Project Background
A Chilean mid-tier mining group required a 600 TPD copper-gold flotation plant to process sulfide ore from a high-altitude (3,800 m) open-pit mine. The site is in a remote Andean region with extreme weather, requiring robust equipment and a compact layout.
Process Design
WSHT engineers completed locked-cycle flotation tests delivering the following circuit:
- Two-stage closed-circuit crushing to -10mm
- Single-stage ball milling to P80 74μm in closed circuit with cyclones
- Rougher flotation (4× BF-8 cells, 16 m³ each)
- Two-stage scavenger + cleaner circuit with 6, 4 and 2 cell banks
- Concentrate thickening & filtration, tailings disposal to paste plant
Equipment & Automation
WSHT supplied 22 KYF flotation cells (8-24 m³), 2 ball mills, 8 slurry pumps, 2 thickeners and a fully automated reagent dosing system with online pH and ORP measurement. PLC-based control with remote monitoring from Santiago office.
Civil & Installation
Modular containerized design enabled the entire plant to be erected in 5 months despite the 4-month winter season. Total steel structure: 1,500 t. Concrete: 4,200 m³. Local workforce (60%) trained by WSHT specialists.
Performance & Results
Final concentrate grade 28.4% Cu at 92% Cu recovery, with payable gold credit. Reagent consumption within 5% of design. Plant availability 96% in first year.