Simulation of grinding circuit: Ortaklar copper processing plant, Gaziantep/Türkiye

In this master's thesis, the performance of the grinding circuit at the Miryıldız Copper Processing Plant (Gaziantep, Türkiye) was evaluated through simulation and mass balance analyses. It was determined that the ore currently fed to the plant had completely different mineralogical and chemical properties compared to the ore studied during the plant's design phase. Therefore, three different simulation studies were conducted to determine whether the current flow sheet was suitable for the beneficiation of the ore being processed. The grinding circuit performance was simulated using METSIM (DEMO version) software. Simulations were conducted at three different feed tonnages: 70 t/h, 90 t/h, and 100 t/h. When the feed tonnage was set at 70 t/h, the P80 value was reduced from 33.72 mm to 0.036 mm, and the solid content of the flotation feed was found to be 35.27%. The P80 value of the hydrocyclone overflow was reduced to 0.040 mm, while the solid content was maintained at 31.06% when the feed tonnage was increased to 90 t/h. As a third simulation, the feed tonnage was raised to 100 t/h, and the P80 value of the hydrocyclone overflow was 0.044 mm, with the solid content of the flotation feed at 32.39%. In the mass balance analyses, two different grinding circuits were evaluated using Model-1 and Model-2. In Model-1, a slurry with a solid concentration of 73% was obtained by feeding 70 t/h of solids and 26 t/h of water to the SAG mill. As a result of this process, the recirculation load was determined to be 250%, and the bypass ratio was 34.66%. In Model-2, a solid concentration of 66% was obtained by feeding 95 t/h of solids and 49 t/h of water, with the recirculation load again determined to be 250% and the bypass ratio calculated as 25.79%. The simulation results were compared with similar studies using JKSimMet software, and a high consistency was found between the two simulations. These simulation and mass balance analyses provide valuable insights for improving current grinding circuit conditions and transitioning to a more sustainable beneficiation process.