ORWAY MINERAL CONSULTANTS (WA) PTY LTD Level 4, 1 Adelaide Terrace, East Perth WA 6004, A.B.N 40 093 277 126 Tel: +61 8 6210 5601 Fax: +61 8 6210 5555 Email: [email protected] Web: www.orway.com.au Scope of Work The scope of work for Ok-Tedi was to conduct modelling of the grinding circuits to assess the benefits of adding recycle pebble crushing to the existing SAB circuits and to conceptualize and estimate, to a scoping level, the cost of implementing the upgrade. Flowsheet Traditionally processing very soft ore types, recycle crushing was not necessary to the success of the Ok Tedi grinding circuits. However, with future ore types becoming more competent, it was envisaged that the circuits would become SAG mill limited in the future with a corresponding reduction in throughput. It was anticipated that recycle crushing would relieve the SAG mill restriction, allowing throughput to be maintained and ensure that good energy efficiency could be maintained. Notable Feature When the modelling was completed, the existing circuit was found to swing between being SAG mill limited and ball mill limited, depending upon the ore blend being treated. The high variability in the ore competency and ore SG contributed to the power imbalances in the circuit. The power balance was also highly dependant upon the product size being targeted. Outcome Due to the challenging site location and layout, the capital costs involved with this project were found to be significant when compared with the modest throughput increases predicted by the modelling with the addition of a recycle crusher. In order to achieve significant throughput increases, the overall power available in the circuit would need to be increased substantially, by way of more grinding power. Case Study – Ok Tedi Kambalda Mill Survey Project Category: Recycle Crushing Study Client: Ok Tedi Mining Ltd Location: Western Province, Papua New Guinea Capacity: 20 Mtpa Commodity: Copper / Gold SAG Mill Scats

Case Study – Ok Tedi - Orway Mineral Consultants become SAG mill limited in the future with a corresponding reduction in throughput. It was anticipated that recycle crushing would

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Page 1: Case Study – Ok Tedi - Orway Mineral Consultants become SAG mill limited in the future with a corresponding reduction in throughput. It was anticipated that recycle crushing would

ORWAY MINERAL CONSULTANTS (WA) PTY LTD Level 4, 1 Adelaide Terrace, East Perth WA 6004, A.B.N 40 093 277 126

Tel: +61 8 6210 5601 Fax: +61 8 6210 5555 Email: [email protected] Web: www.orway.com.au

Scope of Work

The scope of work for Ok-Tedi was to conduct modelling of the grinding circuits to assess the benefits of adding recycle pebble crushing to the existing SAB circuits and to conceptualize and estimate, to a scoping level, the cost of implementing the upgrade.

Flowsheet

Traditionally processing very soft ore types, recycle crushing was not necessary to the success of the Ok Tedi grinding circuits. However, with future ore types becoming more competent, it was envisaged that the circuits would become SAG mill limited in the future with a corresponding reduction in throughput. It was anticipated that recycle crushing would relieve the SAG mill restriction, allowing throughput to be maintained and ensure that good energy efficiency could be maintained.

Notable Feature

When the modelling was completed, the existing circuit was found to swing between being SAG mill limited and ball mill limited, depending upon the ore blend being treated. The high variability in the ore competency and ore SG contributed to the power imbalances in the circuit. The power balance was also highly dependant upon the product size being targeted.

Outcome

Due to the challenging site location and layout, the capital costs involved with this project were found to be significant when compared with the modest throughput increases predicted by the modelling with the addition of a recycle crusher. In order to achieve significant throughput increases, the overall power available in the circuit would need to be increased substantially, by way of more grinding power.

Case Study – Ok Tedi

Kambalda Mill Survey

Project Category: Recycle Crushing Study

Client: Ok Tedi Mining Ltd

Location: Western Province, Papua New Guinea

Capacity: 20 Mtpa

Commodity: Copper / Gold

SAG Mill Scats