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Conference Proceedings

Mill Operators Conference Proceeding 2026

Conference Proceedings

Mill Operators Conference Proceeding 2026

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Commissioning coarse flotation at BHP Carrapateena

Carrapateena is an iron oxide copper–gold (IOCG) deposit located in the Gawler Craton, South Australia. The ore, located at depths greater than 500 m, is mined by sub-level caving methods and processed by a conventional sulfide flotation concentrator. A copper-gold-silver (Cu-Au-Ag) concentrate is produced with chalcopyrite and bornite as the main copper bearing minerals. Carrapateena was commissioned in 2020 as a 4 mega-tonne per annum (Mt/a) concentrator, however a growth pathway to a 7 Mt/a concentrator was developed by the site processing team to keep pace with an increasingly productive mine. A key aspect of this pathway was to relax the primary grind size from the design P80 of 75 µm to 125 µm as processing rates increased. To address associated recovery losses, a coarse flotation technology – Eriez HydroFloat® cell – was selected for use in a rougher tailings scavenger duty. HydroFloat® laboratory studies commenced in 2019, transitioning to a pilot plant operating on-site in 2021. Through subsequent engineering phases, these studies transformed into a fully-fledged coarse flotation facility. Inclusive of three stages of desliming cyclones preparing a coarse feed to a pair of HydroFloat® cells, which recovers a coarse concentrate for treatment by a Metso Vertimill® VTM3500 for regrinding to a P80 of 20 µm, and a two-stage cleaning circuit consisting of four Glencore Technology Jameson Cells, producing a final copper-gold-silver concentrate. Construction of this facility commenced in 2024, with commissioning and subsequent optimisation activities occurring in 2025. This paper outlines a process description of the operating coarse flotation circuit at Carrapateena and presents details on the commission challenges faced and optimisation path required for the circuit to achieve its design intent.
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  • Published: 2026
  • Pages: 22
  • PDF Size: 1.396 Mb.
  • Unique ID: P-05648-S6K4L0

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