Project Overview
The Kyrgyzstan Talas Oblast Flotation Concentrator is a greenfield EPC project processing polymetallic sulfide ore containing copper (1.2% Cu), zinc (2.8% Zn), and gold (0.8 g/t Au). WSHT Mining Group delivered the complete mineral processing facility from ROM ore reception through to final concentrate filtration and dispatch.
Ore Characteristics
The deposit is a volcanogenic massive sulfide (VMS) type with chalcopyrite, sphalerite, and pyrite as the principal ore minerals. The ore has a Bond Work Index of 14.5 kWh/t (medium-hard) and requires fine grinding to 80% passing 45 microns for optimal mineral liberation. The sequential flotation circuit separates copper, zinc, and pyrite concentrates in a differential flotation arrangement.
Process Flow
Crushing: ROM ore (P80 = 800 mm) is reduced to P80 = 10 mm through a three-stage crushing circuit comprising a C140 jaw crusher (primary), two HP500 cone crushers (secondary and tertiary), and a 3YK-2460 vibrating screen for closed-circuit classification. Total crushing capacity: 250 t/h.
Grinding: The crushing product is stored in a 5,000-tonne live stockpile, then metered to a Φ4.0×6.0 m overflow ball mill (2,200 kW) operating in closed circuit with a cluster of 8× NX350 hydrocyclones. Target grind: 80% passing 45 microns. The mill processes 120 t/h at 65% solids density.
Flotation: Ground slurry is conditioned with sodium isopropyl xanthate (collector) and methyl isobutyl carbinol (MIBC frother) before entering the sequential flotation circuit. The rougher circuit consists of 8× OK-160 forced-air flotation cells (160 m³ each) providing 30 minutes residence time. Copper is selectively floated first, followed by zinc activation with copper sulfate and subsequent zinc flotation. Pyrite is recovered in the scavenger circuit.
Concentrate Handling: Copper concentrate (28% Cu) and zinc concentrate (55% Zn) are separately thickened in 15 m diameter high-rate thickeners, then dewatered on 60 m² pressure filters to 9% moisture. Concentrates are stored in separate covered bins before dispatch by truck.
Key Equipment
| Equipment | Specification | Capacity |
|---|---|---|
| C140 Jaw Crusher | 1400×1060 mm feed opening | 250-400 t/h |
| 2× HP500 Cone Crushers | Medium and fine crushing | 150-300 t/h each |
| 3YK-2460 Vibrating Screen | 3-deck, 2400×6000 mm | 200-400 t/h |
| Φ4.0×6.0 m Ball Mill | 2,200 kW, rubber liners | 120 t/h |
| 8× NX350 Hydrocyclones | Classification cluster | 120 t/h total |
| 8× OK-160 Flotation Cells | Forced-air, 160 m³ each | 1,280 m³ rougher |
| 2× 15m Thickeners | High-rate, paste discharge | 80 t/h each |
| 2× 60m² Pressure Filters | Membrane type | 40 t/h each |
Project Highlights
- Capacity: 2,000 TPD (600,000 TPA) polymetallic ore
- Copper Concentrate: 28% Cu grade, 92% recovery
- Zinc Concentrate: 55% Zn grade, 87% recovery
- Gold Recovery: 78% into copper concentrate
- Water Recycling: 85% process water recycled
- Power: 8 MW connected load, 5.5 MW average
- Timeline: 18 months EPC delivery
- Location: Talas Oblast, Kyrgyzstan
