1. cPlant A Modular Approach for Flotation Solutions
Luis Rudolphy
Astana: 15/06/2016

2. Agenda 1. 2. 3. Introduction to Outotec cPlant
Applications & Business Drivers 3.
Case Study
cPlant: A Modular Approach for Flotation Solutions

3. Can a Flotation plant be modular like this?
cPlant: A Modular Approach for Flotation Solutions

4. Introduction to Outotec® Flotation cPlant
Outotec goes fully modular
Small & mid capacity Flotation Plant ( tph) using Outotec proven technologies and products
Pre-installed into standard container sized steel frames
Low investment costs thanks to pre- fabricated modules that can be easily transported and installed and connected quickly (plug-and-play) to the process
The Flotation cPlant is available as a basic version with a full list of optional functionalities and modules, such as different levels of automation and intelligence.
Service and maintenance is planned in the concept so that the modules can be serviced one by one with an empty container as the service rack
cPlant: A Modular Approach for Flotation Solutions

5. This is how we do it
Flotation machines including piping, electrification and instrumentation are pre-installed into standard container sized steel frames
All assembly work is made at workshop with high quality and efficiency.
Cold commissioning made at work shop
Transportation to site fast, easy and at low cost
Fast installation due to repeatable modules
Shorter hot commissioning time
Proven FloatForce® and Outotec Automation & Analyzer options technologies
Designed to maintenance
cPlant: A Modular Approach for Flotation Solutions

6. Main Modules Outotec® cPlant cPlant Additional Modules Pumping module
cPlant Flotation cells Modules
Blower module
C11 Flotation module
MCC module
C6 Flotation module
Reagent Preparation
C3 Flotation module
Reagent Dosing
C1.5 Flotation module
Conditioner
Launder module
Control Room
Automation room
Analyzer
Stairs & Platforms
cPlant: A Modular Approach for Flotation Solutions

7. cPlant Flotation cells Modules
C11 Flotation module
Includes two containers
Drive container
Tank container
Cell volume 11 m3
Rotationally cast polyethylene tanks and launders
Available configurations:
C11-4: 4 cells/shafts in 40 foot container
C11-3: 3 cells/shafts in 30 foot container
C11-2: 2 cells/shafts in 20 foot container
No intermediate steps inside module available
Step between modules (600 mm)
Feed and discharge boxes included as a separate structure
FloatForce® 500 mechanism
cPlant: A Modular Approach for Flotation Solutions

8. cPlant Flotation cells Modules
C11 Flotation module
Level control with discharge dart box or pinch valve
Electric actuators
Belt drive, 15 kW (TC-10)
Preinstalled flotation air and launder water piping, cabling, instrumentation and electrical equipment in drive container
Piping connections with fast couplings
Power and control connections with fast couplings
cPlant: A Modular Approach for Flotation Solutions

9. Automation cPlant Flotation Process ADVANCED LEVEL SMART LEVEL
ACT Application Module
Proscon 2100S Application module
Automation
ADVANCED LEVEL
Grade –Recovey Optimization
Elemental Analyzes
Speed Targets
SMART LEVEL
ANALYZER LEVEL
EXACT –level
Froth Speed Control
Froth information
Courier
Elemental
Analyzer
Setpoints
Setpoints
BASIC LEVEL
Setpoints
Level Control
Level Control
Level Control
Air Flow Control
Reagent Control
Level Control
Level Control
Level Control
Air Flow Control
Reagent Control
Launder Water Control
Sump Level Control
Cell Level Control
Air Control
Reagent Dosing Control
Sampling
System
Froth Camera
cPlant Flotation Process
9/21/2018
Internal | Presentation name, Author

10. Agenda 1. 2. 3. Introduction to Outotec cPlant
Applications & Business Drivers 3.
Case Study
cPlant: A Modular Approach for Flotation Solutions

11. Where to use Outotec®Flotation cPlant
Small greenfield ore deposits
Designed to relocate to a new location
Deposits in remote locations
Brownfield expansions
Temporary capacity during expansion
Retreatment of old tailings ponds
Selective Molybdenum Plants (Gas recirculation system is an option)
When Changing capacity needs
Easily adjusted and can be extended as mine operations develop, or dismantled when a deposit is running low on ore
cPlant: A Modular Approach for Flotation Solutions

12. Business Drivers Value proposition Features Benefits
Short lead time for production and low CAPEX investment /
Fast-track projects with savings in means of time, costs, quality and operation
Features
Benefits
Prefabricated and ready to install modules
High quality modules and fast installation with low labour need at site
Easy to transport and fast delivery (product instead of project)
Reduced capital expenditure
Standard modules
Expansions are easy and reliable to estimate
Proven Outotec Flotation Technology
Maximize revenues
cPlant: A Modular Approach for Flotation Solutions

13. Agenda 1. 2. 3. Introduction to Outotec cPlant
Applications & Business Drivers 3.
Case Study
cPlant: A Modular Approach for Flotation Solutions

14. Case Study – TPY
Comparison between a conventional plant delivery and a cPlant delivery in terms of costing and delivery time is presented
Plant located in Middle East
Project considered to be executed in 3 phases in order to reduce extra risk provisions and contingencies
Delivery includes from Concept engineering to commissioning (EPC Basis)
Generic Polymetal Copper – Zinc flotation plant
Capacity of tpy
cPlant: A Modular Approach for Flotation Solutions

15. Design Basis New Capacity: 250.000 t/y Utilization rate: 95%
ROM Ore Mineralogy:
Pyrite - FeS2 10%
Chalcopyrite – CuFeS2 2,5%
Sphalerite – ZnS 8%
Galena – PbS 1,5%
Non Sulphide gang 78%
Head Grades
Copper % 0,8
Zinc % 5,5
Lead % 1
cPlant: A Modular Approach for Flotation Solutions

16. Option 1 Conventional delivery - Flowsheet
Zinc Flotation
Copper Flotation
cPlant: A Modular Approach for Flotation Solutions

17. Option 1 - Main Equipment
Flotation cells
Blowers
Pumps & Pump Sumps
Reagent Plant
Conditioners
Instruments
Automation module
Proscon
Courier 6x
Samplers 2
Cu 2nd Cleaner flotation machines
OK-1.5-2R
Cu 3rd Cleaner flotation machines 6
Zn Rougher Scavenger flotation machines
TC-10 5
Cu Rougher Scavenger flotation machines 4
Zn 1st Cleaner flotation machines
OK-3-2R
Zn 2nd Cleaner flotation machines
cPlant: A Modular Approach for Flotation Solutions

18. Option 2 – cPlant Deliver - Flowsheet
Zinc Flotation
Copper Flotation
cPlant: A Modular Approach for Flotation Solutions

19. Option 2 – Main equipment
Flotation cells cPlant Modules
Blower Module
Pumps & Pump Sumps Modules
Reagent Plant Modules
Conditioners modules
Instruments
Automation module
Proscon
Courier 6x
Samplers
MCC Modules & Electrical equipment 1
Cu 1st Cleaner flotation machines
C-1.5-4
Cu 2nd Cleaner flotation machines
C-1.5-2
Cu 3rd Cleaner flotation machines
Zn Rougher flotation machines
C-11-3
Zn Scavenger flotation machines
Zn 1st Cleaner flotation machines
C-3-4
Zn 2nd Cleaner flotation machines
C-3-2
cPlant: A Modular Approach for Flotation Solutions

20. Cost Comparison
EPC Costs comparison between a conventional plant delivery and cPlant
Total savings with cPlant estimated to be aprox. 25% of project cost
Conventional
cPlant
Conceptual Study
1,7 %
Basic Engineering
3,7 %
3,1 %
Detail Engineering
10,6 %
6,9 %
Flotation Equipment
19,6 %
19,0 %
Auxiliaries
25,4 %
24,2 %
Reagents Plant
8,8 %
7,8 %
EPC Site Supervision
1,6 %
2,0 %
Site Work
14,6 %
7,9 %
Buildings
8,2 %
4,4 %
Commisioning & Start-up
2,4 %
2,3 %
Transport
3,4 %
100,00 %
82,4 %
Estimated further savings in civil works under customer responsibilities are estimated to be approximately an extra 6-8%.
Apart from a 17,6% savings in project costs, delivery time is shorten by aprox. 20%.
cPlant: A Modular Approach for Flotation Solutions

21. Project execution schedule comparison
Conventional Delivery
1 month shorter conceptual and basic engineering phase with cPlant
Predesigned and standardized plants and modules
Preselected manufacturers, partners and implementation methods.
1 month shorter equipment supply and detail engineering phase with cPlant
Due to productized design manufacturing can start immediately after order
Flotation cells manufactured utilizing molds.
Modules delivered as products
2 month shorter Construction and commissioning phase with cPlant
Modules are ”plug and play”
Minimized installation work on site
Construction on site minimized to concrete slab and light building (As required by customer)
cPlant Delivery
cPlant: A Modular Approach for Flotation Solutions

22. Conclusions
Short lead time for production and low CAPEX investment, as well as fast- track projects with savings in means of time, costs, quality and operation can be achieved in minerals processing projects by this new modularized approach. This is thanks to prefabricated modules delivered for quick on site erection. These modules are easy to transport to site and have fast delivery times (product instead of project). The modules are standardized, hence are easy to replace or upgrade in time, securing a sustainable operation of a minerals processing plant. Furthermore, all metallurgical features from conventional flotation plants can be replicated in this new modular flotation plant design.
cPlant: A Modular Approach for Flotation Solutions

23. Thank You
cPlant: A Modular Approach for Flotation Solutions