Performance study

Achieving over 5 million m³ reduction in water to tailings at a Chilean copper-moly mine

A Chilean copper-molybdenum mine significantly reduced water lost to tailings after implementing an advanced process control (APC) solution on its tailings thickeners. The system also reduced flocculant consumption and improved thickener stability and reliability.

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Key benefits

  • 3% w/w

    Increase in underflow density

  • 14%

    Reduction in water to tailings

  • 5.1m m³

    Reduction in water to tailings per year

  • $18m

    Reduction in value of water to tailings (USD)

  • 15%

    Reduction in flocculant

Details of the performance study

CommodityCopper and Molybdenum
TechnologyAdvanced process control system
ApplicationTailings thickeners
Study typeCustomer story
CountryChile

The mine is located 1700 m above sea level in an area of water scarcity. Seawater is supplied from the water-cooling system of a coastal thermoelectric power plant via a 143 km pipeline. It is an expensive undertaking – and likely to become more so. The mine is thus committed to recovering as much water as possible.

Implementation of the APC solution resulted in a:

  • 14% reduction in water to tailings at a potential saving of USD 18 million per year.¹
  • 15% decrease in flocculant consumption at an OPEX saving of USD 350,000 per year.²
  • 3% solids (w/w) increase in underflow density.

As a result, the amount of water sent to tailings has been reduced by 5.1 million cubic meters per year, improving water sustainability in this water-stressed region. Pumping costs and associated energy consumption are also reduced.

 

¹ Based on average water cost of USD 3.50/m3.

² Based on flocculant cost of USD 4.00/kg.