Core Resources was engaged by an African-based copper operation to provide on-site assistance in optimising their grind-flotation processing plant located in Botswana. This Process Plant Optimisation Project was part of a broader campaign by the company to improve production results across the entire operation. 

On-Site Technical Support and Training

Over a four-month period, Core’s Technical Director, Peter Rohner, and Senior Project Manager, Sandeep Yeolekar, delivered technical input and leadership at the processing plant. They identified and implemented optimisations across the crushing, grinding, flotation, and tailings handling processes. Adjustments to plant operating and maintenance strategies were made to optimise throughput, control power consumption, stabilise process conditions, and increase copper recoveries in the flotation plant. This work was conducted in collaboration with local plant staff and operators, providing extensive practical training as part of their role. 

Development of Remote Monitoring Capabilities

In addition to on-site support, Core developed remote monitoring capabilities for the operation. This enabled all stakeholders—including operators, management, and consultants—to view continuous live data from the operation. Core developed a SCADA-type interface (using PI ProcessBook) and sophisticated reporting tools that enabled metallurgists to identify trends and excursions in the operation and truly optimise the process. 

Record-Breaking Results

Core’s comprehensive approach led to the operation’s best quarterly results on record. The production of 5,367 tonnes of copper in concentrate for the quarter marked a 25% increase compared with Q3 FY14. Consequently, C1 cash costs decreased by 19.3% compared to the previous quarter, standing at $US3.17 ($A3.38) per pound. 

Sustainable Optimisation

The optimisation, technical input, and training were all provided with a view to the plant maintaining stability in its increased production well after Core had finished its short-term role. It is not Core’s role to operate plants but to provide a short burst of high-quality technical input to optimise the plant and enable the plant’s staff and management to continue with improved recoveries long after we have gone. 

Client Testimonials

Feedback from the operation’s executive and operational staff highlighted the positive impact of Core’s involvement:

• “We are thrilled with the work that Core has carried out for us. The plant’s operation has been significantly improved, and the record quarterly production has given the company a much-needed boost. We cannot speak too highly of the work Peter and his team carried out on site.” — Chief Executive Officer
• “Thank you very much for all your efforts and support you gave to help optimise and improve our process plant. I hope the team will continue building up on the work you have started, recommendations and suggestions.” — General Manager
• “Thank you so much for your guidance. Your efforts will surely go a very long way into assisting us. It was a very short stay but your technical input has been tremendous.” — Production Metallurgist

This case exemplifies the significant impact Core’s consulting services can have on the optimisation and stabilisation of processing plant operations. Core frequently partners with operations globally to provide this kind of input and leadership. For more on this service, contact us today.