PROCESS DESCRIPTION

00
Rev.

29JAN 11FEB20123
Date

M.A
Pre.

B.G
Chk.

H.A
App.

NICICO
Client Purpose of Issue

Contractor National Iranian Copper Industries Company Nipec

Kavoshgaran Hezar Sanat Date:24 APRIL17 SEP 201211Feb2013 Rev: 03004 Stamps:

Chehel-Koureh Copper Concentration Plant Project

Client Number:61C12-N-P17-00-000000-0021-0304 Nipec Number:

Page 1 of 1621

This document and the information disclosed are the property of NIPEC and are not to be used to furnish any information for making of documents or apparatus except where approved by written agreement.

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

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Revision Record
Page Rev.00 Rev.01 Rev.02 Rev.03 Rev.04 Page Rev.00 Rev.01 Rev.02 Rev.03 Rev.04

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 3 of 24

Table of content:
1. 1- Foreword...................................................................................................................4 2- Beneficiation Process ...................................................................................................4 2-1- Various Sections.................................................................................................4 3- Process Description.......................................................................................................5 3-1-Raw ore material handling...................................................................................5 3-2-Crushing plant......................................................................................................5 3-3-Grinding...............................................................................................................7 3-4-Flotation and regrinding.......................................................................................8 3-5-Concentrate dewatering.................................................................................1217 3-6-Reagent system..............................................................................................1319 3-7-Plant utilities..................................................................................................1420 3-7-1-Water...................................................................................................1420 3-7-2- Air.......................................................................................................1521

1- Foreword
In beneficiation plant, run of mine of 300,000 t/y with 1.08% sulfide copper are charged to plant as feed and copper concentrate of 15840 t/y with 18.55% sulfide copper is gained as product. PLANT working days per year is 300 days , 7200 hours per year.

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 4 of 24

2- Beneficiation Process
2-1- Various Sections This process consists of following stages: 1- Crushing Area 2- Crushed ore storage 3- Grinding Area 4- Concentration Plant (Flotation) 5- Regrinding 6- Concentrate dewatering

3- Process Description 3-1-Raw ore material handling Copper concentration plant shall be installed in the vicinity of Chehel Kureh underground copper mine. The Run Of Mine ore is transferred to jaw crusher by wobblervibrating feeder VFWF-01 and will be crushed by jaw crusher (JC-01) in the underground tunnel.

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 5 of 24

First stage crusher, which is a double toggle jaw crusher, crushed the ore to a size of 70mm (d80) and transferred to first open stockpile by conveying system. 3-2-Crushing plant First open stockpile will store plant feed for 7 days. Crushing plant will be working for 300 days per year and 2 shifts per day. The operating capacity of crushing plant is 71.43 t/h. Maximum particle size of jaw crusher product is 90 mm with size distribution of d80=70mm. The ore is loaded from open stockpile by loaders and then charged to a bin (22-BI-01) at the top of the primary vibrating feeder (22-VF-01). There is a grizzly (opening: 100mm) at the top of this bin and underneath is a vibratory feeder that feeds the ore with adjustable tonnage to CRUSHING PLANT. The jaw crusher productcrusher plant feed is transferred via belt conveyors (22-CV-01/02) to a three-deck vibrating screen (22-VS-01), the apertures of which are 40mm ,25mm, and 8mm.The upper deck is used to lower the force of the impact of the material hitting the screen. Screen's under size , -8mm as crushing plant product, is transferred to crushed ore Stockpile via a belt conveyor (22-CV-05), which has a live capacity of 3 days required feed for flotation plant. Vibrating Screen oversize, +25mm, is transferred to standard cone crusher (22-CC-01) via a belt conveyor (22-CV-03). Product of standard cone crusher with a size of d80=20mm transferred to conveyor (22-CV-01) by gravity. The circulating load of 2 nd stage of crushing is 20%.

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 6 of 24

Vibrating screen middle size, +8-25mm, is transferred to short head cone crushers feed bin (22-BI-02) via a belt conveyor (22-CV-04). Material middle size is fed to short head cone crushers (22-CC-02/03) from bin by gravity. Product of short head cone crusher with a size of d80=8mm transferred to conveyor (22-CV-01) by gravity. The circulating load of 3rd stage of crushing is 20%. Required capacity of 2nd and 3rd stage cone crushers are 60 and 62.55 t/h respectively. The product of all crushers is transferred to three- deck vibrating screen via belt conveyors (22-CV-01/02). To protect downstream equipment from metal scrap, belt conveyors 22-CV-01&03&04
4

are equipped with fixed magnets 22-MG-01~ 3 respectively. Also, one metal detector is used for non-magnetic metallic scrap. If metal detector detects a piece of metal, belt conveyor 22-CV-02 will be stopped automatically and operator should be take it . To protect downstream equipment from metal scrap, belt conveyors 22-CV-01~04 are equipped with fixed magnets 22-MG-01~ 4 respectively. Also, one metal detector is used for non-magnetic metallic scrap. If metal detector detects a piece of metal, chute 22-CH01 will be bypassed to ground and after 10s will be returned to normal position. For feed rating control of crushing plant, vibrating feeder is equipped with a variable speed control drive and is controlled with a belt scale installed under the conveyor belt 22-CV-01. There is a water spray de-dusting system to remove the dust in the crushing plant. In order to prevent forming lots of dust in crushing area of the Chehel Koureh Concentrator Plant, The most effective solution is utilizing spray water system in some transferring points as well as the loading point.

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 7 of 24

For this purpose the following points will be equipped with water spray: Discharge point of primary feeder 22-VF-01 Transferring point from belt conveyor 22-CV-02 to vibrating screen Transferring points from vibrating feeders under stockpile into the skirt board of the belt conveyor 32-CV-01 By spraying at these four points the proper and uniform moisture can be controlled to minimize the required moisture content in order to dust reduction and having perfect material flow in the hopper, chutes and feeders.

3-3-Grinding Feed ore is transported to the primary ball mill (32-BM-01) via belt conveyor 32-CV-01. Belt conveyor 32-CV-01 will be equipped with a belt scale 32-BS-01 to control the feed ore materials discharged from the vibrating feeders (32-VF-01/02, one operating and the other standby). First stage grinding mill, ; which shall is a wet grinding ball mill in a closed circuit with hydro cyclone clusters, grinds the feed to a range of -10mm to 53 microns (d 80). A valve on the inlet pipe can shut off each cyclone in cluster. There are a few cyclones in cluster as standby. The ore enters the ball mill through a chute. Water is added to the chute to obtain 65% solid in the mill. Grinding media in the ball mill is steel balls. Balls, milk of lime and other reagents are fed to ball mill via ball mill feed chute. Maximum ball size is 80mm. Maximum ball mill volumetric load is 40%.

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 8 of 24

Basic data of primary ball mill is as follows: Ball mill type Motor (Kw) Diameter(approx.) Length(approx.) Speed % of critical Circulating load Bond work index Discharge Solid% Over flow discharge 10431200 3.7 8 m 4.645m 8075 250% 14.72 kwh/st 65

Slurry overflow is discharged from the ball mill via the mill trommel and will be transferred to cyclone pump box (32-PB-01) and then is pumped to cyclone by one of cyclone pumps (32-PU-01/02). The pressure drop over the cyclones should be 1 barg. The hydro cyclone underflow, is circulated to the ball mill through ball mill feed chute. The hydro cyclone overflow leaves the grinding circuit for the conditioning tank (33-CT01) by gravity. Reclaimed water is added to dilute the ball mill feed and discharge. 3-4-Flotation and Regrinding Flotation system is designed to separate the copper mineral particles from the gangue minerals. The final concentrate contains about 18.55% copper sulfide and a Cu sulfide recovery of 90%.

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 9 of 24

The cyclone overflow of ball mill cyclones are is fed to the conditioner tank. Rougher flotation cells ( 33-RF-01/10) consist of 10 mechanical cells, each with a volume of 4.7 m3. The pH in the rougher cells is controlled by addition of lime milk in the grinding circuit and conditioner tank to reach around 9.50 in the circuit. The rougher concentrate with a grade of 10.74% is transferred to the regrinding circuit by gravity. Also the tailing of rougher cells with a grade of 0.3% copper is transported to rougher scavenger cells by gravity. The rougher scavenger flotation cells (33-RS-01/09) consist of 9 mechanical cells, each with a volume of 4.7m3. The rougher scavenger concentrate with a grade of 3.62% is transferred to the regrinding mill circuit. The tailing of rougher scavenger cells with a grade of 0.2% copper is transported to tailing thickener via centrifugal pumps (33-PU0301/0402). Oxide copper minerals are recovered in the rougher/scavenger stage by addition of PAX and NaHS reagents. To liberate the Copper and Zinc minerals from the locked particle, the two concentrates of rougher and rougher scavenger stages will be transferred to the regrinding area. These concentrates in addition to the reclaim water will be mixed in the regrinding mill pump box (33-PB-0302) and pumped to regrind hydro cyclone cluster (33-HC-01) via slurry pumps (33-PU-0503/0604). Regrinding mill feed size is 53 microns (d 80) and regrind product size is 20 microns (d80). The overflow of cyclones is fed to the cleaning flotation cells and the underflow materials will be reground in ball mill (33-BM-01). The ground slurry is recycled to the hydro

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 10 of 24

cyclones through slurry pumps (33-PU-03/04). Most of Fflotation reagents are added to the slurry in the regrinding mill cyclone underflow. Hydro cyclone cluster is rather flexible to the extent that the number of operating cyclones can easily be varied. The performance of the hydro-cyclone is related to a number of operational variables.depends on many pressure differences over the cyclones. Basic data of regrinding ball mill is as follows: Ball mill type Motor (Kw) Diameter(approx.) Length(approx.) Speed % of critical Circulating load Bond work index Discharge Solid% Over flow discharge 115160 12.1.8 m 3.3m 75 280% 14.72 kwh/st 50 variables. Easiest parameter in controlling shift-toshift operation are is the dilution of the slurry feed to cyclone and the

The reground rougher and rougher scavenger concentrate is cleaned in two steps. The cleaning stage consists of four mechanical cells, each with a volume of 2.7m 3. Concentrate of cleaner cells with a grade of 20% as total copper and max. 14.25% Zinc as final concentrate is transferred to concentrate thickener by gravity. Also the tailing of cleaner cells is transferred to two mechanical cleaner/ scavenger cells, each with a volume of 2.7m3, by gravity.

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 11 of 24

The concentrate of cleaner/scavenger cells with a grade of 6.13% copper is transferred to regrinding mill pump box (33-PB-02) by gravity and recycled to cleaner cells with rougher and rougher/scavenger concentrate via regrinding cyclone over flow. The tailing of cleaner/scavenger cells with a grade of 0.25% copper is transferred to rougher scavenger tail pump box (33-PB-01) by gravity and then transferred to tailing thickener with rougher scavenger tail via slurry pumps (33-PU-01/02). Three types of reagents are added to the flotation system. These are as follows: Collectors

These reagents produce a hydrophobic layer on the mineral surface, which enables the
4 mineral

to be captured and attached to an air bubble. The collectors utilized in the

flotation area are AP3894 and PAX. Characterizations of these reagents are as follow:
AP3894 AERO 3894 Promoter Thionocarbamate None Mixture Mixture Pale yellow to reddish mobile liquid Pungent Not applicable Not applicable 1.004 >1; (air=1) 100 Not applicable Not applicable Not applicable 120F; 49C 392 F; 200C

Name Chemical Family Synonyms Molecular Formula Molecular WGT Appearance Odor Melting Point Vapor Pressure Specific Gravity Vapor Density %Volatile(By WT) pH Saturation in air(%By Vol) Evaporation rate Flash point Decomposition temp

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number: Negligible Stable Will not occur Strong oxidizing agents Flammable Liquid Not available

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Solubility in water Stability Polymerization Incompatible material Flammable properties Flammable limits(% By Vol)

Potassium Amyl Xantate (PAX) Potassium Amyl Xantate Xanthates; Carbonodithioic acid salt Potassium amyl xanthate; PAX; Carbonodithioic acid, 0-pentyl ester, potassium salt; Potassium pentyl xanthate, Pot. Amyl Xanthogenate; Pot. O-Amyl Dithiocarbamate Appearance Grey/yellow hygroscopic pellets Formula C6H11KOS2 Odor Unpleasant sulphurous odour Melting Point 255-288 C Solubility in water Soluble completely Specific Gravity 0.94(warwe=1) Flash Point Closed Cup 12-13 C pH Not applicable Product is stable if stored and handled under Chemical Stability recommended conditions. Hazardous polymerization will not occur. Vapor pressure (mm Hg) Not applicable Proportion(%) >90 Flammability Flammable Strong oxidizers can cause fire or explosions. Acids will accelerate the hydrolysis of Conditions to avoid xanthates. Incompatible with cooper, brass, bronze. Avoid high temperatures and moisture Hazardous decomposition products carbon disulfide, trithiocarbonate, amyl alcohol Handling Avoid contact with eyes. Use only in well ventilated area. Wash thoroughly after handling. Avoid prolonged or repeated skin contact. Ground containers when transferring Chemical Name Chemical Family Synonyms

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 13 of 24

Storage

material from one to another. Use caution opening containers with xanthates of unknown Keep containers tightly closed in a dry, cool and well-ventilated place. Keep away from heat and sources of ignition. Store containers out of direct sunlight at moderate temperatures. Properly ground storage containers.

Frothers

These reagents modify the surface tension of the liquid. This affects the bubble size and helps to form a stable froth on the slurry surface, which is capable of carrying the mineral
4 particles until they are removed from the cell. The utilized frother in the flotation area is

MIBC. Characterizations of this reagent are as follow:

Methyl Isobutyl Carbinol 4-methylpentan-2-ol 1,3-dimethyl 1-butanol MIBC Methyl Amyl Alcohol Clear. Liquid. Sweet. 130 - 133 C / 266 - 271 F 41 C / 106 F (IP 170) 1 - 5.5 %(V) 305 C / 581 F (ASTM E-659) 420 Pa at 20 C / 68 F 0.81-0.9 at 20 C / 68 F 806 - 808 kg/m3 at 20 C / 68 F (ASTM D4052) 16 g/l at 20 C / 68 F 3.5 70.6 % (EC/1999/13) 0.3 (ASTM D 3539, nBuAc=1)

Material Formal Name Synonyms

Appearance Odor Boiling point Flash point Explosion / Flammability limits in air Auto-ignition temperature Vapor pressure Specific gravity

Density Water solubility Vapor density (air=1) Volatile organic carbon content Evaporation rate (nBuAc=1)

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

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Stability

Conditions to Avoid Materials to Avoid

Stable under normal conditions of use. Reacts with strong oxidising agents. Reacts with strong acids. Avoid heat, sparks, open flames and other ignition sources. Strong oxidising agents. Strong acids.

Modifiers

a. pHPh modifiers, which are used to control the alkalinity/acidity of the slurry final concentrate before thickening to give the optimum collector actionsedimentation of particles. pH will be adjusted with by lime that. I t should be 9.5011up to 10-11 in the rougher stage while in other stagesthickener concentrate thickener feed. Lime isnt added to the flotation circuit. it will operate at normal condition without lime addition. Characterizations of this reagent are is as follow:
Lime White or grayish-white lumps or powder ODOURLESS Calcium Oxide CaO 65-90 Solid N.A. 1345 / 2453 (Apparent) g/cc:1.6-2.8 N.A. N.A. N.A. Reacts with water to produce Ca(OH)2 and large amounts of heat. 12.4 NON FLAMMABLE
4

Appearance Odor Chemical Name Chemical Formula Conc.(%) Physical State Boiling Point (C/F) Melting Point (C/F) Specific Gravity Vapor Pressure (mm Hg) Vapor Density Evaporation Rate Solubility in Water pH (25C/77F) Flammability

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 15 of 24

b. Resurfacing agents, which are commonly used to depress or reactive particular minerals in selective flotation. The zinc lead depressant that is used in this system is SMBS ( sSodium mMeta be bisulfide) and reactive agent that is utilized for oxide copper is NaHS. Characterizations of these reagents are as follow:

Sodium Metabisulfite(SMBS) Trade Names Chemical Formula Appearance ODOUR Boiling point Melting Point C Molecular weight Content ( As Na2S2O5) % MIN Vapor density (Air = 1) Solubility in water Solubility (g/100gH2O@20C) Concentration(%M) he actual concentration of SMBS contained in the storage solution Specific gravity Melting point Evaporation rate
4

Sodium Metabisulfite, Anhydrous Sodium Bisulfite, ABS, Disodium Pyrosulfite, Sodium Pyrosulfite, SMBS (Na2S2O5) White to yellowish, fine crystalline powder Pungent Decomposes above 302F (150C) About 150 (Decomposition) C 190.11 97 Not applicable 100% by weight 65 (5% aqueous soluti on) 0-1% 1.48 >302F Not applicable Yes, increases the natural rate of yield of sulfur dioxide gas. 4.3-4.5 (1% solution)

Water reactive pH

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number: Not applicable non-combustible solid

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Flash point Flammability limits in air % by volume Stability Condition avoid Material to avoid Hazardous decom. Products

Usage Precautions

Storage Precautions

Not applicable Stable under normal conditions of use. Heating can release hazardous gases. Oxidising agents. Acids. Thermal decomposition may release oxides of sulphur (SOx). Product should be used in accordance with good industrial principles for handling and storing of hazardous chemicals. Minimize creation of airborne dust by application of good occupational hygiene principles, appropriate control measures and extraction techniques. Store in closed original container at temperatures between 15C and 25C. Store away from direct sunlight and moisture Store separated from: Acids.

Chemical Family Synonyms

Sodium Hydrosulfide Solution Inorganic salt solution KI-300, sodium hydrogen sulfide, sodium sulfhydrate sodium bisulfide, sodium mercaptan

Formula NaHS Chemical Ingredients (% by wt.) Sodium hydrosulfide 20-45% Sodium sulfide <1.0% (Typical) Sodium Carbonate <3.0% (Typical) Water 55-80% May be yellow to red, to dark green to black Appearance liquid. Strong hydrogen sulfide (rotten egg) odor, Odour hydrocarbon (mercaptan) odor. Boiling point Vapor pressure Vapor density Solubility in water Specific Gravity Freezing point 253 F(122.8 C) - 269 F (131.7 C) 17 mm Hg @ 68 F (20 C) 1.17 (Air = 1.0) Complete 1.152 - 1.303 (9.6 - 10.9 lbs/gal) 0 F (-17.8 C) - 20%

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 17 of 24

pH Volatile Stability Flammable properties Handling

Storage

56 F (13.3 C) - 45% 11.5 - 12.5 Not applicable This is a stable material Flash point: Not flammable Wear proper protective equipment . Avoid breathing product vapors. Avoid contact with skin and eyes. Use only in a well ventilated area. Dilute product only in enclosed containers. Wash thoroughly after handling. Store in well ventilated areas. Do not store combustibles in the area of storage vessels. Keep away from any sources of heat or flame. Store tote and smaller containers out of direct sunlight at moderate temperatures [<80 F (27 C)].

C. c. Dispersant
4

Sodium silicate is used as dispersant and depressant of silicates minerals in the flotation area. Characterizations of this reagent are as follow:
SODIUM SILICATE LIQUID VISCOUS CLEAR TO LIGHT YELLOW LIQUID Liquid and corrosive ODOURLESS 12.8 (1% Solution) (Approximately) 24 mm Hg @ 20C NOT AVAILABLE 100C (Approximately) < 0C AS FOR WATER SOLUBLE 1.3 - 1.56 > 60 % (Water) NON FLAMMABLE

Appearance Physical State Odour pH VapourVapor Pressure VapourVapor Density Boiling Point Melting Point Evaporation Rate Solubility (Water) Specific Gravity % Volatiles Flammability

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number: NOT RELEVANT NOT RELEVANT NOT RELEVANT COMPOSITION Content: >60% Content: 20-40%

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Flash Point Upper Explosion Limit Lower Explosion Limit WATER(H2O) SODIUM SILICATE(Na4SiO4)

3-5-Concentrate Dewatering a. Thickener (34-TH-01) Dewatering process consists of two stages, Cu concentrate thickening and filtering. The purpose of the copper concentrate thickening is to increase the density of the copper concentrate slurry before filtering process. The copper concentrate is transferred to concentrate thickener feed well. The copper concentrate solids are settled to the bottom of the thickener, while water flows via the over-flow launder to the process water reservoir. Flocculants are added to concentrate thickener to increase the particle settling rate. Under-flow product will be pumped to the distribution box 34-DB-01 by variable speed slurry pumps (34-PU-01/02).in normally
4

condition , thickener under flow product should be transferred to pressure filter buffer tank. There are two discharging pipes at the bottom of thickener to prevent any stoppage in case of blockage of the operating pipe. b. Pressure filter

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 19 of 24

The purpose of the filtering is to increase the density of the copper concentrate to 90% solid. Feed to the pressure filter buffer tank is regulated by the density of the concentrate
4

thickener underflow. When the density is within the set point range the filter buffer tank valve is opened and when the density is outside the set point range or the level of buffer tank is greater than the High alarm set point , the thickener re-circulation valve in the 34DB-01 is opened. Buffer filter tank is equipped with a mixer. There are two pressure filters (34-PF-01/02) in dewatering area, one filter is operating and the other is standby. Concentrate slurry is transferred to pressure filter via slurry pumps (34-PU-03/04). Filtrate is transferred to process water reservoir and Final final concentrate is discharged to concentrate storage by gravity.

3-6-Reagents System The reagents are used in the process to achieve optimal result in the flotation area. The reagents for flotation area are prepared in preparation tanks ( except MIBC and Sodium
4

silicate and AP3894 that are in form of liquid) and then transferred to daily tanks by gravity. To prepare and reserve of lime, used a tank. Reagent materials from daily tanks are pumped to the consumption points by metering pumps except lime that will be transfertransferred to cleaner concentrate launder by gravity from preparation tank. One set of each reagent pump is considered to operate and another as standby. Five reagent dosage systems should be considered to supply the reagents by dosing pumps , (centrifugal pump will be used for lime milk distribution), that are distribute the reagents to the following consumption points:

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 20 of 24

a. Lime milk :primary ball mill cyclone under-flow , conditioning tank and cleaner conc. launder b. MIBC and sodium silicate: primary ball mill cyclone under flow, conditioning tank, 5th rougher cell, regrind mill cyclone under flow, first rougher/scavenger cell c. AP3894 and MIBC and sodium silicate: primary ball mill cyclone under flow, conditioning tank, 5th rougher cell, regrind mill cyclone under flow, first rougher/scavenger cell d. SMBS: primary ball mill feedConditioner tank and first cleaner cell as dry by vibrating feeder e. PAX and NaHS: first rougher/scavenger cell, 1ST and 4th rougher scavenger cellsconditioner tank, fourth rougher/scavenger cell and regrind mill cyclone under flow f. NaHS: conditioner tank, regrind mill cyclone under flow

3-7-Plant Utilities: 3-7-1-Water The required fresh water for the plant is estimated to be about 43.11m3/h overall.

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 21 of 24

The clarified water, which is returned from the tailing thickener and concentrate thickener as over-flow, will be collected in the process water reservoir and used as returned water in different points of the plant. Process water consumption in PLANT: PW to ball mill feed chute PW to ball mill discharge pump box PW to conditioner tank PW to rougher conc. launder PW to rougher/scavenger conc. launder PW to cleaner conc. launder PW to cleaner/scavenger conc. launder PW to lime milk preparation PW for floor washing TOTAL 20.87 m3/h 67.85 m3/h 17.54 m3/h 4.8 m3/h 1.7 m3/h 5 m3/h 1 m3/h 0.189 m3/h 3 m3/h 121.95 m3/h

Fresh water consumption in PLANT: FW for reagents preparation FW to pump sealing FW to miscellaneous FW to process water reservoir TOTAL 0.35 m3/h 1 m3/h (approx.) 7.5 m3/h 34.26 m3/h 8.8543.11 m3/h

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 22 of 24

Return water in the PLANT: RW from tailing thickener RW from concentrate thickener RW from pressure filter TOTAL 60.77 m3/h 24.96 m3/h 1.96 m3/h 87.69 m3/h

The required fresh water for the plant is estimated to be about 43.11m3/h overall. The clarified water, which is returned from the tailing thickener and concentrate thickener as over-flow, will be collected in the process water reservoir and used as returned water in different points of the plant. Process water consumption in PLANT: PW to ball mill feed chute PW to ball mill discharge pump box PW to conditioner tank PW to rougher conc. launder PW to rougher/scavenger conc. launder PW to cleaner conc. launder PW to cleaner/scavenger conc. launder PW to lime milk preparation PW for floor washing 20.87 m3/h 67.85 m3/h 17.54 m3/h 4.8 m3/h 1.7 m3/h 5 m3/h 1 m3/h 0.189 m3/h 3 m3/h

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 23 of 24

TOTAL

121.95 m3/h

Fresh water consumption in PLANT: FW for process FW for reagents preparation FW to pump sealing FW to miscellaneous TOTAL 34.26 m3/h 0.35 m3/h 1 m3/h (approx.) 7.5 m3/h 8.8543.11 m3/h

Return water in the PLANT: RW from tailing thickener

5

60.7760.77 m3/h 24.96 m3/h 1.96 m3/h 87.6987.69 m3/h

RW from concentrate thickener RW from pressure filter TOTAL

3-7-2- Air The required air for the process will be supplied from two blowers (41-BL-01/02) and two compressors (41-CM-01/02).

Kavoshgaran Hezar Sanat Document Title: PROCESS DESCRIPTION Date: 24 APRIL201217 SEP 201211Feb2013 Rev:03004

National Iranian Copper Industries Company Chehel-Koureh Copper Concentration Plant Project

Nipec

Client Number: 61C12-N-P17-00-000000-001-0304002 Nipec Number:

Page 24 of 24

Required air for all of flotation cells is supplied by two blowers, one blower is operating and another one is as standby. The maximum required capacity of air for flotation cells is 1087m3/min with a maximum pressure 17kpa. Two compressors, each with a pressure of 7.5 barg with a capacity of 80nm3/h, will be
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installed to supply the required instrument and plant air. The produced compressed air after getting through water trap and filter and being storing in the receiver tank with a 1000 liter capacity, will be dried in a dryer and filtered in final filter to achieve the required quality. The air will then be distributed for instrument air consumers.