Overview
The Blue Moon mineral processing facility is designed to treat 657,000 tonnes per year (1,800 tonnes/day) of mineralized material through a sequential flotation process. The plant produces primary copper and zinc concentrates, with an optional pyrite concentrate as a secondary product. The circuit features crushing, grinding, and selective flotation stages followed by concentrate dewatering and tailings management systems.
Key Process Stages
- Crushing Plant: Primary jaw crusher reduces ROM material to 80% passing 5 inches (127 mm)
- Grinding Circuit: SAG mill (13.8′ dia x 6.9′ EGL) open circuit + ball mill (11.8′ dia x 17.7′ EGL) closed circuit with cyclones to achieve P80 of 74 µm
- Copper Flotation: 5 rougher cells (10 m³ each) + 3-stage cleaning circuit with regrind to 20 µm
- Zinc Flotation: 5 rougher cells (10 m³ each) + 3-stage cleaning circuit with regrind to 20 µm
- Pyrite Flotation (Optional): 5 rougher cells (10 m³ each)
- Concentrate Handling: Dedicated thickeners and filter presses for each product (8% moisture copper/zinc, 15% moisture pyrite)
- Tailings Management: Thickening to 60% solids, filtration to 15% moisture, with options for dry stack storage or paste backfill
Critical Data
| Parameter | Value |
|---|---|
| Annual Throughput | 657,000 t/year |
| Daily Throughput | 1,800 t/day |
| Head Grade (Cu) | 0.56% |
| Head Grade (Zn) | 5.65% |
| Copper Recovery | 93.1% |
| Zinc Recovery | 95.3% |
| Final Grind Size (P80) | 74 µm |
| SAG Mill Power | 927 HP |
| Ball Mill Power | 855 HP |
| Copper Concentrate Grade | 26.5% Cu |
| Zinc Concentrate Grade | 62.3% Zn |
Circuit Highlights
The plant features several innovative design elements including sequential flotation to optimize copper and zinc recovery separately, vertical regrind mills for both concentrates, and flexible tailings management with options for either dry stack storage or paste backfill for underground operations. The optional pyrite circuit provides potential future value through sulphur removal from tailings.
Equipment Summary
- Crushing: JC106 jaw crusher with 115t live capacity bin
- Grinding: 13.8’x6.9′ SAG mill + 11.8’x17.7′ ball mill in closed circuit with cyclones
- Flotation: 10 m³ forced air tank cells for all rougher stages
- Filtration: Tower filter presses for copper/zinc (95 ft² and 363 ft² respectively)
- Tailings: 52.5′ diameter thickener + 1,754 ft² filter press
