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Metallurgical Accounting

Metal balance: feed → concentrate → tailings · Recovery curves · Reagent consumption

Total Feed
2.69Mt
Cu Conc
229kt
Zn Conc
188kt
Avg Cu Rec
85.6%
Avg Zn Rec
87.6%
No plant model linked. Configure Process Plant
PeriodFeed tCu%Zn%Cu ConcCu GrdZn ConcZn GrdTail CuTail ZnCu RecZn RecReagP80

Tailings Metal Loss Analysis

Cu $/t:
Zn $/t:
Au $/oz:
Ag $/oz:
Total Tails
2.28Mt
Cu Lost
10,028t
Zn Lost
13,690t
Au Lost
0oz
Ag Lost
0oz
Gross Value
$123.6M
PeriodTails tCu Lost tZn Lost tAu Lost ozAg Lost ozCu ValueZn ValueAu+Ag ValueTotal $/periodCumulative $
M1171,999344.91484.900$2931k$4158k$0k$7089k$7.09M
M2191,9081025.71094.300$8718k$3064k$0k$11782k$18.87M
M3192,433928.61058.700$7893k$2964k$0k$10857k$29.73M
M4176,4681040.81653.400$8846k$4630k$0k$13476k$43.20M
M5172,527846.71214.500$7197k$3401k$0k$10598k$53.80M
M6203,785707.61490.100$6015k$4172k$0k$10187k$63.99M
M7209,4441093.5436.300$9295k$1222k$0k$10516k$74.51M
M8173,640834.51187.600$7094k$3325k$0k$10419k$84.92M
M9214,193412.51105.600$3506k$3096k$0k$6602k$91.53M
M10181,553983.61427.600$8360k$3997k$0k$12358k$103.88M
M11216,332922.91061.100$7844k$2971k$0k$10815k$114.70M
M12174,372886.7475.800$7537k$1332k$0k$8869k$123.57M
TOTAL10,028t13,690t0oz0oz$85.2M$38.3M$0.0M$123.6M$123.6M

Recovery Improvement Trade-Off

What-if: additional metal recovered per 1% improvement in recovery rate. Based on current feed grades and annual throughput.

+1% Cu Recovery
685t Cu
$5.82M/yr
+1% Zn Recovery
1095t Zn
$3.07M/yr
+1% Au Recovery
0oz Au
$0.00M/yr
+1% All Metals
$8.88M/yr
Justifies reagent/circuit optimization spend

Tailings Value Recovery Strategies

Industry-verified approaches for extracting additional value from tailings. References cited from peer-reviewed and industry sources.

1. Flotation Scavenging Circuit
Install scavenger flotation cells on final tails. Typically recovers additional 2-5% of contained Cu/Zn at marginal cost. Proven at Antamina (Peru), Mount Isa (Aus), and Kidd Creek (Canada).
Ref: Wills & Finch, Mineral Processing Technology, 8th Ed., Ch.12. | Typical CapEx: $2-8M depending on throughput.
2. Gravity Recovery (Gold)
Gravity concentrators (Knelson, Falcon) in grinding circuit recover free gold before flotation. 30-60% of gravity-recoverable gold typically captured. Standard at Newmont Boddington, AngloGold Obuasi.
Ref: Laplante, A.R. (2000), Testing Requirements for Gravity Gold Circuit Design, CIM Bulletin. | CapEx: $1-5M.
3. Tailings Reprocessing (Historical)
Retreatment of old tailings dams using modern flotation/leaching. DRDGold (SA) processes 500ktpm of Witwatersrand gold tailings. KCGM reprocesses tailings at Kalgoorlie Super Pit. Typically economic above 0.3g/t Au or 0.1% Cu.
Ref: Edraki et al. (2014), Designing Mine Tailings for Better Environmental Outcomes, J. Cleaner Production. | NPV depends on head grade and volume.
4. Bioleaching / Heap Leaching
Bacterial oxidation of sulfide tails to liberate locked metals. Used commercially for Cu (BHP Olympic Dam), Au (Fairview, Barberton). Lower CapEx than conventional milling but slower (months vs hours).
Ref: Watling, H.R. (2006), The Bioleaching of Sulphide Minerals, Hydrometallurgy 84(1-2). | Operating cost: $2-6/t tails.
5. Paste Tailings / Dry Stacking
Filtered tails reduce water loss (recover 85-95% process water) and create stable dry-stacked facility. Reduces TMF CapEx and closure liability. Adopted at Escobal (Guatemala), Rosemont (Arizona), Karara (Australia).
Ref: Jewell, R.J. & Fourie, A.B. (2015), Paste and Thickened Tailings: A Guide, ACG. | Water recovery value: $0.50-2.00/m3.
6. Critical Minerals Recovery
Extract cobalt, REE, scandium, indium, or germanium from polymetallic tails. Increasing economic viability due to EV/battery demand. USGS estimates billions in critical minerals locked in US mine tailings alone.
Ref: USGS (2022), Critical Mineral Resources of the United States. | Pre-feasibility study recommended before investment.
Disclaimer: Strategies listed are based on published industry practice. Economic viability depends on site-specific grade, mineralogy, tailings characteristics, and local regulations. Independent engineering assessment required before implementation.
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