Bench-scale to Pilot Plant Trials for Complex Gold-Copper Ore in Africa

Phase 1: Ore Characterization & Bench-Scale Testing

• Sample Preparation: Representative sampling and crushing of the bulk ore sample to -2mm.
• Ore Characterization: Chemical analysis (Au, Cu, S, etc.), mineralogy (XRD), and texture analysis to understand ore composition and gold liberation characteristics.
• Grindability Tests: Bond Ball Mill Work Index (BWi) test to determine grinding energy requirements.
• Batch Flotation Tests: Systematic testing to identify the best reagent scheme (collectors, frothers, depressants) and optimal pH for Au/Cu recovery.
• Batch Leaching Tests: (If applicable) Cyanide leaching tests to assess direct leachability and consumption of cyanide/lime.

Phase 2: Locked-Cycle Flotation Test

• A continuous simulation of the proposed flotation circuit (Rougher-Cleaner-Scavenger) using batch equipment.
• Key Outcome: Generates realistic mass balances, predicts final concentrate grade and recovery, and confirms the stability of the flotation circuit.

Phase 3: Semi-Industrial Continuous Pilot Plant Trials

• A continuous, integrated pilot plant is set up, typically with a capacity of 500 kg/hr to 1 ton/hr.
• Crushing & Grinding Section: Small jaw crusher, cone crusher, and a continuous Ball Mill (or Rod Mill) in closed circuit with a cyclone classifier to achieve and maintain the target grind size (e.g., 80% passing 75µm).
• Flotation Section: A bank of continuous flotation cells (Rougher, Cleaner, Scavenger) to process the entire ore stream under steady-state conditions.
• Solid-Liquid Separation: Pilot-scale thickeners and filter presses for concentrate and tailing dewatering.
• Process Control & Data Logging: Integrated sampling points, flowmeters, and online analyzers (if applicable) for continuous data collection and process control.

Key Deliverables & Outcomes:

• A Comprehensive Technical Report detailing all test work, results, and recommendations.
• Definitive Mass and Water Balance for the full-scale plant design.
• Accurate Equipment Sizing and Selection Data (e.g., ball mill power, flotation cell volume).
• A Reliable Forecast of Operating Costs (reagent consumption, power, grinding media).
• De-risking of the full-scale project by proving the process flowsheet at a semi-industrial scale.
• Several kilograms of high-grade concentrate for downstream marketing or metallurgical testing.