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This document discusses gravity testwork performed on samples from Goldfields' Cerro Corona operation in Peru to evaluate the potential recovery of free gold using Falcon concentrators. Testwork showed over 30% of gold could be recovered from the cyclone feed using this gravity method. The document recommends installing three Falcon SB5200 concentrators to treat 40% of the cyclone feed based on the potential to recover over 100,000 oz of gold per year and increase annual gold revenue by over $3.6 million based on the head grade and recovery estimates. The capital cost of the concentrators is estimated to be less than $500,000.
This document discusses gravity testwork performed on samples from Goldfields' Cerro Corona operation in Peru to evaluate the potential recovery of free gold using Falcon concentrators. Testwork showed over 30% of gold could be recovered from the cyclone feed using this gravity method. The document recommends installing three Falcon SB5200 concentrators to treat 40% of the cyclone feed based on the potential to recover over 100,000 oz of gold per year and increase annual gold revenue by over $3.6 million based on the head grade and recovery estimates. The capital cost of the concentrators is estimated to be less than $500,000.
This document discusses gravity testwork performed on samples from Goldfields' Cerro Corona operation in Peru to evaluate the potential recovery of free gold using Falcon concentrators. Testwork showed over 30% of gold could be recovered from the cyclone feed using this gravity method. The document recommends installing three Falcon SB5200 concentrators to treat 40% of the cyclone feed based on the potential to recover over 100,000 oz of gold per year and increase annual gold revenue by over $3.6 million based on the head grade and recovery estimates. The capital cost of the concentrators is estimated to be less than $500,000.
Goldfields Cerro Corona Project Cajamarca City PERU
Att. Ruben Zevallos Metallurgical Manager cc. Hilario Gorvenia Metalurgist Engineer
Ref. Gold Recovery Circuit at Cerro Corona
Dear Sirs:
The following report discusses the gravity testwork that was done by Eng. Jose Palomino on samples provided by the Cerro Corona operation of Goldfields. Eng. Jose Palomino has been the exclusive representative for Falcon Concentrators in Peru for over 10 years and is an expert in enhanced gravity testwork and applications. All testwork results generated by Eng. Palomino are certified and supported by Falcon as if they were performed directly by Falcon Concentrators Inc.
This report will present data generated by the referred testwork, discuss and make observations regarding these data and then make recommendations for the Cerro Corona gravity circuit. Through the testwork conducted we believe that there would be a strong benefit for Goldfields by installing a gravity recovery circuit at Cerro Corona.
Presentation of Data
The following data is from gravity testwork using a Falcon L40 laboratory-scale concentrator. The L40 concentrator is able to simulate both Falcons Semi-Batch machines for precious metal recovery as well as Falcons Continuous machines for preconcentration and base metal recovery. The testwork shown in this report is for simulation of Falcons Semi-Batch machines for recovery of free gold within a grinding circuit. The recoveries shown in these tables are representative of the theoretical maximum gravity recovery; however, the concentrate grades at the industrial scale will be much higher. The expected concentrate grade at the industrial scale can be simulated by hand panning the L40 concentrate.
Table 1 Cyclone Overflow Test PRUEBA 1 - DEL REBOSE HIDROCICLON (Cyclone O/F) PRODUCTO Leyes Distribucion Directa%
PESO % PESO % Cu Au g/t % Fe CuT AuT FeT CONCENTRADO 147.2 1.5 2.83 31.66 20.7 3.52 28.27 3.93 RELAVE 9852.8 98.5 1.16 1.2 7.56 96.48 71.73 96.07 CABEZA CALCULADA 10000.0 100.00 1.18 1.65 7.75 100.00 100.00 100.00 CABEZA ENSAYADA 1.12 1.52 6.63
Falcon Concentrators Inc. 9663 - 199A St. Langley, BC, Canada V1M 2X7 Phone: +1-604-888-5568 Fax: +1-604-888-5521 Email: falcon@concentrators.net
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Table 2 Cyclone Feed Test PRUEBA 2 - DEL FEED HIDROCICLON (Cyclone Feed) PRODUCTO Leyes Distribucion Directa%
PESO % PESO % Cu Au g/t % Fe CuT AuT FeT CONCENTRADO 194.7 2.1 2.96 36.35 19.52 5.42 33.42 4.26 RELAVE 8980.4 97.9 1.12 1.57 9.5 94.58 66.58 95.74 CABEZA CALCULADA 9175.1 100.00 1.16 2.31 9.71 100.00 100.00 100.00 CABEZA ENSAYADA 1.24 2.28 10.53
Table 3 Cyclone Underflow Test PRUEBA 3 - DE LAS ARENAS HIDROCICLON (Cyclone U/F) PRODUCTO Leyes Distribucion Directa%
PESO % PESO % Cu Au g/t % Fe CuT AuT FeT CONCENTRADO 1 173.3 1.8 2.94 33.59 19.37 4.39 24.41 3.47 RELAVE 9243.8 98.2 1.2 1.95 10.09 95.61 75.59 96.53 CABEZA CALCULADA 9417.1 100.00 1.23 2.53 10.26 100.00 100.00 100.00 CABEZA ENSAYADA 1.25 2.32 10.44
Discussion of Data
The above results show that a significant proportion of gold can be recovered from the cyclone feed, overflow and underflow in Cerro Coronas grinding circuit. Although greater than 24% Au recovery can be expected in the cyclone underflow, we see that an even higher recovery (+33%) can be expected in the cyclone feed. The increased recovery in the cyclone feed compared to the cyclone underflow can be explained through the recovery of fine gold particles by the Falcon Concentrator. Although recovery of coarse Au particles is easier than fine particles, the elevated G-force used by the Falcon Concentrator allows for the recovery of very fine gold particles that would report directly to the cyclone overflow and would never be seen by a gravity concentrator operating in the cyclone underflow. The increased recovery in the cyclone feed compared to the cyclone overflow can be explained by the higher Au grade in the cyclone feed.
Relatively speaking, a gravity recoverable gold content of greater than 30% is considered very high there are many copper-gold producers that have found a positive financial benefit by operating primary gravity circuits with less than 5% gravity recoverable gold in their ore. There are three main reasons why it would be beneficial to operate a gravity recovery circuit even when overall gold recovery may not increase:
Free gold requires the most effort to float. It is necessary to use much more intensive flotation procedures when trying to recovery free gold by flotation compared to sulfide-associated gold. If the free gold is removed from the circuit before flotation then it is very likely that the overall flotation mass yield can be decreased, producing a higher grade copper concentrate while reducing residence time and reagent costs.
Falcon Concentrators Inc. 9663 - 199A St. Langley, BC, Canada V1M 2X7 Phone: +1-604-888-5568 Fax: +1-604-888-5521 Email: falcon@concentrators.net
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Gravity gold concentrate can be sold directly to a refiner or can be processed by an Intensive Leach Reactor to produce a gold product. A gravity gold concentrate will generate more revenue than gold that is sold for credit in a copper concentrate. First, when free gold is removed from the copper concentrate then sampling error is reduced and metallurgical accounting between the plant and the smelter will improve dramatically. Second, free gold sold directly to a refiner as a gold product will be paid at a higher rate than the credit given by a smelter for gold in a copper concentrate. Third, payment for a free gold concentrate will be much faster than waiting for credit from a smelter.
Gravity recovery circuits can better handle changes in grade and circuit upsets. Compared to flotation circuits, centrifugal concentrators can do a much better job in handling changes in feed grade and can act as control over spikes in Au grade, which are typically due to changes in free gold content. Without an installed gravity circuit, spikes in free gold can result in gold being lost to tailing whereas a gravity circuit would recovery this free gold ahead of flotation.
After considering the positive benefits of installing a gravity circuit, the next question to answer is what percentage of the circulating load to treat by gravity. The following graph shows a mathematical model of the expected gravity gold recovery as a percentage of the circulating load treated. Although this particular graph references cyclone underflow data, the same is true for cyclone feed although cyclone feed will show slightly better results.
Graph 1 Expected Recovery vs. Percentage of Circulating Load Treated
We can see from the above graph that the rate of increase in recovery slows as greater percentages of the circulating load are treated. We can also see from the graph that most of the recovery benefit (~90%) is obtained when approximately 40% of the circulating load is being treated. Falcon Concentrators Inc. 9663 - 199A St. Langley, BC, Canada V1M 2X7 Phone: +1-604-888-5568 Fax: +1-604-888-5521 Email: falcon@concentrators.net
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Recommendations
Since Cerro Corona is operating at ~800tph with a 200% circulating load, this means that ~2,400tph are being fed to the cyclones in the grinding circuit. Treating 40% of the cyclone feed requires 960tph being fed to the gravity circuit - this generates a theoretical gold recovery of 30% (33% maximum recovery x 90% gravity recovery effort).
To treat this 960tph in the circulating load, Falcon recommends three SB5200 enhanced gravity concentrators. The SB5200 concentrator has a maximum capacity of 400tph, but an appropriate design throughput would be 350tph, giving an overall design capacity of 1,050tph to accommodate circuit upsets or to provide the potential to increase the gravity recovery effort within the grinding circuit. Further, Falcon recommends the use of an Intensive Leach Reactor to clean the gravity concentrate since the efficiency of a leach reactor is typically much higher than a shaking table or similar device for concentrate cleaning.
Assuming a head grade of 1.5g/t and a recovery of 30% to the grinding circuit, this amounts to over 100,000 oz/year recovered in the gravity circuit, or US$91Mil/year at $900/oz. Assuming that a gravity gold concentrate is paid at 99% value and gold in copper concentrate is paid at 95%, there is the potential for a revenue increase of more than US$3.6Mil/year on Au payment alone. The approximate capital cost of the proposed gravity concentrators is less than US$500,000.
Falcon encourages the personnel at Cerro Corona to contact Goldfields St. Ives mine in Australia which has been successfully operating two Falcon SB2500s and one Falcon SB1350 for a number of years now.
If you have any questions about the material presented in this report, please do not hesitate to contact me directly at Falcons head office in Canada, or Eng. Jose Palomino in Lima, Peru.
Jaramogi Oginga Odinga University of Science and Technology, Kenya - BSC Computer Security & Forensics MSC IT Security & Audit, PHD IT Security & Audit