Development of a Mineral Processing Flowsheet - Case

History, Batu Hijau

Tom de Mull, Stuart Saich and Karen Sobel

ABSTRACT

The Batu Hijau project was the largest mining project executed up to the time of completion. The
concentrator was the largest ever built from “grassroots”. Initial ore discovery was made in May
1990 followed by several years of work investigating the geology and mineralogy, which
culminated in the preparation of a final feasibility study in July 1996. An EPC contract was
awarded to Fluor Daniel for the basic design, detailed engineering and development of the project
in August 1996.
During the detailed engineering phase the original design basis was thoroughly
scrutinised and updated as a result of further flotation testwork carried out using sea water. This
testwork allowed for a second review of the flotation kinetics leading to significant mid stream
changes in circuit design which were incorporated into the final installation at a net cost savings.
A flotation circuit model was developed using pilot plant data obtained from testwork carried out
by AMMTEC in Perth, Australia and subsequently used as the basis for flotation circuit mass
balances and equipment sizing. This flotation model together with a well defined process design
criteria were used to size flotation circuit equipment and associated hydraulic systems.
The initial ramp up rate of the concentrator achieved the aggressive targets set by the
operations personnel. Analysis of early operating data during startup indicated that overall plant
performance was well within original design expectations, but that internal circulating loads where
greater than expected. Debottlenecking studies were subsequently carried out which confirmed
visual observation as to certain equipment modifications that could be made to enhance recoveries.
The flotation kinetic model has been updated to reflect actual operating conditions, and to develop
a greater understanding of scale up issues for the large flotation circuit equipment involved.

INTRODUCTION
The $1.83 billion Batu Hijau project is located in Sumbawa, Indonesia and is owned and operated
by PT Newmont Nusa Tenggara (F’TNNT). FTNNT is an Indonesian company owned 80 percent
by a partnership between Newmont Mining Corporation (Newmont) and Sumitomo Corporation.
A local mining company, PT. Pukuafu Indah, holds the remaining 20 percent.
Fluor Corporation (Fluor) was responsible for engineering, procurement and construction
of Batu Hijau, the world’s largest greenfield startup mining project ever constructed. The copper
concentrator is designed to treat 120,000 tonnes of ore per day. The open-pit mine uses electric
shovels and haul truck to transport the ore to the primary crushers. A 5.6-kilometer long overland
conveyor carries the ore to the concentrator, which consists of a coarse ore stockpile, two-train
SAG and ball mills, primary and scavenger flotation cells, vertical regrind mills, cleaning flotation
cells and counter-current decantation thickeners to wash the sea water from the concentrate. The
thickened concentrate slurry is stored in two tanks, then pumped to the port site where the
concentrate is filtered and stored for shipment.
Tailings produced by the concentrator flow by gravity from the process plant to the
ocean, where they are disposed of via submarine tailings placement. The tailings are deposited
three kilometers from the coast, at a depth of approximately 108 meters below the surface. The
tailings migrate towards the Java Trench and are ultimately deposited at depths of several
thousands meters.
Early metallurgical test work on Batu Hijau ore was carried out at Newmont’s research
facilities. This involved extensive metallurgical testing involving impact crushing, grindability
tests, abrasion, flotation, filtration, flocculation etc to enable the definition of initial process

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configuration. Newmont also enlisted the services of Lakefield Research (Ontario, Canada), and
other testing facilities, during this phase to support their effort.
Fluor first became involved in the Batu Hijau project in 1994 to carry out the
Optimization Study. The purpose of this work was to optimize major aspects of the project such as
plant throughput, process plant location, mode of concentrate transport and location of the port
facilities.
In 1995, Newmont and Fluor began work on the feasibility study. Core samples from the
ore body were initially sent to Lakefield for preliminary laboratory locked cycle testing. Results of
this work were used to define a proposed flotation circuit which was subsequently tested using
composite samples of the expected mine plan feed in a batch pilot plant. This work was completed
in late 1995, with an addendum issued in July 1996. The main deliverables from this stage of work
were the definition of a proposed flotation circuit configuration and preliminary equipment sizing
for the final feasibility study report. The feasibility report was issued in February 1996. This paper
focuses on development of the process from this point forward.

PILOT PLANT TESTWORK

During the preliminary design phase the need for a source of fresh water, suitable tailings location
and subsequent water recovery was investigated. Due to the adverse seismic conditions in the
region an alternative source of water (sea water) was recommended, along with the use of sub-sea
tailings disposal. The proposal to use sea water in the circuit prompted the need to carry out
further pilot plant testwork on suitable composites to confirm flotation kinetics and overall
recovery. This was carried out at AMMTEC in Perth, Australia during the early part of 1996. The
pilot plant used was set up as a scaled version of the proposed circuit developed during the
feasibility study. Results from the revised flotation testwork using sea water instead of fresh water
were made available to the design team in late 1996.
Samples of feed, concentrate and tailings material from the AMMTEC sea water pilot
plant testwork were sent to the Council for Scientific Research Organisation (CSIRO) in Australia
for Scanning Electron Microscopy (SEM) analysis. Results from this work proved invaluable in
interpreting the results of the flotation testwork.

RAW DATA ANALYSIS

Several pilot plant testwork campaigns were carried out at AMMTEC, using sea water and further
composite samples. This work resulted in the generation of a significant amount of raw data that
required further analysis before valid conclusions could be reached. Of the various tesc campaigns
“Trial 12” was run with the desired intent to provide metallurgical information for scale up
Raw data obtained from ‘Trial 12’ included the following typical metallurgical
information.

Solids flow rates.

Pulp densities for each stream.
Particle size distributions for individual streams.
Metallurgical assays (Copper, Gold, Sulphur and Iron) for individual streams and as a
function of particle size within each stream.

To facilitate meaningful conclusions, analysis of the raw data was carried out using the
following methodology:

Mass balancing of raw data using SysCADMassBal.

Visual data smoothing using EXCEL.
Generation of recovery curves for both particles and individual elements within each
stream using EXCEL.

Mass Balancing
As is typical for metallurgical sampling the data obtained from the Trial 12 test runs did not
balance, eg. total mass of copper reporting to concentrate and tailings streams did not equal total

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mass of copper in feed stream. Some form of statistical mass balancing of raw data is required
prior to subsequent analysis or modelling.
In order to achieve a suitable mass balance for solids, liquids, particle sizes and
individual elements a statistical mass balancing package, SysCADMassbal was used. With this
tool a reasonable mass balance of particle sizes across multiple unit operations and grades within
each size fraction was developed. The raw metallurgical data for each process stream (i.e. solids
flow rate, particle size distribution and assays) were used together with typical sample standard
deviations to statistically manipulate the raw data into a mathematically balanced data set. This
‘massaged stream data’, was subsequently used in the data smoothing exercise, detailed below,
prior to use in process modeling. The use of unbalanced data, or only using feed and concentrate
stream data to develop a process mass balance can easily lead to incorrect conclusions.

Visual Data Smoothing

After mass balancing the raw data it became apparent that a discontinuity existed in the particle
size and grade around the 38-micron size fraction. In reviewing the methodology used to analyze
particle sizes and prepare sufficient material for subsequent assaying, it was revealed that the
samples were wet-sieved at 38 microns and that all material finer than 38 microns was
subsequently sized in a “cyclosizer.” This equipment uses a series of very small cyclones to
separate the minus 38 micron material into size fractions. Because the mineral specific gravity
affects the split, any gold or gold bearing material reported to coarser size fractions than their size
warranted. This discontinuity was removed via visual data smoothing and further mass balancing
using EXCEL.

Particle Size (microns)

RawtestwakdalaFeed%bjmass 0 RawtestwakdataCons%bjymass
-+ Raw testwork dala Tails % bj mass -Smwtkddata Feed%bjmass
-Smoothed data Cons %by mass -SmwtheddataTailssbty mass

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RESULTS OBTAINED FROM RAW DATA ANALYSIS
Analysis of the mass balanced and smoothed data focused on the recovery of material to the
concentrate streams as a function of particle size. This analysis was completed both globally
across the overall circuit, and also for specific flotation banks within the circuit. By plotting the
mass of material within each size fraction for both the feed and concentrate streams, the size range
over which preferential flotation occurs could be identified. This method of analysis allowed for
an ‘easy to visualize’ representation of the effect of either ‘over’ or ‘under grinding’ of both the
primary grinding circuit product and the regrind circuit product. The main objective of the
exercise was to minimise (and equalize) flotation losses in either the coarse or fine size fractions
through optimisation of grinding design criteria.
In addition to the above analysis an investigation into the optimum rougher concentrate
polishing mill retention time was carried out. Results are indicated in the following sections:

Optimum Primary Grind size

Analysis of the material mass recovery to the concentrate stream for the overall flotation circuit
was used to identify the optimum primary grind size. Figure 2 indicates the particle size
distribution for both the feed and concentrate streams.

Figure 2 indicates that the flotation circuit does not effectively recover very coarse
material (i.e. > 210 microns), and that recovery of particles finer than 38 microns is diminished.
This is typical of flotation circuits, but of importance was the easily identifiable size range across
which primary grinding should be carried out.
In addition to the mass recovery distribution for individual particle sizes, the recovery of
copper as a function of particle size was also examined. Figure 3 presents the copper distribution
as a function of particle size for both the feed and concentrate streams.

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 Figure 3 - Overall Copper distribution in Flotation circuit

The above figure once again highlights a similar trend in recovery as a function of
particle size with a slightly narrower recovery range indicated.

Optimum Regrind Particle Size

A similar analysis of particle size distributions for the feed and concentrate streams around the
cleaner circuit was also carried out. Figure 4 highlights the results.

Interpretation of Figure 4 indicates that the optimum regrind size lies within the 38-145
micron size range. The relatively large amount of minus 38 micron material present should be
avoided due to the high losses (low recovery) of material within this size fraction. The pilot plant
was operated at the proposed regrind specification of 80.0 percent passing 25 microns, which
resulted in the generation of a significant quantity of ultra fines material.

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 One of the significant conclusions reached from the raw data analysis was the
requirement to increase the regrind size from 80.0 percent passing 25 microns to 80.0 percent
passing 80 microns. Significant cost savings were realized as the design team grinding experts
were able to reduce the regrind milling installation to three mills from the original configuration of
six. The recommendation to increase the regrind size was subsequently confirmed in further
locked cycle flotation tests.

Rougher Concentrate Grinding Optimisation

The concentrate collected from the first cells in the pilot plant ran at a grade just slightly lower
than desired final grade. A review of the SEM photographs of this rougher concentrate identified
that several large (>180 microns), high grade (>30.0% Cu) particles were present. The
recommendation was made that this material be collected separately (split flotation circuit) and
passed through a polishing mill to enable some minor particle breakage without over grinding the
concentrates. In order to determine the effect of polishing on recovery a concentrate sample was
subjected to several batch grind-flotation tests to optimise design basis. Figure 5 indicates the
findings.

-No Regind -30 secs Regrind -45 sec Regrind -360 sec Regrind

The above figure indicates the improved kinetics as a result of polishing the product for
up to 45 seconds but with longer grinding times kinetics drop off and losses occur as a result of
overgrinding. The optimum polishing mill product size found was 80 percent passing 82 microns.

FLOTATION CIRCUIT MODELLING

A flotation kinetic model was developed in EXCEL to reflect the proposed circuit design. The
kinetic model used the following basic parameters:

Simple first order rate equation.

Rate kinetics for each significant copper bearing mineral.
All non-valuable material lumped together as gangue.
Mineralogy obtained from Scanning Electron Microscopy (SEM) work.
Rate kinetics as a function of particle size developed for copper for each unit operation.
Pulp densities from testwork used.

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Rate Equation Used
The form of the rate constant applied within the flotation model was as follows:

Where Ri - Recovery of mineral “i” at time t minutes

Ri(max) = Maximum recovery of mineral “i“ at time t = infinity
Ki - Rate constant for mineral “i”
“i” - Each mineral and gangue modelled

The mass balanced and smoothed data obtained from the sea water pilot plant testwork
was then used as the basis to tune relevant rate constants to equate to actual pilot plant
performance. For the copper balance, recovery data as a function of particle size for each section
of the circuit allowed for the development of flotation rate constants for each size fraction. By
developing the rate constants on a size basis the effect of a change in regrind size criteria could be
analysed. The rate constants for individual particle sizes were then summated to represent overall
copper mineral flotation rate constants. Revised rate constants for the increased regrind size were
used in the final model
Rate constants for gangue and gold were tuned to achieve overall grades and recoveries
as experienced in the pilot plant.

Minerals used in flotation model

The following minerals or elements were included within the flotation model:
Chalcopyrite
Bornite
Covellite
Gold
Gangue

Results from Scanning Electron Microscope (SEM) analysis were used to define the
mineralogy for the original model. The ratio between valuable copper bearing minerals was
changed to suit expected mine plans for final modelling but the rate constants for individual
minerals assumed to be the same.

Pulp Densities
Results from both the Lakefield and AMMTEC pilot plant testwork indicated that the pulp
densities for scavenger concentrate streams were of the order of 510% solids by mass. Review of
similar operations and experience of project consultants (Dr R Klipmel) indicated that operating
pulp densities should be higher at around 10.0- 15.0 % solids by mass.
Lower pilot plant pulp densities were expected as a result of the objective to maximise
recovery at the expense of grade. However when the recommended pulp densities were used
within the flotation model, poor copper recoveries as a result of short pulp residence times
indicated the need to re-evaluate sizing of the cleaner flotation circuit.

Flotation Modelling Results

The kinetic flotation model as based on the sea water pilot plant testwork was then used to predict
performance of the proposed flotation circuit that was, at that time, in the detailed design phase.
Conclusions from the flotation modelling were as follows:

The volume of scavenger concentrate, at the relatively low pulp density, was significantly
higher than expected. Pilot plant pulp densities of the order of 2 4 % were achieved,
whereas the simulated value of 12.0-14.0 % still resulted in excessive volume of
scavenger concentrate.
The original regrind size specified for the scavenger concentrate would result in
excessive losses in the fine size fraction.

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 Overgrinding of concentrates should be avoided due to high losses.
An optimum rougher concentrate polishing mill retention was developed.

Based on these findings several modifications to the original flotation circuit

configuration were recommended and subsequently tested using the flotation model. These were
as follows:

Install a dewatering circuit on the scavenger concentrate stream.

Install regrind screens (as used in the iron ore industry) to avoid overgrinding of high
density, fine particles that would report to cyclone underflows.
Resize cleaner flotation circuit to suit revised mass flows.
Reduce the number of regrind mills from six to three as a result of reduced regrind duty.

PROCESS DESIGN

Process Design Criteria

The basic design criteria for the Batu Hijau project was as follows:

Nominal throughput 43,800,000 tpa

Nominal throughput 120,000 tpd
Plant availability 92.0 %
Plant surge factor +I- 15.0 %
Average plant throughput 5,435 tph
Maximum plant throughput 6,250 tph

In addition to the above listed mass throughputs, a range of expected feed grades (from
the mine plan) was imposed upon the system to enable calculation of concentrate production rates
and grade. The flotation model developed and based on the AMMTEC “Trial 12” data was
updated to reflect the proposed dewatering circuit, the proposed circuit configuration and the
process design criteria to verify equipment selection.

Process Engineering
At the same time of completion of the flotation modelling development the final vendor bids for
flotation equipment were received. This proved opportune as the proposed vendor equipment sizes
were not exactly the same as the equipment listed in the feasibility study. Typical issues identified
were such as one vendor offering six rows of 100.0m3 Rougher scavenger cells versus a
competitor offering five rows of 127.0 m3 cells for the same duty.
Once the preferred vendor (commercial and mechanical) was selected the relevant
equipment sizes were entered into the flotation model and equipment selection optimised. At this
time a detailed review of th? pr.oposed flotation circuit configuration and equipment sizing was
carried out by owner representatives, engineering company personnel and outside consultants (Dr
R Klimpel). During this phase the recommended operating parameters for the dewatering circuit
were set within the flotation model such that the regrind circuit would be fed with a constant pulp
density independent of rougher scavenger circuit operation. The flotation model was then tested
using the ranges specified in the design criteria and overall recovery and grade recorded. Then
number and configuration of rougher/scavenger flotation cells was fixed but he configuration and
number of cleaner cells varied to optimise operating flexibility and maximise recovery. The
following table lists the feasibility study circuit flotation equipment versus final selected
equipment.

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 Rows # Cells/row Cell Size m3 Total volume m3
Rougher cells 6 2 100 1200
Scavenger cells 6 8 100 4800
First cleaner cells 1 4 100 400
Cleaner scavenger cells 1 4 100 400
Second cleaner cells 1 5 20 100
Final cleaner cells 1 3 20 60

Rougher cells 5 1 127 635

Scavenger cells 5 9 127 5715
First cleaner
..- cells
.- .
.- 1 A 47 5 ._.I
i7n
_.-
Cleaner scavenger cells 1 4 42.5 170
Second cleaner cells
~
1 10 17.0 170
Final cleaner cells' 1 4 14.5 58
* The vendor recommended a final installation of five flotation cells due to insufficient
concentrate collection lip length.

Once the final circuit sizing and configuration had been completed the flotation model
was run at three design tonnages and associated grades to generate expected mass balances for
subsequent slurry material handling equipment. Slurry pump and sump design and sizing were
now redone using the new mass balance.

CIRCUIT PERFORMANCE AND DEBOTTLENECKING

Startup of the Batu Hijau copper concentrator and subsequent ramp up to design tonnage went
extremely well. Within ten days of starting the second primary grinding circuit the hourly average
mill throughput had achieved the design 5,435 t/hr. The design maximum throughput of 6,250 t/hr
was achieved four weeks later.
Performance testing was included within the EPC contract. In order to verify the
successful completion of each required performance test, operating data from key process points
was recorded into daily data sheets and reconciled against production reports. These were then
collated over time to verify successful completion of each performance test.
In addition to being a useful method of capturing successful performance, the data was
also used to verify the original design basis and update the flotation kinetic model to identify any
differences in original design expectations versus actual plant performance. Detailed analysis of
the operating data, flotation model updates and equipment sizing has been carried out in the form
of de-bottlenecking studies. Three of these have been completed out to date.
The following are some of the major issues highlighted as a result of reviewing operating
data and updating the flotation model to actual operating conditions.

Initial full scale plant flotation kinetics were significantly lower than pilot plant results.
Rougher and scavenger concentrate pulp densities were significantly higher than
expected.
Circulating load around cleaner circuit higher than expected.

The debottlenecking studies have been used to assist operations personnel in confirming
site conclusions and making changes to the circuits to enhance overall performance. Further
details as to findings are as follows:

Flotation Kinetics
The initial ore fed to the concentrator consisted of slightly oxidised material, which resulted in a
reduced pH of pulp reporting to the rougher-scavenger flotation circuit. Primary lime addition was
re-directed from the regrind circuits to the primary grinding circuits to increase pH and improve

2219
flotation performance. The types of frother and collector, and addition points were also changed
during initial startup to optimize flotation recovery.
The first two cells in each row of rougher-scavenger cells were designed such that
concentrate could be collected from both of them, and sent to the polishing mill. The expected
operating procedure was that only concentrate from the first cell would normally be sent to the
polishing mill. On original startup however, it was found that the collection rate of concentrate
from the first cells in each row was significantly lower than expected. The grade was slightly
higher than expected but due to the low flow rate, concentrate was collected from the first two
cells in each row of cells and sent to the polishing mill.
Discussions with the flotation cell vendor and review of similar operations lead to the
conclusion that internal concentrate collection launders were required. Once installed the kinetics
improved significantly, and were comparable to original pilot plant testwork. One of the key
parameters not investigated within the flotation model was lip loading factors. Back calculation of
expected lip loading from the pilot plant testwork indicated a requirement of approximately 1.05
t/m/hr concentrate whereas the physical maximum obtained was 0.55 t/m/hr.
Figure 6 on the following page indicates the original rate constants used for design and
typical operating values.

-AMTEC Trial 1 2 Data. k = 0.8 -Onginel Design Value. k = 0.442 Apnl2000Avsraga. k I 0.179
:4- . May 2000 Avsrage. k = 0.19 --+-July 2001 Aue k= 0.393 -Novsmbsr2000 w e . h = 0.374

Operation of the rougher-scavenger cells improved back towards original design

expectations once the internal launders were installed in late 2000 and early 2002.

Rougher-Scavenger Concentrate Pulp Densities

The initial expectation of the rougher concentrate pulp density as developed from the pilot plant
testwork was 20.0 to 25.0 percent solids by mass. Once the plant was started and began to operate
at design tonnage it quickly became apparent that the actual pulp densities were significantly
higher. These have been found to run as high as 45.0 percent solids by mass and at the expected
copper grade. Of note is that the flotation feed pulp density ranges from 32.0 to 38.0 percent solids
by mass.

Cleaner Circuit Feed And Circulating Loads

A dewatering cone settler was installed to enable the recycle of excess water back to the scavenger
circuit due to the expected low concentrate pulp densities from the scavenger flotation cells.
Whilst this primary function has become of lesser importance due to higher than expected

2220
concentrate pulp densities, the cone settler served another critical function. This is in the
decoupling of operation of the cleaner circuit from the rougher-scavenger cells as a result of the
large residence time of the settler itself. Surges from the primary grinding and scavenger flotation
circuits do not affect the downstream processes. The feed rate and pulp density of material to the
cleaner circuit was thus very stable and assisted operators in not having a continuously fluctuating
feed to this part of the circuit.
Initially the recirculating load around the first cleaner and first cleaner scavenger flotation
cells was higher than expected. This was found to be due to the reduced flotation rate within the
rougherhcavenger circuit with higher scavenger concentrates reporting to the first cleaner cells.
Once the internal launders in the rougher cells were installed and the load shifted back to rougher
cells and subsequently the second cleaner cells the circulating load improved significantly.

Regrind Screens and Cyclones

The regrind screens as installed became a significant maintenance effort due to continual blocking
and scaling up as a result of the presence of lime. This resulted in a dilute screen product to the
regrind mills. The regrind screens were replaced with cyclones (after startup) which have
performed well. The required pulp density is now being fed to the regrind mills.

Throughput Studies
Three debottlenecking studies have been completed using hourly average operating data over a
minimum of one month operating time frame. As a result of this a valuable database of plant
performance has been used to evaluate flotation kinetics as a function of throughput. This was
analysed on a shift basis and the model tuned to reflect overall performance. An ‘effective
cleaning performance’ of the rougher cells has been developed using the ratio of rate constants for
valuable mineral versus gangue. As the total SAG feed rate increases the grind becomes coarser
and the flotation circuit residence time decreases.
By plotting the ratio of rate constants vs SAG throughput an indication of plant
performance can be gained. Figure 7 illustrates this.

Juv/Oct 2001 Data + Operation pria to internal launders in rwghers --- July/Ocl2W1 Data

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CONCLUSIONS
The successful startup of the Batu Hijau copper concentrator and subsequent ramp up to design
tonnages was the result of extensive metallurgical studies into flotation performance coupled with
simple methods of analysis. The evolution of the flotation circuit design in tandem with detailed
engineering, and subsequent incorporation of resulting recommendations, resulted in the
construction of a flexible and robust installation.
The scale up factor from pilot plant to full scale installation was of the order of 20,000.
Notwithstanding this large scale up factor, initial plant recoveries were within expectations and
individual streams within 30.0 % of initial mass balances. Subsequent equipment and circuit
changes have reduced this to approximately 10.0 %.
By “closing the loop” the original kinetic parameters have been updated using actual
plant data within the original flotation model and equipment performance factors defined. This has
enabled the flotation model to become more accurate resulting in an excellent de-bottlenecking
tool for future plant operations.

ACKNOWLEDGEMENTS
The authors wish to thank the management of PTNNT for their assistance and opportunity to
present this paper. In addition a special note of mention of the invaluable input from Dr R Klimpel
in guiding the team in the flotation circuit sizing and selection.

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