We worked with Luca Mining to identify operational changes to their Campo Morado project including technical support to update the mine plan and blends for the comminution circuit, improved floatation control, calibrated instruments throughout the process plant, tuned control loops and adjusted the reagent dosage scheme. These changes resulted in higher recoveries and increased concentration grades, providing the Luca Mining team with a clear understanding of how to maximize profitability at the operating mine.
The challenge
This underground multi-metal mine in Guererro produces copper-zinc-lead concentrates, with infrastructure and equipment capable of processing 2,400 tons of ore per day. Despite being re-commissioned by the previous company in 2017, the operation faced inconsistent operating margins.
When Luca Mining’s new management team took over in 2023, they were confident in the mine’s potential but recognized it was underperforming. They were determined to identify performance improvement opportunities and turn the operation around.
The better way
Ausenco used an investigative process and put data at the core of planning to drive decision-making. We began with a “back to basics” approach, collecting available data to outline new metallurgical lab testing work, revising the comminution circuit and fine-tuning the mine output blend. The team concentrated on enhancing flotation control, calibrating instruments, and optimizing the control loops. By replicating plant performance in an on-site metallurgical lab and at an external lab (ALS), we recommended a more effective reagent dosage scheme to significantly improve performance. Transitioning from a complex sequential flotation flowsheet to a simplified two-product flowsheet resulted in higher recovery in all concentrates.
The outcome
The results have been significant. The process parameter adjustments were implemented without the need for sustaining capital, allowing Campo Morado to increase overall zinc recovery from 75% to 82% and improve the final concentrate grade from 45% to 51% zinc, dependent on reliable ore feed from the mine. Additionally, the bulk concentrate produced now achieves copper recovery rates exceeding 70% compared to the historical range of 35% to 40%.
This success stemmed from making data central to planning and decision-making. The team updated the project’s benchmark data and presented optimal metrics, parameters, and sequences to client’s team. Ausenco’s experts also reviewed what data to monitor and how to respond to variations outside of the required parameters.
We continue conversations to work with Luca Mining at Campo Morado, to unlock further opportunities and increase profitability.