REV3.

PROCESS DESIGN CRITERIA

Customer Carmen Copper Corporation (CCC)

Date of Submission 14th December 2012

Revision 3.0

Customer Contact Name Sergei Serdzeff

Phone Number +63 917 306 6781

E-Mail Address sserdzeff@carmencopper.com
Outotec Contact Name Sherwin Morgan

Phone Number 0467 061 121 mobile

E-Mail Address sherwin.morgan@outotec.com

SOURCE OF DATA
The following source codes are used to reference the origin of each criterion:

Ref
CCC Supplied Data 1
Calculation 2
Outotec Supplied Data 3
Orway Mineral Consultants (OMC) Report 4
Vendor Supplied Data 5
Assumption 6
Mass Balance 7
Ammtec Supplied Testwork results 8

Page 1
 REV3.0
1 General ROM Ore Characteristics
Value Data
Criteria Units
Expected Design Source

Crusher Throughput dry tpd 60,000 60,000 1

Crushed Ore F80 m 12500 15000 1

Average Moisture Content % 3 2 1

3
Solids Density t/m 2.70 2.70 1

Benefication Plant Availability % 95 95 1

Benefication Plant Throughput tpd 63,158 63,158 2

Overall Recovery Copper % 87.0 88.0 1

Final Concentrate Mass Pull % 1.2 1.6 1

Final Concentrate Grade Copper % 26.5 26.51.0 1

Volcanic % 0.41 0.410.2 8

Expected Head Grade (delivered
to plant)
Diorite % 0.38 0.380.2 8

Current Head Grade Lutopan ore % 0.35 0.350.2 1

Volcanic % 50 5010 1
Expected Ore Split
Diorite % 50 5010 1

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2 Primary Milling Circuit Area 210
Value Data
Criteria Units
Expected Design Source
Configuration Wet, open circuit Ball Milling.

Circuit Operating Schedule

Days per annum days 365 365 1

Hours per day hours 24 24 1

Utilisation % 95 90 1
Annual operating
hours 8322 7884 2
time
Mill Feed Rate Nom.dry t/h 2632 2778 1

Feed Size (F80) m 12500 15000 1

Product Size (P80) m 464 536 4

i
Bond Work Index kWh/t 13.7 13.7 1

Ball Mill 1-5 Type 5.03m x 7.01m EGL overflow discharge 4

Mill Speed % crit. 68 4

Ball Charge Nom. % vol. 36 36 4

Drawn kW 2500 2500 4

Motor Power
Installed kW 2600 4

Ball Size Cast mm 65 65 4

ii
Estimated Ball Consumption kg/ton milled 0.104 0.104 1
iii
Estimated Liner Consumption kg/ton milled 0.030 0.030 1
3
Mill Outlet Density t/m 1.89 1.89 4

Ball Mill 6-7 Type 5.03m x 8.84m EGL overflow discharge 4

Mill Speed % crit. 68 4

Ball Charge Nom. % vol. 37 37 4

Drawn kW 3240 3240 4

Motor Power
Installed kW 3300 4

Ball Size Cast mm 65 65 4

iv
Estimated Ball Consumption kg/ton milled 0.104 0.104 1
v
Estimated Liner Consumption kg/ton milled 0.030 0.030 1

pH of Slurry pulp pH 9.0 9.00.5 1

3
Mill Outlet Density t/m 1.89 1.89 4

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 REV3.0

3 Secondary Milling Circuit Area 220

Value Data
Criteria Units
Expected Design Source
Configuration Wet, closed circuit Ball Milling.

Circuit Operating Schedule

Days per annum days 365 365 1

Hours per day hours 24 24 1

Utilisation % 95 90 1
Annual operating
hours 8322 7884 1
time
Mill Feed Rate Nom.dry t/h 2632 2778 1

Feed Size (F80) mm 464 556 4

Product Size (P80) m 197 224 4

vi
Bond Work Index kWh/t 13.7 13.7 4

Mill 8-9 Type 5.80m x 9.20m EGL overflow discharge 4

Mill Speed % crit. 75 4

Ball Charge Nom. % vol. 35 35 4

Drawn kW 5045 5045 4

Motor Power
Installed kW 6000 4

Ball Size Cast mm 50/38 50/38 4

Topup Ball Split 50mm % 15 15 4

Topup Ball Split 38mm % 85 85 4

vii
Estimated Ball Consumption kg/ton milled 0.345 0.345 1

Estimated Liner Consumption kg/ton milled 0.018 0.018 4

3
Mill Outlet Density t/m 1.95 1.95 7
viii
Circulating Load % 200 250 1
Mill Discharge Sump 8&9
sec 90 90 6
Capacity
Trommel Screen Aperture mm 12 x 50 3

Trommel Length mm 3363 4000 3

Trommel Diameter mm 2681 3000 3

Cyclone Feed 8&9 Pump Dry t/h 3947 4605 7

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 REV3.0
Cyclone Feed 8&9 Pump Solids (w/w) 58 60 7

Type 12 off Krebs Gmax 26-20 5

Sec Mill Classifying Cyclone 8&9 Cut, d50 m 70-80 75 5

Pressure kPa 50 70 70 5

Cyclone Underflow Solids (w/w) 76 76 7

Cyclone Overflow Dry t/h 1316 1447 7

Cyclone Overflow Solids (w/w) 38 38 7

pH of Slurry pulp pH 9.0 9.00.5 1

Trash Screen Aperture mm 1.4 3

Trash Screen Undersize By gravity

4 Regrind Milling Circuit Area 230

Value Data
Criteria Units
Expected Design Source
Configuration Wet, closed circuit Ball Milling.

Circuit Operating Schedule

Days per annum days 365 365 1

Hours per day hours 24 24 1

Utilisation % 95 95 1
Annual operating
hours 8322 8322 1
time
ix
Mill Feed Rate Nom.dry t/h 257 257 1

Feed Size (F80) mm 105 105 6

x
Product Size (P80) m 86 86 1
xi
Bond Work Index kWh/t 18.0 18.0 4

Regrind Mill 1-2 Type 2.74m x 4.57m EGL overflow discharge 4

Mill Speed % crit. 75 4

Ball Charge Nom. % vol. 35 35 4

Drawn kW 390 390 4

Motor Power
Installed kW 450 4

Ball Size Cast mm 30 30 4

3
Mill Outlet Density t/m 2.06 2.06 7

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 REV3.0
Circulating Load % 150 200 7

Regrind Cyclone Feed 1&2 Pump Dry t/h 214 265 7

Regrind Cyclone Feed 1&2 Pump Solids (w/w) 35.8 35.8 7

Regrind Cyclone Underflow Solids (w/w) 76 76 7

Regrind Cyclone Overflow Dry t/h 86 94 7

Regrind Cyclone Overflow Solids (w/w) 20 20 7

pH of Slurry pulp pH 11.5 11.50.5 1

5 Rougher / Scavenger Flotation Circuit Area 310&320

Criteria Units Value Data
Expected Design Source

Circuit Operating Schedule

Days per annum days 365 365 1

Hours per day hours 24 24 1

Utilisation % 95 95 1

Annual operating time hours 8322 8322 1

Plant Surge Capacity % 10 1

Feed Tonnage Rate Dry t/h 2672 2939 7

Feed % Solids (w/w) % 35 37 7

Slurry Density kg/l 1.28 1.28 7

3
Feed Volume Pulp m /h 5951 6092 7

Feed Configuration Parallel 3

3
2 rows off 2 x 300 m + 4 x 200 m3 Outotec Tank Cells, in
Cell Configuration 3
series, gravity flow.

Air Holdup % ~ 13% 3

Froth Height % ~ 3% 3

Metal Recovery Copper % 90 90 8

Laboratory Residence Time min. 10 10 8

Scale up Factor 2.5 2.5 6

Residence Time Required min. 25 25 2

Actual Residence Time min. 26 26 3

Froth Factor Launders 2.5 3.0 6

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 REV3.0
Froth Factor Concentrate Pump 1.25 1.5 6
Concentrate Sump Residence
100% level secs 30 30 6
Time
Ph of Slurry pulp Ph 9.5 9.50.5 1

Level Control by Dual Dart Valves 3

Total Mass Pull (% new Feed) % 8.5 10.0 8

Combined Concentrate Grade Copper % 5 7.5 8

6 HG Cleaner Flotation Circuit Area 340

Criteria Units Value Data
Expected Design Source

Circuit Operating Schedule

Days per annum days 365 365 1

Hours per day hours 24 24 1

Utilisation % 95 95 1

Annual operating time hours 8322 8322 1

Plant Surge Capacity % 10 1

xii
Feed Tonnage Rate Dry t/h 66.3 86.2 7

Feed % Solids (w/w) % 19.2 19.2 7

Slurry Density kg/l 1.15 1.15 7

3
Feed Volume Pulp m /h 301 361 7
xiii
Number of Cleaning stages 3 3 6

Froth Factor Launders 2.5 3.0 6

Froth Factor Concentrate pump 1.25 1.5 6

Concentrate Sump Residence Time 100% level secs 30 30 6

pH of Slurry Pulp pH 11.8 11.8 1

HG Cleaner Bank 1

Cell Configuration 2+3 x OK-16 Outotec Flotation cells 3

Laboratory Residence Time min. 4 4 6

Scale up Factor 2.5 2.5 6

Residence Time Required min. 10 10 2

Actual Residence Time min. 10 10 3

Mass Pull (% new Feed) % 1.0 1.1 7

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 REV3.0
HG Cleaner Bank 2

Cell Configuration 3 x OK-16 Outotec Flotation cells 3

Laboratory Residence Time min. 4 4 6

Scale up Factor 2.5 2.5 6

Residence Time Required min. 10 10 2

Actual Residence Time min. 12 12 3

Mass Pull (% new Feed) % 0.7 0.8 7

HG Cleaner Bank 3

Cell Configuration 2 x OK-16 Outotec Flotation cells 3

Laboratory Residence Time min. 4 4 6

Scale up Factor 2.5 2.5 6

Residence Time Required min. 10 10 2

Actual Residence Time min. 14 14 3

Mass Pull (% new Feed) % 0.5 0.6 7

Final HG Cleaner Concentrate Grade Copper % 26.5 26.5 1

Final HG Cleaner Concentrate Rec Copper % 50 55 6

7 Concentrate Thickener Circuit Area 410

Value Data
Criteria Units
Source
Expected Design

Circuit Operating Schedule

Days per annum days 365 365 1

Hours per day hours 24 24 1

Utilisation % 95 95 1

Annual operating time hours 8322 8322 1

Plant Surge Capacity % 28 1

Feed Tonnage Dry t/h 32 41 7

Concentrate Mass pull (% New Feed) % 1.2 1.6 7

xiv
Feed Size (F80) m 86 39 1&3
3
Feed Flow Rate pulp m /h 290 374 7
3
Feed SG t/m 1.07 1.07 7

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 REV3.0
Thickener Feed % Solids % 10.1 10.1 7
2
Solids Loading t/m h 0.25 0.25 3

Liquor rise rate m/h 1.73 1.73 3

24m diameter (existing), retrofitted with Outotec Vane

Thickener Type 3
feedwell and High rate mechanism

xv
Flocculant Addition g/t 2.0 2.0 3

Thickener Diameter Required m 15.0 3

71
Underflow % Solids (w/w) % 68 3
(achievable)

Underflow SG kg/l 1.95 1.88 7

3
Underflow Flow Rate m /h 23.1 32.1 7

Overflow Clarity ppm <100 <100 3

8 Tailings Thickener Circuit Area 420

Value Data
Criteria Units
Source
Expected Design

Circuit Operating Schedule

Days per annum days 365 365 1

Hours per day hours 24 24 1

Utilisation % 95 95 1

Annual operating time hours 8322 8322 1

Plant Surge Capacity % 10 1

Feed Tonnage Dry t/h 2600 2860 7

Feed Size (F80) m 306 306 3

3
Feed Flow Rate pulp m /h 5572 6129 7
3
Feed SG t/m 1.29 1.29 7

Thickener Feed % Solids % 36.1 36.1 7

2
Solids Loading t/m h 1.20 1.20 3

Liquor rise rate m/h 4.03 4.03 3

2 x 39m diameter (new), retrofitted with Outotec Vane

Thickener Type Option 1 3
feedwell and High rate mechanism

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 REV3.0
Thickener Diameter Required Option 1 m 2 x 39 3

1 x 55m diameter (new), retrofitted with Outotec Vane

Thickener Type Option 2 3
feedwell and High rate mechanism

Thickener Diameter Required Option 2 m 1 x 55 3

Flocculant Addition g/t 5.0 5.0 3

62
Underflow % Solids (w/w) % 55 3
(achievable)

Underflow SG kg/l 1.74 1.61 7

3
Underflow Flow Rate m /h 2406 3234 7

Overflow Clarity ppm <100 <100 3

9 Concentrate Filter Circuit Area 500

Value Data
Criteria Units
Source
Expected Design

Circuit Operating Schedule

Days per annum days 365 365 1

Hours per day hours 24 24 1

Utilisation % 95 95 1

Annual operating time hours 8322 8322 1

Plant Surge Capacity % 28 1

Feed Tonnage Dry t/h 32 41 1

xvi
Feed Size (F80) m 86 39 1&3
3
Feed Flow Rate pulp m /h 25.1 34.9 7
3
Feed SG t/m 1.88 1.81 7

Filter Feed % Solids % 68 65 7

Surge Capacity Filter Storage Tank hrs 8.0 8.0 3

2 xvii
Filter Type Option 1 2 x 32m Outotec Larox PF Filters 3

Filtration Rate 2 709 3

kg D.S. /m h
2
Filter Area Required Option 1 2 2 x 31.5m 3
m
2
Filter Type Option 2 1 x 216m Outotec Larox FFP Filter 3

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 REV3.0
Filtration Rate 2 230 3
kg D.S. /m h
2
Filter Area Required Option 2 2 1 x 198m 3
m
Solids content in the Cake (w/w) % 90 90 1

Primary Milling Circuit - 210

i
The design BWi value is based on testwork completed on Diorite and Volcanic composites.
However, for the Carmen ore CCC predicts periods where the BWi could increase to 15kWh/t. Under
these conditions, it is OMC recommendation to reduce the plant tonnage to 54KTPD to maintain a
flotation feed P80 of 202m. Client Comment This could be upto 15kWh/t based on current
plant

If the plant tonnage is kept at 60KTPD, the estimated rougher flotation feed increases to P80 >
260m. The consequence is that there is a potential for lower copper recovery values i.e. < 85%.

Secondary Milling Circuit - 220

ii
Client Comment Estimated by site calculations for both expected and design
iii
Client Comment Linear wear rate based on actual results for all mills
iv
Client Comment Estimated by site calculations for both expected and design
v
Client Comment Linear wear rate based on actual results for all mills
vi
Same as note (i)
vii
Client Comment Based on site calculation
viii
The design Secondary Mill re-circulating load (250%) is lower when compared to the predicted
maximum value by OMC (300-400%). OMCs prediction is based on their database ores will similar
BWi and feed and product size values. Note that the Mill re-circulating loads is also dependent on the
cyclone cluster operation and ball loading system. The consequence of a higher than designed mill
re-circulating load is that the cyclone feed pumps, cyclone cluster and trommel screen could be under
designed for their duty.

Regrind Milling Circuit - 230

ix
The design Regrind mill feedrate is based on the Scavenger concentrate only being fed to the
Regrind milling circuit. The scavenger concentrate represents ~6.5% mass pull (based on the new
feed) and the Regrind mill re-circulation load is based on 150%.

Ammtec testwork undertaken on the Diorite and Volcanic ore types indicated regrinding of both the
rougher and scavenger concentrate was necessary to achieve the final product grade close to the
target value of 26.5% Cu. Under these conditions the regrind mill feed rate will increase and the
estimated cleaner flotation feed increases to a P80 >125m. The consequence is that the final
copper product is likely to reduce in both Cu grade and recovery.
x
The predicted cleaner flotation feed P80 is based on both Regrind mills operating as duty mills in
parallel feed configuration. Thus, CCC current flexibility of a duty/standby regrind milling circuit will be
removed. The consequence is that during Regrind mill maintenance or breakdowns, the plant tonnage
will need to be reduced to 40KTPD to maintain final product grade / recovery.

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 REV3.0

In addition, the design regrind P80 of 86 m is based on historical performance of the Carmen ore
through the existing plant. Ammtec laboratory testwork on the Diorite and Volcanic composites
suggests a requirement for a significantly finer regrind P80 of <40 m to target the final product grade
of 26.5% Cu. Thus, the current regrind mills (both operating as duty) at the design plant tonnage
(60KTPD) may not be suitable to achieve the target final product grade.

It is estimated that with the current regrind mills, the plant tonnage will need to be reduced to
<30KTPD to achieve the Ammtec P80 of <40 m.

To operate the plant at the design tonnage (60KTPD) and achieve a regrind P80 of <40 m, a new
regrind mill will be required i.e. an Inert Stirred mill with an estimated 4.5MW installed power.
xi
The design BWi is based on OMC database of similar ore types. It is recommended by OMC that
fine grinding test work be undertaken on the rougher and scavenger concentrates to validate this
prediction. If the BWi value is higher than predicted, the consequence is that the cleaner flotation
feed P80 will be coarser and it is likely that the final copper product will reduce in both Cu grade and
recovery.

HG Cleaner Circuit - 340

xii
CCC indicated that the current cleaner circuit is capacity constrained at 50 KTPD. Thus, the
objective of the HG Cleaner circuit was to provide additional cleaner capacity and to produce a final
product grade of 26.5% Cu. The HG Cleaner circuit is designed based on receiving rougher
concentrate material only (i.e. 2.0 % mass pull based on new feed) and is based on the expectation
that the new Carmen ore will behave similarly to the Lutopan ore. If this proves incorrect, the
consequence is that the HG Cleaner circuit will need to be reviewed and potentially could require
additional flotation capacity to accept a larger feed stream.

xiii
The HG Cleaner circuit has been designed with three stages of cleaning. In the current cleaner
circuit, the rougher concentrate bypasses the regrind mill and undergoes three stages of cleaning.
Thus, the design is based on the expectation that the new Carmen ore will behave similarly to the
Lutopan ore. If this proves incorrect, the consequence is that additional cleaner banks may be
required to achieve the target product grade.

Concentrate Thickener Circuit - 410

xiv
The Concentrate thickener design is based on a feed size P80 of 39 m. The selected feed size is
based on the Ammtec testwork results for the Diorite and Volcanic composites, and is significantly
finer than the expected feed size if the Carmen ore behaves similarly to the Lutopan ore (i.e. P80 of
86 m). The consequence is that the Concentrate thickener equipment selection may have spare
capacity.
xv
The Outotec laboratory testwork indicated that flocculant addition of 2g/t was required at feed size
P80 of 39 m. CCC currently does not add flocculant to the Concentrate thickener, and may not
require flocculant addition for the Carmen ore if the feed size remains at P80 of 86 m.

Concentrate Filter Circuit - 500

xvi
The Concentrate filter design is based on a feed size P80 of 39 m. The selected feed size is
based on the Ammtec testwork results for the Diorite and Volcanic composites, and is significantly
finer than the expected feed size if the Carmen ore behaves similarly to the Lutopan ore (i.e. P80 of
86 m). The consequence is that the Concentrate filter equipment selection may have spare
capacity.

Page 12
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xvii
Client Comment Eventually this could be the specification, in the interim, CCC will
purchase short term solution.

Page 13