ere t=ere are minor dierences beteen t=e mass balance and sim#lations+ t=e mass balance res#lts ta'es precedence as t=is is t=e basis or t=e cost estimate.
T);,' 5$5-1 S* = ,) &*+% )% M ) B),)%<' ! *>.,*>.&
!#mber o %A9 Mills (5,1 ? 51) !#mber o 8P9"1s (.5 ? .4 m) !#mber o cone cr#s=ers !#mber o
ea. ea. ea. ea.
B)' C)' SABC-B 7 , 5 *
Pebble/:ertiary &r#s=ers &irc. Load %econdary/Pebble &r#s=ers &%%
mm
*3 7
03 73
Dry %creen
mm mm mm
7 .3 -
53 74 !/A
Pebble/ Get %creens Dec' Apert#re 8P9" &irc#it &irc#lating Load
mm
, !/A
, 3
mm critical v/v
0.4 40 7
3.40 0
E,'='%&
8$
U%*&
!P"R O6&*+% , * 0 *
CAPITAL COST ESTIMATE :=e capital cost estimate or t=e base case is relecting t=e detailed cost estimate prepared or t=e Preeasibility %t#dy. or t=e alternate circ#it+ t=e &APEH estimate is t=e o#tcome o t=e % drat stage. In bot= cases+ t=e major mec=anical e@#ipment is costed rom b#dgetary @#otes+ or inde?ed or dierential siBe rom recent @#otes or similar e@#ipment. Material ta'e6os ere eval#ated on t=e basis o t=e plant area topograp=y and t=e general plant layo#t prepared or t=is p#rpose. :=e precision o eac= estimate varies in relation it= t=e level o st#dy reac=ed it= eit=er one (/63 or P%+ /63 or % drat) :=e res#lting dierential &APEH estimate is presented in :ables *6 belo. !ote t=at indirect cost elements incl#ding EP&M+ initial ills+ vendor representatives+ and Oner1s cost are acco#nted or by a * actor as s=on in :able *6. :=is val#e represents =al o t=e overall 7 bac'6calc#lated rom t=e overall % &APEH estimate+ relecting
t=e act t=at not all t=e indirect costs are variable and only =al co#ld t=#s be saved t=ro#g= a red#ction o t=e project &APEH. A ,.* contingency as also added+ per t=e average level calc#lated rom t=e % Drat &APEH estimate.
T);,' 8-1 D*'('%&*), C)6*&), C+& E&*=)&' ; D*<*6,*%' G B)' C)' 0$ !P"RB)' T+&), D*'('%&*), CAPE M/ BS C+'
DISCIPLINE
Eart=or's &oncrete %tr#ct#ral %teel Arc=itect#ral Mec=anical 3, *, Piping Electrical 4, 0, Instr#mentation T+&), D*('<& C)6' Indirect costs (* o direct) &ontingency (,.*) , /, 7, 5,
CAPE *%<,*%> I%*('<& )% C+%&*%>'%< D*'('%<' !P"R O6&*+% - SA" O6&*+%
%A<&6<
8P9"
0.
-.*
.,
5,.
50./ 3.3
3*.5 .7
735.7
5.4
/7.5 *0. //.3
/*./ 55.4 /4.7
851$1 ,5.
747$4 -.*
*-.,
4-./
24$3
948$3
121$9
:able *6 indicates t=at t=e %A96based scenario o#ld re@#ire a &APEH o#tlay F.-M loer t=an t=e estimation prepared or t=e 8P9"6based circ#it. :able *6 also indicates t=at a large portion o t=is incremental e?pendit#re is associated it= t=e mec=anical components and str#ct#ral steel costs associated it= t=e 8P9"6based circ#it+ partly compensated by =ig=er electrical gear costs or t=e %A96based option. :=e circ#its donstream o t=e ball milling section are pres#med e@#ivalent in t=eir design or bot= conig#rations eval#ated. :=ey only dier in t=e #tiliBed ball milling poer base. &apital cost details are presented in Appendi? <.
7$
OPERATIN" COST ESTIMATE Detailed operating cost calc#lations are presented in Appendi? &. :able 46 belo s#mmariBes t=e poer cons#mption elements+ as e?tracted rom t=e e@#ipment list it= load actors assigned to individ#al e@#ipment+ per Appendi? A6 and A6.
T);,' 7-1 S6'<**< P+'( C+%=6&*+% <+%=' @./& + ('. '' A,&'(%)&* 0' SABC-B !P"R 0.0 6 ,.57 ,.*3
I&'= %A9 Mill Pebble/%econdary &one &r#s=ers 8P9"
6
.-
.*7 .73 23$22
.77 .50 17$37
!otes2 . sing indication t=at .3 times t=e net pebble cr#s=er energy (i.e. e?cl#ding poer cons#mption or no6 load and transmission losses) e@#ates t=e %A9 mill poer red#ction+ t=e e@#ivalent %A9 only circ#it speciic poer cons#mption o#ld be -. 'G=/t. . %peciic poer cons#mption based on test res#lt data indicating .0 'G=/t o 8P9" eed and 33 circ#lating load rom et screens =en operated at a c#t6o siBe o , mm.
:able 46 s=os an e?pected red#ction o t=e speciic poer cons#mption o nearly 3 or t=e 8P9"6based+ vers#s t=e %A96based circ#it. :=e most signiicant dierence =ig=lig=ted by :able 46 is t=e 3.47 'G=/t poer cons#mption dierence beteen t=e to centerpiece major e@#ipment items (%A9 mill vs. 8P9"). Ancillary e@#ipment poer is =ig=er or t=e 8P9" conig#ration as t=is type o circ#it contains more conveyors and eeders t=an t=e simpler %A<&6< circ#it. :able 46 belo s#mmariBes all major cost elements or t=e to conig#rations.
T);,' 7-2 O6'()&* %> C+& S==)(
Poer 9rinding and &r#s=ing Liners 9rinding Media Operating and "epair %#pplies Direct and &ontract Labor
T+&),
SABC /& .44 ,.*5 .0,.70 ,.,04 4$235
!P"R /& .4,7 ,.7-, ,.437 ,.5*4 ,.4 3$429
D*'('%<' /& H 0$ SA" ,.345 3. 6,.* 654.* ,.37* 5.* 6,.565*.0 6,.,7, 675. $5 19$
Per t=e details on t=e OPEH derivation provided in Appendi? &+ it is noted t=at2 •
:=e poer cost as estimated at a price o %F,.,-,/'G= or electricity
•
•
•
:=e cost or spares and maintenance materials or t=e %A96based circ#it is derived by applying a actor o 5.3 to t=e &APEH elements representing e@#ipment (mec=anical+ electrical)+ piping+ instr#mentation and b#l' elements e?posed to ear or damage (lig=t steel+ pipes/cables and associated rac's and s#pports+ b#ilding all panels). :=e res#lting val#e (F0.3M) is t=e yearly e?penses re@#ired to cover maintenance spares and materials costs+ e?cl#sive o manpoer. or t=e 8P9"6based option+ t=e maintenance spares and materials costs ere derived rom a irst6principles approac=+ =ere every piece o e@#ipment as bro'en don into its vario#s main elements and a replacement re@#ency and price as assigned to eac= o t=em. :=e res#lting s#m o all t=ese individ#al amo#nts+ pl#s percentages to cover maintenance o b#l' items s#c= as s#pports+ cabling and instr#mentation (mostly costed as lots in t=e &APEH derivation)+ yields t=e yearly b#dget o F*.-M indicated. :=e details o t=is derivation are o#nd in doc#ment 3-456!6DE67,. Labor costs are based on t=e b#rdened ages i ndicated by &M&.
:able 46 indicates t=at t=e 8P9" circ#it is e?pected to be - c=eaper to operate and maintain t=an t=e e@#ivalent %A<&6< base case circ#it. :=is is attrib#ted to t=e signiicant poer cons#mption advantage oered by t=e 8P9" circ#it+ at 0.- 'G=/t+ vers#s 3. 'G=/t re@#ired by t=e %A<&6< circ#it+ incl#ding motor eiciency and transormation/transmission losses.
$
NET PRESENT #ALUE AND PAYBAC: ANALYSIS :able 0. presents t=e =ig=lig=ts o t=e inancial analysis perormed.
T);,' $1 C+=6)()&*0' E<+%+=* < P)()='&'(
!PC Disco#nted , (FM) !PC Disco#nted 3 (FM) %imple Paybac' (years) I"" () 2
4,.4 77., 5.4 .0
Detailed cas= lo inormation is presented in Appendi? E. :=e analysis is based on t=e olloing ass#mptions2 •
•
•
•
8al o t=e constr#ction capital e?pendit#re is inc#rred to years prior to t=e irst prod#ction it= t=e rest divided e@#ally beteen t=e year beore prod#ction starts and t=e irst year o prod#ction Inlation and or'ing capital dierential eects are ass#med to be negligible Interest earned or paid on c#m#lative cas=lo is not considered All o t=e initial capital ill =ave been ritten o by mine clos#re
ig#re 0. presents t=e sensitivity o t=e indicated !PC(3) to c=anges to t=e 8P9" circ#it1s main cost drivers.
F*>(' -1 F*%)%<*), S'%*&*0*& A%),* + !P"R M)*% D(* 0'( NP#5H S'%*&*0*& 3,, 53, 5,, 73, 7,, 3, ,, 3, ,, 3, 6
D M / H 5 # P N
67, 63 6, 63 6,
63
,
3
,
3
,
3
7,
#)(*)&*+% +% !P"R ;)' <+& -H &APEH
O/A Maint
Liners
Energy
Maint %pares/Mat
9$
CONCLUSIONS AND RECOMMENDATIONS :=e 8P9" circ#it oers an estimated ,.0,3 F/t operating cost saving+ compared to t=e %A<&6< circ#it. 8oever+ t=is is oset by an estimated F.-M in additional capital e?pendit#re re@#ired or t=e 8P9"6based circ#it. :=e comparative inancial analysis indicates an #ndisco#nted cas=lo dierential o F4,.4M+ or F77.,M in avor o t=e 8P9" based circ#it at a 3 disco#nt rate. :=e I"" or t=is comparative scenario is .0. :=e simple paybac' period+ i.e. t=e d#ration re@#ired to pay bac' t=e additional &APEH #sing t=e OPEH saving+ is 5.4 years. On t=is basis+ t=e inancial beneits o adopting a circ#it comprising 8P9" as replacement to t=e %A9 milling step or developing t=e &erro &asale processing plant design criteria =as been reconirmed. AME& is o t=e opinion t=at t=e intangible opport#nities oered by t=e 8P9" circ#it also overs=ado t=e ris's associated it= t=is circ#it+ s#c= as2 •
•
•
•
•
•
:=e %A9 circ#it is simple and proven. :=e 8P9" circ#it is more comple?+ it= signiicantly more e@#ipment. :=#s+ t=ere is more t=at can go rong t=ro#g= imbalances beteen e@#ipment or circ#it capacities in a 8P9" circ#it. :=e et and dry screening sections do not incl#de any bac'#p #nits+ per circ#it. :=e loss o one screen =ile in operation o#ld red#ce t=e t=ro#g=p#t potential o t=e circ#it. 8P9" circ#its contain additional e@#ipment (screens+ c=#tes+ bins+ eeders and conveyors) =ic= demand additional maintenance reso#rces (personnel+ capital and normal spares+ are=o#sing loor space+ administrative processes+ etc.) %econdary cr#s=ing and 8P9" demands e?cellent tramp metal detection and removal to protect st#ds. Eective tramp metal detection on slo moving eeders poses many design problems and t=e scale o t=e &erro &asale operation ill e?acerbate t=is c=allenge. %A9 circ#its can accommodate clayey ore constit#ents easily. &lay in t=e 8P9" circ#it ill ca#se b#ild6#p at material transer points+ c=#te bloc'ages+ conveyor scraper/cleaning iss#es+ red#ced 8P9" t=ro#g=p#t and increased ear d#e to increased eed moist#re content+ incomplete disagglomeration o la'es+ etc. 9eological reports on t=e &erro &asale orebody indicates t=at t=ere are minimal clayey constit#ents in t=e orebody+ alt=o#g= t=e composite prepared or testor' to em#late t=e early mine o#tp#t+ mostly composed o diorite+ =ad almost .3 clay6li'e minerals. It s=o#ld be noted t=at even small localiBed incl#sions in t=is massive orebody co#ld rea' =avoc to t=e 8P9"6based circ#it t=ro#g=p#t capability. A 8P9" circ#it demands additional d#st s#ppression+ containment and e?traction systems. D#st generation represents bot= a cost as ell as potential environmental and =ealt= ris'.
A more complete list o pros and cons as p#blis=ed it= t=e earlier :O% completed at t=e preeasibility stage (doc#ment 3-456!6"E6,7).
Most o t=e ris's listed or t=e 8P9" circ#it can be controlled at t=e design stage t=ro#g= incl#sion o appropriate ris' mitigation meas#res and operating strategies in t=e los=eet. :=e 8P9"6based circ#it is t=ereore recommended to be t=e preerred commin#tion approac= carried or t=e easibility st#dy los=eet.
1$
REFERENCES . <#rc=ardt+ EgbertQ 8ig= Press#re 9rinding+ %creening R 9r indability :ests on a 9old/&opper Ore or t=e &erro &asale Project o $inross/#ne ,,0. (see Appendi? 6 o P% doc#ment 3-456!6"E6,7) . &ontract %#pport %ervicesQ inal report to $inross 9old "es#lts o &erro &asale Proposed &ommin#tion &irc#it 8P9" vs. %A<&6< easibility %im#lation %t#dyQ %eptember ,,0. (see Appendi? 6 o P% doc#ment 3-456!6"E6,7)
APPENDI A EUIPMENT LISTS
A66'%* A-1 !P"R-B)' C*(<*& E*6='%& L*& FSU-,'0', .
A66'%* A-2 SABC-B-B)' C*(<*& E*6='%& L*& 6)&' PFS-, ' 0' ,
3-456!6"E67, 8P9" :O% "ev ,.doc
P;9E , O 73
APPENDI B CAPITAL COST ESTIMATES A66'%* B-1 CAPE '&*=)&' G SA" M*, , C* (<*& S <'%) (* + A ?&' (+= PFS,'0',
3-456!6"E67, 8P9" :O% "ev ,.doc
P 9E O
A66'%* B-2 P(',* =*%)( A ?&' PFS-, ' 0' , CAPE '&*=)&' G SA" M*, , C*(<*& S<'%)(*+
3-456!6"E67, 8P9" :O% "ev ,.doc
P 9E O
A PP END I C O PE RA TI N" C OS T EST IM AT ES T);,' C-1 SABC-B "(*%*% > L *% ' E * 6= '% & )% P+ ' ( C+% =6 &*+ % L * & :=e dra actor represents t=e raction o installed poer being cons#med =en t=e e@#ipment is r#nning normally. :=e circ#it #tiliBation actor acco#nts or all dontime incl#ding intermittent #sage e.g. s#mp p#mps =ic= is #sed only =en spillage occ#rs. :ransmission and transormer losses are ass#med to be less or =ig= voltage s#pply.
3-456!6"E6 7, 8P9" :O% "ev ,.doc
P ;9E 7 O 73
U%*& P+'( A(') E*6='%& D'<( *6&*+% 75, %toc'pile "eclaim eeder 75 :!!EL "E&LAIM D%: &OLLE&:O" 75 %A9 MILL EED &O!CEJO" 75 !EG O"E I< &"A!E O" %A9 LI!E"% 5 %A9 MILL LI!E" 8A!DLE" 5 %A9 MILL POGE"ED EED &8:E :"A!%PO":E" 5 &O!CEJO" S* 6 %A9 MILL %&"EE! OCE"%ITE &O!CEJO" 5 E"IET :JPE MOCI!9
I%&$ K 7 7 7 7 7 7 7 * 7 3 3 3
O6$ K * 7 7 7 7 7 7 7 7 7 5 5 5
I%&),,' @
D() F)<&+(
0, 04 7, 7 ,+00, 5-7 750 ,, , 0 43 , * 3 * 7 5, 453 7,
,.03 ,.03 ,.03 ,.03 ,.03 ,.-,.03 ,.03 ,.03 ,.03 ,.03 ,.-, ,.-, ,.03 ,.03 ,.03 ,.03 ,.03 ,.03 ,.03 ,.03 ,.05 ,.03
F)<&+( D()% @ *0 34 7 ,+*4 5-* 03 0 * *0 , 7 7 7 4 75 *0 -*
M+&+( E $/T()% T()%=$ C*(<*& U&*, L+' ,.- ,.- ,.- ,.- ,.,* ,.- ,.-7 ,.-7 ,.,0 ,.- ,.,0 ,. ,., ,.- ,.- ,.- ,.- ,.- ,.- ,.- ,.03 ,.03 ,.0*
.,5 .,5 .,5 .,5 .,5 ., .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5
A0'$ C+%=6&*+% U%*& @ *3 3 * , -+5- 5,* 0* 4 0 0 , 5 5 * 7, 33* 43
T+&), @ 7- 534 40 5 , 30+547 +4 03 0 0 , 5 5 5 * , +3 4,
U%*& P+'( A(') E*6='%& D'<( *6&*+% 75, %toc'pile "eclaim eeder 75 :!!EL "E&LAIM D%: &OLLE&:O" 75 %A9 MILL EED &O!CEJO" 75 !EG O"E I< &"A!E O" %A9 LI!E"% 5 %A9 MILL LI!E" 8A!DLE" 5 %A9 MILL POGE"ED EED &8:E :"A!%PO":E" 5 &O!CEJO" S* 6 %A9 MILL %&"EE! OCE"%ITE &O!CEJO" 5 E"IET :JPE MOCI!9
I%&$ K 7 7 7 7 7 7 7 * 7 3 3 3 7 * * * *
O6$ K * 7 7 7 7 7 7 7 7 7 5 5 5 7 * * * *
3-456!6"E6 7, 8P9" :O% "ev ,.doc
T ); ,' C -2 !P "R " (* % *% > L *% ' E * 6= '% & ) % P + '( C+% =6 + &* % L*& :=e actors applied =ave t=e same meaning as in :able &6.
I%&),,' @
D() F)<&+(
0, 04 7, 7 ,+00, 5-7 750 ,, , 0 43 , * 3 * 7 5, 453 7, *3 343 3, 33 +,5 *+,,, 70, 3 7+,,,
,.03 ,.03 ,.03 ,.03 ,.03 ,.-,.03 ,.03 ,.03 ,.03 ,.03 ,.-, ,.-, ,.03 ,.03 ,.03 ,.03 ,.03 ,.03 ,.03 ,.03 ,.05 ,.03 ,.03 ,.03 ,.03 ,.03 ,.03 ,.0* ,.-37 ,.-3 ,.03 ,.-3 ,.-3
P;9E 5 O 73
F)<&+( D()% @ *0 34 7 ,+*4 5-* 03 0 * *0 , 7 7 7 4 75 *0 -* 33 3, *5 7 54 +450 3+50 7* 7 +03,
M+&+( E $/T()% T()%=$ C*(<*& U&*, L+' ,.- ,.- ,.- ,.- ,.,* ,.- ,.-7 ,.-7 ,.,0 ,.- ,.,0 ,. ,., ,.- ,.- ,.- ,.- ,.- ,.- ,.- ,.03 ,.03 ,.0* ,.- ,.- ,.- ,.- ,.,3 ,.- ,.- ,.-7 ,.-7 ,.-3 ,.*
.,5 .,5 .,5 .,5 .,5 ., .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5
A0'$ C+%=6&*+% U%*& @ *3 3 * , -+5- 5,* 0* 4 0 0 , 5 5 * 7, 33* 43 3 50 * ,5 +*43 5+*, 73, 7 0 +40
T+&), @ 7- 534 40 5 , 30+547 +4 03 0 0 , 5 5 5 * , +3 4, 3 50 * * ,+,3 04+*,4 +,-0 43 0 +40 189258
T ); ,' C -2 !P "R " (* % *% > L *% ' E * 6= '% & ) % P + '( C+% =6 + &* % L*& :=e actors applied =ave t=e same meaning as in :able &6.
3-456!6"E6 7, 8P9" :O% "ev ,.doc
P;9E 3 O 73
U%*& P+'( A(') E*6='%& D'<(*6&*+% 75 %:O&$PILE "E&LAIM AP"O! EEDE" S 75 %:O&$PILE "E&LAIM AP"O! EEDE" S 75 %:O&$PILE "E&LAIM AP"O! EEDE" S5 75 %:O&$PILE "E&LAIM AP"O! EEDE" S3 75 "E&LAIM &O!CEJO" S 75 "E&LAIM &O!CEJO" S 75 !EG O"E
I%&$ K 0 0 0 0 0
O6$ K 0 0 0 0 0
I%&),,' D() @ F)<&+( 43 ,.0 43 ,.0 43 ,.0 43 ,.0 0, ,.05 0, ,.05 / ,.03 / ,.03 04 ,.07 04 ,.07 *, ,.33 3 ,.03 3 ,.03 0, ,.0 0, ,.0 0 ,.07 / ,.07 43 ,.0* 453 ,.4-, ,.04 +*0, ,.0 +*0, ,.0 / ,.07 / ,.07 04 , 03
D()% @ */ */ */ */
3 3
33 33 00 7 7
5* 5* * *3
3-, 40
+730 +7*
3-
F)<&+(
C*(<*& T()% T()%=$ U&*, L+' .,5 ,.-5 .,5 ,.-5 .,5 ,.-5 .,5 ,.-5 .,5 ,.-5 .,5 ,.-5 .,5 ,.-* .,5 ,.-* .,5 ,.-3 .,5 ,.-3 .,5 ,.- .,5 ,.- .,5 ,.- .,5 ,.-5 .,5 ,.-5 .,5 ,.- .,5 ,.- .,5 ,.03 .,5 ,.03 .,5 ,.- .,5 ,.-5 .,5 ,.-5 .,5 ,.-* .,5 ,.-* ,5 , -
A0'$ C+%=6&*+% U%*& @
T+&), @
*, *, *, *, 55 35 35 05 / / 57 57 * 34 3// 43
*, *, *, *,
+77, +77 3/
55
35 35 05 / /
57 57 50 ,
534 5+4*,, +77, +77
3
U%*& P+'( A(') E*6='%& D'<(*6&*+% 75 %:O&$PILE "E&LAIM AP"O! EEDE" S 75 %:O&$PILE "E&LAIM AP"O! EEDE" S 75 %:O&$PILE "E&LAIM AP"O! EEDE" S5 75 %:O&$PILE "E&LAIM AP"O! EEDE" S3 75 "E&LAIM &O!CEJO" S 75 "E&LAIM &O!CEJO" S 75 !EG O"E
I%&$ K 0 0 0 0 0
O6$ K 0 0 0 0 0
I%&),,' D() @ F)<&+( 43 ,.0 43 ,.0 43 ,.0 43 ,.0 0, ,.05 0, ,.05 / ,.03 / ,.03 04 ,.07 04 ,.07 *, ,.33 3 ,.03 3 ,.03 0, ,.0 0, ,.0 0 ,.07 / ,.07 43 ,.0* 453 ,.4-, ,.04 +*0, ,.0 +*0, ,.0 / ,.07 / ,.07 04 ,.03 43 ,.*3 -4 ,.03 43 ,.0 43 ,.0 43 ,.0 43 ,.0 0 ,.03 0 ,.03 43 ,.03 43 ,.03 43 ,.03 43 ,.03
3-456!6"E6 7, 8P9" :O% "ev ,.doc
D()% @ */ */ */ */
3 3
33 33 00 7 7
5* 5* * *3
3-, 40
+730 +7*
350/ * * * * * * *5 *5 *5 *5
F)<&+(
C*(<*& T()% T()%=$ U&*, L+' .,5 ,.-5 .,5 ,.-5 .,5 ,.-5 .,5 ,.-5 .,5 ,.-5 .,5 ,.-5 .,5 ,.-* .,5 ,.-* .,5 ,.-3 .,5 ,.-3 .,5 ,.- .,5 ,.- .,5 ,.- .,5 ,.-5 .,5 ,.-5 .,5 ,.- .,5 ,.- .,5 ,.03 .,5 ,.03 .,5 ,.- .,5 ,.-5 .,5 ,.-5 .,5 ,.-* .,5 ,.-* .,5 ,.- .,5 ,.- .,5 ,.- .,5 ,.00 .,5 ,.00 .,5 ,.00 .,5 ,.00 .,5 ,., .,5 ,., .,5 ,.- .,5 ,.- .,5 ,.- .,5 ,.-
E*6='%& D'<(*6&*+% D"J %&"EE! !DE"%ITE &O!CEJO" S D"J %&"EE! !DE"%ITE &O!CEJO" S
U%*& @
T+&), @
*, *, *, *, 55 35 35 05 / / 57 57 * 34 3// 43
*, *, *, *,
+77, +77 3/ 54 43* 3* 3* 3* , , * * * *
55
35 35 05 / /
57 57 50 ,
534 5+4*,, +77, +77
3 54 43* 3* 3* 3* , , * * * *
P;9E * O 73
U%*& P+'(
A(') 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73
A0'$ C+%=6&*+%
I%&$ K * * * * * *
O6$ K * * * * * *
I%&),,' @
D() F)<&+(
733 733 3 3 04 53 -4 -4 *, 43 3 3+3,, 3, 33 +*0, +*0, +, * 04 3 3 * *
,.0,.0,.07 ,.07 ,.07 ,.07 ,.03 ,.*3 ,.03 ,.33 ,.03 ,.07 ,.03 ,.04 ,.43 ,.04 ,.04 ,.0* ,.0* ,.0* ,.03 ,.03 ,.33 ,.07 ,.07 ,.07 , 07
F)<&+( D()% @ 7* 7* 30 0 7* *5 7 5+, 55 50 +553 +553 -*7 3 3, 3 3
C*(<*& T()% T()%=$ L+' U&*, ,.-3 ,.-3 ,.-* ,.-* ,.- ,.- ,.-5 ,.- ,. ,. ,.- ,.- ,.- ,.- ,.,.- ,.- ,.-5 ,.-5 ,.- ,.- ,.-* ,.- ,.- ,.- ,. ,
.,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 ,5
A0'$ C+%=6&*+% U%*& @ 77 77 3* 0 , , 7, * 7 7+053 5 5* +53 +53 -7 3, 3, 3 3
T+&), @ 77 77 3* 0 , , 7, 4 7*4 43 7+,*0 3, 43 +53 +53 -7 3, 3, 3 3
U%*& P+'(
A(') 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73 73
E*6='%& D'<(*6&*+% D"J %&"EE! !DE"%ITE &O!CEJO" S D"J %&"EE! !DE"%ITE &O!CEJO" S
I%&$ K * * * * * *
O6$ K * * * * * *
I%&),,' @
D() F)<&+(
733 733 3 3 04 53 -4 -4 *, 43 3 3+3,, 3, 33 +*0, +*0, +, * 04 3 3 * * 0 0 0 -, -4 04 04 *, , 733 733 7 7
,.0,.0,.07 ,.07 ,.07 ,.07 ,.03 ,.*3 ,.03 ,.33 ,.03 ,.07 ,.03 ,.04 ,.43 ,.04 ,.04 ,.0* ,.0* ,.0* ,.03 ,.03 ,.33 ,.07 ,.07 ,.07 ,.07 ,.07 ,.07 ,.07 ,.07 ,.07 ,.03 ,.03 ,.*3 ,.*3 ,.33 ,.04 ,.05 ,.05 ,.03 ,.03
3-456!6"E6 7, 8P9" :O% "ev ,.doc
A0'$ C+%=6&*+%
F)<&+(
C*(<*& T()% T()%=$ L+' U&*,
D()% @ 7* 7* 30 0 7* *5 7 5+, 55 50 +553 +553 -*7 3 3, 3 3 ,* * * 43 0 33 00 -* -0 -0 7 7
,.-3 ,.-3 ,.-* ,.-* ,.- ,.- ,.-5 ,.- ,. ,. ,.- ,.- ,.- ,.- ,.,.- ,.- ,.-5 ,.-5 ,.- ,.- ,.-* ,.- ,.- ,.- ,. ,. ,. ,., ,., ,.- ,. ,.-* ,.-* ,.- ,.- ,.- ,.-5 ,.-5 ,.-5 ,. ,.
.,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5
T+&), @ 77 77 3* 0 , , 7, 4 7*4 43 7+,*0 3, 43 +53 +53 -7 3, 3, 3 3 , , 030 33 05 +5 - - , ,
77 77 3* 0 , , 7, * 7 7+053 5 5* +53 +53 -7 3, 3, 3 3 , , 4 0 33 05 -5 - - , ,
P;9E 4 O 73
U%*& P+'(
A(') E*6='%& D'<(*6&*+% 73 :"A!%E" &O!CEJO" S 73 :"A!%E" &O!CEJO" S 73-
U%*& @
!I: S !I: S !I: S7 !I: S5
I%&$ K
O6$ K
I%&),,' @
D() F)<&+(
0, 0, +7,* +7,* +7,* +7,* +7,* +7,* 70, *+,,, 70, *+,,, 70, *+,,, 70, *+,,,
,.07 ,.07 ,.07 ,.4* ,.4* ,.4* ,.4* ,.4* ,.4* ,.03 ,.03 ,.0 ,.03 ,.03 ,.0 ,.03 ,.03 ,.0 ,.03 ,.03 ,.0
F)<&+( D()% @ 7 7 --7 --7 --7 --7 --7 --7 77 +-*, 77 +-*, 77 +-*, 77 +-*,
C*(<*& T()% T()%=$ L+' U&*, ,.- ,.- ,.-* ,.- ,.- ,.- ,.- ,.- ,.- ,.-7 ,.-7 ,.- ,.-7 ,.-7 ,.- ,.-7 ,.-7 ,.- ,.-7 ,.-7 ,.-
.,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5
A0'$ C+%=6&*+% U%*& @ 7 7 -3 -3 -3 -3 -3 -3 0 77 +5, 0 77 +5, 0 77 +5, 0 77 +5,
T+&), @ 7 7 3 -3 -3 -3 -3 -3 -3 0 77 +5, 0 77 +5, 0 77 +5, 0 77 +5,
U%*& P+'(
A(') E*6='%& D'<(*6&*+% 73 :"A!%E" &O!CEJO" S 73 :"A!%E" &O!CEJO" S 73-
I%&$ K
!I: S !I: S !I: S7 !I: S5 !I: S3 !I: S3
3-456!6"E6 7, 8P9" :O% "ev ,.doc
O6$ K
I%&),,' @
D() F)<&+(
0, 0, +7,* +7,* +7,* +7,* +7,* +7,* 70, *+,,, 70, *+,,, 70, *+,,, 70, *+,,, 70, *+,,, 70, *+,,, 43 +0,,
,.07 ,.07 ,.07 ,.4* ,.4* ,.4* ,.4* ,.4* ,.4* ,.03 ,.03 ,.0 ,.03 ,.03 ,.0 ,.03 ,.03 ,.0 ,.03 ,.03 ,.0 ,.03 ,.03 ,.0 ,.03 ,.03 ,.0 ,.-3 ,.-3
A0'$ C+%=6&*+%
F)<&+( D()% @ 7 7 --7 --7 --7 --7 --7 --7 77 +-*, 77 +-*, 77 +-*, 77 +-*, 77 +-*, 77 +-*, 4 +4,
C*(<*& T()% T()%=$ L+' U&*, ,.- ,.- ,.-* ,.- ,.- ,.- ,.- ,.- ,.- ,.-7 ,.-7 ,.- ,.-7 ,.-7 ,.- ,.-7 ,.-7 ,.- ,.-7 ,.-7 ,.- ,.-7 ,.-7 ,.- ,.-7 ,.-7 ,.- ,.-4 ,.*
.,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,5 .,.,-
U%*& @ 7 7 -3 -3 -3 -3 -3 -3 0 77 +5, 0 77 +5, 0 77 +5, 0 77 +5, 0 77 +5, 0 77 +5, 43 +3
P;9E 0 O 73
T);,' C-3 C+=6)(* +% + ')( C+&
E*6='%& D'<(*6&*+%
%peciic Energy 'G=/t
Gear rate (per replacement re@.) 'g/'G=
g/t
Price F/'g
&ost F/ton
!P"R
%ec. &r#s=er MP ,,, :ert. 8P9" 6 .5 D ? .4 G (m)
,.*, .- .77
,.,7
7.4
5.,0*
,.,,7
7.0
.77*
0.0 ,.73 .*7
,.,,0 ,.,4 ,.,,7
*4.7 3.73.5
.77* 5.,0* .77*
,.,3* ,.*, ,.,45 $39
SABC
%A9 Mill 6 .-m D ? *.4m L ( 5, ? t Pebble &r#s=er MP ,,,
,.34 ,.,5 ,.,07
T+&), @ 7 7 3 -3 -3 -3 -3 -3 -3 0 77 +5, 0 77 +5, 0 77 +5, 0 77 +5, 0 77 +5, 0 77 +5, 43 +3 125959
T);,' C-3 C+=6)(* +% + ')( C+&
E*6='%& D'<(*6&*+%
%peciic Energy 'G=/t
Gear rate (per replacement re@.) 'g/'G=
g/t
Price F/'g
&ost F/ton
!P"R
%ec. &r#s=er MP ,,, :ert. 8P9" 6 .5 D ? .4 G (m)
,.*, .- .77
,.,7
7.4
5.,0*
,.,,7
7.0
.77*
0.0 ,.73 .*7
,.,,0 ,.,4 ,.,,7
*4.7 3.73.5
.77* 5.,0* .77*
,.,3* ,.*, ,.,45 $39
SABC
%A9 Mill 6 .-m D ? *.4m L ( 5, ? t Pebble &r#s=er MP ,,,
,.34 ,.,5 ,.,07 $284
"(*%*%> M'*) C+%=6&*+%
E*6='%& D'<(*6&*+%
%peciic Energy 'G=/t
Gear rate 'g/'G= g/t
Price F/'g
&ost F/ton
!P"R
.77
,.,4,
4-.4
,.-3
,.437 $753
0.0 .*7
,.,53 ,.,4,
7-0.3 00.,
.,.-3
,.53, ,.071$29
SABC
%A9 Mill 6 .-m D ? 4.55m L ( 5, ? 5.5
:=e 8P9" based ear cost o ,.* E#ro/tonne as s#pplied by t=e vendor based on testor' cond#cted and proprietary scale6#p actors calling or a roll lie o *.,,, =o#rs. :=is as adj#sted or an estimated ear lie o 3+7,, =o#rs+ per benc=mar'ing o &erro Cerde1s operations and acco#nting or roll speed and eed moist#re dierentials All ot=er liner ear rates are based on replacement re@#ency benc=mar's. :=e empirical
3-456!6"E67, 8P9" :O% "ev ,.doc
P 9E -- O
T);,' C-4 C+=6)(* +% + O6'()&*%> )% M)*%&'%)%<' S66,*' C+& Estimated ann#al maintenance spares and s#pplies cost (FM) &APEH e?cl. Eart=or's+ &ivil and Installation costs o e@#ipment &APEH e@#ivalent (F/t)
0.3 415$2 ,.,53 $32
*.417$ ,.,*3 $487
:able &65 s#mmariBes t=e calc#lation o t=e estimated ann#al s#pplies and spares costs. :=e &APEH applicable to t=e commin#tion section+ e?cl#ding non6earable civil elements (concrete+ eart=moving and constr#ction) ere obtained rom :able <6 or t=e %A96based circ#it. or t=e 8P9"6based circ#it+ t=e val#e obtained rom t=e % is based on applying a irst6principles approac= to t=e derivation o t=e ann#al b#dget or maintenance spares and materials.
T);,' C-5 C+=6)(* +% + E&*=)&' L);+( C+&
A(') Operations : Operator (9rinding/8P9")
B( 4'%'4 ),)( 6'( '=6,+''
Operator (%ec. &r#s=ing R %creening) 8elper 6 Operations Operator (Get %creens R &onveyors) Maintenance
SABC-B <*(<*& E=6,+''
!P"R <*(<*&
C+& /&+% K /& E=6,+''
57+7 57+7 7+303 57+7
5 , 0 ,
47+00 , *,+*44 ,
,.,,7, ,.,,,, ,.,,53 ,.,,,,
5 5 5
03+*3 54+5 54+5 54+5 7+303 54+5
.77 7.77 *.*4 5.*4
03+*3 54+5 ,+*5*7+0 4+7 +--
,.,,3 ,.,,,0 ,.,,,.,,,.,,70 ,.,,70
.77 .77 7 5 , 4
7+3,+4*3
,.,3*7
57+55* 3+,5+*47
,.,,,0 $973
C+& /)%%=
C+& /&+% /&
47+00 47+00 7-+,* 47+00
,.,,7, ,.,,7, ,.,,*0 ,.,,7,
5+37 *7+0 5+*7 +70+,0 73+054 77+-50
,.,,, ,.,, ,.,,3 ,.,-4 ,.,,3* ,.,,34
7+*4*+-4*
,.,*74
*3+**+4*0+34
,.,, $1172
:
Maintenance Planner Maintenance :ec=nician Instr#mentation :ec=nician Millrig=t/Gelder/
C+& /)%%=
:
8elpers6Metall#rgy
7+303
.77 :otal
!otes2 •
•
•
It as ass#med t=at t=e maintenance and metall#rgy cres assigned to t=e grinding area o#ld be appro?imately one t=ird o t=e total plant strengt=. Additional metall#rgical =elpers are b#dgeted or t=e 8P9" as t=e or'load is e?pected to increase disproportionately it= t=e additional belt c#ts and grading analysis re@#ired or t=e additional conveyors and screens. &ontractors costs ere estimated in detail or t=e base case ,,- easibility %t#dy and is estimated at F7.*0 M/a. :=e e@#ivalent ig#re or t=e %A<& circ#it+ at t=e ,,- Preeasibility level+ as F7.3 M/a.
3-456!6"E67, 8P9" :O% "ev ,.doc
P 9E 7,7, O
APPENDI D DRAI N"S SA"-B)' O6&*+% P(+<' F,+ D*)>()=
3-456!6"E67, 8P9" :O% "ev ,.doc
P 9E 77 O
APPENDI E CALCULATIONS E -1$ SA" P+'( )% S*' C),<,)&*+% %A9 &irc#it 8P9" &irc#it :otal %peciic Poer or &ommin#tion P% P% Ore :onnage % pdated Ore :onnage P% operating % Operating :otal Poer or &ommin#tion P%
'/t
tpd (&alendar) tpd (&alendar) t/op =r
'=/d
'G=/op =r :otal Poer or &ommin#tion %
'=/d
'G=/op =r Dierence
8P9" circ#it et screen c#t siBe 8P9" circ#it &L
-.503 3,+,,, *,+,,, 4+5* -, - 7+,7+7 7-+5-4 7+35+0-3 3-+*5 4
mm
B),, M*,, Mill Diameter Mill Lengt= %peciic Poer P% Micr6crac'ing &redit P% Particle %iBe ines &redit P% Micr6crac'ing &redit % Particle %iBe ines &redit % Drive :rain Eiciency (9irt= gear to pinion)
m m 'G/t
4.7.5 .- .*, , ,.-43
7.3 3,,,, *,+,,, 4+5* -, - +,-+*35 -7+-*3 +745+74,4+0-5 4 , .33
&omments
50 ,, ,,
50 50
4.7.5 -.040 3 .*, 3.,, ,.,, ,.-43
,, ,, 5 ,3 ,3 ,,
6., .5 7.0 7+0,, 3.3+-7, 3, 3, . *.-5 *.-5
-- , *0
.3 loss or girt= gear to pinion drive system losses.
Poer Di or 0, P% Poer Di or 0, % 0, P% 0, % P0, P% P0, % %peciic Poer %
mm microns mm microns microns microns 'G/t 'G=/tonne 'G=/tonne
*.-5 *.-5
'G/t 'G/t 'G/t 'G=/d 'G=/op =r 'G/d 'G=/op =r 'G/mill 'G=/t eac=
7.4* . .57 +*57+,,* 4*+,*3 +,,+,33 -+500 3+50 .* *
3-456!6"E67, 8P9" :O% "ev ,.doc
*.5, *+5,, -.0 -+0, 3, 3,
7.45 .*7 .77 +574+35 **+35, +07+,- 0+3 7+*0* .7 * *
*3 , mm c#t siBe at et screen or 8P9"
, ,, ,,
P 9E 77 O
%A9 &irc#it 8P9" &irc#it %A9 &irc#it Poer or %A9 &irc#it
'G=/d
+3,5+05,
"atio o poer %A92Pebble &r#s=er P% Percentage o !et Poer or Pebble &r#s=er
0.74 .3
Percentage o Poer or Pebble &r#s=er % !et poer or pebble cr#s=er %
'G=/d eac= 'G 'G
.3 74+0,4 +4 5 50 *0
'G=/t 'G=/d
,.5 +5,+7
'G=/op =r
*7+047 7 -+300 +- 0.0
'G=/op =r !#mber o pebble cr#s=ers % !et poer per pebble cr#s=er % 9ross pebble cr#s=er poer % !et Pebble &r#s=er Poer &ons#mption Poer or %A9 Mill % :otal %A9 poer demand !#mber o %A9 Mills % Poer per %A9 Mill %
#nits 'G
'G=/op =r 'G=/t
"atio o %A9 Mill Poer !e vs. P%
N' M*,, D*)='&'( N' M*,, L'%>&.
3-456!6"E67, 8P9" :O% "ev ,.doc
&omments
consider 3, 'G o no load as gross+ 0 drive losses or cr#s=er+ .3 or %A9
incl#de no6load poer and drive losses o 0 . ta'ing credit or net cr#s=ing poer at .3 'G %A9/'G cr#s=er
0+33 =p -.5
installed motor 'G=/t it= pebble cr#s=er poer converted to %A9 e@#ivalent
.
= & = &
12$19 4$ 7$32 24$2
,3
Limit Ma?im#m Diameter to 5, t ma?im#m.
,-
P;9E 77 O 73
E -2$ F*%)%<*), A%),*
3-456!6"E67, 8P9" :O% "ev ,.doc
P;9E 75 O 73
