The BOLEO Copper

Project

September 2002
1
 BOLEO Copper Deposit
• Located in Baja California, Mexico

• Ore is complex, fine grained oxide,

sulphide and mixed oxide / sulphide
containing 40% clay

• Treatment is complex
2
 Project History
1997
• Project optioned by International Curator
Resources
• Fluor Daniel Wright conducted feasibility
study based on extensive testwork by
Lakefield, CMRI, Pocock and others
• Complex process with high capital and
operating costs
• Project put on hold

3
 Fluor 97 Base Case
Boleo Ore Ore Preparation Rejects Filtrate to Leach
Filtration and
- SAG Mill Washing
Wash Water

H2SO4 Air Concentrate SO2 to Leach

Oxidation Roasting
Leach

H2SO4 + SO2 + S Reduction H2SO4 + Water Calcine

Leach Leaching

High Acid
Consuming Ore Copper Cathode
Neutralization Copper SX/EW

H2S In-Pulp Sulfide Zinc Cathode

NaOH
Precipitation Zinc SX/EW

Floatation Tails
Floatation Reagents to Disposal NaOH Cobalt Cathode
Bulk Sulfide
Flotation Cobalt SX/EW

Waste Solution to Disposal 4

 Project History
2001 - 2002
• Project returned by Mintec International
Corporation
• Bateman asked to review 1997 study and
develop a simpler, conventional, process
• Conducted scoping study for simpler, less
expensive process, based on previous test
reports
• Proposal for full feasibility study with
additional testwork

5
 Geology and Mineralogy
• Boleo’s Cu-Co-Zn mineralisation occurs
in mantos with gradation in mineral
type and metal grade from a distinct
(barren conglomerate) footwall overlain
directly by high grade ore to a less
distinct gradational hanging wall.

6
 Mineralogy (Continued)
• 1955 US Geological Survey study of the
Boleo deposit provides an overview of the
complex and highly variable mineralogy of
the manto structures. Notable features
include;

7
 Mineralogy (Continued)
High clay content (up to 60%);
Saline in-situ water content of 20-25%;
Large variety of oxide mineralization,
including simple oxides, carbonates,
oxychlorides, silicates and mixed
(ferrite) oxides;
Sulfides, when present, of extremely fine
grain size.
8
 Process Implications
• Solid – Liquid Separations will be
Challenging due to Clayey Oretypes
• Process in Seawater (high chloride) due
to Salinity of Natural Ore
• Must Use a Variety of Chemistries to
Dissolve all Metal (Cu/Co/Zn) Minerals

9
 Design Objectives
• Keep it Simple
• Inexpensive
• Use proven process steps
• Maximum use of previous testwork data

10
 Design Basis
Annual ore throughput 4,025,000 t/a
11,500 t/d
Average ore grade
Cu (oxide and sulfide) 1.36 %
Co (oxide and sulfide) 0.089 %
Zn (oxide and sulfide) 0.62 %
MnO2 5.54 %

Copper production 47,000 t/a

Cobalt production 2,750 t/a
Zinc production 20,000 t/a
11
 Testwork Review
• Extensive testing done on all unit
operations for previous study
• Some results appeared to have been
overlooked (thickening) and have been
revisited
• Conclusion
– Testwork data would form good basis for
development of new process

12
 Process Options Review
• Seven process options considered and
assessed according to
– Technical viability (proven vs. novel)
– Perceived capital and operating costs
– Operability
• One option chosen as base case for
scoping study

13
 Major Process Changes
• Removal of sulphide flotation and
roasting operations
• Addition of CCD circuit for solid-liquid
separation to allow base metal recovery
from SOLUTION, NOT SLURRY
• Based on high rate thickening test
results from previous work

14
 Thickening Testwork Review
• Tests done by Pocock Industrial Inc on leach residues
• Initial tests indicated settling rates of up to 2 m2/t/day.
These high figures preclude efficient use of CCD circuit –
hence flotation-roasting option considered previously.
• Two high-rate thickening tests at end of test campaign
showed settling rates of 0.1 m2/t/day. These results
appear to have been overlooked in previous study.
• Results reviewed by Bateman and Delkor
• Decision taken to proceed on basis that high-rate
thickening test results are indicative of full-scale
operation.
• Follows Bateman experience on similar clayey ores (eg.
Bulong)
15
 Process - Basic
Acid SO2 Water

Tailings
OXIDISING REDUCING
MILL CCD
LEACH LEACH

Leach H2S
Residue

SULPHIDE SULPHIDE Cu
Oxygen
LEACH PRECIP SX / EW

Tailings Copper

Zn Co
SX / EW SX / EW

Zinc Cobalt
16
 Process - Detail
Limestone
NEUT
Ore

Acid
OX Zinc NaOH
Cathode
Zn EW Zn SX 1 Zn SX 2
LEACH

NaOH

SO2 RED Cu / Cd Zn Dust Cu / Zn

Co SX
LEACH CEMENT IX

HAC Limestone
Fe
NEUT 1 Co EW
Air REMOVAL Air

Cobalt
Water SULPHIDE SULPHIDE Cathode
CCD Cu SX NEUT 3
PRECIP LEACH

HAC H2S O2
HAC
Lime
Copper
NEUT 2 Cu EW Cathode
Air

Decant Tailings
TAILINGS

17
 Process
Crushing & Milling

• Primary jaw crusher

• Scrubber for clay removal
• Single stage ball mill for scrubber
oversize
• Cyclone classification
• 40% w/w solids @ P80 = 200 µm

18
 Process
Leaching

• Two stage leach maximises recoveries

• Oxidising leach
– Majority of copper and some zinc leached
– High acid consumption due to gangue
• Reducing leach
– Metal values associated with manganese
dioxide (mainly cobalt) leached
– Reducing conditions maintained with SO2

19
 Leach Chemistry
• Oxidizing Leach Using Natural MnO2 in ore

MS + MnO2 + 2H2SO4 = MSO4 + MnSO4 + 2H2O + S

where M = Cu, Co, Zn

• Reducing Leach Using Sulfur Dioxide Addition

MnO2 + SO2 = MnSO4

cobalt in Mn-Oxide is leached
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 Ore Characterization Tests
(From Fluor Study)
Bed No. of Sulfide Carbonate Net MnO2
Number Intervals (%) (%) (%)

2 27 0.09 7.06 9.8

3AA 9 0.28 2.15 8.1

3A 78 0.82 4.49 7.9

3 147 0.24 3.40 5.9

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 Process
Leaching

• Overall Leach recoveries

– Copper 91%
– Cobalt 87%
– Zinc 73%
– Manganese 97%
• Acid consumption ~180 kg/t ore
• SO2 consumption ~ 25 kg/t ore

22
 Process
Stage 1 Neutralisation

• Partial neutralisation with high acid

consuming ore (HAC)
• Product solution is amenable to Cu
SX/EW
• Two functions:
– Raise pH after leaching
– Oxidise Cu1+ to Cu2+ (air sparging)

23
 Neutralization Chemistry
• High Acid Consuming Ore is Available at
Site and Contains Ca/Mg Carbonates

H2SO4 + CaCO3 → CaSO4 + H2O + CO2

H2SO4 + MgCO3 → MgSO4 + H2O + CO2

24
 Process
CCD

• Six large thickeners

• Washing with discharge solution from
sulphide precipitation (free of copper,
cobalt and zinc), plus sea water make-
up
• 97% washing efficiency

25
 Process
Stage 2 Neutralisation

• Tailings neutralisation with HAC and

lime
• Neutralisation to pH 5 to 6 for soluble
metal precipitation
• Manganese not precipitated – contained
in soluble form in tailings dam

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 Process
Copper SX from Partially Neutralized Leach Solution
• Extraction with LIX984N @ 15% v/v
• Extraction
– 2 mixer settlers
– 98% extraction
• Scrubbing
– 1 mixer settler
– Removal of entrained manganese and chloride
• Stripping
– 2 mixer settlers
– Stripping with EW spent electrolyte
27
 Process
Copper EW

• Electrowinning under standard

conditions
• LME Grade A copper produced

28
 Process
Stage 3 Neutralization

• Neutralization with HAC

• Two functions:
– Neutralize acid generated in copper SX
– Precipitate residual iron prior to sulphide
precipitation

29
 Process
Sulphide Precipitation

• Acts as primary purification step for zinc

and cobalt
• Zinc, cobalt and residual copper
precipitated with H2S gas
• Iron, manganese, magnesium,
aluminium and calcium remain in
solution (recycled to CCD in wash)

30
 Process
Sulphide Leach

• Precipitated sulphides dissolved at high

efficiency in oxidising pressure leach @
150°C
• Sulphur oxidation controlled to produce
some elemental sulphur (assists with
overall sulphur balance)
• Acid provided in recycle from primary
zinc SX

31
 Process
Solution Purification

• Zinc / cobalt solution purified in two stages

• Stage 1
– Iron removal by precipitation using limestone and
air
– Some copper removed
• Stage 2
– Cadmium removal with zinc dust
– Residual copper removed

32
 Process
Zinc SX
• Extraction with D2EHPA @ 40% v/v
• 2 stage extraction with intermediate
neutralisation
• Primary extraction
– 1 Bateman Pulsed Column
– No pH control
– 60% extraction
– Raffinate split
• 75% to sulphide leach
• 25% to neutralisation

33
 Process
Zinc SX
• Intermediate neutralisation
– pH raised using limestone
– Residue recycled to oxidising leach
• Secondary extraction
– 1 Bateman Pulsed Column
– pH control using sodium hydroxide
– 99.5% extraction
– Loaded organic to primary extraction

34
 Process
Zinc SX
• Scrubbing
– 3 mixer settlers
– Physical removal of entrained impurities as well as
chemical scrubbing of calcium
• Stripping
– 1 Bateman Pulsed Column
– Stripping with EW spent elecrolyte
• Regeneration
– 1 mixer settler
– Iron removal from bleed using 6M HCl
35
 Process
Zinc EW

• Electrowinning under standard

conditions
• SHG zinc produced

36
 Process
Cobalt SX
• Extraction with Cyanex 272® @ 25% v/v
• Extraction
– 1 Bateman Pulsed Column
– pH control using sodium hydroxide
– 99.95% extraction
• Scrubbing
– 2 mixer settlers
– Primarily for nickel removal
• Stripping
– 1 Bateman Pulsed Column
– Strip solution dependant on cobalt product 37
 Process
Cobalt Purification - IX

• Residual copper, zinc and others

removed from cobalt electrolyte by ion
exchange
• IX columns in “lead-lag” configuration
for maximum efficiency

38
 Process
Cobalt EW

• Electrowinning under standard

conditions in undivided cells

• Alternative for cobalt sulphide

production also considered

39
 Process
Reagents

• Elemental sulphur imported for production of

– H2SO4 (produced in acid plant)
– SO2 (produced in acid plant sulphur burner)
– H2S (produced from molten sulpur and
hydrogen from Naphta reformer)
– Acid plant generates 31 MW net power
• Limestone milled on site
• All other reagents used as supplied

40
 Major Reagent Consumptions
Consumption Cost
t/a US$
Sulphuric Acid* 764,400 7,000,000
Sulphur Dioxide* 87,400 1,224,000
Hydrogen Sulphide 14,000 882,000
Flocculant 760 2,038,000
Sodium Hydroxide 7,800 1,948,000
SX Organic Reagents 386,000

41
 Metsim Modelling
General
• Metsim model set up to calculate
– Flows and compositions of major streams,
including recycles
– Major reagent consumptions
– Heating and cooling requirements
• Steady-state simulation using simple unit
operations used to simulate more complex
real-life operations
• Testwork data and information from previous
studies used where possible
42
 Metsim Modelling
Mass Balance Calculations
• High level of accuracy
• 73 components considered in 4 phases
– 42 inorganic solid
– 16 inorganic aqueous
– 8 organic aqueous
– 7 gaseous
• Major elements include Cu, Co, Zn, Ni, Fe,
Mn, Mg, Na, S, Ca, Si, Cl

43
 Metsim Modelling
Energy Balance Calculations

• Lower level of accuracy

• All stream temperature calculations done by
Metsim using thermo data from Metsim
database and other sources
• Heat loss from equipment not simulated
• Heat exchangers simulated using steam or
cooling water – no solution interchange
simulated due to model stability

44
 Metsim Modelling
Feed Mineralogy

• Not readily available from previous work

• Mineralogy developed based on
– Previous test results
– Recent sample analyses
• Oxide / sulphide split difficult to determine
with any accuracy
• Mineralogy adjusted to produce acid and SO2
consumptions consistent with test results

45
 Metsim Modelling
Feed Mineralogy
% %
Cu2S 0.41 FeOOH 9.23
CuO 1.28 MnO2 5.54
CoS 0.026 CaCO3 4.00
CoO 0.08 MgCO3 5.77
ZnS 0.33 MgSO4 0.35
ZnO 0.56 SiO2 Balance
NiO 0.02
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 Metsim Modelling
Results
• Model results compare well with available test
data and general plant operating data
• Excellent tracking of impurities and water
balance issues
• Energy balance results suitable for sizing of
heat exchangers
• Metsim model an invaluable tool for accurate
plant design
• Model can be easily and quickly adapted for
more detailed design during feasibility study
53
 Capital Costs
Direct Field Costs (US$)
Vendor Supply and Install Packages 56,495,000
Mechanical Equipment 53,681,000
Site Development / Earthworks 6,134,000
Concrete 18,748,000
Structures 13,430,000
Pipework 17,885,000
Electrical 14,639,000
Instrumentation 5,862,000
Infrastructure 8,296,000
Transport 7,269,000

TOTAL DIRECT FIELD COSTS 202,439,000

54
 Operating Costs

US$/a US$/t
Labour 4,559,194 1.14
Maintenance 2,558,652 0.64
Consumables 17,715,687 4.40
Power 7,086,347 1.76

TOTAL OPERATING COST 28,964,551 7.96

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 Summary and Conclusions
• Boleo ores can be settled in High Rate
Thickeners
• Conventional CCD will work
• Cu, Co and Zn recovered from solution
as high quality, saleable products

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Example Projects - Bateman

57
 Mt Gordon

Insert picture of Mt Gordon Expansion Project

58
Gunpowder Autoclave

59
 Bulong Nickel Plant

Ore Preparation
Pressure Leach
CCD

SX

Electrowinning

60
Kasese Cobalt

61
 Olympic Dam Expansion

62
Modularisation at Port Augusta