Title: 250tph Gold Processing Plant
Date: 14th April 2012
Tel: +27 11 748 8800 - Fax: +27 11 748 8898
P.O. Box 750, Benoni, 1500, South Africa
[email protected] - www.manhattancorp.com
Tel: +27 11 748 8800 www.manhattancorp.com
1996/002400/07
Page 1 of 17
Q62623_347437
Attention:
Ms. Claudette Thorne Our Ref: 62623_347437
C.E.O. Saturday, 14 April 2012
Skyview Minerals (Pvt) Ltd
Dear Ms. Thorne
Manhattan takes pleasure in offering to you the following: Alluvial gold processing plant.
Manhattan’s focus is to be your Preferred Business Partner for your Mining and Mineral Processing
requirements. We specialise in the supply of Latest Technology, Turnkey Process Plants, associated
equipment and services using our 20 year track record and worldwide capacity to ensure Best Value
solutions.
Benefits of our supply include:
- Turnkey supply of mineral processing plants, equipment and solutions
- Quality controlled manufacturing and engineering programs
- Operational Mining experience in underground and surface mining operations
- Strategic Alliances with ISO9001 quality standard OEM's around the world
- Favourable delivery periods
- After sales service and support
- Skills Development and Training
Company achievements and portfolio:
- Voted as one of South Africa's Top 5 Mining Service Companies for 2008 - 2011
- Voted as one of South Africa's Top 500 Companies for 2008 - 2011
- Owns and Operates a portfolio of Diamond and Gold Mining operations
- 20 year track record
- Manhattan is a branded supplier of Best Value business solutions in design, construction and
manufacture as well as post-sale support for mining and mineral processing equipment
- 30 representative offices outside of South Africa
- Manhattan has a presence on 4 Continents around the Globe
- 250,000m2 corporate head office and manufacturing facility
Yours faithfully
Michael Pouroullis
Chief Executive Officer
Tel: +27 11 748 8800 www.manhattancorp.com
1996/002400/07
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Table of Contents
1. Executive Summary .................................................................................................................... 4
2. Process Description and Design Criteria ...................................................................................... 5
2.1. Design Criteria ..................................................................................................................... 5
2.2. Process Description .............................................................................................................. 7
3. Technical Specifications .............................................................................................................. 9
3.1. Design .................................................................................................................................. 9
3.2. Equipment List ..................................................................................................................... 9
3.3. Instrumentation .................................................................................................................. 11
3.4. Civil design ........................................................................................................................ 12
3.5. Electrical ............................................................................................................................ 12
4. Commercial................................................................................. Error! Bookmark not defined.
5. Concept layout drawings ........................................................................................................... 14
Appendix A: Standard Terms and Conditions of Sale ...................... Error! Bookmark not defined.
Tel: +27 11 748 8800 www.manhattancorp.com
1996/002400/07
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1. Executive Summary
Manhattan Corporation is pleased to offer a turnkey supply of an alluvial gold plant. Our proposed design is
based on a plant feed of 250 tons per hour of ore. The ore undergoes washing, screening, gravity
concentration and intensive cyanide leaching.
Manhattan Corporation has made the following assumptions based on recent discussions, viewing of the
site and recent laboratory feedback.
95% of feed material reports to the scrubber discharge screen
Ore grade is in the order of 10g/ton head feed
The plant is fed by a front end loader at 250tph. The ROM feed is received into a 50m³ feed bin with a static
grizzly to limit the feed size to 150mm. The material is discharged by means of a feed belt and then
conveyed into scrubber for washing.
The scrubber is fitted with a 50mm aperture trommel screen removing the -150mm +50mm material which
is conveyed to a stockpile. The trommel undersize (-50mm) is passed over a single deck vibrating screen for
sizing. The oversize from the screen is conveyed to a waste stockpile.
The screen undersize (-2mm) is pumped into a cyclone cluster for classification. The cyclone underflow
reports to the conditioner tank before it is pumped to the gravity concentrator and the overflow is pumped
to a dewatering cyclone with underflow reporting to a slimes dam and overflow to a water settling dam.
The concentrate is conditioned and leached through an intensive cyanide leaching circuit and the final
concentrate is sent to the gold room for smelting. The tailings from the concentration plant reports to a
sump, where it is pumped to the dewatering cyclone cluster. The water, re-claimed from the water settling
pond, is pumped into the process water tank for re-use.
Proposal changes
The following changes have been made with regard to the original proposal dated 8 th December 2011:
1) feed bin increased from 40m³ to 50m³
2) belt feeder added below feed bin
3) scrubber increased from 2.6x6m to 3x8m due to high fines and clay content
4) impact crusher removed
5) shaking table replaced by intensive cyanide leach reactor
6) reagent plants included
7) dewatering cyclone added
8) instrumentation included for plant monitoring
9) cyanide destruction circuit added for environmental safety
10) process water tank increased from 175m³ to 427m³
11) compressed air system added complete with filters and dryer
12) bunded containment areas complete with spillage pumps added below scrubber and concentrator
13) auxiliary power generator excluded
14) full installation allowed for instead of supervision only
15) accommodation costs included for installation team
16) operating personnel training included.
Tel: +27 11 748 8800 www.manhattancorp.com
1996/002400/07
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2. Process Description and Design Criteria
2.1. Design Criteria
1.0 Assumption of PSD of alluvial gold ore
Size (mm) % Passing before Scrubbing % Passing after Scrubbing
150
100
75
50
30
20
10
5 100 100
1.5 80 90
1 50 60
The - 3 mm fraction will be processed for gravity concentration using a Knelson Concentrator
1.1 Ore Characteristics
UNITS VALUE SOURCE COMMENTS
Mine Operations:
- Ore production rate tonnes/m 72 000 Manhattan
- Operating days per year days 360
- Mine life years
Schedule: shifts per day 3
hours per shift hours 8
Plant performance:
- Availability % 90 Manhattan
- Daily throughput (design) tonnes 250
Specific Gravity:
- Average, design 2.7 Client
3
- Bulk density tonnes/m 1.65 Client
ROM: - ore size mm 150
- Moisture content % 4 Assumption
Average Feed Assay:
- gold g/t 10 Client
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1996/002400/07
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1.2 Washing
Feed Rate tonnes/h 250 Client
Scrubber:
- Size : mxm 3Øx8 Calculated
- Power : kW 200-300
- Trommel Aperture mm 50 Max 75 mm
3
Scrubber Wash Water m /h 250
Vibrating Screen
- Size : mxm 3.1 x 6.7 Calculated
- Cut Size: mm 3
3
Spray Water On Vibrating Screen m /h 14.2 Calculated
1.3 Gravity Concentration
Feed Rate tonnes/h
Mass pull to concentrate % 0.025
Gold recovery to concentrate % 90
Knelson Concentrator
- Model: KC-QS48MS
- Capacity: tph 200-400 Vendor Info
3
- Fluidization water m /h 60 Vendor Info
- Power kW 75 Vendor Info
Intensive Leach Reactor
- Capacity: t/h 2.8 Vendor Info
- Model: ILR 1000 BA Vendor Info
- Power: kW 10.5 Vendor Info
1.4 Smelting
Furnace : Induction furnace Vendor Info
- Type:
- Power: kW 100 Vendor Info
Crucible
Silicon Carbide
Type Carbon Vendor Info
Capacity
Bullion Mould
Type
Capacity
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1996/002400/07
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2.2. Process Description
The run of mine (ROM) ore is fed into feed hopper fitted with static grizzly cutting at 150 mm. From the
feed hopper the ROM, is withdrawn using a belt feeder and transfers to a feed conveyor that feeds a
scrubber 3 Ø x 8 m fitted with a trommel screen. In the scrubber the ore is washed using process water
in the ratio 1/1.
The trommel oversize materials are stockpiled using a stockpile conveyor and the trommel undersize
materials are screened on a vibrating screen 3.1 x 6.7 m at 3 mm. The +3 mm are stockpiled and the – 3
mm materials are fed to a desliming cyclone-cluster for the removal of the – 38 microns on the
overflow and the underflow gravitates into a surge tank (10 min retention time) and pumped to a
knelson concentrator KC-QS48MS with a capacity of treating 200-400 tph.
Tailing from the Knelson Concentrator is pump to the tailing dam.
The concentrate from the Knelson concentrator is fed to the Intensive Leach Reactor (ILR) for
gold recovery.
The concentrate from the primary recovery device (Knelson concentrator) reports to the feed cone for
de-watering, with the water overflowing and returning to the Scrubber circuit. Solids are stored in the
feed cone until the beginning of each leach cycle.
The InLine Leach Reactor works on the principal of the laboratory bottle roll to keep the solids in contact
with the liquor. A horizontal drum rotating at low speed with a set of specially designed baffles and
aeration system for maximum leach performance. Residence time is predicted in the laboratory and
controlled by leach cycle time. During leaching, solution is continually recirculated through the solids
from the solution storage tank to ensure a fresh supply of reagents, including oxygen, is always available
for leaching.
At the completion of the leach cycle the pregnant solution is clarified then pumped to the
electrowinning circuit. Barren solids are emptied by reversing the drum rotation and pumped to the mill
circuit. Pregnant liquor is pumped to the electrowinning circuit where it can be recovered in a dedicated
electrowinning cell or mixed with the main elution solution. The barren solution from electrowinning is
then pumped to the ILR to reuse the residual cyanide.
Tel: +27 11 748 8800 www.manhattancorp.com
1996/002400/07
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The gold slimes are dried in a calciner oven before smelting the slimes and fluxes in a titled induction
furnace fitted with a silicon carbide carbon bonded crucible. The furnace is filled with the mixture and
heated to operating feed. As the charge melts, additional material is added to the furnace and melted until
the furnace is full. If the feed material grade is high, the furnace will contain sufficient dore for a pour. Low-
grade feed will require several slag pours to accumulate sufficient metal for a pour of dore. The slag may
be saved for further processing.
Tel: +27 11 748 8800 www.manhattancorp.com
1996/002400/07
Page 8 of 17
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3. Technical Specifications
3.1. Design
Complete design and engineering is included in the supply. The design disciplines include:
Mechanical
Process
Draughting
Electrical and instrumentation
Interlock
Structural
Civils
Site Visits x 2
3.2. Equipment List
The following equipment list defines the main items of supply:
Installed
Equipme
Item Description Qty Condition Size Power
nt
(kW)
Washing
1 FB-01 Feed Bin + Static Grizzly 1 New 50 m3
2 BF-01 Belt Feeder 1 New 1200mm x 8m 5.5
3 CON-01 Scrubber Feed Conveyor 1 New 900 mm x 25 m 11
4 BW-01 Belt Weigher 1 New BW100-900
5 CH-01 Scrubber Feed chute 1 New
Scrubber + Trommel
6 SCR-01 Screen 1 New 3 x 8 m, capacity 250 tph
Trommel Oversize
7 CON-02 Conveyor 1 New 450mm x 15m 3
Single Deck Vibrating
8 VS-01 Screen 1 New 8 x 20 2 x 12.5
9 CH-02 Screen Feed chute 1 New
Screen Oversize
10 CON-03 Conveyor 1 New 450mm x 15m 3
11 PMP-01 Desliming Cyclone Pump 1 New Warman 8/6 AH Metal 55
12 PMP-02 Desliming Cyclone Pump 1 New Warman 8/6 AH Metal 55
Desliming Cyclone
13 CYL-01 Cluster 1 New 100 mm x (5)
14 TK-01 Slurry Tank + Agitator 1 New 30 m3 5.5
15 PMP-03 Concentrator Feed Pump 1 New Warman 6/4 AH Metal 37
16 Spillage Pump 1 New Warman 3" DTV 15
Concentration
Model KC-QS48MS,
17 CCT-01 Knelson Concentrator 1 New Capacity 200-400 tph 75
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Concentrator Tailing
18 SMP-01 Sump 1 New 10 m3
Concentrator Tailing
19 PMP-04 Pump 1 New Warman 8/6 AH Metal 55
ILR 1000 BA, Capacity 2.8
20 ILR ILR Gekko System 1 New tons 10.5
21 SMP-02 ILR Tailing Sump 1 New 1 m3
22 PMP-05 ILR Tailing Pump 1 New Warman 2/1.5 AH Metal 15
23 Spillage Pump 1 New Warman 3" DTV 15
Gold Room
24 CCF-01 Calcine Oven 1 New
25 SMF-01 Smelting Furnace 1 New Induction Furnace 100.0
26 MLD-01 Cascade Moulds 1 New
27 SAF-01 Bullion Safe 1 New
Water
Dewatering Cyclone
28 CYL-02 Cluster 1 New 100 mm x (5)
29 PMP-06 Return Water Pump 1 New Warman 4/3 AH Metal 18.5
30 PMP-07 Return Water Pump 1 New Warman 4/3 AH Metal 18.5
31 TK-02 Process Water Tank 1 New 427m3
32 PMP-08 Process Water Pump 1 New Warman 8/6 AH Metal 45
33 PMP-09 Process Water Pump 1 New Warman 8/6 AH Metal 45
Detox
34 TK-03 Detox Tank + Agitator 1 New 10 m3 5.5
35 Reagent System 1
Reagents
15 kg/t concentrate NaCN,
36 Sodium Cyanide 1 New 10 - 20% w/w 7.5
20 kg NaOH/t Concentrate,
37 Sodium Hydroxide 1 New 25-50% w/w 7.5
0.2-3 kg/t concentrate /leach
38 Oxygen 1 New hour at 400 kPa
50 g/t concentrate, 0.1-0.3%
39 Flocculant 1 New w/w 7.5
Air
40 Compressor 1 New 8.86 m3/min, 8 bar, air cooled 55
41 Air-Prefilter 1 New ACT-100
42 Air Dryers 1 New ACT-100 3 x 1.7
43 Air Filter 1 New FT-080 X
44 Instrument Air Receiver 1 New 2.5 m3 , 8 bar
Bunded
area
45 Spillage Pump 1 New Warman 3" DTV 15
46 Spillage Pump 1 New Warman 3" DTV 15
Tel: +27 11 748 8800 www.manhattancorp.com
1996/002400/07
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3.3. Instrumentation
The following instrumentation is included in the supply scope:
Instrumentation
Item Description Quantity
1 Flowmeter cyclone feed line 1
2 Flow meter Knelson Feed Line 1
3 Flow meter Tailing Line 1
4 Flow meter return water line 1
5 Flow meter process water line 1
6 Level meter TK-01 1
7 Level meter SUMP-01 1
8 Level meter SUMP-02 1
9 Level meter TK-02 1
10 Pressure Indicator Cyclone Cluster-01 1
11 Pressure Indicator Cyclone Cluster-02 1
12 Pump VSDs 6
13 PLC Hardware Y
14 Computer Hardware Y
15 Software Engineering Y
16 Weightometer 1
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1996/002400/07
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3.4. Civil design
The civil design includes the following:
Retaining wall for loading ramp
Foundation for feed bin
Foundation and bund wall for scrubber
Foundation and bund wall for concentrator
Gold room foundation
Gold room building
Notes:
Our design will allow for local civil contractors to implement the required civil works.
We will require a geotechnical report in order to conduct the required design.
3.5. Electrical
Electrical supply scope:
Motor
Specification Power Cable Control Cable
No
Conveyorlengt
Equipment
Description of Number Length Total Total
kW Size Size
Equipment of Motors of Cable Length Length
0 0 2.5 0
BF-01 Belt Feeder 5.5 1 45 2.5 45 2.5 135
CON-01 Scrubber Feed Conveyor 25 11 1 25 4 25 2.5 100
SCR-01 Scrubber + Trommel Screen 160 2 25 240 100 2.5 75
CON-02 Trommel Oversize Conveyor 20 3 1 45 2.5 45 2.5 180
Single Deck Vibrating
VS-01 Screen 12.5 2 25 4 50 2.5 75
CON-03 Screen Oversize Conveyor 20 3 1 45 2.5 45 2.5 180
PMP-01 Desliming Cyclone Pump 55 1 15 35 30 2.5 45
PMP-02 Desliming Cyclone Pump 55 1 15 35 30 2.5 45
TK-01 Slurry Tank + Agitator 5.5 1 25 2.5 25 2.5 75
PMP-03 Concentrator Feed Pump 37 1 25 25 50 2.5 75
CCT-01 Knelson Concentrator 75 1 25 70 50 2.5 75
PMP-04 Concentrator Tailing Pump 55 1 25 35 50 2.5 75
ILR ILR Gekko System 10.5 1 25 2.5 25 2.5 75
PMP-05 ILR Tailing Pump 15 1 25 6 25 2.5 75
Gold Room 100 1 50 95 50 2.5 150
PMP-06 Return Water Pump 18.5 1 50 6 50 2.5 150
PMP-07 Return Water Pump 18.5 1 50 6 50 2.5 150
PMP-08 Process Water Pump 45 1 50 25 100 2.5 150
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1996/002400/07
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PMP-09 Process Water Pump 45 1 50 25 100 2.5 150
TK-03 Detox Tank + Agitator 5.5 50 2.5 0 2.5 150
Sodium Cyanide 7.5 1 25 2.5 25 2.5 75
Sodium Hydroxide 7.5 1 25 2.5 25 2.5 75
Oxygen 25 0 0 2.5 75
Flocculant 7.5 1 25 2.5 25 2.5 75
Compressor 55 1 50 35 100 2.5 150
Air Dryers 1.7 3 50 2.5 150 2.5 150
Scrubber Spillage
Pump 15 1 40 6 40 2.5 120
Concentrator Spillage Pump 15 1 40 6 40 2.5 120
Total number of motors 30
Power requirement 1015.1
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1996/002400/07
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5. Concept layout drawings
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1996/002400/07
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Exclusions:
- Civil excavation, foundations, buildings
- Concrete building for the gold room
- On-site gold laboratory
- Craneage for installation
- Site standby power
- Spares and consumables
- Oxygen plant
- Battery limits of supply are as per our quotation- should you require any additional components,
etc, please enquire for the associated cost.
By signing this document the customer agrees to the Manhattan Standard terms and conditions.
Signed and accepted by customer: Signed and accepted by Manhattan
(Who is duly authorised to do so): Corporation commercial department:
Signature Signature
Date Date
Designation Designation
Manhattan’s Standard Terms and Conditions of Sale apply. Refer to Appendix A.
Kindest Regards
MICHAEL POUROULLIS
Chief Executive Officer
Tel : +27 (0)11 748 8800
Fax : +27 (0)11 748 8898
[email protected]
Tel: +27 11 748 8800 www.manhattancorp.com
1996/002400/07
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