IMPC 2020-Multiple Ore Types Can Result in Multiple Processing Plants - Newell and Doherty - Final

IMPC 2020: XXX International Mineral Processing Congress, Cape Town, South Africa, 18-22 October 2020
Multiple Ore Types Can Result in Multiple Processing Plants

A.J.H.Newella* and K.Dohertyb
a
RPMGlobal, Brisbane, 4000, QLD, Australia
b
WSP Australia; formerly Havilah Resources Limited, Dulwich, SA, Australia
*Corresponding author: anewell@rpmglobal.com
ABSTRACT
A copper-gold project has required a number of trade-off studies underpinned by test work to settle on
pragmatic flowsheets and throughputs to support a Pre-Feasibility Study that provides a compelling financial
case.
The primary trade-off studies were based on the mine schedule, ore type feed-grade recovery
relationships, likely concentrate grades and typical marketing terms as well as the estimated capital and
operating costs for a range of throughputs and mining strategies. Secondary trade-off studies were conducted
for specific circuits and additional processing options. Although the details of these studies are not presented,
the technical options and subsequent flowsheets are discussed.
While the flowsheets will be optimised during the Feasibility Study stage, the basis is now fixed for the
four ore types that would be mined from the cooper-gold orebody.
The ore types, resulting from a strong weathering profile, exhibit a wide range of copper mineralization
and gold associations, as well as gangue types. They display a range of characteristics that necessitated a
nuanced approach to flowsheet development. The primary separation techniques that have been employed
include gravity, classification, flotation and leaching while a range of comminution methods have been
selected to suit the properties of the ore types.
While technical issues are important factors in terms of maximising the quality of separations, recoveries
and revenues, attention to material handling, equipment characteristics, the mine schedule, and capital and
operating costs are equally important considerations for settling upon a suitable and robust flowsheet.
Keywords: Flowsheet, Test Work, Studies, Saprolite Gold, Native Copper, Chalcocite, Chalcopyrite
1 Introduction
Havilah Resources Limited, based in Adelaide, South Australia, has discovered a number of cobalt-
copper-gold deposits in the Curnamona Craton located in northeastern South Australia, near the mining district
of Broken Hill (refer to Figure 1).
The largest deposit is Kalkaroo, which has JORC 2012 Mineral Resources of 1.1Mt copper, 3.15Moz
gold and 23,200t cobalt (Havilah Resources, 2020) with JORC 2012 Ore Reserves of 100.3 million tonnes of
ore averaging 0.47% Cu and 0.44g/t gold in the Proved and Probable categories (RPMGlobal, 2017).
A feature of this deposit is the presence of four ore types, including the Oxide ore types, namely Saprolite
Gold and Native Copper ores, which are in addition to the Chalcocite and Chalcopyrite Sulphide ores.
1
Pre-Feasibility Study (RPM, 2017)

Figure 1 : Location of the Kalkaroo Deposit
While processing flowsheets are largely based on the mineralogical and subsequent metallurgical
responses of ore types, other factors need to be taken into consideration. Mining aspects are particularly
important, such as whether ore types can be mined separately as well as when ore types would become
available for processing. Capital and operating costs also impinge on the flowsheet selection, such as the ability
to either blend ores or campaign ores through a common processing facility. Finally, the potential processing
product revenue plays an important role; flowsheets that maximize the revenue by yielding products with
marketable grades and penalty elements below threshold levels are sought.
Note that the suitability and robustness of the proposed flowsheet for adoption in Pre-Feasibility and
Feasibility Study needs to be confirmed by conducting test work on samples reflecting the mine schedule
notably where variations in ore types or blends, head grade excursions and gangue dilution would be
experienced.
This paper presents the outcomes of the work conducted to date to support the Kalkaroo flowsheet
development for the handling and processing of the ores to yield marketable products.
2 Mineralogy and Ore Types

The Kalkaroo deposit is defined by four ore types which have arisen from prolonged weathering of the
hypogene zone, called Chalcopyrite ore. The layer above the supergene zone known as Chalcocite ore which
is, in turn, overlain by the partially to fully weathered Native Copper ore. The ore type closest to the surface,
known as Saprolite Gold ore, is fully weathered and contains copper and gold. Figure 2 shows the ore type
proportions in the Kalkaroo deposit, with the Chalcopyrite ore dominating the resource.
2
14.7%
13.8%
48.1%
23.4%
Saprolite Gold Native Copper Chalcocite Chalcopyrite

Figure 2 : Kalkaroo Ore Type Proportions
All ore types exhibit different mineralogies that impact both the handling and separation properties and
influence the development of suitable flowsheets (refer to Table 2). While Chalcopyrite ore is the dominant
ore type, in order to access this ore, the other ore types need to be removed, and since they offer significant
revenue opportunities, it is highly desirable to process them.
Table 2 : Kalkaroo Ore Types and Properties
Bond Ball Life of Mine
Degree of Mill Work Head Grade
Ore Type Economic Minerals Gangue Minerals
Weathering Index Cu Au
(kWh/t) (%) (g/t)
Native gold and copper with
Saprolite Gold
Completely 6.3 - 8.2 0.16 0.79 some unidentified copper Carbonates
(oxide)
minerals
Native Copper Complete / Geothite, carbonates
8.7 - 9.1 0.64 0.63 Native copper and gold
(oxide) Partially and quartz
Chalcocite Partially /
11.2 0.75 0.41 Chalcocite and pyrite Quartz and mica
(supergene) Fresh rock
Chalcopyrite Chalcopyrite, pyrite and
Fresh rock 16.5-21.7 0.39 0.29 Quartz and biotite
(hypogene) molybdenite
The Saprolite Gold ore is essentially clay, with an increasing content of more competent material
(saprock) with depth. Native Copper ore maintains this characteristic and for ease of reference, they are both
classified as Clay ores. The more competent ores, namely Chalcocite and Chalcopyrite ores, identified as
Sulphide ores, have significant differences in mineralogy and ore hardness.
Clay bearing ores present a number of handling and separation challenges, which can be addressed by a
suitable choice of comminution and dispersion equipment, as well as employing lower percent solid slurries
in flotation and leaching circuits. In the latter case, carbon in slurry flowsheets may be ruled out
Saprolite Gold ore contains fine gold and a small amount of copper mineralisation that floats to some
extent, however does not respond to sulphidisation.
Native Copper ore naturally contains native copper, predominantly as relatively coarse particles,
however also contains free native gold. Minor quantities of pyrite and chalcocite are also present, particularly
closer to the supergene boundary.
3
The Sulphide ores are characterized by the presence of copper as sulphides, namely chalcocite and the
iron bearing chalcopyrite. The gangue present with this mineralisation means that Chalcocite ores are
moderately competent while Chalcopyrite ores are very hard.
Native gold and pyrite is present in the Chalcocite ore, with some native copper in the upper levels. The
pyrite, as measured in the flotation concentrate, contains both gold (3.7g/t) and cobalt (2,900g/t). The
chalcopyrite is also associated with pyrite which also contains gold (2.45g/t) and an elevated cobalt
concentration (3,400g/t) in the concentrate (Havilah Resources, 2019). Molybdenite is present although
economic levels are not observed throughout the Chalcopyrite ore zone. The copper sulphide minerals are
relatively fine and regrinding of the rougher flotation concentrate has been found to be required to achieve
marketable copper concentrate grades.
3 Study Process
The process of determining the technical and economic feasibility of a project includes a number of
study phases of increasing detail and accuracy. Further study is justified by demonstrable flowsheets and
suitability positive economic indicators including Net Present Values (NPV), assuming that no Fatal Flaws are
revealed (Newell, 2015). As the studies progress, the development of robust flowsheets requires more test
work on a range of samples to reliably characterise the handling and metallurgical behavior. Needless to say,
the confidence in a selected flowsheet and meaningfulness of the subsequent engineering design and equipment
selection is highly dependent upon the test work program and the nature of the samples (Newell, Munro and
Fielder, 2018). Note that drilling often continues during the study phases which can increase the size of the
resource. This in turn can impact processing plant throughput as well as identifying additional ore types that
may require more test work.
Havilah Resources Limited has undertaken a number of studies which include a Project Evaluation
Study (Havilah/GR Engineering), a Scoping Study (Simulus), Pre-Feasibility Study (Havilah/RPMGlobal) and
a currently, an update of the Pre-Feasibility Study (Havilah/RPMGlobal). All test work for the project was
conducted by ALS Metallurgy in Pooraka, South Australia with the metallurgical results captured in the
various studies.
The Project Evaluation Study (Havilah, 2010) was based on a suitable body of test work that identified
the mineralogical and metallurgical separation characteristics of the individual ore types as well as a mixed
ore composite consisting of Sulphide ores and Native Copper ore. Based on bulk rather than selective mining
methodology, a flowsheet was selected to process a blend of all four ore types (refer to Figure 3). Test work
was not conducted on the proposed blend to verify the suitability of the proposed flowsheet.
4
Project Evaluation Study (GRES, 2010)

Figure 3 : Project Evaluation Study Flowsheet
Flowsheets treating blended multiple ore types rarely enjoy success in practice for a number of reasons;
the most relevant example is the recently shuttered CuDeco Limited operation at Rocklands in North
Queensland, which attempted to treat a blend of a similar array of copper ore types.
The Scoping Study (Simulus, 2013) was based on the existing test work data and settled on three
flowsheets: dedicated flowsheets for the two Clay ores and a combined flowsheet for the Sulphide ores (refer
to Figures 4, 5 and 6). Simulus introduced some pragmatic flowsheet improvements for the Clay ores, such as
roll toothed crushers and scrubbing (Native Copper ore).
Scoping Study (Simulus, 2013)

Figure 4 : Scoping Study Saprolite Ore Flowsheet
5

Figure 5 : Scoping Study Native Copper Ore Flowsheet

Figure 6 : Scoping Study Sulphide Ore Flowsheet
Between studies, Havilah conducted further test work to better understand the Chalcocite and
Chalcopyrite ores and the potential for increased gold recovery. The recovery of molybdenum from the
Sulphide ores was also examined with success.
Additional test work was undertaken to the support the Pre-Feasibility Study, examining variability,
scrubbing, separation and dewatering properties as well as feed grade-recovery relationships. Trade-off studies
were subsequently undertaken to develop the mining strategy as well as the viability of selected processing
options, such as SART (Sulphidisation, Acidification, Recycling and Thickening) to recover copper and gold
from cyanide leach solutions.
The current update of the Pre-Feasibility Study being undertaken by Havilah is based on targeted test
work to resolve flowsheet options as well as support mining trade-off studies based on improvements in
flowsheets and metallurgy.
4 Flowsheet Development
4.1 Clay Ores
4.1.1 Saprolite Gold
Table 3 summarises the key test work results for Saprolite Gold ore processing options.
Table 3 : Saprolite Gold Ore Key Separation Test Work Results
Stage Product [g/t,

Head
Mass Recovery %] / Solution
Grade
Separation Process Recovery (%) Grade [mg/L]
(%)
Cu Au
Au Cu Au Cu
(%) (g/t)
Gravity 0.21 33.4 26.8 140.0 50.9
0.39 0.87 Flotation (Cl2) 0.84 12.8 20.4 39.4 19.2
Combined 1.05 46.2 47.3 59.5 25.5
0.10 0.70 Cyanide Leach (24 hours) - 96.9 2.2 0.43 21.2
6
A reasonable quantity of the gold was coarse enough to be recoverable by gravity (approximately 33%),
and supported the inclusion of a gravity circuit in the flowsheet. However, further processes were required to
increase recovery and found to be limited to around 13% using flotation.
Cyanide leaching test work on Saprolite Gold ore identified the potential for high gold recoveries and a
leaching flowsheet was adopted in the Scoping Study as shown in Figure 4. The Pre-Feasibility Study
discarded cyanide leaching due to the amount of copper reporting to the leach solution (copper to gold ratios
in solution of up 360:1 in early test work). Without further investigation to confirm that the copper could be
rejected before electrowinning, it was unlikely a saleable gold doré would be produced. In addition, the slurry
rheology would also impact the suitability of a Carbon-In-Leach/Carbon-In-Pulp (CIL/CIP) circuit.
Test work indicated that flotation recovered both the gold and the copper to a concentrate that was
likely to attract copper sulphide concentrate marketing terms, although recoveries were strongly feed grade
dependent (RPMGlobal, 2017). Flotation was subsequently incorporated into the Pre-Feasibility Study
flowsheet.
In terms of handling and disaggregating clay materials, experiences with roll tooth crushers and
hydrocyclone de-sliming (Havilah’s North Portia gold project test work) supported the inclusion of these
techniques into the Pre-Feasibility Study flowsheet. Scrubbing test work also demonstrated as low as one third
of ore containing significant saprolite would require grinding (Havilah Resources, 2019), which would
decrease both the mill size (lower capital costs) and milling operating costs. De-sliming test work has
demonstrated that a significant proportion of the ore could be rejected with an acceptable gold loss, allowing
a reduction in the size of the downstream processing plant (capital costs). Subsequently, the Pre-Feasibility
Study adopted a gravity-flotation flowsheet, employing roll toothed crushers, scrubber, hydrocyclone de-
sliming and a ball mill for the scrubber oversize.
Recent test work undertaken as part of the updated Pre-Feasibility Study has demonstrated that the
copper cyanides loaded onto the carbon can be selectively removed using cold caustic cyanide elution. While
the flowsheet for the recovery of both copper and cyanide from the cold eluate is under development, this
finding has allowed cyanide leaching to be adopted as the preferred flowsheet. Additionally, de-sliming
remains as a crucial upstream process to allow a sufficiently high percent solids slurry (approximately 50%
solids) to be achieved in a CIL/CIP flowsheet with standard carbon screens.
4.1.2 Native Copper

A feature of the Native Copper ore is that the majority of the copper is coarse and readily separated by
classification, with gravity recovering a significant portion of the gold and remaining fine copper. It was found
that some of the remaining copper and gold was recoverable by flotation, however not economically attractive
enough to consider as a dedicated processing stage. More so than the Saprolite Gold ore, recovering gold
through cyanidation of the gravity tailings is more difficult due to increased quantities of highly cyanide
soluble native copper. Nonetheless, high gold leach recoveries were achieved in the presence of high copper
levels in the leach solution. Some key test work results are presented in Table 4.
7
Table 4 : Native Copper Ore Key Separation Test Work Results

S tage Product [g/t,
Head
Recovery %] / S olution
Grade Mass
(%) Grade [mg/L]
S eparation Process Recovery
Cu Au (%)
Cu Au Cu Au
(%) (g/t)
Screen Classification (+2mm) 0.51 62.7 0.4 48.1 0.5

0.39 0.71 Gravity 0.31 15.5 18.9 15.5 42.6
Flotation (Cl2) 0.14 3.7 24.5 9.9 120
Combined 0.96 81.9 43.7 32.0 31.5
Screen Classification (+2mm/+600µm) 0.49 37.2 0.3 85.5 0.4
Gravity 0.61 26.9 58.2 49.3 75.6
1.12 0.79
Flotation (Cl2) 0.57 9.2 11.8 18.2 16.5
Combined 1.67 73.3 70.3 49.3 33.4
Screen Classification (3.35mm/+600µm) 0.32 30.2 0.2 71.1 0.5
Gravity 0.68 32.8 23.4 36.2 21.8
0.75 0.62 Combined 1.00 63.0 23.6 47.4 15.0
Gravity Tailings -Cyanide Leach (CIL, 24 - 20.7 90.7 11,800 0.005
Overall - 83.7 92.9 - -
0.2 0.8 Leaching (CIL,24 hours) - 4.6 97 59.9 0.003
Following with the success demonstrated with cold caustic elution test work with Saprolite Gold ore to
support the updated Pre-Feasibility Study, cyanide leaching and carbon elution test work is progressing on the
Native Copper ore gravity tailings.
4.1.3 Clay Ores Flowsheet

To save on capital and operating costs, the Pre-Feasibility Study selected a flowsheet that would
satisfactorily process either Saprolite Gold ore or Native Copper ore on a campaign basis (refer to Figure 7).
The two ore types share similar comminution requirements with the ball milling duty designed for the Native
Copper ores due to the presence of more saprock.

Figure 7 : Pre-Feasibility Study Clay Ores Flowsheet
Subsequently, the updated Pre-Feasibility Study aims to adopt cyanide leaching as the primary
separation technology for Saprolite Gold ore and the secondary separation method for Native Copper ore. The
proposed flowsheet for treating each ore type on a campaign basis is shown in Figure 8.
8
Figure 8: Updated Pre-Feasibility Study Clay Ore Flowsheet
4.2 Sulphide Ores

The Project Evaluation Study proposed treating a blended ore consisting of all four ore types in a
conventional hard rock milling-flotation flowsheet (refer to Figure 3). Later studies recognised that this
flowsheet was not appropriate and that a dedicated Sulphide ore flowsheet was required.
Some key test work results for the Sulphide ores are summarised in Table 5, based on a flotation
flowsheet with re-grinding of the rougher concentrate and a minimum of 2 cleaner stages. Both Sulphide ores
responded well to preliminary gravity separation, although the concentrate is basically gold bearing pyrite.
Table 5: Sulphide Ore Key Test Work Results
S tage
Head Product
Mass Recovery
Grade S eparation Grade
Ore Type Recovery (%)
Process
Cu Au (%) Cu Au
Cu Au
(%) (g/t) (%) (g/t)
Gravity 0.17 1.6 20.5 8.0 81.7
0.85 0.69 Flotation 2.12 73.5 42.0 29.4 13.7
Chalcocite
Combined 2.29 75.1 62.5 27.8 18.7
0.81 0.67 Flotation (LCT) 2.20 77.1 69.6 27.6 21.4
Gravity 0.10 0.6 30.9 2.6 77.0
0.44 0.25 Flotation 1.64 91.1 54.3 24.7 8.3
Chalcopyrite
Combined 1.74 91.7 85.2 23.4 12.2
0.42 0.24 Flotation (LCT) 1.57 93.4 66.2 24.9 10.2
The key difference between the two Sulphide ores is ore hardness and the type of crushing and milling
circuit that would be adopted for the flowsheet. Supergene ores, and particularly chalcocite, are prone to
sliming and a conventional ball mill route was preferred. On the other hand, the competent Chalcopyrite ore
lends itself to SAG-Ball milling, with crushing of the SAG mill discharge oversize (SABC). Additionally, due
to increased complexity with mineral intergrowth in Chalcocite ore (refer to Figure 9) compared to
Chalcopyrite, the requirement for different target regrind sizes would necessitate different media and
classification operating conditions.
9
ASX Media Release (Havilah Resources, 2019)

Figure 9: Pyrite, Chalcopyrite and Chalcocite Intergrowths (Chalcocite Concentrate)
The Chalcocite ores would be mined initially and separately, requiring a simpler comminution
flowsheet, namely a single stage crusher and a ball mill. The later treatment of Chalcopyrite ores would be
achieved through the installation of a SAG mill and pebble crusher. Additionally, duplication of the gravity,
flotation and dewatering circuits would be required due to greater throughputs. The proposed flowsheet is
presented in Figure 10.

Figure 10: Pre-Feasibility Study Sulphide Ore Flowsheet
4.3 Other Flowsheet Considerations

On-going test work and engineering studies are examining the processing options for recovering the
gold and cobalt in pyrite found in the Sulphide ores.
During the Pre-Feasibility Study, it was noted that test work had shown that the pyrite in the Chalcocite
and Chalcopyrite ores tailings floated well with good gold recoveries achievable after cyanide leaching. Finer
grinding enhanced the gold recovery for Chalcocite ores. However, excessive cyanide consumption was
observed due to a significant amount of copper that was leached. In order produce to gold cathodes, and recover
the copper and cyanide, a high level study was undertaken to evaluate the economics of a SART flowsheet.
However, the scale and the economics of the proposed flowsheet were not sufficiently attractive. As discussed
in Section 4.1.1, the effectiveness of cold stripping in selectively removing copper cyanides from loaded
carbon means that it would be incorporated in a gold recovery flowsheet.
10
A test work program is proposed to investigate the technical feasibility of recovering cobalt and
refractory gold from the pyrite, based on Havilah’s positive experiences with the nearby Mutooroo project. A
trade-off study would be conducted to compare the technical and economic feasibility of the various oxidative
processing routes, such as roasting, bacterial leaching (ferric leaching), pressure oxidation and the Albion
process.
5 Conclusions
Flowsheets are driven by a number of key factors including ore properties (mineralogy, ore types and
proportions), mining factors (such as the mine schedule which dictates the project development schedule) and
capital and operating costs.
In addition, flowsheets reflect the Study stage, the state of orebody knowledge and the amount of test
work results available to confidently demonstrate a processing behavior and allow selection of appropriate
processing technology and equipment.
Often, ore types can be blended and treated in a common processing facility, as long there are reasonable
similarities in handling and processing characteristics which requires a good understanding of these properties
based on test work on appropriate samples.
At Kalkaroo, the four ore types can be mined separately and the subsequent flowsheets have changed as
the studies and the metallurgical test work have progressed, resulting in two flowsheets to handle Clay ores
and Sulphide ores, with adaptions to handle the specific processing differences within each category.
6 Acknowledgements
The authors would like to thank the Havilah Resources Limited, in particular Dr. Chris Giles, for
permission to present and publish this paper.
7 References
GR Engineering Services (GRES), 2010. Section 9 Metallurgy, Kalkaroo Copper Project 4.5Mtpa to
6.0Mtpa Bulk Mining and Processing Project Evaluation Study, Havilah Resources N.L., pp. 1–30.
Havilah Resources, 2019. Positive Kalkaroo PFS Metallurgy Testwork, ASX Media Release
21 May, pp. 1-14.
Havilah Resources, 2020. Kalkaroo Copper-Gold-Cobalt, https://www.havilah-
resources.com.au/operations/kalkaroo.
Newell, A.J.H., 2015. Processing Fatal Flaws in Technical Due Diligences. In: Proceedings of MetPlant
2015 Conference, AusIMM, Perth, pp. 61–77.
Newell, A., Munro, P. D. and Fiedler, K. 2018. Metallurgical Test Work – Between a Rock and a Hard
Place. In: Proceedings of 14th AusIMM Mill Operators Conference, Brisbane, pp.15-32.
RPMGlobal, 2017. Kalkaroo Copper Gold Project Pre-Feasibility Study, Wanbao Mining (Hong Kong)
Limited, pp.1-237.
11
Simulus Engineers (Simulus) 2013. Havilah Resources Kalkaroo Copper Gold Project Processing
Scoping Study, pp. 1-74.
12

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IMPC 2020: XXX International Mineral Processing Congress, Cape Town, South Africa, 18-22 October 2020

Multiple Ore Types Can Result in Multiple Processing Plants

Pre-Feasibility Study (RPM, 2017)

2 Mineralogy and Ore Types

Saprolite Gold Native Copper Chalcocite Chalcopyrite

Pre-Feasibility Study (RPM, 2017)

Project Evaluation Study (GRES, 2010)

Scoping Study (Simulus, 2013)

Scoping Study (Simulus, 2013)

Scoping Study (Simulus, 2013)

Stage Product [g/t,

4.1.2 Native Copper

Table 4 : Native Copper Ore Key Separation Test Work Results

Screen Classification (+2mm) 0.51 62.7 0.4 48.1 0.5

4.1.3 Clay Ores Flowsheet

Pre-Feasibility Study (RPM, 2017)

Figure 8: Updated Pre-Feasibility Study Clay Ore Flowsheet

4.2 Sulphide Ores

ASX Media Release (Havilah Resources, 2019)

Pre-Feasibility Study (RPM, 2017)

4.3 Other Flowsheet Considerations

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