Overview
The Lumwana processing plant is a major copper concentrator that was originally designed for 20 Mtpa throughput but expanded to 27 Mtpa in 2020. The facility is undergoing a significant expansion project to double capacity to 54 Mtpa, featuring parallel processing plants with advanced crushing, grinding, and flotation circuits.
Key Process Stages
- Primary Crushing: Four gyratory crushers (existing + expansion) with variable-speed apron feeders and overland conveyors to coarse ore stockpiles
- Grinding: Two parallel SABC circuits (SAG mill + ball mill + pebble crusher) with cyclone classification to P80 300 µm
- Flotation: Three parallel rougher trains with forced-air mechanisms, followed by multi-stage cleaner circuits with high-intensity cells
- Concentrate Dewatering: Thickening followed by pressure filtration (two parallel filters) with automated cake handling
- Tailings Management: Cyclone-thickener combination systems with underflow pumping to TSF
Critical Data
| Parameter | Value |
|---|---|
| Design Throughput | 54 Mtpa (peak) |
| Power Demand | 107 MW (steady-state) |
| Water Consumption | 38.2 Mm³/yr (reclaim) + 10.4 Mm³/yr (raw) |
| Grinding Product Size | P80 300 µm |
| SAG Mill Power | 16 MW (each) |
| Ball Mill Power | 18 MW (each) |
Expansion Highlights
- New parallel processing plant with identical SABC grinding circuit
- Upgraded flotation with high-intensity cells and improved reagent systems
- Advanced process control with online particle size and metal grade analyzers
- Enhanced metallurgical accounting with automated sampling and analysis
- Doubled filtration capacity with new pressure filter installation
Based on filing data from 2024-2025.
