PROJECT METALLURGIST

Comparison between
conventional circuits having
Milling in water with pre-
leach thickener, Milling in
water with pre-leach filter
and Milling in raffinate unit
operations: Reagent
consumption

KAFUMBILA KASONTA JOSEPH

2022
Comparison between conventional circuits having Milling in water with pre-
leach thickener, Milling in water with pre-leach filter and Milling in raffinate
unit operations: Reagent consumption
© Joseph Kafumbila 2022
[email protected]

Joseph Kafumbila Page 1

 Process simulation
Chemical engineering can be defined from many different aspects. However, all
the scientists and professionals agree that the process is the center of it. To make a
distinction from any other discipline, the role of chemical engineering could be defined
with its purpose to develop, design, construct, control, optimize and mange any process
involving physical and/or chemical changes and make this process profitable.

Process simulation as discipline uses mathematical models as basis for analysis

prediction, testing, detection of a process behavior unrelated to whether the process is
existing in reality or not. Process simulation is there to increase the level of knowledge
for a particular process and chemical engineering in general.

So, when those two concepts are put together, we can look into the chemical
engineering as a discipline defining how the process should be developed and
simulation as the tool helping us to explore the options. Chemical engineering needs to
know how the process should be designed while chemical engineers use the simulation
to explore all the process design options and define the optimal one.

Joseph Kafumbila Page 2

 Abstract
The region of Copper-belt areas of Zambia and the Democratic Republic of
Congo (DRC) remains an important resource for copper and cobalt for future years. The
production plant of copper and cobalt follows the hydrometallurgical route. The
mineralogy of ores in this area is typically associated with high gangue acid
consumption during the leaching process. The idea is to minimize the lost acid in the
water balance bleed to decrease plant acid consumption. One of the ways for lost acid
minimization in this bleed stream is to reduce the flow rate of bleed stream by the
reduction of incoming water flow rate in the copper circuit. The introduction of pre-
leach filter unit operation in conventional circuit having Milling in water with pre-leach
thickener unit operations or .the use of Milling in raffinate in place of Milling in water
decrease the incoming water associated to the feed material.

The goal of this publication is to compare the conventional circuit having Milling
in water with pre-leach thickener to the conventional circuit having Milling in water
with pre-leach filter or the conventional circuit having Milling in raffinate. The
simulation is done by using Realistic Simulation Model (RSM) that can simulate the
saturation concentrations of Gypsum and Copiapite and the effect of other ions,
phosphate anion and dithionate anion on Copper and Iron solvent extraction recoveries.

The simulation results show that the introduction of pre-leach filter or the use
of Milling in raffinate decreases the bleed stream flow rate of 30%. In consequence there
is 32% reduction of lost acid in the bleed stream and the increase of the concentrations
of Co, Mn and Fe in the leach solution. The increase in element concentrations in leach
solution decreases the percent of conversion of SO2 to SO4 in leach solution from 67.35%
to of 52.30% because of the increase in dithionate production. The combination of the
reduction of lost acid in the bleed stream and the increase in dithionate production
decreases elementary sulfur consumption of 4% only.

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 SUMMARY
Table A: Mass balance result summary

Description Milling in Milling in Milling in

Water with Water with raffinate
pre-leach pre-leach
thickener filter
Number of thickener in CCD train 7 7 7
Water balance bleed flow rate 941.90 657.70 637.88 m3/hr
Water balance bleed copper concentration 0.155 0.163 0.164 g/L
Water balance bleed acid concentration 11.031 10.846 10.831 g/L
Lost acid – CCD TK7 UF 0.44 0.36 0.36 Kg/t feed
Lost acid – RE2B 13.27 9.12 8.84 Kg/t feed
Acid consumption – Leach circuit 57.05 52.69 51.81 Kg/t feed
Acid consumption – CuEW circuit 1.19 2.12 2.22 Kg/t feed
Acid consumption – wash CCD circuit 0.39 0.42 0.42 Kg/t feed
Total acid consumption 58.63 55.22 54.45 Kg/t feed
SO2 consumption – Leach circuit 14.74 14.76 15.10 Kg/t feed
Leach - Percent of Sulfur in SO2 converted to SO4 67.35 52.30 52.36 %
Leach – Percent of incoming SO4 from SO2 21.35 18.62 19.25 %
Elementary sulfur consumption 27.08 25.96 25.88 Kg/t feed
Leach S2O6 concentration 6.021 13.05 13.790 g/L
Leach Cobalt 4.514 6.683 6.910 g/L
Leach Manganese 0.590 0.873 0.903 g/L
Leach Iron (2) 0.818 1.212 1.253 g/L
Flocculants consumption 194.8 254.80 139.32 g/t feed
PLS flow rate 2052.31 2096.82 2100.09 m3/hr
Extractant percent in organic phase (v/v%) 19.07 19.05 19.05 %
Saturation ratio (LO/ML) 0.700 0.700 0.700
PLS copper concentration 5.567 5.536 5.535 g/L
PLS S2O6 concentration 5.015 10.519 11.079 g/L
PLS PO4 total concentration 0.769 1.101 1.135 g/L
Cu/Fe in LOE1 2046.63 1319.62 1270.16
SX Copper extraction recovery 97.22 97.06 97.04 %
SX Copper stripping recovery 61.37 61.18 61.16 %
Copper Net transfer 0.228 0.227 0.227 g/L/(v/v%)
Copper production 13.75 13.83 13.84 Kg/t feed
Ratio Copper in EWB onto Copper production 0.92 1.76 1.85 %
Lost copper in CCD-TK7 UF 0.10 0.07 0.07 Kg/t feed
Lost copper in RE2B 0.18 0.13 0.13 Kg/t feed
Soluble copper recovery 97.96 98.54 98.58 %
Lost Lix984N (raffinate and advance electrolyte) 2.06 2.08 2.08 kg/tCu
Lost Kerosene (raffinate and advance electrolyte) 7.52 7.62 7.63 kg/tCu
CCD wash ratio 1.21 1.29 1.30 m3/ton
Cobalt concentration in TK7 UF 0.086 0.085 0.085 g/L

Joseph Kafumbila Page 4

 By introducing pre-leach filter unit operation in the conventional circuit having
Milling in water with pre-leach thickener unit operations or by using Milling in the
raffinate in place of Milling in water with pre-leach thickener unit operations, there is
30% reduction in water balance bleed flow rate because of reduction of incoming water
of the copper circuit associated with the feed. In consequence:

 There is the decrease in lost acid in bleed stream of 32%.

 There is the increase in concentration of Co, Mn and Fe in the leach circuit. In
consequence:
o There is 15% reduction in percent of conversion of SO2 to SO4 in the
leach unit operation. This phenomenon decreases the gain in
reduction of elementary consumption. There is only 4% reduction
in elementary sulfur consumption.
o There is little reduction in Copper solvent extraction recovery.
o There is the decrease of the ratio Cu/Fe in loaded organic of 35%.
Therefore there is the increase in ratio Copper in EWB onto Copper
production of 50%.
o There is the increase of the CCD wash ratio of 6%.
 There is the decrease in lost copper in water balance bleed of 28%. In
consequence there is the increase of copper production of 0.6%.
 There is the increase of flocculants consumption of 31% where pre-leach
filter is introduced and there is the decrease of flocculants consumption of
28% when Milling in raffinate is used.

Joseph Kafumbila Page 5

 Contents

1. Introduction 8
2. Conventional circuit having Milling in water with pre-leach thickener unit operations 10
2.1. Configuration 10
2.1.1. Flow diagram 10
2.1.2. Plant description 13
2.2. Mass balance 13
2.2.1. Design criteria 13
2.2.2. Mass balance results 20
2.3. Reagent consumption 21
2.3.1. Design criteria 21
2.3.2. Results 23
3. Conventional circuit having Milling in water with pre-leach filter unit operations 24
3.1. Configuration 24
3.1.1. Flow diagram 24
3.1.2. Plant description 27
3.2. Mass balance 27
3.2.1. Design criteria 27
3.2.2. Mass balance results 29
3.3. Reagent consumption 31
3.3.1. Design criteria 31
3.3.2. Results 32
4. Conventional circuit having Milling in raffinate unit operation 33
4.1. Configuration 33
4.1.1. Flow diagram 33
4.1.2. Plant description 36
4.2. Mass balance 36
4.2.1. Design criteria 36
4.2.2. Mass balance results 38
4.3. Reagent consumption 40
4.3.1. Design criteria 40

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 4.3.2. Results 41
5. References 42

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1. Introduction
In the Copper-belt areas of Zambia and the Democratic Republic of Congo
(DRC), the production plants utilize an agitation leach followed by solvent extraction
and electrowinning to recover both copper and cobalt. The mineralogy of ores in the
area is typically associated with high gangue acid consumption during the leaching
process. Decrease in water flow rate accompanying the feed materials will reduce the
flow rate of water balance bleed from copper circuit. Therefore there will be reduction
of acid lost in the water balance. Comparatively to conventional circuit having Milling in
water with pre-leach thickener unit operations, the reduction of feed incoming water
flow rate can be realizable by using conventional circuit having Milling in water with
pre-filter. In the case where the filterability of feed materials is bad, the use of Milling in
raffinate unit operations will be the option.

In the DRC and to some extent in Zambia, the copper and cobalt oxide ores are
leached in atmospheric systems. The dominant Copper mineralization is Malachite with
accessory Azurite and Chrysocolla and minor other secondary copper minerals. The
cobalt is present as Heterogenite with cobalt in both the Co(II) and Co(III) oxidation
state. The cobaltic minerals are about 50 per cent of the total cobalt; and are not direct
acid leachable at normal temperatures and pressures. Alternate methods of enhancing
the cobalt leaching are required.

Copper leaching is generally taken close to completion in four hours. Those

projects that do not have significant secondary copper minerals can achieve high
leaching efficiencies in as little as two hours from the rapidly leaching malachite and
azurite. About 50 per cent of the cobalt is leached (along with the copper) mainly from
the Co(II) minerals. The other cobaltic minerals need to be reduced to the 2+ state in
order for them to leach. This is achieved with controlled reductive leaching. The main
reductant used to date has been sodium meta bi-sulfite (SMBS: Na2S2O5). A more recent
development has been the use of gas from a sulfur burning acid plant (SO2 and N2) as a
direct Eh management tool. Other newer projects are considering the use of liquefied
SO2 to remove the voluminous nitrogen (Miller G. M., 2009).

Sulfite compounds are only partially utilized for cobalt (III) reduction during
copper-cobalt leaching. This low utilization is due to the secondary reactions of sulfur
dioxide and the sulfur dioxide gas lost in outlet leach tank gases due to low solubility of
sulfur dioxide gas in water. The secondary reactions are the reduction reactions of iron,
manganese from ore and the production of sulfate and dithionate with surface oxygen
catalyzed by Co, Mn and Fe ions. (Kafumbila J., 2020a and Kafumbila J., 2022a).

Joseph Kafumbila Page 8

 The goals of the publication are:

 To reevaluate the reduction in acid consumption by using conventional

circuit with Milling in raffinate or Milling in water with pre-leach filter
comparatively the conventional circuit with Milling in water with pre-
leach thickener in the condition of reductive leaching of Cobalt using SO2
as reducing agent.
 To take account of the presence of dithionate and phosphate in the
solution in the simulation of copper solvent extraction (Kafumbila J.
2022b).
 To take account of ferric solvent extraction on organic phase (Kafumbila J.
2022b).

The goals are realizable by using:

 The new realistic simulation model of hydrometallurgical plant that uses

the thermodynamic equilibrium of soluble species in solution. This
simulation model allows the find the saturation concentrations of gypsum
and Copiapite (Kafumbila J. 2022c).
 The new realistic simulation model of copper solvent extraction
configuration that uses the thermodynamic equilibrium of soluble species
in solution to determine the concentration of free hydrogen and copper
ions and uses the new equilibrium correlation on extraction and stripping
between copper concentration in aqueous and organic phases (Kafumbila
J. 2022b).

Joseph Kafumbila Page 9

2. Conventional circuit having Milling in
water with pre-leach thickener unit
operations

2.1. Configuration

2.1.1. Flow diagram

Figure (2.1) gives the flow diagram of Copper conventional circuit having
Milling in water with pre-leach thickener unit operations on which the mass balance is
done.

Abbreviations of unit operations:

 BM: Ball Mill.

 CY: Hydrocyclone.
 PRLTK: Pre-leach thickener.
 LC : Leach circuit.
 PKT: Primary thickener.
 KTn: Thickener of rank “n” in CCD train.
 SX En: Stage of rank “n” in CuSX - extraction train.
 ACT: Aqueous coalescing Tank.
 SX Sn: Stage of rank “n” in CuSX - stripping train.
 EW: .Copper electrowinning.

Abbreviations of lines between unit operations:

 Feed: Ores.
 BMW: Ball Mill water.
 UFCY: Hydrocyclone underflow.
 OBM: Outlet Ball Mill.
 SW: Sump water.
 FeCY: Feed hydrocyclone.
 UFCY: Hydrocyclone underflow.
 OFCY: Hydrocyclone overflow.

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 Figure 2.1: Flow diagram of conventional circuit

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  PRLTFC: Pre-leach thickener flocculants.
 PRLTOF: Pre-leach thickener overflow.
 PRLTUF: Pre-leach thickener underflow.
 LCA: Leach concentrated acid.
 RE2L: Raffinate of stage 2 of CuSX - extraction train to leach.
 RE2B: Raffinate of stage 2 of CuSX extraction train to water balance
bleed.
 OLC: Outlet leach circuit.
 PTKFC: Flocculants of primary thickener.
 PTKUF: Underflow of primary thickener.
 PTKOF: Overflow of primary thickener.
 TKFCn: Flocculants of thickener of rank “n” in CCD train.
 TKnUF: Underflow of thickener of rank “n” in CCD train.
 TKnOF: Overflow of thickener of rank “n” in CCD train.
 WW: Wash water of CCD train.
 PLS: Pregnant leach solution.
 REn: Raffinate of stage of rank “n” in CuSX - extraction train.
 LOEn: Loaded organic of stage of rank “n” in CuSX - extraction train.
 ALOEn: Aqueous entrainment in loaded organic of stage of rank “n” in
CuSX - extraction train.
 LOAC: Loaded organic from aqueous coalescing tank.
 ALOAC: Aqueous entrainment in loaded organic from aqueous coalescing
tank.
 ACTD: Drain of aqueous coalescing tank.
 SOSn: Stripping organic of stage of rank “n” in CuSX - stripping train.
 SOASn: Aqueous entrainment in stripping organic of stage of rank “n” in
CuSX - stripping train.
 ADSn: Advance electrolyte of stage of rank “n” in CuSX - stripping train.
 RADSn: Recirculated advance electrolyte of stage of rank “n” in CuSX -
stripping train.
 SPE: Spent electrolyte.
 EWO: Oxygen produced in Copper electrowinning circuit.
 EWCC: Copper cathode produced in Copper electrowinning circuit.
 EWS: Sulfur produced in Copper electrowinning circuit.
 EWW: Water for Copper electrowinning circuit.
 EWCA: Concentrated acid for Copper electrowinning circuit.
 OEW: Outlet of Copper electrowinning circuit.
 EWB: Bleed of Copper electrowinning circuit.
 ACS: Acid solution.

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2.1.2. Plant description

Feed material from crusher is fed in Ball Mill together with water and
hydrocyclone underflow. Outlet of Ball Mill is discharged in the sump. Water is also
added to the sump to reach the requirement of Feed hydrocyclone pulp density. The
hydrocyclone overflow is fed in the pre-leach thickener and underflow of pre-leach
thickener is fed in leach circuit with one part of raffinate from raffinate pond.
Concentrated acid and sulfur dioxide gas are also added in the leach circuit for pH and
redox potential control. Slurry discharged from the leach circuit is thickened in primary
thickener. Underflow of primary thickener is fed to counter current decantation circuit
where leach residue is washed with acidulated water.

Overflow of primary thickener is called pregnant leach solution and is fed to the
copper solvent extraction circuit. One part of raffinate of solvent extraction step is sent
back to leach and the remaining is sent to cobalt circuit.

The loaded organic from organic CuSX – extraction train is sent to aqueous
coalescing tank to remove a maximum volume of aqueous entrainment solution. Loaded
organic from aqueous coalescing tank is sent to CuSX - stripping train.

Spent electrolyte from copper electrowinning circuit is sent to CuSX - stripping

train. Advance electrolyte from CuSX - stripping train is sent back to Copper
electrowinning circuit. Concentrated acid and water are also added in Copper
electrowinning circuit. Copper cathode, Oxygen gas and sulfur are produced in Copper
electrowinning circuit. Iron bleed solution from Copper electrowinning circuit is sent
back to PLS pond.

2.2. Mass balance

2.2.1. Design criteria

2.2.1.1. Ball Mill (in water)

Design criteria of Ball Mill mass balance are the following:

 Feed moisture content: 20%.

 Specific gravity of feed solid: 2.7t/m3.
 Solid percent in outlet Ball Mill: 70%.

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2.2.1.2. Hydrocyclone

Design criteria of hydrocyclone mass balance are the following:

 Specific gravity of feed solid: 2.7t/m3.

 Volume percent of solid in overflow: 20%.
 Volume percent of solid in underflow: 52%

2.2.1.3. Pre-leach thickener

Design criteria of pre-leach thickener mass balance are the following:

 Flocculants dosage: 40 g/ton.

 Flocculants concentration: 0.25%.
 Solid percent in underflow: 58%.

2.2.1.4. Leach circuit

Design criteria of leach circuit mass balance are the following:

 Specific gravity of residue solid: 2.5t/m3.

 Solid percent in outlet leach circuit: 30% (maximum for reductive
leaching of Cobalt).
 Leach redox potential (LRP): 350 mV (Ag/AgCl).
 Leach pH: 1.7.
 Leach test (Kafumbila J., 2021):
o Gangue acid consumption (GAC): 43.260 kg/ton.
o SO2 consumption (SO2C): 14.850 kg/ton.
o CO2 production (CO2P): 7.510 kg/ton.
o Leach weight lost (LWL): 32.5 kg/ton.
o Leaching efficiency of sulfide minerals: 0% (assumption).
o Solubility:
 Cu: 14.041 kg/ton.
 P: 0.300 kg/ton.
 Fe: 0.861 kg/ton.
 Al: 0.688 kg/ton.
 Co: 4.500 kg/ton.
 Zn: 0.500 kg/ton.
 Ni: 0.068 kg/ton.
 Mn: 0.788 kg/ton.
 Mg: 1.002 kg/ton.

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  Sulfur percentage in solid:
o Percentage of sulfur in the feed:0.1%.
o Sulfur percentage in the leach residue: 1.5%.
 SO2 consumption: Equation (2.1) gives empirical Equation giving
6 (G(S2 O−2
concentration of S2 O−2 6 )
) (g/L) as function of Eh (v) (leach
redox potential) and sum of concentration of Co (G(Co) ), Mn (G(Mn) ) and
Fe(II) (G(Fe(II)) ) in leach solution (Kafumbila J., 2022a). The assumption
is that: SO2 consumption in the plant is obtained from sulfur mass
balance on leach circuit.
o Percent of sulfur in SO2 gas: 50.052%.

G(S2 O−2
6 )
=19.380+2.471*[G(Co)+G(Mn)+G(Fe(II)) ]-49.112*Eh (2.1)

 Acid consumption is obtained from gangue acid consumption from leach

test. In the case of conventional circuit Equation (2.2) gives concentrated
acid consumption.
o Percent of acid in concentrated acid: 98%
o Specific gravity of concentrated acid: 1.80.

OLC L
CAC=Gac *FOLC +FFS *(GAC+SolCu ∗ 1.543)- Gac
RE2L L
*FRE2L (2.2)

𝑂𝐿𝐶
Where “𝐺𝑎𝑐 ” is free acid concentration in outlet leach solution (g/L),
“𝐹𝑂𝐿𝐶 ” is the liquid flow rate of outlet leach solution, “𝐹𝐹𝑆 ” is solid flow
𝐿

rate of feed (t/hr), “GAC” is gangue acid consumption (kg/t), “𝑆𝑜𝑙𝐶𝑢 ” is

𝑅𝐸2𝐿
the solubility of copper, “𝐺𝑎𝑐 ” is free acid concentration in the SX
𝐿
raffinate (g/L), “𝐹𝑅𝐸2𝐿 ” is the liquid flow rate of raffinate pumped to leach
and “CAC” is pure acid consumed to leach (kg/h).

 Chemical reaction (2.a) gives gypsum precipitation reaction. Equation

(2.3) gives the precipitation condition of reaction (2.a).

Ca+2 + SO−2
4 + 2H2 O =CaSO4 . 2H2 O (2.a)

4.60=-log(a(Ca(+2)) )-log(a(SO−2
4 )
)-2*log(aw ) (2.3)

Where “𝑎(𝐶𝑎(+2)) ”, “𝑎(𝑆𝑂4−2 ) ” and “𝑎𝑤 ” are the activities of calcium ion,
sulfate anion and water.

 Chemical reaction (2.b) gives Copiapite precipitation reaction. Equation

(2.4) gives precipitation condition of chemical reaction (5.b). In this

Joseph Kafumbila Page 15

 simulation is that the iron dissolution stops when the concentration of
Iron in leach solution reaches the saturation concentration.

Fe+2+4Fe+3 +6SO−2
4 + 22H2 O = Fe5 (SO4 )6 (OH)2 . 20H2 O + 2H
+
(2.b)

33.737=-2*pH-log(a(Fe(+2)) )-4*log(a(Fe(+3)) )-6*log(a(SO−2

4 )
)-22*log(aw ) (2.4)

Where “𝑎(𝐹𝑒 (+2)) ”, “𝑎(𝐹𝑒 (+3))”, “𝑎(𝑆𝑂4−2 ) ” and “𝑎𝑤 ” are the activities of Fe(II)
ion, Fe(III) ion, sulfate anion and water.

2.2.1.5. Primary thickener

Design criteria of primary thickener mass balance are the following:

 Flocculants dosage: 40 g/ton.

 Flocculants concentration: 0.25%.
 Solid percent in underflow of primary thickener: 54%.
 Chemical reaction (2.a) gives gypsum precipitation reaction. Equation
(2.3) gives the precipitation condition of reaction (2.a).

2.2.1.6. CCD circuit

Design criteria of CCD circuit mass balance are the following:

 The number of thickener in the CCD train: 7 that is a maximum number

in Copper industrial practice.
 Solid percent in thickener underflow: 54%.
 Flocculants concentration: 0.25%.
 Flocculants dosage for the first thickener: 60% of flocculants dosage of
primary thickener.
 Flocculants dosage for other thickeners: 40% of flocculants dosage of
primary thickener.
 Mixing efficiency: 100%
 Wash efficiency: concentration of Co in the liquid of the last thickener in
the CCD train must be between 0.08 to 0.1g/L.
 pH of wash solution: 2.5.
 Chemical reaction (2.a) gives gypsum precipitation reaction. Equation
(2.3) gives the precipitation condition of reaction (2.a).

2.2.1.7. CuSX – extraction train

Design criteria of CuSX - extraction circuit mass balance are the following:

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  Type of extractant: Lix984N.
 Saturation ratio (LO/ML): ranges from 70 to 80% the ratio Cu/Fe in E1
loaded organic must be greater than 1000.
 O/A ratio (Loaded organic of stage of rank “2” on extraction train onto
overflow of primary thickener): 1.25.
 Number of stage: 2.
 Volume percent of extractant in organic phase: depends on saturation
ratio.
 Mixing efficiency for Copper:
o Stage E1: 95%.
o Stage E2: 97%.
 Aqueous entrainment in organic:
o Stage E1: 1000ppm.
o Stage E2: 1000ppm.
 Equilibrium copper concentration: Equation (2.5) gives equilibrium
condition of chemical reaction (2.c) (Kafumbila J., 2022b).

Cu+2 +2HR=CuR 2 +2H + (2.c)

Ce(CuR2 ) ∗ (Ce + ∗γ(H+ ) )2

(H )
=(-109.99 * v/v%(−1.699) ) ∗ Cue(or)+ 46.386 * v/v%(−0.618) (2.5)
Ce(Cu+2 ) ∗γ(Cu+2 ) ∗ (Ce(HR) )2

 Equilibrium Fe(III) concentration: Data of Lix984 (Kafumbila J., 2022b)

on extraction train. Equation (2.6) gives equilibrium condition of
chemical reaction (2.d).

Fe+3+3HR=FeR 3 +3H + (2.d)

[FeR ]∗([H+ ])3

10(−3.431) =[Fe+33]∗([HR])3 (2.6)

 Mixing efficiency for Fe(III) (assuming the same as for Copper):

o Stage E1: 95%.
o Stage E2: 97%.

2.2.1.8. Aqueous coalescing tank

Design criterion of aqueous coalescing tank is:

 Aqueous entrainment in organic: 400 ppm

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2.2.1.9. CuSX – stripping train

Design criteria of CuSX - stripping circuit mass balance are the following:

 O/A (internal): 1.25

 Number of stage: 2.
 Concentration of copper in advance electrolyse: 49-50 g/L.
 Spent electrolyte composition:
o Copper concentration: 35 g/L.
o Acid concentration: 180 g/L.
o Fe(II) concentration: 1.0 g/L.
o Fe(III) concentration: 1.0 g/L.
 Mixing efficiency:
o Stage S1: 95%.
o Stage S2: 90%.
o Aqueous entrainment in organic:
o Stage S1: 300ppm.
o Stage S2: 300ppm.
o Equilibrium copper concentration: Equation (2.7) gives equilibrium
condition of chemical reaction (2.e) (Kafumbila J., 2022b).

CuR 2 +2H + =Cu+2 +2HR (2.e)

Ce(CuR2 ) ∗ (Ce + ∗γ(H+ ) )2

(H )
=(-80.719 * v/v%(−1.508) ) ∗ Cue(or)+ 87.123* v/v%(−0.826) (2.7)
Ce(Cu+2 ) ∗γ(Cu+2 ) ∗ (Ce(HR) )2

 Ferric stripping efficiency: Concentration of Ferric in stripped organic –

1ppm (Hans Hein, 2005).

2.2.1.10. Copper electrowinning

Design criteria of Copper electrowinning circuit mass balance are the following:

 Spent electrolyte and iron bleed composition:

o Copper concentration: 35 g/L.
o Acid concentration: 180 g/L.
o Fe(II) concentration: 1.0 g/L.
o Fe(III) concentration: 1.0 g/L.
 Percent of acid in concentrated acid: 98%
 Specific gravity of concentrated acid: 1.80.
 Chemical reaction (2.f). Equation (2.8) gives the production of oxygen.

Joseph Kafumbila Page 18

 2CuSO4 +2H2 O=2Cu° +O2 +2H2 SO4 (2.f)

O2P=0.252CCP (2.8)

Where “O2P” is the quantity of oxygen produced in copper electrowinning

and “CCP” is copper cathode produced in copper electrowinning.

 Dithionate decomposition:

o Half of dithionate is oxidized to sulfate by oxygen on anode

according to the chemical (2.g). Equation (2.9) gives mass of
oxygen gas (CM(O2 ) ) used to oxidize M(S O(−2)) mass of dithionate
2 6

to sulfate. Equation (2.10) gives the mass of sulfate produced

during the oxidation of M(S O(−2)) mass of dithionate
2 6

(−2) (−2)
2S2 O6 +O2 +2H2 O=4SO4 +4H + (2.g)

CM(O2 ) =0.100*M(S (−2) (2.9)

2 O6 )

PM(SO(−2)) =1.200*M(S (−2) (2.10)

4 2 O6 )

o Half of dithionate is reduce to elementary sulfur on cathode

according to the chemical reaction (2.h). Equation (2.11) gives
mass of oxygen gas produced (PM(O2 ) ) during the production of
elementary sulfur from M(S O(−2)) mass of dithionate. Equation
2 6

(2.12) gives mass of elementary sulfur produced from M(S (−2)

2 O6 )
mass of dithionate

(−2)
S2 O6 +2H + =O2 +2S ° +H2 O (2.h)

PM(O2 ) =0.200*M(S (−2) (2.11)

2 O6 )

PM(S° ) =0.401*M(S (−2) (2.12)

2 O6 )

 Flowrate of concentrated acid: sulfur mass balance on CuEW

Joseph Kafumbila Page 19

2.2.2. Mass balance results

Tables from (A.1) to (A.9) in the appendix (A) give the mass balance obtained
by using the realistic simulation model (Kafumbila J. 2022b and Kafumbila J. 2022c) of
conventional circuit having Milling in water with pre-leach thickener unit operations.

Table (2.1) gives the summary of simulation results. Here are some
observations:

Table 2.1: Result summary

Description
Number of thickener in CCD train 7
Water balance bleed flow rate 941.90 m3/hr
Water balance bleed copper concentration 0.155 g/L
Water balance bleed acid concentration 11.031 g/L
Lost acid (free acid and acid associated with Copper) – CCD TK7 UF 0.44 Kg/t feed
Lost acid (free acid and acid associated with Copper) – RE2B 13.27 Kg/t feed
Acid consumption – Leach circuit 57.05 Kg/t feed
Acid consumption – CuEW circuit 1.19 Kg/t feed
Acid consumption – wash CCD circuit 0.39 Kg/t feed
Total acid consumption 58.63 Kg/t feed
SO2 consumption – Leach circuit 14.74 Kg/t feed
Leach - Percent of Sulfur in SO2 converted to SO4 67.35 %
Leach – Percent of incoming SO4 from SO2 21.35 %
Leach S2O6 concentration 6.021 g/L
Leach Cobalt 4.514 g/L
Leach Manganese 0.590 g/L
Leach Iron (2) 0.818 g/L
Flocculants consumption 194.8 g/t feed
PLS flow rate 2052.31 m3/hr
Extractant percent in organic phase (v/v%) 19.07 %
Saturation ratio (LO/ML) 0.700
PLS copper concentration 5.567 g/L
PLS S2O6 concentration 5.015 g/L
PLS PO4 total concentration 0.769 g/L
Cu/Fe in LOE1 2046.63
SX Copper extraction recovery 97.22 %
SX Copper stripping recovery 61.37 %
Copper Net transfer 0.228 g/L/(v/v%)
Copper production 13.75 Kg/t feed
Ratio Copper in EWB onto Copper production 0.92 %
Lost copper in CCD-TK7 UF 0.10 Kg/t feed
Lost copper in RE2B 0.18 Kg/t feed
Soluble copper recovery 97.96 %
CCD wash ratio 1.21 m3/ton
Cobalt concentration in TK7 UF 0.086 g/L

Joseph Kafumbila Page 20

  The Iron concentration in the leach solution is not the saturation
concentration (Fe(2): 0.818g/L and Fe(3): 0.045g/L).
 The increase of sulfur grade in the leach residue is due to gypsum
precipitation.
 The Calcium concentration in the leach solution and CCD train solutions
are the saturation concentrations. Therefore there is dissolution of
gypsum from primary thickener to the last thickener of CCD train.
 The concentration of Iron LOE1 (0.0035ppm) is lower than the
concentration of Iron in LOE2 (0.0044ppm). There is rejection of Iron
from organic phase in the E1 due to the increase of copper concentration
in LOE1 (7.083 g/L) comparatively to LOE2 (3.457g/L).
 The ratio Cu/Fe in LOE1 (2046.63) is greater than 1000 at the ratio
LO/ML equal to 0.7 at volume percent of Lix984N in organic about
19.07%, at Fe(3) concentration in PLS about 0.039g/L and at phosphate
and dithionate concentrations respectively about 0.769g/L and 5.015g/L
(Kafumbila J., 2022b).

2.3. Reagent consumption

2.3.1. Design criteria

2.3.1.1. Acid and SO2

Acid and SO2 are produced from sulfur. The percent of conversion of sulfur to
acid and SO2 is 98%. Table (2.2) gives the specific consumption of sulfur. Molar mass of
sulfur, SO2 and acid are respectively 32.065 g/mol, 64.063g/mol and 98.075g/mol.
Equations (2.11) and (2.12) give the specific consumption of sulfur from specific
consumptions of acid and SO2.

Table 2.2: Sulfur specific consumption

Specific consumption Unit

Acid consumption 58.63 Kg/t feed
Sulfur to acid 19.56 Kg/t feed
SO2 consumption 14.74 Kg/t feed
Sulfur to SO2 7.52 Kg/t feed
Total sulfur consumption 27.08 Kg/t feed

32.065
SCS=SCAC* (2.11)
98.075∗SCV

32.065
SCS=SCSO* (2.12)
64.063∗SCV

Joseph Kafumbila Page 21

 Where “SCS” is specific consumption of sulfur, “SCAC” is specific consumption of
acid, “SCSO” is specific consumption of SO2 and “𝑆𝐶𝑉” is sulfur conversion.

2.3.1.2. Lix984N and Kerosene

The concentrations of organic phase in raffinate and advance electrolyte are

respectively 50mg/L and 150mg/L. The recoveries of organic phase from raffinate and
advance electrolyte are respectively 30 and 70%. The specific gravity of Lix984N and
Kerosene are respectively 0.94 and 0.81 t/m3.

Equations (2.13) and (2.14) give the lost organic in the raffinate and advance
electrolyte respectively.

30
LOR=F(RE2) *50*(1- )*10(−6) (t/h) (2.13)
100

70
LOA=F(ADS1) *150*(1- )*10(−6) (t/h) (2.14)
100

Where “LOR” is lost organic in the raffinate (t/h), “LOA” is lost organic in the
advance electrolyte (t/h), “𝐹(𝑅𝐸2) ” is raffinate flow rate (m3/hr) and “𝐹(𝐴𝐷𝑆1) ” is
advance electrolyte flow rate (m3/hr)

Equations (2.15) give the approximate specific gravity of organic phase.

v v
% %
d(Or) = v
*d(Lix) +(1- v
)* d(Ker) (2.15)
100 100

Where “𝑑(𝑂𝑟) ” is specific gravity of organic phase, “𝑑(𝐿𝑖𝑥) ” is specific gravity of

𝑣
Lix984N, “𝑑(𝐾𝑒𝑟) ” is specific gravity of Kerosene and “𝑣 %” is Lix984N percent in
organic phase

Equations (2.16) and (2.17) give specific consumption of Lix984N and

Kerosene.

v
(LOR+LOA) v% 1000
SCLix= * *d(Lix) * (kg/tCu) (2.16)
d(Or) 100 EWCC

v
(LOR+LOA) % 1000
SCKer= *(1- v
)*d(Ker) * (kg/tCu) (2.17)
d(Or) 100 EWCC

Where “SCLix” is specific consumption of Lix984N (kg/tCu) and “SCKer” is

specific consumption (kg/tCu)
Joseph Kafumbila Page 22
 Table (2.3) gives specific consumptions of Lix984N and Kerosene.

Table 2.3: Specific consumptions of Lix984N and Kerosene

Specific consumption Unit

Lix984N 2.06 Kg/tCu
Kerosene 7.52 Kg/tCu

2.3.1.3. EW-Guar

The specific consumption of Guar is 0.2 kg/tCu.

2.3.2. Results

Table (2.4) gives reagent consumption.

Table 5.4: reagent consumption

Unit
Hours per year 8 322 hrs
Feed 6 657 600 t/y
Copper production 91 578 t/y
Sulfur 180 281 t/y
Flocculants 1297 t/y
Lix984N 188 t/y
Kerosene 688 t/y
Guar 18 t/y

Joseph Kafumbila Page 23

3. Conventional circuit having Milling in
water with pre-leach filter unit
operations

3.1. Configuration

3.1.1. Flow diagram

Figure (3.1) gives the flow diagram of conventional circuit having Milling in
water with pre*leach filter unit operations.

Abbreviations of unit operations:

 BM: Ball Mill.

 CY: Hydrocyclone.
 PRLTK: Pre-leach thickener.
 PRLFL: Pre-leach thickener.
 LC: Leach circuit.
 PKT: Primary thickener.
 KTn: Thickener of rank “n” in CCD train.
 SX En: Stage of rank “n” in CuSX - extraction train.
 ACT: Aqueous coalescing Tank.
 SX Sn: Stage of rank “n” in CuSX - stripping train.
 EW: .Copper electrowinning.

Abbreviations of lines between unit operations:

 Feed: Ores.
 BMW: Ball Mill water.
 UFCY: Hydrocyclone underflow.
 OBM: Outlet Ball Mill.
 SW: Sump water.
 FeCY: Feed hydrocyclone.
 UFCY: Hydrocyclone underflow.
 OFCY: Hydrocyclone overflow.

Joseph Kafumbila Page 24

Figure 3.1: Flow diagram of conventional circuit having Milling in water with pre-leach
filter unit operations

Joseph Kafumbila Page 25

  PRLTFC: Pre-leach thickener flocculants.
 PRLTOF: Pre-leach thickener overflow.
 PRLTUF: Pre-leach thickener underflow.
 PRLFFC: Pre-leach filter flocculants.
 PRLFFL: Pre-leach filter filtrate.
 PRLFCa: Pre-leach filter cake.
 LCA: Leach concentrated acid.
 RE2L: Raffinate of stage 2 of CuSX - extraction train to leach.
 RE2B: Raffinate of stage 2 of CuSX extraction train to water balance
bleed.
 OLC: Outlet leach circuit.
 PTKFC: Flocculants of primary thickener.
 PTKUF: Underflow of primary thickener.
 PTKOF: Overflow of primary thickener.
 TKFCn: Flocculants of thickener of rank “n” in CCD train.
 TKnUF: Underflow of thickener of rank “n” in CCD train.
 TKnOF: Overflow of thickener of rank “n” in CCD train.
 WW: Wash water of CCD train.
 PLS: Pregnant leach solution.
 REn: Raffinate of stage of rank “n” in CuSX - extraction train.
 LOEn: Loaded organic of stage of rank “n” in CuSX - extraction train.
 ALOEn: Aqueous entrainment in loaded organic of stage of rank “n” in
CuSX - extraction train.
 LOAC: Loaded organic from aqueous coalescing tank.
 ALOAC: Aqueous entrainment in loaded organic from aqueous coalescing
tank.
 ACTD: Drain of aqueous coalescing tank.
 SOSn: Stripping organic of stage of rank “n” in CuSX - stripping train.
 SOASn: Aqueous entrainment in stripping organic of stage of rank “n” in
CuSX - stripping train.
 ADSn: Advance electrolyte of stage of rank “n” in CuSX - stripping train.
 RADSn: Recirculated advance electrolyte of stage of rank “n” in CuSX -
stripping train.
 SPE: Spent electrolyte.
 EWO: Oxygen produced in Copper electrowinning circuit.
 EWCC: Copper cathode produced in Copper electrowinning circuit.
 EWS: Sulfur produced in Copper electrowinning circuit.
 EWW: Water for Copper electrowinning circuit.
 EWCA: Concentrated acid for Copper electrowinning circuit.
 OEW: Outlet of Copper electrowinning circuit.

Joseph Kafumbila Page 26

  EWB: Bleed of Copper electrowinning circuit.
 ACS: Acid solution.

3.1.2. Plant description

Feed material from crusher is fed in Ball Mill together with water and
hydrocyclone underflow. Outlet of Ball Mill is discharged in the sump. Water is also
added to the sump to reach the requirement of Feed hydrocyclone pulp density. The
hydrocyclone overflow is fed in the pre-leach thickener and underflow of pre-leach
thickener is fed to pre-leach filter. The pre-leach filter cake is fed in leach circuit with
one part of raffinate from raffinate pond. Concentrated acid and sulfur dioxide gas are
also added in the leach circuit for pH and redox potential control. Slurry discharged from
the leach circuit is thickened in primary thickener. Underflow of primary thickener is
fed to counter current decantation circuit where leach residue is washed with acidulated
water.

Overflow of primary thickener is called pregnant leach solution and is fed to the
copper solvent extraction circuit. One part of raffinate of solvent extraction step is sent
back to leach and the remaining is sent to cobalt circuit.

The loaded organic from organic CuSX – extraction train is sent to aqueous
coalescing tank to remove a maximum volume of aqueous entrainment solution. Loaded
organic from aqueous coalescing tank is sent to CuSX - stripping train.

Spent electrolyte from copper electrowinning circuit is sent to CuSX - stripping

train. Advance electrolyte from CuSX - stripping train is sent back to Copper
electrowinning circuit. Concentrated acid and water are also added in Copper
electrowinning circuit. Copper cathode, Oxygen gas and sulfur are produced in Copper
electrowinning circuit. Iron bleed solution from Copper electrowinning circuit is sent
back to PLS pond.

3.2. Mass balance

3.2.1. Design criteria

3.2.1.1. Ball Mill (in water)

Design criteria of Ball Mill mass balance are the following:

 Feed moisture content: 20%.

 Specific gravity of feed solid: 2.7t/m3.
 Solid percent in outlet Ball Mill: 70%.

Joseph Kafumbila Page 27

3.2.1.2. Hydrocyclone

Design criteria of hydrocyclone mass balance are the following:

 Specific gravity of feed solid: 2.7t/m3.

 Volume percent of solid in overflow: 20%.
 Volume percent of solid in underflow: 52%

3.2.1.3. Pre-leach thickener

Design criteria of pre-leach thickener mass balance are the following:

 Flocculants dosage: 40 g/ton.

 Flocculants concentration: 0.25%.
 Solid percent in underflow: 58%.

3.2.1.4. Pre-leach filter

Design criteria of pre-leach filter mass balance are the following:

 Flocculants dosage: 40 g/ton.

 Flocculants concentration: 0.25%.
 Solid percent in filter cake: 78%.

3.2.1.5. Leach circuit

Design criteria of leach circuit mass balance are the following:

 As for conventional circuit having Milling in water with pre-leach

thickener.

3.2.1.6. Primary thickener

Design criteria of primary thickener mass balance are the following:

 As for conventional circuit having Milling in water with pre-leach

thickener.

3.2.1.7. CCD circuit

Design criteria of CCD circuit mass balance are the following:

Joseph Kafumbila Page 28

  As for conventional circuit having Milling in water with pre-leach
thickener.

3.2.1.8. CuSX – extraction train

Design criteria of CuSX - extraction circuit mass balance are the following:

 As for conventional circuit having Milling in water with pre-leach

thickener.

3.2.1.9. Aqueous coalescing tank

Design criterion of aqueous coalescing tank is:

 As for conventional circuit having Milling in water with pre-leach

thickener.

3.2.1.10. CuSX – stripping train

Design criteria of CuSX - stripping circuit mass balance are the following:

 As for conventional circuit having Milling in water with pre-leach

thickener.

3.2.1.11. Copper electrowinning

Design criteria of Copper electrowinning circuit mass balance are the following:

 As for conventional circuit having Milling in water with pre-leach

thickener.

3.2.2. Mass balance results

Tables from (B.1) to (B.9) in the appendix (B) give the mass balance obtained
by using the realistic simulation model (Kafumbila J. 2022b and Kafumbila J. 2022c) of
conventional circuit having Milling in water with pre-leach filter unit operations.

Table (3.1) gives the summary of simulation results. Here are some
observations:

Joseph Kafumbila Page 29

 Table 3.1: Result summary

Description
Number of thickener in CCD train 7
Water balance bleed flow rate 657.70 m3/hr
Water balance bleed copper concentration 0.163 g/L
Water balance bleed acid concentration 10.846 g/L
Lost acid (free acid and acid associated with Copper) – CCD TK7 UF 0.36 Kg/t feed
Lost acid (free acid and acid associated with Copper) – RE2B 9.12 Kg/t feed
Acid consumption – Leach circuit 52.69 Kg/t feed
Acid consumption – CuEW circuit 2.12 Kg/t feed
Acid consumption – wash CCD circuit 0.42 Kg/t feed
Total acid consumption 55.22 Kg/t feed
SO2 consumption – Leach circuit 14.76 Kg/t feed
Leach - Percent of Sulfur in SO2 converted to SO4 52.30 %
Leach – Percent of incoming SO4 from SO2 18.62 %
Leach S2O6 concentration 13.05 g/L
Leach Cobalt 6.683 g/L
Leach Manganese 0.873 g/L
Leach Iron (2) 1.212 g/L
Flocculants consumption 254.80 g/t feed
PLS flow rate 2096.82 m3/hr
Extractant percent in organic phase (v/v%) 19.05 %
Saturation ratio (LO/ML) 0.700
PLS copper concentration 5.536 g/L
PLS S2O6 concentration 10.519 g/L
PLS PO4 total concentration 1.101 g/L
Cu/Fe in LOE1 1319.62
SX Copper extraction recovery 97.06 %
SX Copper stripping recovery 61.18 %
Copper Net transfer 0.227 g/L/(v/v%)
Copper production 13.83 Kg/t feed
Ratio Copper in EWB onto Copper production 1.76 %
Lost copper in CCD-TK7 UF 0.07 Kg/t feed
Lost copper in RE2B 0.13 Kg/t feed
Soluble copper recovery 98.54 %
CCD wash ratio 1.29 m3/ton
Cobalt concentration in TK7 UF 0.085 g/L

 The Iron concentration in the leach solution is not the saturation

concentration (Fe(2): 1.212g/L and Fe(3): 0.066g/L).
 The increase of sulfur grade in the leach residue is due to gypsum
precipitation.
 The Calcium concentration in the leach solution and CCD train solutions
are the saturation concentrations. Therefore there is dissolution of
gypsum from primary thickener to the last thickener of CCD train.
 The concentration of Iron LOE1 (0.0054ppm) is lower than the
concentration of Iron in LOE2 (0.0066ppm). There is rejection of Iron
from organic phase in the E1 due to the increase of copper concentration
in LOE1 (7.062 g/L) comparatively to LOE2 (3.476g/L).

Joseph Kafumbila Page 30

  The ratio Cu/Fe in LOE1 (1319.62) is greater than 1000 at the ratio
LO/ML equal to 0.7 at volume percent of Lix984N in organic about
19.05%, at Fe(3) concentration in PLS about 0.056g/L and at phosphate
and dithionate concentrations respectively about 1.101g/L and
10.519g/L (Kafumbila J., 2022b).

3.3. Reagent consumption

3.3.1. Design criteria

3.3.1.1. Acid and SO2

Acid and SO2 are produced from sulfur. The percent of conversion of sulfur to
acid and SO2 is 98%. Table (3.2) gives the specific consumption of sulfur. Molar mass of
sulfur, SO2 and acid are respectively 32.065 g/mol, 64.063g/mol and 98.075g/mol.
Equations (2.11) and (2.12) give the specific consumption of sulfur from specific
consumptions of acid and SO2.

Table 3.2: Sulfur specific consumption

Specific consumption Unit

Acid consumption 55.22 Kg/t feed
Sulfur to acid 18.42 Kg/t feed
SO2 consumption 14.76 Kg/t feed
Sulfur to SO2 7.54 Kg/t feed
Total sulfur consumption 25.96 Kg/t feed

3.3.1.2. Lix984N and Kerosene

The concentrations of organic phase in raffinate and advance electrolyte are

respectively 50mg/L and 150mg/L. The recoveries of organic phase from raffinate and
advance electrolyte are respectively 30 and 70%. The specific gravity of Lix984N and
Kerosene are respectively 0.94 and 0.81 t/m3.

Equations (2.13) and (2.14) give the lost organic in the raffinate and advance
electrolyte respectively. Equations (2.15) give the approximate specific gravity of
organic phase. Equations (2.16) and (2.17) give specific consumption of Lix984N and
Kerosene. Table (3.3) gives specific consumptions of Lix984N and Kerosene.

Table 3.3: Specific consumptions of Lix984N and Kerosene

Specific consumption Unit

Lix984N 2.08 Kg/tCu
Kerosene 7.62 Kg/tCu

Joseph Kafumbila Page 31

3.3.1.3. EW-Guar

The specific consumption of Guar is 0.2 kg/tCu.

3.3.2. Results

Table (3.4) gives reagent consumption.

Table 3.4: reagent consumption

Unit
Hours per year 8 322 hrs
Feed 6 657 600 t/y
Copper production 92 117 t/y
Sulfur 172 846 t/y
Flocculants 1 697 t/y
Lix984N 192 t/y
Kerosene 702 t/y
Guar 18 t/y

Joseph Kafumbila Page 32

4. Conventional circuit having Milling in
raffinate unit operation

4.1. Configuration

4.1.1. Flow diagram

Figure (4.1) gives the flow diagram of conventional circuit having Milling in
raffinate unit operation.

Abbreviations of unit operations:

 BM: Ball Mill.

 CY: Hydrocyclone.
 LC: Leach circuit.
 PKT: Primary thickener.
 KTn: Thickener of rank “n” in CCD train.
 SX En: Stage of rank “n” in CuSX - extraction train.
 ACT: Aqueous coalescing Tank.
 SX Sn: Stage of rank “n” in CuSX - stripping train.
 EW: .Copper electrowinning.

Abbreviations of lines between unit operations:

 Feed: Ores.
 RaBM: Raffinate to Ball Mill.
 UFCY: Hydrocyclone underflow.
 OBM: Outlet Ball Mill.
 RaS: Raffinate to Sump.
 FeCY: Feed hydrocyclone.
 UFCY: Hydrocyclone underflow.
 OFCY: Hydrocyclone overflow.

Joseph Kafumbila Page 33

Figure 4.1: Flow diagram of conventional circuit having Milling in raffinate unit
operation

Joseph Kafumbila Page 34

  LCA: Leach concentrated acid.
 RE2L: Raffinate of stage 2 of CuSX - extraction train to leach.
 RE2B: Raffinate of stage 2 of CuSX extraction train to water balance
bleed.
 OLC: Outlet leach circuit.
 PTKFC: Flocculants of primary thickener.
 PTKUF: Underflow of primary thickener.
 PTKOF: Overflow of primary thickener.
 TKFCn: Flocculants of thickener of rank “n” in CCD train.
 TKnUF: Underflow of thickener of rank “n” in CCD train.
 TKnOF: Overflow of thickener of rank “n” in CCD train.
 WW: Wash water of CCD train.
 PLS: Pregnant leach solution.
 REn: Raffinate of stage of rank “n” in CuSX - extraction train.
 LOEn: Loaded organic of stage of rank “n” in CuSX - extraction train.
 ALOEn: Aqueous entrainment in loaded organic of stage of rank “n” in
CuSX - extraction train.
 LOAC: Loaded organic from aqueous coalescing tank.
 ALOAC: Aqueous entrainment in loaded organic from aqueous coalescing
tank.
 ACTD: Drain of aqueous coalescing tank.
 SOSn: Stripping organic of stage of rank “n” in CuSX - stripping train.
 SOASn: Aqueous entrainment in stripping organic of stage of rank “n” in
CuSX - stripping train.
 ADSn: Advance electrolyte of stage of rank “n” in CuSX - stripping train.
 RADSn: Recirculated advance electrolyte of stage of rank “n” in CuSX -
stripping train.
 SPE: Spent electrolyte.
 EWO: Oxygen produced in Copper electrowinning circuit.
 EWCC: Copper cathode produced in Copper electrowinning circuit.
 EWS: Sulfur produced in Copper electrowinning circuit.
 EWW: Water for Copper electrowinning circuit.
 EWCA: Concentrated acid for Copper electrowinning circuit.
 OEW: Outlet of Copper electrowinning circuit.
 EWB: Bleed of Copper electrowinning circuit.
 ACS: Acid solution.

Joseph Kafumbila Page 35

4.1.2. Plant description

Feed material from crusher is fed in Ball Mill together with raffinate and
hydrocyclone underflow. Outlet of Ball Mill is discharged in the sump. Raffinate is also
added to the sump to reach the requirement of Feed hydrocyclone pulp density. The
hydrocyclone overflow is fed in leach circuit with one part of raffinate from raffinate
pond. Concentrated acid and sulfur dioxide gas are also added in the leach circuit for pH
and redox potential control. Slurry discharged from the leach circuit is thickened in
primary thickener. Underflow of primary thickener is fed to counter current
decantation circuit where leach residue is washed with acidulated water.

Overflow of primary thickener is called pregnant leach solution and is fed to the
copper solvent extraction circuit. One part of raffinate of solvent extraction step is sent
back to leach and the remaining is sent to cobalt circuit.

The loaded organic from organic CuSX – extraction train is sent to aqueous
coalescing tank to remove a maximum volume of aqueous entrainment solution. Loaded
organic from aqueous coalescing tank is sent to CuSX - stripping train.

Spent electrolyte from copper electrowinning circuit is sent to CuSX - stripping

train. Advance electrolyte from CuSX - stripping train is sent back to Copper
electrowinning circuit. Concentrated acid and water are also added in Copper
electrowinning circuit. Copper cathode, Oxygen gas and sulfur are produced in Copper
electrowinning circuit. Iron bleed solution from Copper electrowinning circuit is sent
back to PLS pond.

4.2. Mass balance

4.2.1. Design criteria

4.2.1.1. Ball Mill (in water)

Design criteria of Ball Mill mass balance are the following:

 Feed moisture content: 20%.

 Specific gravity of feed solid: 2.7t/m3.
 Solid percent in outlet Ball Mill: 70%.
 Element leach efficiencies: 0% (assumption)

Joseph Kafumbila Page 36

4.2.1.2. Hydrocyclone

Design criteria of hydrocyclone mass balance are the following:

 Specific gravity of feed solid: 2.7t/m3.

 Volume percent of solid in overflow: 20%.
 Volume percent of solid in underflow: 52%
 Element leach efficiencies: 0% (assumption)

4.2.1.3. Leach circuit

Design criteria of leach circuit mass balance are the following:

 As for conventional circuit having Milling in water with pre-leach

thickener.

4.2.1.4. Primary thickener

Design criteria of primary thickener mass balance are the following:

 As for conventional circuit having Milling in water with pre-leach

thickener.

4.2.1.5. CCD circuit

Design criteria of CCD circuit mass balance are the following:

 As for conventional circuit having Milling in water with pre-leach

thickener.

4.2.1.6. CuSX – extraction train

Design criteria of CuSX - extraction circuit mass balance are the following:

 As for conventional circuit having Milling in water with pre-leach

thickener.

4.2.1.7. Aqueous coalescing tank

Design criterion of aqueous coalescing tank is:

Joseph Kafumbila Page 37

  As for conventional circuit having Milling in water with pre-leach
thickener.

4.2.1.8. CuSX – stripping train

Design criteria of CuSX - stripping circuit mass balance are the following:

 As for conventional circuit having Milling in water with pre-leach

thickener.

4.2.1.9. Copper electrowinning

Design criteria of Copper electrowinning circuit mass balance are the following:

 As for conventional circuit having Milling in water with pre-leach

thickener.

4.2.2. Mass balance results

Tables from (C.1) to (C.9) in the appendix (C) give the mass balance obtained by
using the realistic simulation model (Kafumbila J. 2022b and Kafumbila J. 2022c) of
conventional circuit having Milling in raffinate unit operation.

Table (4.1) gives the summary of simulation results. Here are some
observations:

 The Iron concentration in the leach solution is not the saturation

concentration (Fe(2): 1.253g/L and Fe(3): 0.069g/L).
 The increase of sulfur grade in the leach residue is due to gypsum
precipitation.
 The Calcium concentration in the leach solution and CCD train solutions
are the saturation concentrations. Therefore there is dissolution of
gypsum from primary thickener to the last thickener of CCD train.
 The concentration of Iron LOE1 (0.0056ppm) is lower than the
concentration of Iron in LOE2 (0.0069ppm). There is rejection of Iron
from organic phase in the E1 due to the increase of copper concentration
in LOE1 (7.063 g/L) comparatively to LOE2 (3.479g/L).

Joseph Kafumbila Page 38

 Table 4.1: Result summary

Description
Number of thickener in CCD train 7
Water balance bleed flow rate 637.88 m3/hr
Water balance bleed copper concentration 0.164 g/L
Water balance bleed acid concentration 10.831 g/L
Lost acid (free acid and acid associated with Copper) – CCD TK7 UF 0.36 Kg/t feed
Lost acid (free acid and acid associated with Copper) – RE2B 8.84 Kg/t feed
Acid consumption – Leach circuit 51.81 Kg/t feed
Acid consumption – CuEW circuit 2.22 Kg/t feed
Acid consumption – wash CCD circuit 0.42 Kg/t feed
Total acid consumption 54.45 Kg/t feed
SO2 consumption – Leach circuit 15.10 Kg/t feed
Leach - Percent of Sulfur in SO2 converted to SO4 52.36 %
Leach – Percent of incoming SO4 from SO2 19.25 %
Leach S2O6 concentration 13.790 g/L
Leach Cobalt 6.910 g/L
Leach Manganese 0.903 g/L
Leach Iron (2) 1.253 g/L
Flocculants consumption 139.32 g/t feed
PLS flow rate 2100.09 m3/hr
Extractant percent in organic phase (v/v%) 19.05 %
Saturation ratio (LO/ML) 0.700
PLS copper concentration 5.535 g/L
PLS S2O6 concentration 11.079 g/L
PLS PO4 total concentration 1.135 g/L
Cu/Fe in LOE1 1270.16
SX Copper extraction recovery 97.04 %
SX Copper stripping recovery 61.16 %
Copper Net transfer 0.227 g/L/(v/v%)
Copper production 13.84 Kg/t feed
Ratio Copper in EWB onto Copper production 1.85 %
Lost copper in CCD-TK7 UF 0.07 Kg/t feed
Lost copper in RE2B 0.13 Kg/t feed
Soluble copper recovery 98.58 %
CCD wash ratio 1.30 m3/ton
Cobalt concentration in TK7 UF 0.085 g/L

 The ratio Cu/Fe in LOE1 (1270.16) is greater than 1000 at the ratio
LO/ML equal to 0.7 at volume percent of Lix984N in organic about
19.05%, at Fe(3) concentration in PLS about 0.058g/L and at phosphate
and dithionate concentrations respectively about 1.135g/L and
11.079g/L (Kafumbila J., 2022b).

Joseph Kafumbila Page 39

4.3. Reagent consumption

4.3.1. Design criteria

4.3.1.1. Acid and SO2

Acid and SO2 are produced from sulfur. The percent of conversion of sulfur to
acid and SO2 is 98%. Table (4.2) gives the specific consumption of sulfur. Molar mass of
sulfur, SO2 and acid are respectively 32.065 g/mol, 64.063g/mol and 98.075g/mol.
Equations (2.11) and (2.12) give the specific consumption of sulfur from specific
consumptions of acid and SO2.

Table 4.2: Sulfur specific consumption

Specific consumption Unit

Acid consumption 54.45 Kg/t feed
Sulfur to acid 18.17 Kg/t feed
SO2 consumption 15.10 Kg/t feed
Sulfur to SO2 7.71 Kg/t feed
Total sulfur consumption 25.88 Kg/t feed

4.3.1.2. Lix984N and Kerosene

The concentrations of organic phase in raffinate and advance electrolyte are

respectively 50mg/L and 150mg/L. The recoveries of organic phase from raffinate and
advance electrolyte are respectively 30 and 70%. The specific gravity of Lix984N and
Kerosene are respectively 0.94 and 0.81 t/m3.

Equations (2.13) and (2.14) give the lost organic in the raffinate and advance
electrolyte respectively. Equations (2.15) give the approximate specific gravity of
organic phase. Equations (2.16) and (2.17) give specific consumption of Lix984N and
Kerosene. Table (4.3) gives specific consumptions of Lix984N and Kerosene.

Table 4.3: Specific consumptions of Lix984N and Kerosene

Specific consumption Unit

Lix984N 2.08 Kg/tCu
Kerosene 7.63 Kg/tCu

4.3.1.3. EW-Guar

The specific consumption of Guar is 0.2 kg/tCu.

Joseph Kafumbila Page 40

4.3.2. Results

Table (4.4) gives reagent consumption.

Table 4.4: reagent consumption

Unit
Hours per year 8 322 hrs
Feed 6 657 600 t/y
Copper production 92 120 t/y
Sulfur 172 289 t/y
Flocculants 928 t/y
Lix984N 192 t/y
Kerosene 703 t/y
Guar 18 t/y

Joseph Kafumbila Page 41

5. References
Miller G. M., Design of Copper-Cobalt hydrometallurgical circuits, ALTA Nickel –
Cobalt conference, 2009.

Kafumbila J. Utilization efficiency of sulfur dioxide during reductive leaching of

Copper – Cobalt ores, 2020a.
(PDF) Utilization efficiency of sulfur dioxide during reductive leaching of Copper -
Cobalt ores (researchgate.net)

Kafumbila J., Prediction of dithionate and iron saturation concentrations in

solution during reductive leaching of cobalt using sulfur dioxide gas as reducing
agent, 2022a.
(PDF) Prediction of dithionate and iron saturation concentrations in solution
during reductive leaching of cobalt using sulfur dioxide gas as reducing agent
(researchgate.net)

Kafumbila J., Design of Copper solvent extraction circuit: Effect of dithionate on

copper solvent extraction recovery in sulfate media, 2022b.
(PDF) Design of Copper solvent extraction circuit Effect of dithionate on copper
solvent extraction recovery in sulfate media (researchgate.net)

Kafumbila J., Comparison between conventional and split circuits: Iron behaviors,
Reagent consumptions and Equipment sizes, 2022c.
(PDF) Comparison between conventional and split circuits: Iron behaviors,
Reagent consumptions and Equipment sizes (researchgate.net)

Kafumbila J., Design of agitated leach circuit: reductive leaching of Copper and
Cobalt ores, 2021.
(PDF) Design of agitated leach circuit (researchgate.net)

Hans Hein, Importance of a wash stage in copper solvent extraction,

Hydrocopper, 2005.

Joseph Kafumbila Page 42

Appendix A – conventional circuit having Milling in water
with pre-leach thickener unit operations

Joseph Kafumbila Page 43

 Table A.1: Mass balance – conventional circuit having Milling in water
with pre-leach thickener

1,00 2,00 3,00 4,00 5,00 6,00 7,00 8,00

Feed BMW UFCY OBM SW FeCY OFCY PRLTFC
Solid/Gas
mass t/h 800,00 2000,00 2800,00 2800,00 800,000 0,032
volume m3/h 296,30 740,74 1037,04 1037,04 296,296 0,012
SG solid t/m3 2,700 2,700 2,700 2,700 2,700 2,650
S % 0,100 0,100
CaSO4,2H2O
Pulp
mass t/h 1000,00 2683,76 4000,00 4668,95 1985,18 12,80
volume m3/h 496,30 1424,50 2237,04 2905,98 1481,48 12,78
SG solid t/m3 2,015 1,884 1,788 1,607 1,340 1,002
%solid 80,00 74,52 70,00 59,97 40,30 0,25
Liquid
mass t/h 200,00 316,24 683,76 1200,00 668,95 1868,95 1185,18 12,77
volume m3/h 200,00 316,24 683,76 1200,00 668,95 1868,95 1185,18 12,77
SG liquid t/m3 1,000 1,000 1,000 1,000 1,000 1,000 1,000 1,000
CT
H g/l
PO4 g/l
SO4 g/l
S2O6 g/l
Cu g/l
Co g/l
Zn g/l
Ni g/l
Mn g/l
Mg g/l
Al g/l
Ca g/l
Fe2 g/l
Fe3 g/l
S g/l
P g/l
AC g/l

Joseph Kafumbila Page 44

 Table A.2: Mass balance – conventional circuit having Milling in water
with pre-leach thickener

9,00 10,00 11,00 12,00 13,00 14,00 15,00 16,00

PRLTOF PRLTUF LCA SO2 RE2L CO2 OLC PTKFC
Solid/Gas
mass t/h 800,03 11,775 6,012 774,03 0,031
volume m3/h 296,31 309,61 0,012
SG solid t/m3 2,700 2,500 2,650
S % 0,100 50,052 1,500
CaSO4,2H2O 7,411
Pulp
mass t/h 1379,37 2580,11 12,38
volume m3/h 875,64 2030,24 12,37
SG solid t/m3 1,575 1,271 1,002
%solid 58,00 30,00 0,25
Liquid
mass t/h 618,62 579,33 45,64 1149,34 1806,07 12,35
volume m3/h 618,62 579,33 25,35 1107,70 1720,62 12,35
SG liquid t/m3 1,000 1,000 1,800 1,038 1,050 1,000
CT 39,58 52,73
H g/l 0,275 0,114
PO4 g/l 0,769 0,923
SO4 g/l 1727,78 25,917 30,235
S2O6 g/l 5,016 6,021
Cu g/l 0,155 6,628
Co g/l 3,762 4,514
Zn g/l 0,418 0,502
Ni g/l 0,056 0,068
Mn g/l 0,492 0,590
Mg g/l 0,838 1,005
Al g/l 0,575 0,690
Ca g/l 0,582 0,577
Fe2 g/l 0,683 0,818
Fe3 g/l 0,036 0,045
S g/l 576,73 10,660 12,504
P g/l 0,251 0,301
AC g/l 1764,00 11,031 2,910

Joseph Kafumbila Page 45

 Table A.3: Mass balance – conventional circuit having Milling in water
with pre-leach thickener

17,00 18,00 19,00 20,00 21,00 22,00 23,00 24,00

PTKOF PTKUF TK1FC TK1OF TK1UF TK2FC TK2OF TK2UF
Solid/Gas
mass t/h 774,03 0,019 774,03 0,012 774,042
volume m3/h 309,61 0,007 309,61 0,005 309,613
SG solid t/m3 2,500 2,650 2,500 2,650 2,500
S % 1,499 1,499 1,499
CaSO4,2H2O 7,407 7,405 7,404
Pulp
mass t/h 1433,39 7,43 1433,40 4,95 1433,41
volume m3/h 942,39 7,42 950,78 4,95 956,46
SG solid t/m3 1,521 1,002 1,508 1,002 1,499
%solid 54,00 0,25 54,00 0,25 54,00
Liquid
mass t/h 2134,08 659,36 7,41 974,98 659,36 4,94 967,55 659,37
volume m3/h 2048,06 632,78 7,41 948,08 641,17 4,94 949,19 646,85
SG liquid t/m3 1,042 1,042 1,000 1,028 1,028 1,000 1,019 1,019
CT 44,350 44,350 29,683 29,683 20,118 20,118
H g/l 0,095 0,095 0,063 0,063 0,043 0,043
PO4 g/l 0,770 0,770 0,502 0,502 0,327 0,327
SO4 g/l 25,486 25,486 17,176 17,176 11,758 11,758
S2O6 g/l 5,022 5,022 3,273 3,273 2,132 2,132
Cu g/l 5,528 5,528 3,603 3,603 2,346 2,346
Co g/l 3,765 3,765 2,454 2,454 1,598 1,598
Zn g/l 0,418 0,418 0,273 0,273 0,178 0,178
Ni g/l 0,056 0,056 0,037 0,037 0,024 0,024
Mn g/l 0,492 0,492 0,321 0,321 0,209 0,209
Mg g/l 0,838 0,838 0,546 0,546 0,356 0,356
Al g/l 0,576 0,576 0,375 0,375 0,244 0,244
Ca g/l 0,582 0,582 0,592 0,592 0,599 0,599
Fe2 g/l 0,683 0,683 0,445 0,445 0,290 0,290
Fe3 g/l 0,038 0,038 0,025 0,025 0,016 0,016
S g/l 10,519 10,519 7,044 7,044 4,778 4,778
P g/l 0,251 0,251 0,164 0,164 0,107 0,107
AC g/l 2,590 2,590 1,960 1,960 1,479 1,479

Joseph Kafumbila Page 46

 Table A.4: Mass balance – conventional circuit having Milling in water
with pre-leach thickener

25,00 26,00 27,00 28,00 29,00 30,00 31,00 32,00

TK3FC TK3OF TK3UF TK4FC TK4OF TK4UF TK5FC TK5OF
Solid/Gas
mass t/h 0,012 774,056 0,012 774,073 0,012
volume m3/h 0,005 309,618 0,005 309,625 0,005
SG solid t/m3 2,650 2,500 2,650 2,500 2,650
S % 1,499 1,499
CaSO4,2H2O 7,404 7,405
Pulp
mass t/h 4,95 1433,44 4,95 1433,47 4,95
volume m3/h 4,95 960,35 4,95 963,01 4,95
SG solid t/m3 1,002 1,493 1,002 1,489 1,002
%solid 0,25 54,00 0,25 54,00 0,25
Liquid
mass t/h 4,94 962,61 659,38 4,94 957,69 659,40 4,94 952,77
volume m3/h 4,94 949,99 650,73 4,94 948,95 653,38 4,94 946,68
SG liquid t/m3 1,000 1,013 1,013 1,000 1,009 1,009 1,000 1,006
CT 13,763 13,763 9,503 9,503 6,629
H g/l 0,029 0,029 0,019 0,019 0,013
PO4 g/l 0,210 0,210 0,132 0,132 0,079
SO4 g/l 8,159 8,159 5,748 5,748 4,125
S2O6 g/l 1,372 1,372 0,862 0,862 0,516
Cu g/l 1,511 1,511 0,949 0,949 0,568
Co g/l 1,029 1,029 0,646 0,646 0,387
Zn g/l 0,114 0,114 0,072 0,072 0,043
Ni g/l 0,015 0,015 0,010 0,010 0,006
Mn g/l 0,134 0,134 0,084 0,084 0,051
Mg g/l 0,229 0,229 0,144 0,144 0,086
Al g/l 0,157 0,157 0,099 0,099 0,059
Ca g/l 0,605 0,605 0,613 0,613 0,624
Fe2 g/l 0,187 0,187 0,117 0,117 0,070
Fe3 g/l 0,010 0,010 0,006 0,006 0,004
S g/l 3,273 3,273 2,264 2,264 1,583
P g/l 0,069 0,069 0,043 0,043 0,026
AC g/l 1,111 1,111 0,831 0,831 0,619

Joseph Kafumbila Page 47

 Table A.5: Mass balance – conventional circuit having Milling in water
with pre-leach thickener

33,00 34,00 35,00 36,00 37,00 38,00 39,00 40,00

TK5UF TK6FC TK6OF TK6UF TK7FC TK7OF TK7UF WW
Solid/Gas
mass t/h 774,093 0,012 774,11 0,012 771,50
volume m3/h 309,633 0,005 309,64 0,005 308,51
SG solid t/m3 2,500 2,650 2,500 2,650 2,50
S % 1,499 1,499 1,44
CaSO4,2H2O 7,405 7,406 7,09
Pulp
mass t/h 1433,51 4,95 1433,54 4,95 1428,71
volume m3/h 964,83 4,95 966,09 4,95 963,59
SG solid t/m3 1,486 1,002 1,484 1,002 1,48
%solid 54,00 0,25 54,00 0,25 54,00
Liquid
mass t/h 659,41 4,94 947,85 659,43 4,94 942,93 657,21 933,14
volume m3/h 655,20 4,94 943,56 656,45 4,94 939,87 655,07 932,98
SG liquid t/m3 1,006 1,000 1,005 1,005 1,000 1,003 1,003 1,000
CT 6,629 4,679 4,679 3,350 3,350 0,182
H g/l 0,013 0,009 0,009 0,006 0,006 0,004
PO4 g/l 0,079 0,043 0,043 0,018 0,018 0,000
SO4 g/l 4,125 3,026 3,026 2,280 2,280 0,182
S2O6 g/l 0,516 0,278 0,278 0,115 0,115 0,000
Cu g/l 0,568 0,307 0,307 0,126 0,126 0,000
Co g/l 0,387 0,209 0,209 0,086 0,086 0,000
Zn g/l 0,043 0,023 0,023 0,010 0,010 0,000
Ni g/l 0,006 0,003 0,003 0,001 0,001 0,000
Mn g/l 0,051 0,027 0,027 0,011 0,011 0,000
Mg g/l 0,086 0,046 0,046 0,019 0,019 0,000
Al g/l 0,059 0,032 0,032 0,013 0,013 0,000
Ca g/l 0,624 0,636 0,636 0,649 0,649 0,000
Fe2 g/l 0,070 0,038 0,038 0,016 0,016 0,000
Fe3 g/l 0,004 0,002 0,002 0,001 0,001 0,000
S g/l 1,583 1,122 1,122 0,807 0,807 0,061
P g/l 0,026 0,014 0,014 0,006 0,006 0,000
AC g/l 0,619 0,458 0,458 0,337 0,337 0,334

Joseph Kafumbila Page 48

 Table A.6: Mass balance – conventional circuit having Milling in water
with pre-leach thickener

41,00 42,00 43,00 44,00 45,00 46,00 47,00 48,00

ACS PLS RE1 LOE1 ALOE1 RE2 LOE2 ALOE2
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 5,136 2139,22 2130,23 2,560 2126,65 2,560
volume m3/h 4,327 2052,31 2051,60 2560,08 2,466 2049,60 2560,08 2,467
SG liquid t/m3 1,187 1,042 1,038 1,038 1,038 1,038
CT 223,50 44,730 40,364 40,364 39,575 39,575
H g/l 3,013 0,102 0,245 0,245 0,275 0,275
PO4 g/l 0,408 0,769 0,769 0,769 0,769 0,769
SO4 g/l 189,47 25,833 25,842 25,842 25,917 25,917
S2O6 g/l 1,715 5,015 5,017 5,017 5,016 5,016
Cu g/l 23,743 5,567 1,043 7,083 1,043 0,155 3,457 0,155
Co g/l 1,997 3,762 3,763 3,763 3,762 3,762
Zn g/l 0,222 0,418 0,418 0,418 0,418 0,418
Ni g/l 0,030 0,056 0,056 0,056 0,056 0,056
Mn g/l 0,261 0,492 0,492 0,492 0,492 0,492
Mg g/l 0,445 0,838 0,838 0,838 0,838 0,838
Al g/l 0,305 0,575 0,575 0,575 0,575 0,575
Ca g/l 0,309 0,582 0,582 0,582 0,582 0,582
Fe2 g/l 0,902 0,683 0,683 0,683 0,683 0,683
Fe3 g/l 0,682 0,039 0,040 0,0035 0,040 0,036 0,0044 0,036
S g/l 63,933 10,632 10,635 10,635 10,660 10,660
P g/l 0,133 0,251 0,251 0,251 0,251 0,251
AC g/l 124,03 2,806 9,392 9,392 11,031 11,031

Joseph Kafumbila Page 49

 Table A.7: Mass balance – conventional circuit having Milling in water
with pre-leach thickener

49,00 50,00 51,00 52,00 53,00 54,00 55,00 56,00

RE2B ACTD LOAC ALOAC ADS1 RADS1 SOS1 ASOS1
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 977,309 1,536 1,024 934,85 1633,65 0,768
volume m3/h 941,901 1,479 2560,08 0,986 746,43 1304,37 2560,08 0,613
SG liquid t/m3 1,038 1,038 1,038 1,252 1,252 1,252
CT 39,575 40,364 40,364 301,637 326,16
H g/l 0,275 0,245 0,245 3,881 3,881 3,881
PO4 g/l 0,769 0,769 0,769 0,217 0,217 0,217
SO4 g/l 25,917 25,842 25,842 268,51 268,505 268,51
S2O6 g/l 5,016 5,017 5,017 0,007 0,007 0,007
Cu g/l 0,155 1,043 7,083 1,043 49,664 49,664 3,692 49,664
Co g/l 3,762 3,763 3,763 1,060 1,060 1,060
Zn g/l 0,418 0,418 0,418 0,118 0,118 0,118
Ni g/l 0,056 0,056 0,056 0,016 0,016 0,016
Mn g/l 0,492 0,492 0,492 0,139 0,139 0,139
Mg g/l 0,838 0,838 0,838 0,236 0,236 0,236
Al g/l 0,575 0,575 0,575 0,162 0,162 0,162
Ca g/l 0,582 0,582 0,582 0,164 0,164 0,164
Fe2 g/l 0,683 0,683 0,683 0,994 0,994 0,994
Fe3 g/l 0,0364 0,040 0,0035 0,040 1,0015 1,002 0,0010 1,002
S g/l 10,660 10,635 10,635 89,629 89,629 89,629
P g/l 0,251 0,251 0,251 0,071 0,071 0,071
AC g/l 11,031 9,392 9,392 143,89 143,894 143,89

Joseph Kafumbila Page 50

 Table A.8: Mass balance – conventional circuit having Milling in water
with pre-leach thickener

57,00 58,00 59,00 60,00 61,00 62,00 63,00 64,00

ADS2 RADS2 SOS2 ASOS2 EWCA EWW EWCC EWO
Solid/Gas
mass t/h 11,004 2,773
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 926,19 1627,98 0,768 0,955 5,392
volume m3/h 742,78 1305,59 2560,08 0,616 0,530 5,392
SG liquid t/m3 1,247 1,247 1,247 1,800 1,000
CT 301,637 316,65
H g/l 4,274 4,274 4,274
PO4 g/l 0,217 0,217 0,217
SO4 g/l 270,01 270,012 270,01
S2O6 g/l 0,000 0,000 0,000
Cu g/l 38,258 38,258 2,736 38,258
Co g/l 1,062 1,062 1,062
Zn g/l 0,118 0,118 0,118
Ni g/l 0,016 0,016 0,016
Mn g/l 0,139 0,139 0,139
Mg g/l 0,236 0,236 0,236
Al g/l 0,162 0,162 0,162
Ca g/l 0,164 0,164 0,164
Fe2 g/l 0,999 0,999 0,999
Fe3 g/l 0,9988 0,999 0,0010 0,999
S g/l 90,129 90,129 90,129 576,699
P g/l 0,071 0,071 0,071
AC g/l 171,83 171,830 171,83 1764,000

Joseph Kafumbila Page 51

 Table A.9: Mass balance – conventional circuit having Milling in water
with pre-leach thickener

65,00 66,00 67,00 68,00 69,00 70,00 71,00 72,00

EWS OEW SPE EWB
Solid/Gas
mass t/h 0,0010
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 927,42 923,823 3,600
volume m3/h 744,75 741,86 2,891
SG liquid t/m3 1,245 1,245 1,245
CT 313,85 313,85 313,85
H g/l 4,384 4,384 4,384
PO4 g/l 0,217 0,217 0,217
SO4 g/l 270,35 270,348 270,348
S2O6 g/l 0,000 0,000 0,000
Cu g/l 35,000 35,000 35,000
Co g/l 1,063 1,063 1,063
Zn g/l 0,118 0,118 0,118
Ni g/l 0,016 0,016 0,016
Mn g/l 0,139 0,139 0,139
Mg g/l 0,237 0,237 0,237
Al g/l 0,162 0,162 0,162
Ca g/l 0,164 0,164 0,164
Fe2 g/l 1,000 1,000 1,000
Fe3 g/l 1,0000 1,000 1,000
S g/l 90,242 90,242 90,242
P g/l 0,071 0,071 0,071
AC g/l 180,00 180,000 180,000

Joseph Kafumbila Page 52

Appendix B – Conventional circuit having Milling in water
with pre-leach filter unit operations

Joseph Kafumbila Page 53

 Table B.1: Mass balance – conventional circuit having Milling in water
with pre-leach filter

1,00 2,00 3,00 4,00 5,00 6,00 7,00 8,00

Feed BMW UFCY OBM SW FeCY OFCY PRLTFC
Solid/Gas
mass t/h 800,00 2000,00 2800,00 2800,00 800,00 0,032
volume m3/h 296,30 740,74 1037,04 1037,04 296,296 0,012
SG solid t/m3 2,700 2,700 2,700 2,700 2,700 2,650
S % 0,100 0,100
CaSO4,2H2O
Pulp
mass t/h 1000,00 2683,76 4000,00 4668,95 1985,18 12,80
volume m3/h 496,30 1424,50 2237,04 2905,98 1481,48 12,78
SG solid t/m3 2,015 1,884 1,788 1,607 1,340 1,002
%solid 80,00 74,52 70,00 59,97 40,30 0,25
Liquid
mass t/h 200,00 316,24 683,76 1200,00 668,95 1868,95 1185,18 12,77
volume m3/h 200,00 316,24 683,76 1200,00 668,95 1868,95 1185,18 12,77
SG liquid t/m3 1,000 1,000 1,000 1,000 1,000 1,000 1,000 1,000
CT
H g/l
PO4 g/l
SO4 g/l
S2O6 g/l
Cu g/l
Co g/l
Zn g/l
Ni g/l
Mn g/l
Mg g/l
Al g/l
Ca g/l
Fe2 g/l
Fe3 g/l
S g/l
P g/l
AC g/l

Joseph Kafumbila Page 54

 Table B.2: Mass balance – conventional circuit having Milling in water
with pre-leach filter

9,00 10,00 11,00 12,00 13,00 14,00 15,00 16,00

PRLTOF PRLTUF PRLFFC PRLFFL PRLFCa LCA SO2 RE2L
Solid/Gas
mass t/h 800,03 0,048 800,08 11,808
volume m3/h 296,31 0,018 296,33
SG solid t/m3 2,700 2,650 2,700
S % 0,100 0,100 50,052
CaSO4,2H2O
Pulp
mass t/h 1379,37 19,20 1025,74
volume m3/h 875,64 19,17 521,99
SG solid t/m3 1,575 1,002 1,965
%solid 58,00 0,25 78,00
Liquid
mass t/h 618,62 579,33 19,15 372,82 225,66 42,15 1506,58
volume m3/h 618,62 579,33 19,15 372,82 225,66 23,42 1436,23
SG liquid t/m3 1,000 1,000 1,000 1,000 1,000 1,800 1,049
CT 51,98
H g/l 0,288
PO4 g/l 1,102
SO4 g/l 1727,78 29,463
S2O6 g/l 10,521
Cu g/l 0,163
Co g/l 5,389
Zn g/l 0,599
Ni g/l 0,081
Mn g/l 0,704
Mg g/l 1,200
Al g/l 0,824
Ca g/l 0,618
Fe2 g/l 0,980
Fe3 g/l 576,73 0,051
S g/l 14,048
P g/l 1764,00 0,359
AC g/l 10,846

Joseph Kafumbila Page 55

 Table B.3: Mass balance – conventional circuit having Milling in water
with pre-leach filter

17,00 18,00 19,00 20,00 21,00 22,00 23,00 24,00

CO2 OLC PTKFC PTKOF PTKUF TK1FC TK1OF TK1UF
Solid/Gas
mass t/h 6,012 774,08 0,031 774,07 0,019 774,06
volume m3/h 309,63 0,012 309,63 0,007 309,62
SG solid t/m3 2,500 2,650 2,500 2,650 2,500
S % 1,500 1,499 1,498
CaSO4,2H2O 7,410 7,406 7,402
Pulp
mass t/h 2580,27 12,39 1433,47 7,43 1433,45
volume m3/h 2006,33 12,37 935,83 7,42 947,49
SG solid t/m3 1,286 1,002 1,532 1,002 1,513
%solid 30,00 0,25 54,00 0,25 54,00
Liquid
mass t/h 1806,19 12,35 2200,76 659,40 7,41 1041,58 659,39
volume m3/h 1696,70 12,35 2089,98 626,20 7,41 1007,59 637,87
SG liquid t/m3 1,065 1,000 1,053 1,053 1,000 1,034 1,034
CT 69,26 56,41 56,414 35,417 35,417
H g/l 0,128 0,10 0,104 0,065 0,065
PO4 g/l 1,366 1,10 1,104 0,675 0,675
SO4 g/l 35,155 28,73 28,735 18,242 18,242
S2O6 g/l 13,054 10,546 10,546 6,446 6,446
Cu g/l 6,758 5,460 5,460 3,337 3,337
Co g/l 6,683 5,399 5,399 3,300 3,300
Zn g/l 0,743 0,600 0,600 0,367 0,367
Ni g/l 0,100 0,081 0,081 0,050 0,050
Mn g/l 0,873 0,705 0,705 0,431 0,431
Mg g/l 1,488 1,202 1,202 0,735 0,735
Al g/l 1,022 0,825 0,825 0,505 0,505
Ca g/l 0,610 0,619 0,619 0,634 0,634
Fe2 g/l 1,212 0,979 0,979 0,599 0,599
Fe3 g/l 0,066 0,054 0,054 0,033 0,033
S g/l 16,963 13,815 13,815 8,671 8,671
P g/l 0,446 0,360 0,360 0,220 0,220
AC g/l 2,915 2,552 2,552 1,866 1,866

Joseph Kafumbila Page 56

 Table B.4: Mass balance – conventional circuit having Milling in water
with pre-leach filter

25,00 26,00 27,00 28,00 29,00 30,00 31,00 32,00

TK2FC TK2OF TK2UF TK3FC TK3OF TK3UF TK4FC TK4OF
Solid/Gas
mass t/h 0,012 774,061 0,012 774,063 0,012
volume m3/h 0,005 309,619 0,005 309,619 0,005
SG solid t/m3 2,650 2,500 2,650 2,500 2,650
S % 1,498 1,498
CaSO4,2H2O 7,400 7,399
Pulp
mass t/h 4,95 1433,45 4,95 1433,45 4,95
volume m3/h 4,95 954,96 4,95 959,77 4,95
SG solid t/m3 1,002 1,501 1,002 1,494 1,002
%solid 0,25 54,00 0,25 54,00 0,25
Liquid
mass t/h 4,94 1034,13 659,39 4,94 1029,17 659,39 4,94 1024,22
volume m3/h 4,94 1012,11 645,35 4,94 1014,75 650,15 4,94 1014,64
SG liquid t/m3 1,000 1,022 1,022 1,000 1,014 1,014 1,000 1,009
CT 22,654 22,654 14,727 14,727 9,748
H g/l 0,041 0,041 0,027 0,027 0,017
PO4 g/l 0,414 0,414 0,252 0,252 0,150
SO4 g/l 11,863 11,863 7,901 7,901 5,414
S2O6 g/l 3,955 3,955 2,407 2,407 1,435
Cu g/l 2,047 2,047 1,246 1,246 0,743
Co g/l 2,025 2,025 1,233 1,233 0,735
Zn g/l 0,225 0,225 0,137 0,137 0,082
Ni g/l 0,030 0,030 0,018 0,018 0,011
Mn g/l 0,265 0,265 0,161 0,161 0,096
Mg g/l 0,451 0,451 0,274 0,274 0,164
Al g/l 0,310 0,310 0,188 0,188 0,112
Ca g/l 0,642 0,642 0,646 0,646 0,649
Fe2 g/l 0,367 0,367 0,224 0,224 0,133
Fe3 g/l 0,020 0,020 0,012 0,012 0,007
S g/l 5,544 5,544 3,602 3,602 2,382
P g/l 0,135 0,135 0,082 0,082 0,049
AC g/l 1,361 1,361 0,993 0,993 0,727

Joseph Kafumbila Page 57

 Table B.5: Mass balance – conventional circuit having Milling in water
with pre-leach filter

33,00 34,00 35,00 36,00 37,00 38,00 39,00 40,00

TK4UF TK5FC TK5OF TK5UF TK6FC TK6OF TK6UF TK7FC
Solid/Gas
mass t/h 774,07 0,012 774,07 0,012 774,08 0,012
volume m3/h 309,621 0,005 309,622 0,005 309,62 0,005
SG solid t/m3 2,500 2,650 2,500 2,650 2,500 2,650
S % 1,497 1,497 1,497
CaSO4,2H2O 7,398 7,397 7,395
Pulp
mass t/h 1433,46 4,95 1433,47 4,95 1433,47 4,95
volume m3/h 962,85 4,95 964,83 4,95 966,10 4,95
SG solid t/m3 1,489 1,002 1,486 1,002 1,484 1,002
%solid 54,00 0,25 54,00 0,25 54,00 0,25
Liquid
mass t/h 659,39 4,94 1019,27 659,40 4,94 1014,33 659,40 4,94
volume m3/h 653,23 4,94 1012,80 655,21 4,94 1009,84 656,48 4,94
SG liquid t/m3 1,009 1,000 1,006 1,006 1,000 1,004 1,004 1,000
CT 9,748 6,593 6,593 4,578 4,578
H g/l 0,017 0,011 0,011 0,008 0,008
PO4 g/l 0,150 0,086 0,086 0,044 0,044
SO4 g/l 5,414 3,839 3,839 2,835 2,835
S2O6 g/l 1,435 0,818 0,818 0,422 0,422
Cu g/l 0,743 0,423 0,423 0,219 0,219
Co g/l 0,735 0,419 0,419 0,216 0,216
Zn g/l 0,082 0,047 0,047 0,024 0,024
Ni g/l 0,011 0,006 0,006 0,003 0,003
Mn g/l 0,096 0,055 0,055 0,028 0,028
Mg g/l 0,164 0,093 0,093 0,048 0,048
Al g/l 0,112 0,064 0,064 0,033 0,033
Ca g/l 0,649 0,653 0,653 0,656 0,656
Fe2 g/l 0,133 0,076 0,076 0,039 0,039
Fe3 g/l 0,007 0,004 0,004 0,002 0,002
S g/l 2,382 1,609 1,609 1,115 1,115
P g/l 0,049 0,028 0,028 0,014 0,014
AC g/l 0,727 0,537 0,537 0,403 0,403

Joseph Kafumbila Page 58

 Table B.6: Mass balance – conventional circuit having Milling in water
with pre-leach filter

41,00 42,00 43,00 44,00 45,00 46,00 47,00 48,00

TK7OF TK7UF WW ACS PLS RE1 LOE1 ALOE1
Solid/Gas
mass t/h 771,26
volume m3/h 308,41
SG solid t/m3 2,50
S % 1,43
CaSO4,2H2O 7,06
Pulp
mass t/h 1428,27
volume m3/h 963,32
SG solid t/m3 1,48
%solid 54,00
Liquid
mass t/h 1009,38 657,00 999,22 8,500 2209,26 2200,19 2,612
volume m3/h 1006,17 654,91 999,04 7,018 2096,82 2095,98 2612,48 2,489
SG liquid t/m3 1,003 1,003 1,000 1,211 1,054 1,050 1,050
CT 3,281 3,281 0,182 258,87 57,096 52,792 52,792
H g/l 0,005 0,005 0,004 3,524 0,116 0,257 0,257
PO4 g/l 0,017 0,017 0,000 0,375 1,101 1,102 1,102
SO4 g/l 2,189 2,189 0,182 219,71 29,376 29,388 29,388
S2O6 g/l 0,167 0,167 0,000 2,239 10,519 10,523 10,523
Cu g/l 0,086 0,086 0,000 28,014 5,536 1,067 7,062 1,067
Co g/l 0,085 0,085 0,000 1,834 5,388 5,390 5,390
Zn g/l 0,009 0,009 0,000 0,204 0,599 0,599 0,599
Ni g/l 0,001 0,001 0,000 0,028 0,081 0,081 0,081
Mn g/l 0,011 0,011 0,000 0,240 0,704 0,704 0,704
Mg g/l 0,019 0,019 0,000 0,408 1,200 1,200 1,200
Al g/l 0,013 0,013 0,000 0,280 0,824 0,824 0,824
Ca g/l 0,660 0,660 0,000 0,210 0,618 0,618 0,618
Fe2 g/l 0,015 0,015 0,000 1,002 0,980 0,980 0,980
Fe3 g/l 0,001 0,001 0,000 0,806 0,056 0,058 0,0054 0,058
S g/l 0,798 0,798 0,061 74,236 14,019 14,024 14,024
P g/l 0,006 0,006 0,000 0,122 0,359 0,359 0,359
AC g/l 0,310 0,310 0,334 144,93 2,946 9,240 9,240

Joseph Kafumbila Page 59

 Table B.7: Mass balance – conventional circuit having Milling in water
with pre-leach filter

49,00 50,00 51,00 52,00 53,00 54,00 55,00 56,00

RE2 LOE2 ALOE2 RE2B ACTD LOAC ALOAC ADS1
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 2196,50 2,612 689,921 1,567 1,045 947,37
volume m3/h 2093,93 2612,48 2,490 657,705 1,493 2612,48 0,995 757,07
SG liquid t/m3 1,049 1,049 1,049 1,050 1,050 1,251
CT 51,982 51,982 51,982 52,792 52,792
H g/l 0,288 0,288 0,288 0,257 0,257 3,867
PO4 g/l 1,102 1,102 1,102 1,102 1,102 0,177
SO4 g/l 29,463 29,463 29,463 29,388 29,388 267,05
S2O6 g/l 10,521 10,521 10,521 10,523 10,523 0,014
Cu g/l 0,163 3,476 0,163 0,163 1,067 7,062 1,067 49,666
Co g/l 5,389 5,389 5,389 5,390 5,390 0,867
Zn g/l 0,599 0,599 0,599 0,599 0,599 0,096
Ni g/l 0,081 0,081 0,081 0,081 0,081 0,013
Mn g/l 0,704 0,704 0,704 0,704 0,704 0,113
Mg g/l 1,200 1,200 1,200 1,200 1,200 0,193
Al g/l 0,824 0,824 0,824 0,824 0,824 0,132
Ca g/l 0,618 0,618 0,618 0,618 0,618 0,099
Fe2 g/l 0,980 0,980 0,980 0,980 0,980 0,994
Fe3 g/l 0,051 0,0066 0,051 0,0510 0,058 0,0054 0,058 1,0082
S g/l 14,048 14,048 14,048 14,024 14,024 89,147
P g/l 0,359 0,359 0,359 0,359 0,359 0,058
AC g/l 10,846 10,846 10,846 9,240 9,240 143,81

Joseph Kafumbila Page 60

 Table B.8: Mass balance – conventional circuit having Milling in water
with pre-leach filter

57,00 58,00 59,00 60,00 61,00 62,00 63,00 64,00

RADS1 SOS1 ASOS1 ADS2 RADS2 SOS2 ASOS2 EWCA
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 1671,39 0,784 938,60 1665,52 0,784 1,693
volume m3/h 1335,65 2612,48 0,626 753,40 1336,89 2612,48 0,629 0,940
SG liquid t/m3 1,251 1,251 1,246 1,246 1,246 1,800
CT 301,637 324,29 301,637 314,75
H g/l 3,867 3,867 4,260 4,260 4,260
PO4 g/l 0,177 0,177 0,177 0,177 0,177
SO4 g/l 267,051 267,05 268,54 268,536 268,54
S2O6 g/l 0,014 0,014 0,000 0,000 0,000
Cu g/l 49,666 3,696 49,666 38,274 38,274 2,742 38,274
Co g/l 0,867 0,867 0,864 0,864 0,864
Zn g/l 0,096 0,096 0,096 0,096 0,096
Ni g/l 0,013 0,013 0,013 0,013 0,013
Mn g/l 0,113 0,113 0,113 0,113 0,113
Mg g/l 0,193 0,193 0,192 0,192 0,192
Al g/l 0,132 0,132 0,132 0,132 0,132
Ca g/l 0,099 0,099 0,099 0,099 0,099
Fe2 g/l 0,994 0,994 0,999 0,999 0,999
Fe3 g/l 1,008 0,0010 1,008 0,9988 0,999 0,0010 0,999
S g/l 89,147 89,147 89,637 89,637 89,637 576,699
P g/l 0,058 0,058 0,058 0,058 0,058
AC g/l 143,815 143,81 171,78 171,778 171,78 1764,000

Joseph Kafumbila Page 61

 Table B.9: Mass balance – conventional circuit having Milling in water
with pre-leach filter

65,00 66,00 67,00 68,00 69,00 70,00 71,00 72,00

EWW EWCC EWO EWS OEW SPE EWB
Solid/Gas
mass t/h 11,069 2,789 0,0021
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 7,909 943,11 936,182 6,932
volume m3/h 7,909 758,04 752,47 5,572
SG liquid t/m3 1,000 1,244 1,244 1,244
CT 311,93 311,93 311,93
H g/l 4,370 4,370 4,370
PO4 g/l 0,177 0,177 0,177
SO4 g/l 268,87 268,870 268,870
S2O6 g/l 0,000 0,000 0,000
Cu g/l 35,000 35,000 35,000
Co g/l 0,865 0,865 0,865
Zn g/l 0,096 0,096 0,096
Ni g/l 0,013 0,013 0,013
Mn g/l 0,113 0,113 0,113
Mg g/l 0,193 0,193 0,193
Al g/l 0,132 0,132 0,132
Ca g/l 0,099 0,099 0,099
Fe2 g/l 1,000 1,000 1,000
Fe3 g/l 1,0000 1,000 1,000
S g/l 89,748 89,748 89,748
P g/l 0,058 0,058 0,058
AC g/l 180,00 180,000 180,000

Joseph Kafumbila Page 62

Appendix C – Conventional circuit having Milling in raffinate unit
operation

Joseph Kafumbila Page 63

 Table C.1: Mass balance – conventional circuit having Milling in raffinate

1,00 2,00 3,00 4,00 5,00 6,00 7,00 8,00

Feed RaBM UFCY OBM RaS FeCY OFCY LCA
Solid/Gas
mass t/h 800,00 2000,00 2800,00 2800,00 800,00
volume m3/h 296,30 740,74 1037,04 1037,04 296,30
SG solid t/m3 2,700 2,700 2,700 2,700 2,700
S % 0,100 0,100 0,100 0,100 0,100
CaSO4,2H2O
Pulp
mass t/h 1000,00 2712,43 4000,00 4747,32 2034,88
volume m3/h 496,30 1424,50 2194,40 2905,98 1481,48
SG solid t/m3 2,015 1,904 1,823 1,634 1,374
%solid 80,00 73,73 70,00 58,98 39,31
Liquid
mass t/h 200,00 287,57 712,43 1200,00 747,32 1947,32 1234,88 41,45
volume m3/h 200,00 273,84 683,76 1157,37 711,63 1868,95 1185,19 23,03
SG liquid t/m3 1,000 1,050 1,042 1,037 1,050 1,042 1,042 1,800
CT 53,255 0,000 38,76 53,26 44,28 44,279
H g/l 0,289 0,241 0,211 0,289 0,241 0,241
PO4 g/l 1,136 0,944 0,826 1,136 0,944 0,944
SO4 g/l 29,83 24,805 21,713 29,833 24,805 24,805 1727,78
S2O6 g/l 11,08 9,213 8,064 11,081 9,213 9,213
Cu g/l 0,16 0,136 0,119 0,164 0,136 0,136
Co g/l 5,56 4,619 4,043 5,555 4,619 4,619
Zn g/l 0,62 0,513 0,449 0,617 0,513 0,513
Ni g/l 0,08 0,069 0,061 0,083 0,069 0,069
Mn g/l 0,73 0,604 0,528 0,726 0,604 0,604
Mg g/l 1,24 1,028 0,900 1,237 1,028 1,028
Al g/l 0,85 0,706 0,618 0,849 0,706 0,706
Ca g/l 0,62 0,516 0,452 0,621 0,516 0,516
Fe2 g/l 1,01 0,840 0,735 1,010 0,840 0,840
Fe3 g/l 0,05 0,044 0,038 0,053 0,044 0,044
S g/l 14,40 11,970 10,477 14,396 11,970 11,970 576,73
P g/l 0,37 0,308 0,270 0,370 0,308 0,308
AC g/l 10,83 9,381 8,451 10,831 9,381 9,381 1764,00

Joseph Kafumbila Page 64

 Table C.2: Mass balance – conventional circuit having Milling in raffinate

9,00 10,00 11,00 12,00 13,00 14,00 15,00 16,00

SO2 RaLC CO2 OLC PTKFC PTKOF PTKUF TK1FC
Solid/Gas
mass t/h 12,080 6,012 774,00 0,031 773,99 0,019
volume m3/h 309,60 0,012 309,60 0,007
SG solid t/m3 2,500 2,650 2,500 2,650
S % 50,052 1,500 1,499
CaSO4,2H2O 7,411 7,406
Pulp
mass t/h 2580,00 12,38 1433,32 7,43
volume m3/h 2003,69 12,36 935,07 7,42
SG solid t/m3 1,288 1,002 1,533 1,002
%solid 30,00 0,25 54,00 0,25
Liquid
mass t/h 497,60 1806,00 12,35 2206,25 659,33 7,41
volume m3/h 473,84 1694,09 12,35 2092,96 625,47 7,41
SG liquid t/m3 1,050 1,066 1,000 1,054 1,054 1,000
CT 53,26 70,98 57,654 57,654
H g/l 0,289 0,130 0,105 0,105
PO4 g/l 1,136 1,413 1,138 1,138
SO4 g/l 29,833 35,667 29,073 29,073
S2O6 g/l 11,081 13,790 11,109 11,109
Cu g/l 0,164 6,772 5,455 5,455
Co g/l 5,555 6,910 5,567 5,567
Zn g/l 0,617 0,768 0,619 0,619
Ni g/l 0,083 0,104 0,083 0,083
Mn g/l 0,726 0,903 0,727 0,727
Mg g/l 1,237 1,539 1,240 1,240
Al g/l 0,849 1,057 0,851 0,851
Ca g/l 0,621 0,612 0,622 0,622
Fe2 g/l 1,010 1,253 1,010 1,010
Fe3 g/l 0,053 0,069 0,055 0,055
S g/l 14,396 17,428 14,154 14,154
P g/l 0,370 0,461 0,371 0,371
AC g/l 10,831 2,913 2,548 2,548

Joseph Kafumbila Page 65

 Table C.3: Mass balance – conventional circuit having Milling in raffinate

17,00 18,00 19,00 20,00 21,00 22,00 23,00 24,00

TK1OF TK1UF TK2FC TK2OF TK2UF TK3FC TK3OF TK3UF
Solid/Gas
mass t/h 773,98 0,012 773,978 0,012 773,979
volume m3/h 309,59 0,005 309,587 0,005 309,587
SG solid t/m3 2,500 2,650 2,500 2,650 2,500
S % 1,498 1,498 1,498
CaSO4,2H2O 7,403 7,401 7,399
Pulp
mass t/h 1433,30 4,95 1433,29 4,95 1433,29
volume m3/h 947,06 4,95 954,71 4,95 959,60
SG solid t/m3 1,513 1,002 1,501 1,002 1,494
%solid 54,00 0,25 54,00 0,25 54,00
Liquid
mass t/h 1047,18 659,32 4,94 1039,73 659,31 4,94 1034,77 659,32
volume m3/h 1012,48 637,47 4,94 1017,36 645,13 4,94 1020,17 650,02
SG liquid t/m3 1,034 1,034 1,000 1,022 1,022 1,000 1,014 1,014
CT 35,994 35,994 22,907 22,907 14,825 14,825
H g/l 0,065 0,065 0,041 0,041 0,026 0,026
PO4 g/l 0,692 0,692 0,422 0,422 0,256 0,256
SO4 g/l 18,360 18,360 11,887 11,887 7,889 7,889
S2O6 g/l 6,752 6,752 4,121 4,121 2,497 2,497
Cu g/l 3,316 3,316 2,024 2,024 1,226 1,226
Co g/l 3,384 3,384 2,065 2,065 1,251 1,251
Zn g/l 0,376 0,376 0,229 0,229 0,139 0,139
Ni g/l 0,051 0,051 0,031 0,031 0,019 0,019
Mn g/l 0,442 0,442 0,270 0,270 0,163 0,163
Mg g/l 0,753 0,753 0,460 0,460 0,279 0,279
Al g/l 0,517 0,517 0,316 0,316 0,191 0,191
Ca g/l 0,638 0,638 0,645 0,645 0,649 0,649
Fe2 g/l 0,614 0,614 0,375 0,375 0,227 0,227
Fe3 g/l 0,034 0,034 0,021 0,021 0,012 0,012
S g/l 8,833 8,833 5,618 5,618 3,633 3,633
P g/l 0,226 0,226 0,138 0,138 0,083 0,083
AC g/l 1,858 1,858 1,352 1,352 0,983 0,983

Joseph Kafumbila Page 66

 Table C.4: Mass balance – conventional circuit having Milling in raffinate

25,00 26,00 27,00 28,00 29,00 30,00 31,00 32,00

TK4FC TK4OF TK4UF TK5FC TK5OF TK5UF TK6FC TK6OF
Solid/Gas
mass t/h 0,012 773,983 0,012 773,986 0,012
volume m3/h 0,005 309,588 0,005 309,589 0,005
SG solid t/m3 2,650 2,500 2,650 2,500 2,650
S % 1,498 1,497
CaSO4,2H2O 7,398 7,397
Pulp
mass t/h 4,95 1433,30 4,95 1433,31 4,95
volume m3/h 4,95 962,72 4,95 964,72 4,95
SG solid t/m3 1,002 1,489 1,002 1,486 1,002
%solid 0,25 54,00 0,25 54,00 0,25
Liquid
mass t/h 4,94 1029,82 659,32 4,94 1024,87 659,32 4,94 1019,93
volume m3/h 4,94 1020,16 653,14 4,94 1018,36 655,13 4,94 1015,42
SG liquid t/m3 1,000 1,009 1,009 1,000 1,006 1,006 1,000 1,004
CT 9,776 9,776 6,594 6,594 4,572
H g/l 0,017 0,017 0,011 0,011 0,008
PO4 g/l 0,152 0,152 0,086 0,086 0,044
SO4 g/l 5,392 5,392 3,819 3,819 2,822
S2O6 g/l 1,482 1,482 0,841 0,841 0,433
Cu g/l 0,728 0,728 0,413 0,413 0,212
Co g/l 0,742 0,742 0,421 0,421 0,217
Zn g/l 0,082 0,082 0,047 0,047 0,024
Ni g/l 0,011 0,011 0,006 0,006 0,003
Mn g/l 0,097 0,097 0,055 0,055 0,028
Mg g/l 0,165 0,165 0,094 0,094 0,048
Al g/l 0,114 0,114 0,064 0,064 0,033
Ca g/l 0,652 0,652 0,655 0,655 0,658
Fe2 g/l 0,135 0,135 0,076 0,076 0,039
Fe3 g/l 0,007 0,007 0,004 0,004 0,002
S g/l 2,393 2,393 1,612 1,612 1,115
P g/l 0,049 0,049 0,028 0,028 0,014
AC g/l 0,718 0,718 0,531 0,531 0,399

Joseph Kafumbila Page 67

 Table C.5: Mass balance – conventional circuit having Milling in raffinate

33,00 34,00 35,00 36,00 37,00 38,00 39,00 40,00

TK6UF TK7FC TK7OF TK7UF WW ACS PLS RE1
Solid/Gas
mass t/h 773,99 0,012 771,160
volume m3/h 309,59 0,005 308,369
SG solid t/m3 2,500 2,650 2,501
S % 1,497 1,433
CaSO4,2H2O 7,395 7,054
Pulp
mass t/h 1433,31 4,95 1428,07
volume m3/h 966,00 4,95 963,20
SG solid t/m3 1,484 1,002 1,483
%solid 54,00 0,25 54,00
Liquid
mass t/h 659,32 4,94 1014,97 656,91 1004,78 8,871 2215,12 2206,03
volume m3/h 656,41 4,94 1011,75 654,83 1004,61 7,315 2100,09 2099,23
SG liquid t/m3 1,004 1,000 1,003 1,003 1,000 1,213 1,055 1,051
CT 4,572 3,276 3,276 0,182 261,16 58,368 54,068
H g/l 0,008 0,005 0,005 0,004 3,558 0,117 0,259
PO4 g/l 0,044 0,017 0,017 0,000 0,372 1,135 1,136
SO4 g/l 2,822 2,183 2,183 0,182 221,68 29,747 29,759
S2O6 g/l 0,433 0,170 0,170 0,000 2,263 11,079 11,083
Cu g/l 0,212 0,084 0,084 0,000 28,298 5,535 1,070
Co g/l 0,217 0,085 0,085 0,000 1,818 5,554 5,556
Zn g/l 0,024 0,009 0,009 0,000 0,202 0,617 0,617
Ni g/l 0,003 0,001 0,001 0,000 0,027 0,083 0,083
Mn g/l 0,028 0,011 0,011 0,000 0,238 0,726 0,726
Mg g/l 0,048 0,019 0,019 0,000 0,405 1,237 1,237
Al g/l 0,033 0,013 0,013 0,000 0,278 0,849 0,850
Ca g/l 0,658 0,661 0,661 0,000 0,203 0,621 0,621
Fe2 g/l 0,039 0,015 0,015 0,000 1,009 1,010 1,010
Fe3 g/l 0,002 0,001 0,001 0,000 0,814 0,058 0,060
S g/l 1,115 0,797 0,797 0,061 74,911 14,367 14,372
P g/l 0,014 0,006 0,006 0,000 0,121 0,370 0,370
AC g/l 0,399 0,308 0,308 0,334 146,31 2,961 9,228

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 Table C.6: Mass balance – conventional circuit having Milling in raffinate

41,00 42,00 43,00 44,00 45,00 46,00 47,00 48,00

LOE1 ALOE1 RE2 LOE2 ALOE2 RE2B ACTD LOAC
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 2,616 2202,34 2,616 669,858 1,570
volume m3/h 2616,20 2,490 2097,18 2616,20 2,491 637,875 1,494 2616,20
SG liquid t/m3 1,051 1,050 1,050 1,050 1,051
CT 54,068 53,255 53,255 53,255 54,068
H g/l 0,259 0,289 0,289 0,289 0,259
PO4 g/l 1,136 1,136 1,136 1,136 1,136
SO4 g/l 29,759 29,833 29,833 29,833 29,759
S2O6 g/l 11,083 11,081 11,081 11,081 11,083
Cu g/l 7,063 1,070 0,164 3,479 0,164 0,164 1,070 7,063
Co g/l 5,556 5,555 5,555 5,555 5,556
Zn g/l 0,617 0,617 0,617 0,617 0,617
Ni g/l 0,083 0,083 0,083 0,083 0,083
Mn g/l 0,726 0,726 0,726 0,726 0,726
Mg g/l 1,237 1,237 1,237 1,237 1,237
Al g/l 0,850 0,849 0,849 0,849 0,850
Ca g/l 0,621 0,621 0,621 0,621 0,621
Fe2 g/l 1,010 1,010 1,010 1,010 1,010
Fe3 g/l 0,0056 0,060 0,053 0,0069 0,053 0,0526 0,060 0,0056
S g/l 14,372 14,396 14,396 14,396 14,372
P g/l 0,370 0,370 0,370 0,370 0,370
AC g/l 9,228 10,831 10,831 10,831 9,228

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 Table C.7: Mass balance – conventional circuit having Milling in raffinate

49,00 50,00 51,00 52,00 53,00 54,00 55,00 56,00

ALOAC ADS1 RADS1 SOS1 ASOS1 ADS2 RADS2 SOS2
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 1,046 948,55 1673,79 0,785 939,76 1667,90
volume m3/h 0,996 758,06 1337,65 2616,20 0,627 754,38 1338,89 2616,20
SG liquid t/m3 1,051 1,251 1,251 1,251 1,246 1,246
CT 54,068 301,637 324,16 301,637
H g/l 0,259 3,866 3,866 3,866 4,259 4,259
PO4 g/l 1,136 0,174 0,174 0,174 0,174 0,174
SO4 g/l 29,759 266,95 266,952 266,95 268,43 268,435
S2O6 g/l 11,083 0,015 0,015 0,015 0,000 0,000
Cu g/l 1,070 49,666 49,666 3,697 49,666 38,275 38,275 2,743
Co g/l 5,556 0,853 0,853 0,853 0,850 0,851
Zn g/l 0,617 0,095 0,095 0,095 0,094 0,095
Ni g/l 0,083 0,013 0,013 0,013 0,013 0,013
Mn g/l 0,726 0,111 0,111 0,111 0,111 0,111
Mg g/l 1,237 0,190 0,190 0,190 0,189 0,189
Al g/l 0,850 0,130 0,130 0,130 0,130 0,130
Ca g/l 0,621 0,095 0,095 0,095 0,095 0,095
Fe2 g/l 1,010 0,994 0,994 0,994 0,999 0,999
Fe3 g/l 0,060 1,0089 1,009 0,0010 1,009 0,9988 0,999 0,0010
S g/l 14,372 89,114 89,114 89,114 89,603 89,603
P g/l 0,370 0,057 0,057 0,057 0,057 0,057
AC g/l 9,228 143,81 143,809 143,81 171,77 171,774

Joseph Kafumbila Page 70

 Table C.8: Mass balance – conventional circuit having Milling in raffinate

57,00 58,00 59,00 60,00 61,00 62,00 63,00 64,00

ASOS2 EWCA EWW EWCC EWO EWS OEW SPE
Solid/Gas
mass t/h 11,073 2,790 0,0022
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 0,785 1,774 8,188 944,65 937,345
volume m3/h 0,630 0,986 8,188 759,32 753,45
SG liquid t/m3 1,246 1,800 1,000 1,244 1,244
CT 314,62 311,80 311,80
H g/l 4,259 4,369 4,369
PO4 g/l 0,174 0,174 0,174
SO4 g/l 268,43 268,77 268,77
S2O6 g/l 0,000 0,000 0,000
Cu g/l 38,275 35,000 35,000
Co g/l 0,850 0,851 0,851
Zn g/l 0,094 0,095 0,095
Ni g/l 0,013 0,013 0,013
Mn g/l 0,111 0,111 0,111
Mg g/l 0,189 0,190 0,190
Al g/l 0,130 0,130 0,130
Ca g/l 0,095 0,095 0,095
Fe2 g/l 0,999 1,000 1,000
Fe3 g/l 0,999 1,0000 1,0000
S g/l 89,603 576,699 89,714 89,714
P g/l 0,057 0,057 0,057
AC g/l 171,77 1764,000 180,00 180,00

Joseph Kafumbila Page 71

Table C.9: Mass balance – conventional circuit having Milling in raffinate

65,00 66,00 67,00 68,00 69,00 70,00 71,00 72,00

EWB
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 7,301
volume m3/h 5,869
SG liquid t/m3 1,244
CT 311,80
H g/l 4,369
PO4 g/l 0,174
SO4 g/l 268,77
S2O6 g/l 0,000
Cu g/l 35,000
Co g/l 0,851
Zn g/l 0,095
Ni g/l 0,013
Mn g/l 0,111
Mg g/l 0,190
Al g/l 0,130
Ca g/l 0,095
Fe2 g/l 1,000
Fe3 g/l 1,0000
S g/l 89,714
P g/l 0,057
AC g/l 180,00

Joseph Kafumbila Page 72