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Metallurgical Accounting

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

Total Feed
2.69Mt
Cu Conc
205kt
Zn Conc
184kt
Avg Cu Rec
85.5%
Avg Zn Rec
90.0%
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
2.30Mt
Cu Lost
8,823t
Zn Lost
10,985t
Au Lost
0oz
Ag Lost
0oz
Gross Value
$105.8M
PeriodTails tCu Lost tZn Lost tAu Lost ozAg Lost ozCu ValueZn ValueAu+Ag ValueTotal $/periodCumulative $
M1170,240676.31042.900$5748k$2920k$0k$8668k$8.67M
M2181,701501.8389.600$4265k$1091k$0k$5356k$14.02M
M3204,252904.71110.100$7690k$3108k$0k$10798k$24.82M
M4191,748494.4774.400$4203k$2168k$0k$6371k$31.19M
M5200,031812.01707.300$6902k$4780k$0k$11682k$42.88M
M6192,3621006.0590.700$8551k$1654k$0k$10205k$53.08M
M7187,6041118.0669.500$9503k$1875k$0k$11377k$64.46M
M8190,798608.5686.800$5173k$1923k$0k$7096k$71.55M
M9201,159541.51236.500$4603k$3462k$0k$8065k$79.62M
M10195,802865.11487.500$7353k$4165k$0k$11518k$91.14M
M11198,105768.0893.500$6528k$2502k$0k$9030k$100.17M
M12185,836526.2396.700$4473k$1111k$0k$5584k$105.75M
TOTAL8,823t10,985t0oz0oz$75.0M$30.8M$0.0M$105.8M$105.8M

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
606t Cu
$5.15M/yr
+1% Zn Recovery
1058t Zn
$2.96M/yr
+1% Au Recovery
0oz Au
$0.00M/yr
+1% All Metals
$8.11M/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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