Mineral Processing
Mineral Processing
Mineral Processing
8 July 2010
Materials
Mineral Processing 101: Base And Precious Metals
Materials | Metals & Mining | Australia
Event:
In this note we outline the common processing methods relevant to the stocks in our coverage. This primarily includes gold, copper, zinc, nickel and platinum group elements (PGE).
Investment View:
The ability to recognise value in a project ahead of the market presents a significant value opportunity for investors. A better understanding of the likely processing method and costs can offer the potential to form a measured opinion of a project while other participants are waiting for feasibility study results. We do not suggest that the data presented herein is definitive, however it may be approximated with a level of accuracy commensurate with a scoping study (+/- 30%). An understanding of the potential throughput rate and process required for extraction of the economic minerals at an early stage can allow early estimates of capital and operating costs. These assumptions can help assign some initial estimates to the likely value of a project (at least to orders of magnitude) and therefore its significance to the market. Different ore types will have different in-situ values and hence the economics of the scale of mining and processing is the deciding factor in assessing feasibility.
All figures in A$ unless otherwise advised Important disclosures and the Reg AC Certification appear at the back of this report
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8 July 2010
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Grinding Crushed material is fed into one or more mills, which further reduce the size of the particles, in order to liberate individual particles or ore minerals. There are several types of mill, with the primary design being a rotating cylinder which reduces particle size through the impact of the rock against either other rocks, or against grinding media (steel balls or rods). The action of the rock being lifted up and then falling back (much like a cement mixer), imparts energy onto the rock which reduces its size through abrasion and impact. Usually a grinding medium is added, such as steel balls, which assist the process. Most mills would be used to reduce the size of particles to <<1mm. Mills are generally lined with steel or rubber liners, which periodically need replacing. For example, the SAG mill at Prominent Hill (OZL) requires a reline approximately quarterly, and this can take up to 144 hours (depending on size). In the same plant, the ball mill only requires a reline annually, and this can take up to 70 hours. These planned maintenance events will affect production and need to be allowed for. Often a regrind is introduced after milling those particles that have not been fully reduced in size to that required for post-processing. It is also important to note that a significant amount of energy is required for both crushing and grinding and, as a result, material should only be ground small enough to liberate the particles of interest. Over-grinding can result in "sliming" which adversely affects metal recovery. There is clearly a trade-off between finer grinding (which generally increases recovery) and increased energy costs. Most companies would undergo this optimisation process once plant commissioning is complete. Common mills amongst our companies include: SAG Mill: Semi-Autogenous Grinding (SAG) mills primarily rely on the rock itself as the primary agent of abrasion (but can have supplemental grinding media added for assistance). As a result, SAG mills are generally much larger in diameter (to allow a larger fall from the top of the rotation) and shorter in length than a ball mill. SAG mills can replace secondary and tertiary crushers, and can typically handle feed material up to 15cm in diameter. The addition of grinding media assists in increasing the throughput. Ball Mill: Generally cylindrical or conical in shape and charged with steel balls as the grinding media. As a general rule, the diameter and length of both ball and SAG mills control the throughput and the length influences the grind size. As a comparison, ball and SAG mills generally achieve the same outcome (although ball mills have the ability to grind finer), however SAG mills are generally less efficient, but require less ongoing maintenance, and consume less grinding media. As a reference point, PNA uses its ball mills to achieve a P80 of approximately 100-110m. The finer the material entering the mill, the smaller the diameter of the grinding media which is added. ISA Mill: These mills are of a similar shape to a ball mill, except they are approximately 1/2 the size and are used for ultra-fine grinding (down to ~10m). The Isa mills also use a grinding medium, which can be ceramic balls (similar to bean bag beans) and are assisted by a series of rotating discs within the mill. This technology was developed by Mount Isa Mines in the 1990s in order to treat the fine zinc ore from Macarthur River and is now used around the world. It is now commonly used to optimise the recovery of ores, (for example at Prominent Hill and Phu Kham), by grinding the material that has passed through the initial flotation stages prior to cleaning and scavenging (see below).
It is also important to note that crushing and grinding often represent the largest cost component of processing plants (particularly for base metals). This is primarily due to the consumables, maintenance (this is a high-wear activity) and power. To highlight this, we note the difference between the cost component of EQN and PNA, which have access to hydroelectric power, compared to AQP and PLA, which have coal-fired power.
Base Metals
Sulphide Ore With some exceptions, the majority of ore sourced for any particular project is primary - that is, the rock is fresh and as a result the common ore minerals are sulphides. Taking this into account, most projects will construct a plant that is designed to treat sulphide material. However, the initial stages of many mines (particularly open pits) will produce oxidised material, (usually termed weathered, or "oxide zone") grading to transitional ores, and then
8 July 2010
Materials
primary (sulphide) ore at greater depth, and, as such, the plant must be able to treat this material also, albeit to less than optimal parameters. The processing fundamentals for most base metal sulphides are very similar. Once the ore is ground to a sufficient size to liberate the ore minerals (e.g. individual chalcopyrite or sphalerite grains) it is subject to flotation, thickened and filtered to produce a concentrate which is shipped to a smelter. For the purpose of this document we will discuss the production of a concentrate, given that this is the most common end-process for the companies in our coverage. A generic flow sheet for a flotation circuit is shown below:
Source: OZ Minerals
Flotation is the process whereby fine ore and water are agitated in large tanks, while air is blown through the agitators (from the bottom up) and reagents are added. The most important of these reagents is a "collector". One end of the collector molecule has an affinity for the ore mineral, and therefore sticks to it; the other end repels water, and therefore adheres to the air bubbles rising through the tank. These air bubbles form a froth at the top of the tank which overflows into a launder and which can be thickened and dewatered to form a concentrate. Most plants will contain a combination of rougher, cleaner and scavenger flotation cells, which operate using the same chemical processes. These different methods use different scale throughput and reagent consumption rates. One set of operating parameters will be insufficient to optimise recovery of ore, so using a combination of these three cells allows a first-pass to float the bulk of the concentrate (rougher), and then sequentially more selective circuits to extract the remainder, or clean the material claimed from the rougher. Each plant will have an optimum operating condition, which trades off throughput with recovery. There are generally relationships between the size of the particles in the slurry which is fed into the flotation cells and the speed at which the minerals will float and, therefore, the required residence time in the cell required to achieve separation. Some minerals will also float preferentially to others, which can complicate the circuit when the ore is polymetallic. In some copper process circuits, the gold is contained within the copper minerals, and rather than including an additional circuit to extract gold on-site, many companies sell a copper concentrate and are then paid a credit by the smelter/refiner for the gold contained. Once the slurry has been recovered from the flotation cells it is dewatered, usually through the use of a thickener tank, and then a filter press which, simplistically, removes the water from the fines to produce a concentrate. The moisture level of the concentrate is generally in the order of 8-12% and is optimised as transport to the smelters is charged by weight with the moisture content deducted from the total. We would also note that treatment and refining charges (TC/RCs) for those companies shipping their concentrate to a smelter would generally be of similar order to those costs incurred on-site.
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Materials
A table outlining common base metal ore minerals, and their actual metal endowment, is included below:
Sulphide Mineral Native Copper Chalcopyrite Bornite Chalcocite Covellite Galena Sphalerite Pentlandite
Source: Webmineral.com
Metal Cu Cu Cu Cu Cu Pb Zn Ni
Metal Abundance in Mineral 100% 35% 63% 80% 66% 87% 43% 34%
Finally, a critical element of any processing is the concept of recovery. For not only sulphide flotation, but all processing methods, the recovery is a variable which has a significant impact on the economics of a project. There will be a component of any ore which cannot physically be recovered, and there will also be a further component which can be won, but will come at the expense of incremental increases in power consumption and reagent usage which render it uneconomic. As a result, all processing will be optimised to manage this trade-off between recovery and throughput. Lateritic Ore (Nickel) Lateritic ore is different to primary rock in that the minerals have been oxidised or partially oxidised as a result of their proximity to the surface and therefore atmospheric elements. A common feature of lateritic ores is that they generally contain cobalt as a by-product. The weathered nature of lateritic ore translates into shallow, sparse ore bodies that facilitate open pit mining (and, as a result, mining costs makes up a smaller portion of the total unit cost). The treatment of lateritic ore is not as straightforward as flotation and, as a result, there are varying examples of success. The lateritic nickel deposits in Western Australia (Murrin Murrin, Cawse and Bulong) were initially plagued by processing difficulties, however similar processes in Cuba (Moa Bay) and at Coral Bay in the Philippines have worked well. Unlike common sulphide flotation, there does not appear to be a standardised approach to the treatment of lateritic nickel ores, which adds some level of technical risk in the transition from bench/lab to full scale. High pressure acid leach (HPAL) involves acid leaching at high temperatures using sulphuric acid in a high temperature and pressure autoclave to dissolve the nickel and cobalt. The autoclaves use a mixture of ore slurry and sulphuric acid at 280C under ~5,400 kilopascals of pressure. Following this, for example, Murrin Murrin (MRE) precipitates the metals as sulphides, redissolves them with oxygen under pressure and finally separates with solvent extraction and hydrogen reduction. The final product is produced after an electro-winning process to give very high grade nickel briquettes. HPAL processing is employed for two types of nickel laterite ores. a. b. Ores with a limonitic character such as Goro, where nickel is bound in goethite and asbolite. Ores where nickel is bound within clay or secondary silicate substrates in the ores (such as Murrin Murrin).
The advantages of HPAL plants are that they are not as selective toward the type of ore minerals, grades and nature of mineralisation. The disadvantage is the energy required to heat the ore material and acid, and the wear and tear hot acid causes upon plant and equipment. Higher energy costs demand higher ore grades. The process, by nature, leads to higher capital costs (due to plant complexity and the requirement for bespoke plant designs) and higher operating costs due to the high pressures and temperatures leading to greater wear rates on components. An additional processing method which deserves mention is on-site smelting. Some nickel laterites are amenable to on-site smelting, as an alternative to HPAL. In these instances, ore is fed directly to a smelter at the mine, along with a reductant and flux, in order to produce a ferro-nickel alloy. This material is generally shipped directly to third-parties for use in the production of stainless steel. An example of this processing stream is Cerro Matoso (BHPBilliton).
8 July 2010
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8 July 2010
Materials
that typically the water that is recovered from tailings dams for re-use is of drinking water quality. Refractory Gold Some gold can be contained within the chemical structure of other minerals (typically arsenopyrite or pyrite), and this material is said to be refractory and is not suitable for recovery using simple cyanide-leaching processes, unless very low levels of recovery are acceptable, typically ~50%. For these ore types, additional processes must be undertaken prior to recovery of the gold using the methods mentioned above. These methods include: Roasting is an older technology in which the sulphide in the host mineral is physically burnt off using the equivalent of a sinter plant. The arsenic and iron sulphides will be decomposed at high temperatures to produce elemental arsenic and sulphur vapour that react with the oxygen present in air and are released as gas. Bio-oxidation relies upon bacteria to break down the sulphide mineral matrix in the ore being treated. The bacteria attach themselves to the metal sulphide surfaces in the ore, resulting in the accelerated oxidation of the sulphides. Goldfields has patented a particular method of bacterial leaching called BIOX. Sino Gold used this process at its operation, Jinfeng, in China. Pressure Leach (such as Lihir Island), is a process that removes sulphur in an autoclave at high pressures and temperatures. Ultrafine grinding - such as the ISA mills mentioned above. This method is not always appropriate as the gold may be too fine to grind sufficiently small to liberate the individual particles.
The ore is generally processed using the sulphide flotation method outlined above to derive a concentrate. For the companies under our coverage (AQP and PLA) this concentrate is sold to third-parties who smelt and refine the concentrate into its constituent parts for sale. It is also worth pointing out that the concentrate produced on site by both of our PGE stocks (AQP and PLA) contains economic quantities of both copper and nickel, which are generally removed at the smelting stage, with the companies receiving a credit for these metals. In the case of AQP, given the particular nature of the ore it is mining (primarily sourced from the UG2 reef in the Bushveld), the chromite levels are sufficient to warrant pre-treatment (before sale) in order to ensure the chromite content of the product is sufficiently below certain values to avoid any penalty rates. This is due to differing metallurgical properties of chromite, which can otherwise hinder the smelting process. As an example, we have included a table below which highlights some average feed grades of 4E ore produced by both AQP and PLA (our PGE stocks) and their individual components. From a cost perspective, with the exception of the chromite pre-treatment, treatment costs
8 July 2010
Materials
would be comparable to those outlined above for similar plant types (eg crush, grind, flotation and dewatering).
Company AQP PLA
1 2
4E Metal
koz
Pt 59% 44%
Au 0.5% 1%
103 8.3
Source: Company data; GSJBW research estimates Mar Q 2010, 100% basis Mar Q 2010
Gold
Company PNA MDL MDL
1 2 3
Type
Expansion
Source: GSJBW Research estimates plant only whole project - includes power station and pre-strip - assume US$100-150 for plant excludes gyratory crusher
Base Metals
Copper
Company OZL PNA EQN CGG
` nameplate ^ approximate - may include additional infrastructure such as roads, workshops, TSF etc
Throughput`
mtpa
Capital Cost^
US$m
Operating Cost^
US$/t
8 12 20 3
Nickel
Company WSA IGO MRE
` nameplate ^ approximate
Current Throughput^
ktpa
Capital Cost
US$m
Operating Cost^
A$/t
250
(toll treatment)
~2900
32 >1000^
8 July 2010
Materials
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Earnings Momentum:
Catalysts: Price:Base Case DCF: For Insurers EVA Trend: 1 Balance Sheet:
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