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Economics of flotation plant against different size reduction alternatives and flotation grades

Tuzcu E. Tuğcan, Demirtaş Zafer

Physicochemical Problems of Mineral Processing

2022

Vol. 58, iss. 5

art. no. 154813

This paper quantitatively shows the effect of run-of-mine (ROM) feed grade on flotation plant capacity, and also the combined effects of different feed grades and the size reduction alternative combinations on the project economics. Project economics are defined as CAPEX and OPEX The project profitability was estimated based on a “Cash Flow Model” along the life of the mine, which is ten years. The parameter for tracking project return or profitability is called NPV and IRR (internal rate of return), respectively. These parameters are standard parameters for control of project return in all engineering studies. In the scope of the study, there are a series of case studies including three different comminution alternatives in combination with three different ROM feed grade alternatives. Therefore, the nine case studies were compared based on economics which resulted from different equipment combinations and as well as the different types/amounts of process consumables. Among all the cases, Case 1 (Conventional circuit with 0.1% feed grade) gave the lowest CAPEX whereas Case 9 (High Pressure Grinding Rolls_HPGR circuit with 0.3% feed grade) gave the highest CAPEX. OPEX wise, Case 7 (HPGR circuit with 0.1% feed grade) produced the lowest whereas Case 6 (Semi-Autogenous Ball mill Crusher_SABC circuit with 0.3% feed grade) gave the highest value of OPEX. The NPV of the HPGR circuit with 0.3% feed grade case was found as maximum, which showed the quantitative effect of feed grade and equipment combination on flotation plant economics.