LUANSHYA, AKATITI DAM TAILINGS LEACH PROJECT

INTRODUCTION: Akatiti dam was the second tailings dam in Luanshya to be built. It was constructed when: The feed grade of the ore from the mine was very high, and The processing in the plant was not efficient. Because of these two factors, the grade of copper in the dam is extremely high, equivalent to ore grade in many countries. Because of the age of the copper minerals in the dam, they are heavily oxidised, and amenable to leaching and solvent extraction. It is recommended that 12 auger samples be taken diagonally from the four corners of the dam to: Establish the grade of the copper, and the acid soluble content of the tailings. The thickness of the tailings, for tonnage estimation purposes. and Establish the price to pay ZCCM-IH for the dam. They will want to charge based on total copper content, the investor will only pay for recoverable copper acid soluble copper, content. The financial plan was based on memory, as the author was in charge of rehabilitating this dam from 1989 to 1992. The financial model, attached, shows a very lucrative. Using conservative figures, a profit of $10-$12m per year is anticipated. A capital expenditure of $10m is required. Treatment rate is estimated at about 4,500 tonnes per day. The infrastructure in the area is excellent with roads and housing nearby. There are two independent power lines bordering the property, to the East and South. The Chonga dam is less than 5 kilometres away, this dam will be used to take the tailings effluent. PROCESSING: It is proposed to slurry the tailings using hydraulic monitors and pump the tailings to Leaching tanks. Leaching will be carried out using sulphuric acid, most of which will be generated from within the system. Leached tailings will be thickened and washed by counter current decantation before discarding of the residue in Chonga dam. Pregnant leach solution (PLS) will be fed to extraction mixer-settlers where the copper laden PLS will be contacted with solvent extraction reagents to make a loaded organic (Figures 1 and 2).

Figure 1: Diagrammatic representation of the solvent extraction process

Figure 2: Solvent

extraction reagent

The loaded organic will then be fed to the strip-mixer settler in which the copper will be extracted with spent electrolyte coming from the electrowinning section to make a strong electrolyte (Figure 3).

Figure 3: Block diagram showing the solvent extraction process

The raffinate generated is used to leach new copper. This might need topping up with fresh acid; the amount of acid needed is controlled by the gangue acid consumption of the tailings. In this case, it is not expected to exceed 40gt-1. That strong electrolyte (advance electrolyte) will be fed to the electrolytic tankhouse where a DC current will be used to plate to copper onto stainless steel cathodes (Figure 4 and 5).

Figure 4: DC rectiformer

The whole process from leaching to harvesting plated copper is expected to take 28 days.

Figure 5: Electrolytic tankhouse showing busbar, anodes and cathodes There is a plethora of such processing skill within Zambia, as at least four plants are using this technology within the country. Luanshya is one of the more attractive towns in Zambia and many workers will cherish the opportunity to live and work there. The property will be located only 25 kms from Ndola, the export hub. The limited access to the property will enhance security.

Figure 6: Harvested copper cathodes, ready for sale

Sulphuric acid will constitute a major cost component; since it is made as a by-product from copper smelting, astute negotiations can secure it at a bargain price. The feasibility study was done using world market price. CAPITAL BUDGET:
Leaching/Solvent Extraction Electrowinning Purchasing the Dam Environmental licence Construction Chemicals Ponds construction and lining Acid Contingency TOTAL $800,000 $1,200,000 $6,000,000 $100,000 $500,000 $850,000 $475,000 $115,000 $150,000 $10,190,000

OPERATING COST:
Assuming a 15-year life of the project TNS TAILS 23,595,000 0.45 106,178 60 63,707 6,500 3,694 $414,092,250 $235,360,125 $178,732,125 $11,915,475 0.9

AS Cu GRADE TNS Cu CONTAINED PLANT RECOVERY TNS COPPER RECOVERED COPPER PRICE ($/t) OPS COST ($/t) SALES EXPENSE PROFIT Profit per year Payback period (years)

ORGANISATION STRUCTURE: The proposed organisation structure is shown below.

General Manager Metallurgical Manager Receptionist (1) HR Superintendent Process Superintendent General Foreman Maintanance Superintendent Sectional Engineer Maintenance Foreman Shift Foreman A Accountant Storekeeper Clerk (1) Issuer (1) Driver (1) Security Officer Guards (4) Payroll Clerk Clerk (1) Reclaim (4) Leaching (1) Solvent Extraction (2) Ponds/Utilities (2) CCD/Tailings (3) Electrowinning (1) Tails Dam (2) Reagents Mixing (2) Forklift Driver (1) Driver (1) Reclaim (4) Leaching (1) Solvent Extraction (2) Ponds/Utilities (2) CCD/Tailings (3) Electrowinning (1) Tails Dam (2) Reagents Mixing (2) Forklift Driver (1) Driver (1) Reclaim (4) Leaching (1) Solvent Extraction (2) Ponds/Utilities (2) CCD/Tailings (3) Electrowinning (1) Tails Dam (2) Reagents Mixing (2) Forklift Driver (1) Driver (1) Shift Foreman Swing Shift Foreman B Fitter Artisans (6) Helper (1) Driver (1) 1 1 1 3 2 Electrical Foreman Instrumentation Foreman Boilermaker Foreman 4 3 Electricians (2) Instrument Artisans (2) Boilermakers (2) 16 12 Helper (1) Helper (1) Helper (1) 14 6 8 9 3 6 6 3 3 TOTAL 101

RECOMMENDATIONS: It is recommended that the following be carried out: A full reconnaissance of the area is conducted to establish the possible location of the processing plant in relation to the power supply. The service of a person knowledgeable in the area and with the tailings dam should be sought 12 auger samples be taken across the dam to accurately assess the leachable copper content and the thickness of the deposit (Figure 7)
Old Dam

Proposed Plant

Sample Points

Reliable Power Line

Lake Success

AKATITI DAM

Less Reliable Power Line To Masaiti

Figure 7: Proposed sampling

The dam be accurately measured to establish its area A suitable local contractor is taken to the site to establish logistics of working in the area. It is hoped that by working round the clock, the construction can be completed in 12 months The proximity to Chonga dam be established to calculate the pumping requirements of tailings effluent A full sensitivity analysis be carried out using the attached spreadsheet to establish how lucrative the project is Negotiations be opened with second-hand equipment suppliers, like Manhattan in South Africa, to establish the availability of such equipment A consortium of financiers be approached to provide funding The possibility of purchasing Old Dam. This dam is richer, but is geotechnically unstable, as it was built in a swamp to combat blackwater fever when the mine started in the 1930s. Should it break and block the Fisansa stream, the environmental council will shut down the operation. However, there is a judicious way of mining the tailings without causing breakage Establishing the above, will improve on the accuracy of this management brief, which is currently only 20%

Figure 8: The ultimate objective of the proposed project Ramoutar (Ken) Seecharran Mining/Metallurgical Consultant