Test Report
TESTING
20705T1 Bozshakol Project Sales
24.06.2010
Customer:
Kazakhmys, Bozshakol Project
Contact Person(s):
Mr. Willie Coetzee, Mr. Kelvin Fiedler
Country:
Australia
Place:
Brisbane
Application:
1.1
Product of Test:
Copper concentrate
Case. No.:
20705
Case Manager:
Venkatesh Viswanathan
Test Case No.:
20705T1
Test Performed by:
Adam McFarland
Date of Test:
May 11-12, & June 3, 2010
Location of Test:
Outotec lab, Burlington, Canada
Test equipment:
Labox 100
Date of Test report:
May 12, 2010
1 / 11
CONTENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
GENERAL INFORMATION ....................................................................................................... 2 OBJECTIVE OF TESTS AND SELECTED TEST EQUIPMENT ............................................... 3 CUSTOMER PROCESS DATA AND SIMPLIFIED FLOWSHEET ............................................ 3 PRODUCTION DATA REQUIREMENTS .................................................................................. 4 DESCRIPTION OF FILTRATION PROCESS AND SIMPLIFIED FLOW SHEET ..................... 4 TEST – PRODUCT AND WASH LIQUID DATA........................................................................ 4 FILTRATION TEST DATA ......................................................................................................... 4 ANALYSIS OF SAMPLES ......................................................................................................... 5 EXPLANATION OF TESTS ....................................................................................................... 5 CONCLUSIONS AND RECOMMENDATIONS ......................................................................... 8
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1.
TEST CASE NO.:
20705T1
TESTING 7.2.12 2 / 11
GENERAL INFORMATION
Kazakhmys Copper has two major copper growth projects, Aktogay and Bozshakol. These have both successfully completed their pre-feasibility stage. Both projects showed economic value on conservative pricing assumptions, with significant net present value at Bozshakol. The pre-feasibility study was successfully completed for the Bozshakol sulphide ore deposit in April 2009. The study confirmed that Bozshakol is an economically viable project with net production costs expected to have an attractive position on the cost curve. The study also identified value engineering opportunities to reduce capital costs, and additional engineering was completed in the latter half of 2009 to confirm these opportunities and enhance the robustness of the project’s financial return. The Bozshakol deposit is substantial with a management estimated geological resource of 1,169 MT of ore and a copper grade of 0.36%, a gold grade of 0.21 g/t, a silver grade of 4.9 g/t and molybdenum and rhenium by-products. Based on current projections of production levels, the resource base supports a mine life of 40 years.
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TEST CASE NO.:
20705T1
TESTING 7.2.12 3 / 11
In January 2010, Kazakhmys commenced the feasibility study on the deposit which will continue during 2010 to confirm the project’s scope and execution strategy prior to moving to the development stage. Aker Solutions has been appointed as the study contractor and will develop the project in conjunction with the Kazakhmys Projects team. The feasibility study is expected to be completed in the fourth quarter of 2010 with the potential for construction to commence in 2011. The construction phase is estimated to be three to four years in duration. The ore will be mined by an open pit truck and shovel operation, with total extraction volumes at the deposit increasing to 60 MT per annum including stripping works. The Bozshakol processing plant is expected to be a conventional copper concentrator with an ultimate throughput rate of approximately 25 MT per annum. The feasibility study will consider the optimal sales options, which include the sale of concentrate to China or the sale of cathode after smelting internally. The development of the project will be funded by the loan facility negotiated with the China Development Bank and Samruk. From the loan facility, Kazakhmys has allocated up to $2 billion to fund the development of the project. Some items of large equipment are likely to be ordered towards the end of 2010. The total capital investment will be around $1.5 to $2 billion. The sample tested was a copper / molybdenum concentrateproduced from pilot lant testwork conducted by G&T Metallurgical Services Ltd, Kamloops, Canada. Filtration tests were performed at Outotec Canada Ltd.’s Burlington laboratory. The sample had previously been used for thickening tests by Outotec, at the same test location. Solids content of the “as received” slurry was increased by re-pulping one or two filter cakes (from Labox 100 unit) prior to test 1. Solids in slurry tested had a reportedly fine particle distribution (d80 30μm), tested cakes appeared quite dry, even at 11% moisture.
2.
OBJECTIVE OF TESTS AND SELECTED TEST EQUIPMENT
To determine: filter cloth selection cake thickness maximum filtration rate moisture content of the cake cake handling Based upon available quantity of slurry, a Labox 100 test unit was used to perform testing to simulate the operation of a Larox PF filter.
3.
CUSTOMER PROCESS DATA AND SIMPLIFIED FLOWSHEET
The Bozshakol processing plant is expected to be a conventional copper concentrator with an ultimate throughput rate of approximately 25 MT per annum. Customer process is a standard copper flotation/concentration plant, thickener underflow density of 65% used as filter feed. Concentrate will be shipped by rail from the mine, requiring afilter cake discharge moisture less than 9%wt to prevent the concentrate freezing in the rail cars.
TESTING
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4.
TEST CASE NO.:
7.2.12 4 / 11
20705T1
PRODUCTION DATA REQUIREMENTS
Solids quantity:
81,600 kg D.S./h
Filter cake: -
5.
Cake contains:
<9 wt%
DESCRIPTION OF FILTRATION PROCESS AND SIMPLIFIED FLOW SHEET
Filtration process is a standard short program dewatering. Slurry is pumped into the chamber, the diaphragm inflated to compress the cake and remove free moisture, followed by compressed air blown through the cake to remove additional liquid. Testing also investigated using hot water during the “hose wash” step of the filter cycle. During the operation of a production PF filter, water is used to flush/displace solids from the feed header/hoses, once the filter feed pumping step has been completed. If this water is hot (8090oC), this water will have a lower viscosity or surface tension than the water present in the filter cake. By displacing water in the cake with this lower viscosity hot water, the hot water will be easier to remove/displace in the diaphragm pressing and air drying stage, possibly resulting in a lower overall filter cake moisture.
6.
TEST – PRODUCT AND WASH LIQUID DATA
Kind of process/product Product : Slurry Temperature Density Solids content pH Solids phase Composition Liquid phase Composition
7.
Copper concentrate
: : : :
10-20 oC 1896 g/l ~65 wt% 10-11
:
copper concentrate
:
water
FILTRATION TEST DATA
Larox PF The following results are achieved with a chamber height of 60 mm by using Tamfelt 2106L1 filter cloth in cycle 10. -
Specific filtration rate Residual filter cake moisture Cake thickness Cake density Total cycle time Pumping time in test unit Hose washing Pressing II
508 9.6 43 2.55 11.5 1.5 1.0 1
kgDS/m2h % w/w mm kg/l min min min min
TESTING
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TEST CASE NO.: -
Air drying Technical time*
-
Pumping pressure Hose washing pressure Pressing pressure II Air drying pressure
7.2.12 5 / 11
20705T1 4 min 4 min 6 6 16 9
bar bar bar bar
*Technical Time is the time required for cloth wash, plate pack opening & closing, manifold flushing and sundry valve operations and varies with the size of the filter.
8.
ANALYSIS OF SAMPLES Samples were analyzed for moisture by drying in an oven overnight at 90oC.
9.
EXPLANATION OF TESTS
The Labox 100 filter has been designed to permit bench scale testing of Larox Pressure Filter (PF) technology and to mimic the characteristics of large scale pressure filters so that the full-scale filter size can be accurately calculated based on the test results. The filter is equipped with a 0.01m2 x 45 (or 60) mm filter chamber, comprised of a polypropylene chamber with diaphragm above and filter cloth and collection tray below. The diaphragm can be pressurized with compressed air to compress the cake and assist in dewatering the cake.
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TEST CASE NO.:
20705T1
TESTING 7.2.12 6 / 11
Test Procedure • • • • • •
Slurry is pumped into the chamber via the slurry pump, a loose filter cake will form on the filter cloth. After a sufficient volume of slurry has been pumped into the chamber, the slurry pump is shut off. The diaphragm is inflated up to its maximum pressure of 16 bar, compressing the cake and driving out free moisture. Compressed air is introduced into the filter via the same port as the feed slurry, pushing free moisture out of the cake. After sufficient drying with compressed air, all pressure is released from the chamber. The chamber is opened and the filter cake removed.
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TEST CASE NO.:
20705T1
TESTING 7.2.12 7 / 11
Testing began May 11 with available slurry previously used in thickener testing. This slurry did contain some residual flocculant content. Types and concentrations of active flocculant is unknown. Test 1 used the slurry in a baseline configuration, using a 45mm chamber and filter cloth 2106L1. Due to the high capacity requirements, testing used a minimum pumping time of 90 seconds. The material filtered easily, quickly forming a filter cake and pressing, requiring only 15 seconds to reach the G-point. The G-point is the point of most efficient use of the diaphragm for compressing the cake, where there is insufficient free moisture in the chamber to hydraulically transmit pressure back to the slurry manifold. The filter was then operated in a pressing overlap** mode for 15 seconds into the air drying process. Due to the ease of filtration observed in test #1, test #2 switched to a 60mm filtration chamber so that a higher specific filtration rate (kg/m2) additional cake could be built in the chamber and a greater filtration capacity per square meter (kg/m2.hr). Tests 2-5 were used to form a drying curve, using drying times of 1, 2, 3, and 4 minutes to determine the effect of drying duration on final cake moisture using a 60mm chamber. ** pressing over lap is when the pressing medium (compressed air in tests) is still kept extended into the air drying operation so that the cake movement within the chamber is avoided
TESTING
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TEST CASE NO.:
7.2.12 8 / 11
20705T1
Drying time v final moisture 16
Moisture (%wt)
14 12 10 8 6 4 2 0 0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
Drying time (min)
Test 6 used 2 minutes for pumping rather than 1.5 minutes. The lowest moisture reached by any test 2-6 being 10%wt. Prior to test 7-10, slurry was re-pulped, using dried solids from tests 1-6 and filtrate to reconstitute slurry to a density of 1.88kg/l (~64%wt). This was slightly higher than the previous slurry density of 1.80kg/l (~61%wt) and resulted in slightly thicker and heavier cakes. Test 7 repeated the conditions used in test 5, while test 8 repeated the conditions from test 6. These resulted in approximately a 9% increase in solids throughput capacity as compared to previous tests using lower density slurry. Tests 9 and 10 experimented with using hot water hose washing. These tests repeated the conditions of test 7, but used 30 second and 1 minute hot water hose wash respectively. Displacing some of the moisture in the cake with hot water via the hose wash should result in lower final cake moistures. Test 9 reached a final moisture content of 7.5%wt, while test 10 reached 9.6%wt. It is likely that test 9 is an outlier, especially given that the moisture content was lower with less hot water hose washing. On June 3, three additional tests were done, using the same feed slurry. In these tests, slurry was heated to the 37 to 40C range. Cycle times were similar to those used in the previous tests. In test 14, a short hot wash water step was performed. The lowest resulting moisture, 9.1%, was obtained in test 14. Generally speaking, the cake moistures from these three additional tests were not significantly better (lower) than the previous tests.
10.
CONCLUSIONS AND RECOMMENDATIONS
Larox Pressure Filters are well suited to dewatering the Bozshakol copper concentrate slurry. Moisture levels in one test reached below the <9%wt moisture target, but this reading may have been an outlier. Using hot water for hose washing reduced moisture levels in the cake by approximately 0.5%wt. Based upon test 10, filtration capacity was 508 kgD.S./m2hr, with moisture levels of 9.6%wt.
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TEST CASE NO.:
20705T1
TESTING 7.2.12 9 / 11
As was seen during tests, achieving an optimum thickener underflow density – of >65 % solids w/w – increases the cake loading factor and reduce the cycle time will in turn improve the filtration capacity. The cake moistures obtained during the tests will be very similar to the ones achieved for plant scale operation, with a similar feed characteristics & filter operating parameters and cycle times.
TESTING
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TEST CASE NO.: TEST FILTRATION DATASHEET
7.2.12 10 / 11
20705T1 TEST FILTRATION NO.
1
Vineyard no. DATE
11-May-10
CUSTOMER
Kazakhmys, Bozshakol
Labox 100
BY
Amc
INDUSTRY GROUP
1.1
PLACE
Outotec Burlington
TEST FILTER
0.01
m²
to
12-May-10
ENCL. NO. PAGE NO.
SUSPENSION DESCRIPTIOCopper Concentrate
WASH LIQUID DESCRIPTION
SUSPENSION DESCRIPTION
PARTICLE SIZE DISTRIBUTION d80 30um
TEST NO.
20705
1
2
3
4
5
6
7
8
1
9
THE TEST FILTRATION VERIFICATION CYCLE Process conditions Density of
5/12/10 slurry
kg/l
1.800
1.800
1.800
1.800
1.800
1.800
1.880
1.880
1.880
liquid in slurry
kg/l
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
S.G of solids in
slurry
kg/dm3
3.700
3.700
3.700
3.700
3.700
3.700
3.700
3.700
3.700
Solids in slurry
calculated
%w/w
60.9
60.9
60.9
60.9
60.9
60.9
64.1
64.1
64.1
Density of
wash liquid
kg/l
Temperature of
slurry
°C
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
wash liquid
°C
pH of
85.0
slurry wash liquid
Filtration parameters Duration of
pumping
min
1.5
1.5
1.5
1.5
1.5
2.0
1.5
2.0
1.5
pressing I
min
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
washing
min
pressing II
min
0.5
drying
min
1.0
1.0
2.0
3.0
4.0
4.0
4.0
4.0
technical time
min
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
min
7.5
7.5
8.5
9.50
10.5
11.0
10.5
11.0
11.0
Calculated cycle time
4.0
Measured process parameters during filtration tests Pressure of
slurry feed
bar
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
pressing I
bar
16.0
16.0
16.0
16.0
16.0
16.0
16.0
16.0
16.0
wash liquid
bar
pressing II
bar
Quantity of slurry
calculated
l
0.6
0.8
0.8
0.9
0.8
0.8
0.7
0.8
0.8
Quantity of filtrate during
pumping
l
0.200
0.180
0.180
0.200
0.195
0.225
0.145
0.185
0.150
pressing (I + II)
l
0.120
0.190
0.190
0.205
0.190
0.170
0.170
0.090
0.145
washing
l
air drying
l
0.062
0.065
0.070
0.121
0.080
0.090
0.083
0.093
0.121
0.382
0.435
0.44
0.526
0.465
0.485
0.398
0.368
0.416
low / 8
low / 9
low / 9.5
low / 9.5
low / 9.5
low / 9
high / 9
high / 9
low / 9
% w/w
11.8
14.3
11.1
10.2
10.2
10.0
10.3
10.8
7.5
mm
32.0
40.0
39.0
39.0
33.0
38.0
40.0
42.0
43.0
TOTAL
l
Consumption of
wash liquid
l
Air flow / air pressure
beginning
Temperature of
pH of
l/min / bar
at 1 min
l/min / bar
end
l/min / bar
filtrate
°C
wash filtrate
°C
0.050
0.05
filtrate wash filtrate
Process results Moisture in cake Cake thickness Wet cake weight Dry cake weight
kg
0.800
0.965
0.945
1.090
0.921
0.998
0.998
1.081
1.099
calculated
kg
0.706
0.827
0.840
0.979
0.827
0.898
0.895
0.964
1.017
Wet cake S.G
calculated
kg/dm3
2.501
2.412
2.423
2.795
2.792
2.625
2.494
2.573
2.555
Filtration rate (dry solids)
calculated
kg/m²h
565.0
661.4
592.9
618.2
472.6
489.9
511.5
525.9
554.6
Filtration rate (filtrate)
calculated
l/m²h
305.6
348.0
310.6
332.2
265.7
264.5
227.4
200.7
226.9
Wash liquid consumption
calculated
m³/ton D.S.
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Washing result Solids ratio in cake (vol/vol) calculated
%
59.7
55.9
58.2
67.8
67.7
63.9
60.5
62.0
63.9
Air in cake vs void volume
calculated
%
27.2
21.9
35.6
11.3
11.5
27.5
35.1
26.9
47.2
Solids content in
filtrate
mg/l
wash filtrate
mg/l
Filter cloth: Tamfelt
S-
Chamber thickness Chamber type F= Flat or C = Cup Remarks
2106 L1
2106 L1
2106 L1
2106 L1
2106 L1
2106 L1
2106 L1
2106 L1
2106 L1
mm
45
60
60
60
60
60
60
60
60
F or C
F
F
F
F
F
F
F
F
F
#1 G-point at 15 seconds, pressing overlap 15 seconds. #2-6 G-point at 50 seconds, Pressing overlap 15 seconds
#7 repulp tests 1-6, G-point at 15 sec, pressing overlap 30 sec. #8 air drying slow first 60 seconds, cake appears to have obstructed feed port. #9 hot (85C) hose wash, 30 sec pressing overlap
TESTING
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TEST CASE NO.: TEST FILTRATION DATASHEET
7.2.12 11 / 11
20705T1
TEST FILTRATION NO.
1
Vineyard no. PF
TEST FILTER
0.0
m²
DATE
11-May-10
CUSTOMER
Kazakhmys, Bozshakol
BY
Amc
INDUSTRY GROUP
1.1
PLACE
Outotec lab
to
WASH LIQUID DESCRIPTION
PARTICLE SIZE DISTRIBUTION d80 30um 10
11
12
ENCL. NO
0
PAGE NO.
2
0
SUSPENSION DESCRIPTIOCu Con SUSPENSION DESCRIPTIO0 TEST NO.
20705
12-May-10
13
14
15
16
17
18
0.0
0.0
0.0
0.0
4.0 4.0
4.0 4.0
4.0 4.0
4.0 4.0
0.0
0.0
0.0
0.0
0
0
0
0
THE TEST FILTRATION VERIFICATION CYCLE Process conditions Density of
3/6/10 slurry
kg/l
1.880
1.950
1.950
1.950
liquid in slurry
kg/l
1.000
1.000
1.000
1.000
3.700 64.1
3.700 66.8
3.700 66.8
3.700 66.8
37.0
40.0
40.0
S.G of solids in Solids in slurry
slurry calculated
kg/dm3 %w/w
Density of
wash liquid
kg/l
Temperature of
slurry
°C
15.0
wash liquid
°C
80.0
pumping
min
1.5
1.5
1.5
I pressing
min
1.0
1.0
1.0
I washing
min
1.0
pH of
0.0
78.0
slurry wash liquid
Filtration parameters Duration of
II pressing
min
drying technical time
min min min
Calculated cycle time
4.0 4.0 11.5
1.5 1.0 0.5
4.0 4.0
4.0 4.0 10.5
4.0 4.0 10.50
4.0 4.0 11.0
Measured process parameters during filtration tests Pressure of
slurry feed
bar
6.0
6.0
6.0
6.0
pressing I
bar
16.0
12.0
12.0
12.0
wash liquid I / II
bar
6.0
pressing III
bar
6.0
Quantity of slurry
calculated
l
0.8
0.8
0.6
0.7
Quantity of filtrate during
pumping
l
0.160
0.241
0.196
0.198
0.150
0.060
0.088
0.083
0.090
0.119
0.474
0.346
0.405
high / 9
high / 9
low / 7
high / 8
high / 7.5
low / 9
high / 8
high / 7
low / 9
pressing (I / II)
l
0.135
washing (I / II)
l
0.200
air drying
l
0.121
TOTAL
l
0.416
Consumption of
wash liquid (I / II)
l
Air flow / air pressure
beginning
l/min / bar
at 1 min
l/min / bar
end
l/min / bar
Temperature of
pH of
filtrate
°C
wash filtrate
°C
0.0
0
low / 8 low / 9
filtrate wash filtrate
Process results Moisture in cake
% w/w
Cake thickness
9.6
9.5
10.4
9.1
mm
43.0
40.0
35.0
38.0
Wet cake weight Dry cake weight
calculated
kg kg
1.077 0.973
0.000
1.100 0.996
0.907 0.812
0.993 0.902
0.000
0.000
0.000
0.000
Wet cake S.G
calculated
kg/dm3
2.504
0.000
2.751
2.590
2.612
0.000
0.000
0.000
0.000
Filtration rate (dry solids)
calculated
kg/m²h
507.7
0.0
569.0
464.2
492.0
0.0
0.0
0.0
0.0
Filtration rate (filtrate)
calculated
l/m²h
217.0
0.0
270.9
197.7
220.9
0.0
0.0
0.0
0.0
Wash liquid consumption
calculated
m³/ton D.S.
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Washing result Solids ratio in cake (vol/vol) calculated
%
61.2
0.0
67.3
62.7
64.1
0.0
0.0
0.0
0.0
Air in cake vs void volume
calculated
%
37.9
0.0
20.1
27.7
33.4
0.0
0.0
0.0
0.0
Solids content in
filtrate
mg/l
wash filtrate
mg/l
Filter cloth: Tamfelt
S-
Chamber thickness Chamber type F= Flat or C = Cup Remarks
2106 L1
2106 L1
2106 L1
2106 L1
mm
60
60
45
45
F or C
F
F
F
F
#10 G-point 10 seconds, pressing overlap 30 sec, hot (80C) hose wash 60 seconds.
#12 pressing overlap 30 seconds, air drying @2min 70ml, @3min 9ml, @4min 4ml. #13 30 sec pressing overlap, air drying @2min 78ml, @3 min 8ml, @4min 4ml #14 30 sec hot hose wash, pressing overlap 30seconds air drying @2min 104ml, @3min 10ml, @4min 5ml. Slowly increased air drying pressure from 5bar-9bar over 1m
