S/No.

Description
1 Sizing Cyclone
Feed tonage (TPH)
Feed solids specific gravity
% solids in the Feed
% solids in the O/F
% solids in the U/F

350
3.57
41.33%
33.10%
55.00%

O/F passing target 98.5%

(-)150

Feed size

(-) 850

-1000 + 850
-850 + 500
-500 + 300
-300 + 150
- 150

2 Desliming cyclone
Feed tonage (TPH)
Feed solids specific gravity
% solids in the Feed
% solids in the O/F
% solids in the U/F
O/F passing target 80%

5
10
10
20
55
100

277
3.57
26.60%
10.34%
53.00%
(-)20

3 Bal mill Cyclone

Fresh feed
Cyclone Feed tonage (TPH)
Feed solids specific gravity
% solids in the Feed
% solids in the O/F
% solids in the U/F
O/F passing target 80%

211.75
571.73
4.33
38.00%
21.38%
70.00%
(-) 63

C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11

Feed

550 TPH

Base capacity
open area factor
Oversize factor
undersize
efficency
deck
screen slope
slot
particle shape
wet screening
moisture content

7 t/h/m2
1
1.1
1.2
1.2
1
1.2
1.6
0.95
1
1.75

35.3929
15.53984
6.374012

Size, mm Wt., %
Cum. wt., %
6
8.61
8.61
-6+3
11.21
19.82
-3+2
13.11
32.93
-2+1
10.53
43.46
-1+0.85
3.2
46.66
-0.85 + 0.5
3.04
49.7
-0.5 + 0.3
3.88
53.58
-0.3 + 0.21
4.04
57.62
-0.21 +0.15
3
60.62
-0.15+0.106
4.7
65.32
-0.106+ 0.075
3.9
69.22
-0.075+0.045
6.44
75.66
-45
24.33
99.99
Total
100
Bulk

100
91.39
80.19
67.08
56.55
53.35
50.31
46.43
42.39
39.38
34.68
30.78
24.33

Screen
6
-6+3
-3+2
-2+1

-1+0.85
-0.85 + 0.5
-0.5 + 0.3
-0.3 + 0.21
-0.21 +0.15
-0.15+0.106
-0.106+ 0.075
-0.075+0.045
-45

8.61
11.21
13.11
10.53
43.46

19.81132 19.81132
25.79383 45.60515
30.16567 75.77082
24.22918
100
100

3.2
3.04
3.88
4.04
3
4.7
3.9
6.44
24.33
56.53

5.660711
5.377676
6.863612
7.146648
5.306917
8.314169
6.898992
11.39218
43.03909
100

5.660711
11.03839
17.902
25.04865
30.35556
38.66973
45.56872
56.96091
100

Fe, %
Cum. Fe, %
58.08
58.08
58.22
58.16
56.96
57.68
54.87
57
53.19
56.74
51.94
56.45
50.96
56.05
51.52
55.73
54.73
55.68
58.64
55.89
59.75
56.11
60.45
56.48
41.46
52.83
52.35

100
80.18868
54.39485
24.22918

58.08
58.08
58.22 58.15918
56.96 57.68177
54.87 57.0005

100
94.33929
88.96161
82.098
74.95135
69.64444
61.33027
54.43128
43.03909

53.19
51.94
50.96
51.52
54.73
58.64
59.75
60.45
41.46

53.19
52.58103
51.95953
51.83412
52.3404
53.69484
54.61158
55.77926
49.61638

Size, mm

Wt., %

6
-6+3
-3+2
-2+1
-1+0.85
-0.85 + 0.5
-0.5 + 0.3
-0.3 + 0.21
-0.21 +0.15
-0.15+0.106
-0.106+ 0.075
-0.075+0.045
-45
Total
Bulk

8.61
11.21
13.11
10.53
3.2
3.04
3.88
4.04
3
4.7
3.9
6.44
24.33
100

Cum.
wt., %
8.61
19.81
32.92
43.45
46.65
49.69
53.57
57.61
60.62
65.32
69.22
75.67
100

Fe, %
100
91.39
80.19
67.08
56.55
53.35
50.31
46.43
42.39
39.38
34.68
30.78
24.33

58.08
58.22
56.96
54.87
53.19
51.94
50.96
51.52
54.73
58.64
59.75
60.45
41.46
52.35

Screen
6
-6+3
-3+2
-2+1

8.61
11.21
13.11
10.53
43.46

19.81
25.79
30.17
24.23
100

19.81
45.61
75.77
100.00

100
80.19
54.39
24.23

-1+0.85
-0.85 + 0.5
-0.5 + 0.3
-0.3 + 0.21
-0.21 +0.15
-0.15+0.106
-0.106+ 0.075
-0.075+0.045
-45

3.2
3.04
3.88
4.04
3
4.7
3.9
6.44
24.33
56.53

5.66
5.38
6.86
7.15
5.31
8.31
6.90
11.39
43.04
100.00

5.66
11.04
17.90
25.05
30.36
38.67
45.57
56.96
100.00

100
94.34
88.96
82.10
74.95
69.64
61.33
54.43
43.04

-1+0.85
-0.85 + 0.5
-0.5 + 0.3
-0.3 + 0.21
-0.21 +0.15
-0.15+0.106
-0.106+ 0.075
-0.075+0.045
-45

3.2
3.04
3.88
4.04
3
4.7
3.9
6.44
24.33
56.53

-2+1

-3+2
0
0
0
0
1
6
2
1
0.53
10.53

-6+3
0
0
0
4.01
3.4
3.2
2
0.5
0
13.11

1
3.52
2.5
1.2
1.5
1.5

11.22

Cum. Fe, %
58.08
58.16
57.68
57
56.74
56.45
56.05
55.73
55.68
55.89
56.11
56.48
52.83

58.08
58.22
56.96
54.87

58.08
58.16
57.68
57.00

53.19
51.94
50.96
51.52
54.73
58.64
59.75
60.45
41.46

53.19
52.58
51.96
51.83
52.34
53.69
54.61
55.78
49.62

1
3
2
2.61
0
0
0
0
0
8.61

5.2
9.56
8.38
11.86
8.9
15.4
7.9
7.94
24.86
100

0+6

-150

56.1

General Process Plant Design criteria

1

S/No.
1
2
3
4
5
6
7

Process Plant Throughput

Description
Annual throughput (dry)
Available days
Available hours
Plant utilisation(incl. availability)
Plant Operating hours
Hourly throughput
Overall recovery (design)
Fe
Nominal concentrate produced

ROM Pararmeters

S/No.
1
2
3
4
5

Parameter
Fe
Design:Total Fe
ROM solids content
Ore SG
Bond work index
ROM Particle size distribution
6
3
1
0.045
-0.045

3
S/No.
1
2
3
4
4
S/No.
1
2
3
4
5
S/No.
1
2

Units
t/a
d/a
h/a
%
h/a
t/h

Values
2.07
300
7200
83.33
6000
350

%
t/a

60.46
1.25

Units

Values

%
%
t/m3
kWh/t

53
93
3.57
11.96

% Retained
% Retained
% Retained
% Retained
% Retained

8.61
11.21
23.64
32.21
24.33

Wet screen
Parameter
Feed rate
Feed size ( maximum)
Under size (d80)
Screen type

Units
tph
mm
m

Values
510
10
850
Wet screening

Rod mill
Parameter
Feed rate
Feed size ( d80)
Product (d80)
Power required

Units
tph
m
m
kW

Values

Units
m3/hr
m3

Values

314
3000
850
700

Rod Mill discharge Sump

Parameter
Feed rate slurry
Sump capacity

147
12

Page7 of 48

6
S/No.
1
2
3
7
S/No.
1
2
8
S/No.
1
2
3
9
S/No.
1
2
3
10
S/No.
1
2
4
5
6
11
S/No.
1
2
12
S/No.
1
2
3
13
S/No.
1
2
4
5
6

Pump- feeding the rod mill discharge to wet screen

Parameter
Feed rate (solids)
Feed rate slurry
Solids%

Units
TPH
m3/hr
%

Values

Units
m3/hr
m3

Values

Units
TPH
m3/hr
%

Values

Units
tph
%
m

Values

Units
tph
%
%
%
no

Values

Units
m3/hr
m3

Values

Units
TPH
m3/hr
%

Values

136
147
55.00%

Sump- Screen under flow collection

Parameter
Feed rate slurry
Sump capacity

533
23

Pump- Feeding to cyclone

Parameter
Feed rate (solids)
Feed rate slurry
Solids%

350
595
41%

Sizing Cyclone
Parameter
Feed rate (dry solids)
Solids%
cyclone cut size

350
41%
50

Rougher spiral
Parameter
Feed rate (dry solids)
Solids%
Mass to concentrate
Mass to tailing
No. spiral banks ( 2 starts with 12 no. of spirls in one bank)

137
40
67
33
3

Sump- Rougher Spiral Concentrate collection sump

Parameter
Feed rate slurry
Sump capacity

82
12

Pump- Pumping to cleaner spiral

Parameter
Feed rate (solids)
Feed rate slurry
Solids%

91
158
40%

Cleaner Spiral
Parameter
Feed rate (dry solids)
feed density
Mass to concentrate
Mass to tailing
No. spiral banks ( 2 starts with 12 no. of spirls in one bank)

Units
Values
tph
91
% solids w/w
40%
%
81%
%
19%
no
2

Page8 of 48

14
S/No.
1
2
15
S/No.
1
2
3

Sump- Spiral tails collection sump

Parameter
Feed rate slurry
Sump capacity

Parameter
Feed rate (solids)
Feed rate slurry
Solids%
Desliming Cyclone

S/No.
1
2
3

Parameter
Feed rate (dry solids)
Solids%
cyclone cut size

Parameter
Feed rate (dry solids)
Solids%
Drum Dia
Drum Length

18

Magnetic Separator

S/No.
1
2

Parameter
Feed rate (dry solids)
Solids%

S/No.
1
2
20
S/No.
1
2
3

Units
TPH
m3/hr
%

Values

Units
tph
%
m

Values

Units
tph
%
m
m

Values

Units
tph
%

Values

Units
m3/hr
m3

Values

Units
TPH
m3/hr
%

Values

Units
tph
%

Values

818
23

277
818
27%

277
27%
10

LIMS

S/No.
1
2
3
4

19

Values

Pump- Pumping to desliming cyclone

16

17

Units
m3/hr
m3

210
35%
1.2
2.5

201
34%

Sump- Magnetic separator Cons. collection sump

Parameter
Feed rate slurry
Sump capacity

539
23

Pump- Pumping to desliming cyclone

Parameter
Feed rate (solids)
Feed rate slurry
Solids%

21

Magnetic Separator

S/No.
1
2

Parameter
Feed rate (dry solids)
Solids%

154
539
24%

154
24%

Page9 of 48

22
S/No.
1
2
23

Sump- Magnetic separator-2 Cons. collection sump

Parameter
Feed rate slurry
Sump capacity

Units
m3/hr
m3

Values
381
12

Pump- Feed to Ball Mill sump

S/No.
1
2
3

Parameter
Feed rate (solids)
Feed rate slurry
Solids%

Units
TPH
m3/hr
%

Values

24
S/No.
1
2
3

Pump- tailings to thickener

Parameter
Feed rate (solids)
Feed rate slurry
Solids%

Units
TPH
m3/hr
%

Values

Units
m3/hr
m3

Values

Units
TPH
m3/hr
%

Values

Units
tph
%
m

Values

Units
tph
m
m
kW

Values

25
S/No.
1
2

26
S/No.
1
2
3
27
S/No.
1
2
3
28
S/No.
1
2
3
4

130
381
27%

67
910
8%

Sump- Ball mill discharge sump

Parameter
Feed rate slurry
Sump capacity

1065
55

Pump- Pumping to Ball mill cyclone

Parameter
Feed rate (solids)
Feed rate slurry
Solids%

572
1065
38%

Sizing Cyclone
Parameter
Feed rate (dry solids)
Solids%
cyclone cut size

572
38%
80

Ball Mill
Parameter
Feed rate
Feed size ( d80)
Product (d80)
Power required

314
500
75
2000

Page10 of 48

1
2
5
screen

Rod mill
6

4
7

Sump-1

Sump-2
10
11

23

Cyclone
12

Sump-5

14
13
15
Tails
17

Rougher Spirals
16 Cons

19
Sump-3
18
20
22 (Tails)
cleaner spirals
21 (Cons)

Sump-4

1
TPH
350
% WT
100.00%
% Fe
52.79%
Sp.Gr.
3.57
% Solids
93.00%
Water TPH
26.34
Pulp(Cu.m/hr)
124.33
Pulp Density
3.03

372.99

3
152.11
43.46%
57.00%
3.79
85.00%
26.84
66.95
2.67

4
350
100.00%
52.83%
3.57
41.33%
496.94
594.87
1.42

38.35

6
152.11
43.46%
57.00%
3.79
70.00%
65.19
105.29
2.06

59.26

8
152.11
43.46%
57.00%
3.79
55.00%
124.45
164.56
1.68
2.742667

Sump

Sump
25
TPH
% WT
% Fe
Sp.Gr.
% Solids
Water TPH
Pulp(Cu.m/hr)
Pulp Density

203.77

26
210.00
60.00%
55.00%
3.69
35.00%
390
446.94
1.34

27
201.25
57.50%
54.52%
3.66
34.38%
384.17
439.11
1.33

28
8.75
2.50%
66.00%
4.77
60.00%
5.83
7.67
1.9

29

500

30
154.00
44.00%
59.66%
3.93
23.55%
500
539.16
1.21

31
47.25
13.50%
37.77%
2.75
10.95%
384.17
401.35
1.07

8.986 6.689167
26.958 20.0675

Equip Name
Screen
Rod Mill
Sump-1
Pump-1
Sump-2
Pump-2
D-slime Cyclone
Rougher Spirals
Sump-3
Pump-3
cleaner spirals
Sump-4
Pump-4
Sump-5
Pump-5
D-water cyclone

Capacity
350
152.11
164.55
164.55
350
350
350
594.87
175.00
157.56
157.56
91.00
65.09
65.09
844.14
844.14
276.50
844.14

Unit
TPH
TPH
m3/hr
m3/hr
m3/hr
m3/hr
TPH
m3/hr
TPH
m3/hr
m3/hr
TPH
m3/hr
m3/hr
m3/hr
m3/hr
TPH
m3/hr

8.228
32

350

0
0

6
3
1
0.045
-0.045

8.61
11.21
23.64
32.21
24.33
100

58.08
0.57
58.22
56.03
55.78
41.46 0.496179

Tailing Dam
47
48
filters
45
46
Tailing Thickener
44
43
Sump-5

Cyclone
24
25
26
28
LIMS
27

29

Rougher magnetic
Separator
30 Cons

31

42
Sump-8

Ball mill
Sump-6

32

Cleaner Magnetic
Separator
33 Cons

34
36

35

37
Sump-7

10
350
100.00%
52.83%
3.57
41.33%
496.94
594.87
1.42

11
175.00
50.00%
47.79%
3.31
33.10%
353.76
406.63
1.3

12
175.00
50.00%
57.87%
3.84
55.00%
143.18
188.77
1.69
3.146167

13

14

72

119.32

15
175.00
50.00%
57.87%
3.84
40.00%
262.5
308.09
1.42

16
91.00
26.00%
62.70%
4.32
60.00%
60.67
81.73
1.86

17
84.00
24.00%
52.64%
3.56
23.47%
273.83
297.4
1.2

33
129.50
37.00%
61.60%
4.17
27.01%
350
381.06
1.26

34
24.50
7.00%
49.41%
3.39
4.67%
500
507.22
1.03

35
211.75
60.50%
62.79%
4.33
34.34%
404.83
453.69
1.36

6.351 8.453667
19.053
25.361

7.5615
22.6845

9.4385
36

373.7

37
571.73
163.35%
62.79%
4.33
38.00%
932.81
1064.75
1.41

38
359.98
102.85%
62.79%
4.33
70.00%
154.28
237.34
2.17

39
211.75
60.50%
62.79%
4.33
21.38%
778.53
827.39
1.2

40
211.75
60.50%
62.79%
4.33
67.00%
104.29
153.16
2.06

0 17.74583 3.955667 13.78983 2.552667

0 53.2375
11.867 41.3695
7.658

41

674.24

0
0

spirals
87.5
52
43.75
26
3.645833 2.166667
3
2
72
48

49
Reservoir

41
40
Conc. Thickener

50
Filters
51

39
Cyclone
38

18
91.00
26.00%
62.70%
4.32
40.00%
136.5
157.56
1.44
2.626

37

19

20

75.83

48

21
73.50
21.00%
64.50%
4.57
60.00%
49
65.09
1.88

22
17.50
5.00%
55.14%
3.70
11.44%
135.5
140.24
1.09

23
276.50
79.00%
49.73%
3.41
26.60%
763.09
844.14
1.23

24
210.00
60.00%
55.00%
3.69
53.00%
186.23
243.17
1.63

25
66.50
19.00%
33.08%
2.75
10.34%
576.86
601.04
1.07

14.069 4.052833 10.01733

7.878
42
71.75
20.50%
41.75%
2.80
7.51%
884.17
909.81
1.05

43
66.50
19.00%
33.08%
2.75
10.34%
576.86
601.04
1.07

44
138.25
39.50%
37.58%
2.75
8.64%
1461.03
1511.3
1.06

45
138.25
39.50%
37.58%
2.75
40.00%
207.38
257.65
1.34

15.1635 10.01733 25.18833 4.294167

45.4905
30.052
75.565 12.8825

46

1253.65

0
0

42.207
47
138.25
39.50%
37.58%
2.75
80.00%
34.56
84.84
2.04

12.1585
48

30.052
49

172.82

2100.71

50
211.75
60.50%
62.79%
4.33
91.50%
19.67
68.54
3.38

51

84.62

1
2
5
screen

Rod mill
6

4
7

Sump-1

Sump-2
10
11

23

Cyclone
12

Sump-5

14
13
15
Tails
17

Rougher Spirals
16 Cons

19
Sump-3
18
20
22 (Tails)
cleaner spirals
21 (Cons)

Sump-4

1
TPH
350
% WT
100.00%
% Fe
52.79%
Sp.Gr.
3.57
% Solids
93.00%
Water TPH
26.34
Pulp(Cu.m/hr)
124.33
Pulp Density
3.03

372.99

3
152.11
43.46%
57.00%
3.79
85.00%
26.84
66.95
2.67

4
350
100.00%
52.83%
3.57
41.33%
496.94
594.87
1.42

38.35

6
152.11
43.46%
57.00%
3.79
70.00%
65.19
105.29
2.06

59.26

8
152.11
43.46%
57.00%
3.79
55.00%
124.45
164.56
1.68

25
TPH
% WT
% Fe
Sp.Gr.
% Solids
Water TPH
Pulp(Cu.m/hr)
Pulp Density

203.77

26
210.00
60.00%
55.00%
3.69
35.00%
390
446.94
1.34

Equip Name
Screen
Rod Mill
Sump-1
Pump-1
Sump-2
Pump-2
D-slime Cyclone
Rougher Spirals
Sump-3
Pump-3
cleaner spirals
Sump-4
Pump-4
Sump-5
Pump-5
D-water cyclone

27
201.25
57.50%
54.52%
3.66
34.38%
384.17
439.11
1.33

Capacity
350
152.11
164.55
164.55
350
350
350
594.87
136.50
157.56
157.56
91.00
65.09
65.09
817.89
817.89
276.50
817.89

28
8.75
2.50%
66.00%
4.77
60.00%
5.83
7.67
1.9

Unit
TPH
TPH
m3/hr
m3/hr
m3/hr
m3/hr
TPH
m3/hr
TPH
m3/hr
m3/hr
TPH
m3/hr
m3/hr
m3/hr
m3/hr
TPH
m3/hr

29

500

30
154.00
44.00%
59.66%
3.93
23.55%
500
539.16
1.21

31
47.25
13.50%
37.77%
2.75
10.95%
384.17
401.35
1.07

32

350

6
3
1
0.045
-0.045

8.61
11.21
23.64
32.21
24.33
100

58.08
0.57
58.22
56.03
55.78
41.46 0.496179

Tailing Dam
47
48
Paste Thickener
45
46
Tailing Thickener
44
43
Sump-5

Cyclone
24
25
26
28
LIMS
27

29

Rougher magnetic
Separator
30 Cons

31

42
Sump-8

Ball mill
Sump-6

32

Cleaner Magnetic
Separator
33 Cons

34
36

35

37
Sump-7

10
350
100.00%
52.83%
3.57
41.33%
496.94
594.87
1.42

11
213.50
61.00%
49.61%
3.41
35.66%
385.26
447.96
1.34

12
136.50
39.00%
57.87%
3.84
55.00%
111.68
147.24
1.69

13

14

72

93.07

15
136.50
39.00%
57.87%
3.84
40.00%
204.75
240.31
1.42

16
91.00
26.00%
62.70%
4.32
60.00%
60.67
81.73
1.86

17
45.50
13.00%
48.21%
3.33
17.39%
216.08
229.74
1.14

33
129.50
37.00%
61.60%
4.17
27.01%
350
381.06
1.26

34
24.50
7.00%
49.41%
3.39
4.67%
500
507.22
1.03

35
211.75
60.50%
62.79%
4.33
34.34%
404.83
453.69
1.36

36

373.7

37
571.73
163.35%
62.79%
4.33
38.00%
932.81
1064.75
1.41

38
359.98
102.85%
62.79%
4.33
70.00%
154.28
237.34
2.17

39
211.75
60.50%
62.79%
4.33
21.38%
778.53
827.39
1.2

40
211.75
60.50%
62.79%
4.33
67.00%
104.29
153.16
2.06

41

674.24

spirals
68.25
52
34.125
26
2.84375 2.166667
3
2
72
48

49
Reservoir

41
40
Conc. Thickener

39
Cyclone
38

18
91.00
26.00%
62.70%
4.32
40.00%
136.5
157.56
1.44

37

19

20

75.83

48

21
73.50
21.00%
64.50%
4.57
60.00%
49
65.09
1.88

22
17.50
5.00%
55.14%
3.70
11.44%
135.5
140.24
1.09

23
276.50
79.00%
49.73%
3.41
27.29%
736.84
817.89
1.24

24
210.00
60.00%
55.00%
3.69
53.00%
186.23
243.17
1.63

25
66.50
19.00%
33.08%
2.75
10.78%
550.61
574.79
1.07

42
71.75
20.50%
41.75%
2.80
7.51%
884.17
909.81
1.05

43
66.50
19.00%
33.08%
2.75
10.78%
550.61
574.79
1.07

44
138.25
39.50%
37.58%
2.75
8.79%
1434.78
1485.05
1.06

45
138.25
39.50%
37.58%
2.75
40.00%
207.38
257.65
1.34

46

1227.4

47
138.25
39.50%
37.58%
2.75
75.00%
46.08
96.36
1.91

48

49

161.3

2062.94

1
2
5
screen

Rod mill
6

4
7

Sump-1

Sump-2
10
11
Cyclone
12
14
13
15
Tails
17

Rougher Spirals
16 Cons

23
Sump-4

19
Sump-3
18
20
22 (Tails)
cleaner spirals
21 (Cons)

Sump-4

1
TPH
350
% WT
100.00%
% Fe
52.79%
Sp.Gr.
3.57
% Solids
93.00%
Water TPH
26.34
Pulp(Cu.m/hr)
124.33
Pulp Density
3.03

372.99

3
152.11
43.46%
57.00%
3.79
85.00%
26.84
66.95
2.67

4
350
100.00%
52.83%
3.57
41.33%
496.94
594.87
1.42

38.35

6
152.11
43.46%
57.00%
3.79
70.00%
65.19
105.29
2.06

59.26

8
152.11
43.46%
57.00%
3.79
55.00%
124.45
164.56
1.68

TPH
% WT
% Fe
Sp.Gr.
% Solids
Water TPH
Pulp(Cu.m/hr)
Pulp Density

25
167.75
47.93%
54.04%
3.64
22.92%
564
610.11
1.2

26
8.75
2.50%
65.00%
4.63
60.00%
5.83
7.72
1.89

27
87.50
25.00%
59.66%

28
80.25
22.93%
47.92%

6
3
1
0.045
-0.045

8.61
11.21
23.64
32.21
24.33
100

58.08
58.22
56.03
0.57
55.78
41.46 0.496179

magnetic separator

24
Sump-4

26
LIMS
25

Rougher magnetic
Separator
27 Cons

28
Tailing thickener

Cleaner Magnetic
Separator

Ball mill

Sump-5

10
350
100.00%
52.83%
3.57
41.33%
496.94
594.87
1.42

11
100
28.57%
41.16%
2.78
18.81%
431.75
467.69
1.14

12
250
71.43%
57.50%
3.82
55.00%
65.19
270.01
1.68

13

14

120

309.81

15
250
71.43%
57.50%
3.82
40.00%
375
440.46
1.42

16
91.00
26.00%
62.70%
4.32
60.00%
60.67
81.73
1.86

17
159.00
45.43%
54.52%
3.66
26.80%
434.33
477.74
1.24

spirals
125
52
62.5
26
5.208333 2.166667
5
2
120
48

Cyclone

18
91.00
26.00%
62.70%
4.32
40.00%
136.5
157.56
1.44

19

20

75.83

48

21
73.50
21.00%
64.50%
4.57
60.00%
49
65.09
1.88

22
17.50
5.00%
55.14%
3.70
11.44%
135.5
140.24
1.09

23
176.50
50.43%
54.58%
3.67
23.65%
569.83
617.97
1.21

24
176.50
50.43%
54.58%
3.67
23.65%
569.83
617.97
1.21

25
8.75
2.50%

Details
ROM

Material balance of process Flowsheet of sample B

Wt%
Fe%
TPH
100.00
52.79
350.00

Screw Srubber
Under flow
Over flow
Screw Scrubber U/F sujected to screen 1 mm size fraction
+ 1mm
- 1 mm
+1 mm size fraction ground to below 1 mm size
-1000+50 microns
- 50
Blending
-1 mm
-1000 + 50 microns
Rougher
Rougher spiral conc
Rougher spiral tailing
Cleaner spiral
Cleaner spiral conc
Cleaner spiral tailings
Screw scrubber o/f subjected to desliming hydrocyclone
Underflow
overflow
Blending
Rougher spiral tailings
Cleaner spiral tailings
-50 micron size
Desliming hydrocyclone U/F
Rougher WHIMS study
Rougher WHIMS Concentrate
Rougher whims tailings
Cleaner WHIMS study
Cleaner WHIMS Concentrate
Cleaner whims tailings
overall concentrate ( without flotation)
Spiral concentrate
WHIMs concentrate

Overall tailings
desliming hydrocyclone O?F
Rougher whims tailings
Cleaner whims tailings

overall material balance

Concentrate
Tailings

51.86
48.14
100.00

57.50
47.72

181.51
168.49
350.00

31.64
20.22
51.86

57.84
56.97

110.74
70.77
181.51

18.67
12.97
31.64

58.92
56.29

65.35
45.40
110.74

20.22
18.67
38.89

56.97
58.92

70.77
65.35
136.12

26.31
12.58
38.89

62.70
47.88

92.09
44.03
136.12

21.33
4.98
26.31

64.50
54.99

74.66
17.43
92.09

28.53
19.61
48.14

53.00
40.03

99.86
68.64
168.49

12.58
4.98
12.97
28.53
59.06

47.88
54.99
56.29
53.00
52.80

44.03
17.43
45.40
99.86
206.71

44.32
14.74
59.06

59.66
32.17

155.12
51.59
206.71

39.14
5.18
44.32

61.60
45.03

136.99
18.13
155.12

21.33
39.14
60.47

64.50
61.60
62.62

74.66
136.99
211.65

19.61
14.74
5.18
39.53

40.03
32.17
45.03
37.75

68.64
51.59
18.13
138.36

60.47
39.53

62.62
37.75

211.65
138.36

Feed
Concentrate
Tailings
Feed Fe%
Product Fe%
Tailings Fe%

MTPA
TPH
No. of Days Hrs/Day
2.07
345.16
1.25
208.69
0.82
136.47
300.00
20.00
52.70
62.62
37.53

Yield
60.46%
39.54%

MTPA
2.09
1.25
0.83
53
63
38.00

Feed
Concentrate
Tailings
Feed Fe%
Product Fe%
Tailings Fe%

TPH
316.2
189.7
126.5

No. of Days

Hrs/Day

330

Yield
60.00%
40.00%

20

1252140
###### 56.75%
29%
449.69
316
93%

BIN

100%
23.8

53.0%
112.05

43.46% 58.0%
24.25 59.99

3.85
2.7

316.2
47%

SCREEN

34.64

100%
359.95

53.0%
448.2

269.140 85.12% 63.5%

65%
144.92 205.8

3.58
1.51

+ 1 mm
137.42
70%

ROD MILL

43%
58.89

60.0%
93.68

178.78
35%

3.95
2.1

53.54

137.4
55%

56.54%
335.7
- 1 mm

43%
112.4

100%
448.13

53.0%
536.38
-1mm

63.2394
60%

3.64
1.57
90.1161
45%

116
227.53

3.33
1.09

SUMP

20%
63.5%
42.16
56.43
-1mm +.5mm

4.43
1.87

59.0%
124.8

3.90
1.11

203.47
39%

-0.500mm + 0.020 mm
28.50%
52.9%
3.58
110.14
135.34
1.48

54.0%
381

21.50%
1050.97

42.0%
1075.13

46.244
12%

14.63%
325

Conc

138.731
44%

60.3%
214.79

3.99
1.48

SUMP
152.605
34%

- 1.0 mm + 0.020 mm

13.87
10%

4%
120

61.0%
123.39

4.09
1.08

48%
300

60.3%
338.19

4.00
1.34

300
116.188
39%

Cleaner WHIMS

22.544
7%

7.13%
300

44.00%
307.62

36.75%
180

63.4%
206.28

4.42
1.44

2.96
1.05
-0.020mm

46.244
12%

Tailing thickner
14.63% 33.00%
325
341.82

2.75
1.09

63.5%
262.71

4.42
1.53

TPH
% Solids

- 1.0 mm + 0.020 mm

43.88%
180

56.75%
222.16

2.81
1.04

3.63
1.39

Mids

Tails
33.0% 2.75
341.82 1.09

4.42
1.5

-0.020mm

300
Rougher WHIMS

###### 141.86% 63.5%

43%
594.61
696

D/Cyclone

67.98
6%
64%
325

179
45%

-0.150 mm

SUMP
6%
120

0.0%
0

4.42
1.95

Slimes
Coarse

18.5
13%

179.43 56.75% 63.5%

63% 105.38 145.9

3.58
1.42

48.2%
1208.57

Fines

30%
54.0%
94.86
120.95
-1 mm + .150mm

0%
344.3

BALL MILL

3.38
1.32

158.10 50.00%
12% 1161.11

ALLFLUX

3.95
1.7

0
0%

CONC
THICKENER

4.42
2.01

850

60.0%
147.22

94.86
50%

49.2%
388.57

316.2
41%

SUMP

SUMP

4.42
1.28

CYCLONE

336.15
137.42
85%

63.5%
490.2

3.58
3.03

90.526
6%

Intermediate thickner
28.63% 42.50%
1351
1382.74

Flotation

2.85
1.04

% WT
Water TPH

% Fe
Pulp(Cu.m/hr)

Sp.Gr.
Pulp Density

0.00
1

MTPA
2.64
1.50
1.14
53
63
39.85

Feed
Concentrate
Tailings
Feed Fe%
Product Fe%
Tailings Fe%

TPH
400
227.3
172.8

No. of Days

Hrs/Day

330

Yield
56.81%
43.19%

20

###### 56.75%
29%
568.93
400
93%

BIN

100%
30.11

53.0%
141.76

43.46% 58.0%
30.68 75.89

3.85
2.7

400
47%

SCREEN

43.83

100%
455.39

53.0%
567.04

340.504 85.12% 63.5%

65%
183.35 260.3

3.58
1.51

+ 1 mm
173.86
70%

ROD MILL

43%
74.51

60.0%
118.5

226.18
35%

3.95
2.1

67.74

173.9
55%

56.54%
424.71
- 1 mm

43%
142.3

100%
566.96

53.0%
678.61
-1mm

80.0076
60%

3.64
1.57
114.011
45%

116
335.59

3.33
1.11

SUMP

20%
63.5%
53.34
71.39
-1mm +.5mm

4.43
1.87

59.0%
126

3.90
1.14

257.42
40%

-0.500mm + 0.020 mm
28.50%
52.9%
3.58
139.35
171.22
1.48

54.0%
450.21

21.50%
1104.26

42.0%
1134.82

58.506
13%

14.63%
379.36

Conc

175.517
49%

60.3%
224.02

3.99
1.59

SUMP
193.068
39%

- 1.0 mm + 0.020 mm

17.55
13%

4%
120

61.0%
124.29

4.09
1.11

48%
300

60.3%
348.31

4.00
1.42

300
146.995
45%

Cleaner WHIMS

28.521
9%

7.13%
300

44.00%
309.64

36.75%
180

63.4%
213.25

4.42
1.53

2.96
1.06
-0.020mm

58.506
13%

Tailing thickner
14.63% 33.00%
379.36 400.63

2.75
1.09

63.5%
284.64

4.42
1.62

TPH
% Solids

- 1.0 mm + 0.020 mm

43.88%
180

56.75%
233.34

2.81
1.05

3.63
1.41

Mids

Tails
33.0% 2.75
400.63 1.09

4.42
1.5

-0.020mm

300
Rougher WHIMS

###### 141.86% 63.5%

43%
752.28 880.5

D/Cyclone

86.01
7%
64%
379.36

227
49%

-0.150 mm

SUMP
6%
120

0.0%
0

4.42
1.95

Slimes
Coarse

23.4
16%

227.00 56.75% 63.5%

63% 133.32 184.6

3.58
1.42

48.2%
1303.65

Fines

30%
54.0%
120.01
153.02
-1 mm + .150mm

0%
435.6

BALL MILL

3.38
1.32

200.02 50.00%
14% 1243.61

ALLFLUX

3.95
1.7

0
0%

CONC
THICKENER

4.42
2.01

850

60.0%
186.26

120
50%

49.2%
491.6

400
41%

SUMP

SUMP

4.42
1.28

CYCLONE

425.28
173.86
85%

63.5%
620.2

3.58
3.03

114.530
8%

Intermediate thickner
28.63% 42.50%
1404.3
1444.45

Flotation

2.85
1.05

% WT
Water TPH

% Fe
Pulp(Cu.m/hr)

Sp.Gr.
Pulp Density

0.00
1

Size, mm

Wt., %

+6
-6+3
-3+2
-2+1

13.66
16.16
22.11
11.16
3.85
3.85
4.67
5.07
4.6

-1+0.85
-0.85 + 0.5
-0.5 + 0.3
-0.3 + 0.21

-0.21 +0.15

Cum.
Wt., %
13.66
29.82
51.93
63.08
66.94
70.79
75.46
80.53
85.13

25.27%
35.37%
29.73%
9.64%

-0.15+0.106

8.05

93.17

-0.106+ 0.075

3.99

97.16

-0.075+0.045
-0.045
Total

1.62
1.22
100

98.78
100

MTPA
1.98
1.34
0.64
57
65.1
39.98

Feed
Concentrate
Tailings
Feed Fe%
Product Fe%
Tailings Fe%

TPH
299.7
203
96.62

No. of Days

Hrs/Day

330

Yield
67.75%
32.25%

20

###### 64.19%
35%
355.97
299.7
93%

BIN

100%
22.55

57.0%
101.56

34.54% 60.0%
18.26 44.47

3.95
2.74

299.7
48%

SCREEN

26.1

100%
327.23

57.0%
406.24

128.300 42.82% 65.1%

65%
69.08
96.7

3.79
1.54

+ 1 mm
103.5
70%

ROD MILL

35%
44.36

60.0%
70.56

196.154
39%

3.95
2.1

40.32

103.5
55%

65.46%
308.97
- 1 mm

35%
84.68

100%
393.65

57.0%
472.66
-1mm

38.9551
60%

3.90
1.59
104.879
45%

116
150

3.61
1.09

SUMP

13%
64.5%
25.97
34.5
-1mm +.5mm

4.57
1.88

56.0%
123

3.74
1.07

226.84
39%

-0.500mm + 0.020 mm
35%
57.2%
3.81
128.19
155.75
1.5

58.0%
418.02

15.00%
978.62

45.0%
993.46

45.308
11%

15.12%
359.06

Conc

- 1.0 mm + 0.020 mm

56.88%
180

65.0%
216.83

4.63
1.62

SUMP
187.488
38%

- 1.0 mm + 0.020 mm

17.04
12%

6%
120

62.0%
124.03

4.23
1.1

63%
300

64.7%
340.82

4.59
1.43

300
153.399
46%

Cleaner WHIMS

17.044
5%

5.69%
300

44.00%
305.76

51.19%
180

67.3%
211

4.95
1.58

2.96
1.04
-0.020mm

45.308
11%

Tailing thickner
15.12% 32.50%
359.06 375.54

2.75
1.08

4.86
1.62

TPH
% Solids

0.47569444
170.444
49%

66.7%
245.52

3.03
1.03

3.85
1.4

Mids

Tails
32.5% 2.75
375.54 1.08

4.65
1.51

-0.020mm

300
Rougher WHIMS

###### 107.01% 65.1%

43%
425.05 494.1

D/Cyclone

44.95
4%
76%
359.06

###### 64.19%
48%
205.97

-0.150 mm

SUMP
4%
120

0.0%
0

4.65
1.98

Slimes
Coarse

11.09
8%

192.35 64.19% 65.1%

63% 112.97 154.4

3.79
1.47

53.6%
1148.28

Fines

37%
59.0%
110.87
139.32
-1 mm + .150mm

0%
243

BALL MILL

3.71
1.4

149.83 50.00%
12% 1106.81

ALLFLUX

3.95
1.7

0
0%

CONC
THICKENER

4.65
2.04

850

60.0%
110.89

110.9
50%

55.4%
361.85

299.7
43%

SUMP

SUMP

4.65
1.38

CYCLONE

304.68
103.5007
85%

65.1%
397.4

3.79
3.17

61.993
5%

Intermediate thickner
20.69% 44.73%
1278.6
1299.22

Flotation

3.01
1.03

% WT
Water TPH

% Fe
Pulp(Cu.m/hr)

Sp.Gr.
Pulp Density

0.00
1

MTPA
1.98
1.34
0.64
57
65.1
39.98

Feed
Concentrate
Tailings
Feed Fe%
Product Fe%
Tailings Fe%

TPH
299.7
203
96.62

No. of Days

Hrs/Day

330

Yield
67.75%
32.25%

20

###### 67.66%
29%
508.13
299.7
93%

BIN

100%
22.55

57.0%
101.56

34.54% 60.0%
18.26 44.47

3.95
2.74

299.7
48%

SCREEN

26.1

100%
327.23

57.0%
406.24

304.119 101.49% 65.1%

65%
163.76 229.2

3.79
1.54

+ 1 mm
103.5
70%

ROD MILL

35%
44.36

60.0%
70.56

196.154
39%

3.95
2.1

40.32

103.5
55%

65.46%
308.97
- 1 mm

35%
84.68

100%
393.65

57.0%
472.66
-1mm

74.9136
60%

3.90
1.59
104.879
45%

116
278.19

3.54
1.09

SUMP

25%
64.5%
49.94
66.35
-1mm +.5mm

4.57
1.88

56.0%
124.8

3.74
1.11

197.77
38%

-0.500mm + 0.020 mm
35%
55.4%
3.71
128.19
156.48
1.49

56.8%
375.39

15.00%
990.61

45.0%
1005.45

37.756
10%

12.60%
323.1

Conc

142.036
44%

63.4%
212.2

4.41
1.52

SUMP
156.240
34%

- 1.0 mm + 0.020 mm

14.2
11%

5%
120

62.0%
123.36

4.23
1.09

52%
300

63.2%
335.56

4.39
1.36

300
127.833
42%

Cleaner WHIMS

14.204
5%

4.74%
300

44.00%
304.8

42.66%
180

65.5%
207.19

4.70
1.49

2.96
1.03
-0.020mm

37.756
10%

Tailing thickner
12.60% 32.50%
323.1 336.83

2.75
1.07

4.65
1.58

TPH
% Solids

- 1.0 mm + 0.020 mm

47.40%
180

65.1%
273.53

3.03
1.03

3.78
1.39

Mids

Tails
32.5% 2.75
336.83 1.07

4.65
1.51

-0.020mm

300
Rougher WHIMS

###### 169.15% 65.1%

43%
671.89
781

D/Cyclone

44.95
4%
66%
323.1

###### 67.66%
47%
229.94

-0.150 mm

SUMP
6%
120

0.0%
0

4.65
2.11

Slimes
Coarse

17.98
13%

202.75 67.66% 65.1%

67%
99.86 143.5

3.79
1.47

52.3%
1161.08

Fines

25%
59.0%
74.91
94.13
-1 mm + .150mm

0%
408.3

BALL MILL

3.71
1.4

149.83 50.00%
12%
1118.8

ALLFLUX

3.95
1.7

0
0%

CONC
THICKENER

4.65
2.04

850

60.0%
110.89

74.91
50%

55.4%
361.85

299.7
43%

SUMP

SUMP

4.65
1.29

CYCLONE

304.68
103.5007
85%

65.1%
551.8

3.79
3.17

59.152
4%

Intermediate thickner
19.74% 44.76%
1290.6
1310.25

Flotation

3.01
1.03

% WT
Water TPH

% Fe
Pulp(Cu.m/hr)

Sp.Gr.
Pulp Density

0.00
1

Fe%
30%
36%
40.00%
41.80%
46.00%
47.60%
60.00%
64.00%
67.00%
70.00%
60.70%

Sp_Gr
2.75
2.75
2.75
2.80
3.10
3.30
3.95
4.50
4.90
5.40
4.05

3
4

423443
564591

#VALUE!

8.61
11.21
13.11
10.53
3.2
3.04
3.88
4.04
3
4.7

Cum.
wt., %
8.61
19.82
32.93
43.46
46.66
49.7
53.58
57.62
60.62
65.32

Cum wt%
Passing
100
91.39
80.18
67.07
56.54
53.34
50.3
46.42
42.38
39.38

-0.106+ 0.075

3.9

69.22

34.68

59.75

-0.075+0.045
-45
Total
Bulk

6.44
24.34
100

75.66
100

30.78
24.34

60.45
41.46

Size, mm

Wt., %

6
-6+3
-3+2
-2+1
-1+0.85
-0.85 + 0.5
-0.5 + 0.3
-0.3 + 0.21
-0.21 +0.15
-0.15+0.106

Fe, %

31.64

20.22

58.08
58.22
56.96
54.87
53.19
51.94
50.96
51.52
54.73
58.64

52.35

Cum. Fe,
%
58.08
58.16
57.68
57
56.74
56.45
56.05
55.73
55.68
55.89
56.11
56.48
52.83

51.86
48.14

Cum.Pas
sing, %

8.73
12.22
10.27
3.33
3.91
2.91
2.91
2.33
4.74
6.9

Cum.
wt., %
8.73
20.95
31.21
34.54
38.45
41.35
44.26
46.59
51.33
58.23

-0.106+ 0.075

7.65

-0.075+0.045
-45
Total
Bulk

9.31
24.81
100

Size, mm

Wt., %

6
-6+3
-3+2
-2+1
-1+0.85
-0.85 + 0.5
-0.5 + 0.3
-0.3 + 0.21
-0.21 +0.15
-0.15+0.106

Fe, %

Cum. Fe, %

91.27
79.05
68.79
65.46
61.55
58.65
55.74
53.41
48.67

61.29
61.29
59.89
58.36
56.56
56.4
53.33
52.91
57.38
62.27

61.29
61.29
60.83
60.59
60.18
59.92
59.48
59.15
58.99
59.38

65.88

41.77

61.43

59.62

75.19
100

34.12
24.81

62.27
47.89

59.95
56.95

100

59.01344

56.96

Screen + 1 mm Product

Size, mm

Wt., %

6
-6+3
-3+2
-2+1

8.73
12.22
10.27
3.33
34.55

25.27%
35.37%
29.73%
9.64%
100.00%

Cum.
wt., %
8.73
20.95
31.21
34.54

Cum.Pas
sing, %
91.27
79.05
68.79
65.46

Fe, %
61.29
61.29
59.89
58.36

Cum. Fe,
%
61.29
61.29
60.83
60.59 60.60899

Screen-1 mm Product

-1+0.85
-0.85 + 0.5
-0.5 + 0.3
-0.3 + 0.21
-0.21 +0.15
-0.15+0.106

3.91
2.91
2.91
2.33
4.74
6.9

Cum.
wt., %
38.45
41.35
44.26
46.59
51.33
58.23

-0.106+ 0.075

7.65

65.88

34.12

61.43

59.62

-0.075+0.045

9.31

75.19

24.81

62.27

59.95

Size, mm

Wt., %

Cum.Pas
sing, %
61.55
58.65
55.74
53.41
48.67
41.77

Fe, %

Cum. Fe, %

56.56
56.4
53.33
52.91
57.38
62.27

60.18
59.92
59.48
59.15
58.99
59.38

235.3038
174.3672
173.0868
137.8195
279.6126
409.722
456.093
558.1345

-45

24.81

100

Cum.Pas
sing, %
75
62.65
55.74
53.41
48.67
41.77

47.89

56.95

Fe, %

Cum. Fe, %

56.56
56.4
53.33
52.91
57.38
62.27

60.32370568
59.92
59.48
59.15
58.99
59.38

65.47

Feed to allflux

Size, mm

Wt., %

-1+0.85
-0.85 + 0.5
-0.5 + 0.3
-0.3 + 0.21
-0.21 +0.15
-0.15+0.106

25
12.35
6.91
2.33
4.74
6.9

Cum.
wt., %
25
37.35
44.26
46.59
51.33
58.23

-0.106+ 0.075

7.65

65.88

34.12

61.43

59.62

-0.075+0.045
-45

9.31
24.81

75.19
100

24.81
0

62.27
47.89

59.95
56.95

100

1412.93
3837.069

59.51538

21
10
4

62.00068
23.86
54.80762

9.34
58.03099
47.89

70

58.60805

58.60805