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Chemech Consulting | Motheo Copper Project case study |  Sandfire Resources copper processing | copper metallurgical testwork program | copper project design review

OUR TRACK RECORD

SANDFIRE RESOURCES - MOTHEO COPPER PROJECT

The Details

TIMEFRAME: 2018 - 2022

CLIENT: Sandfire Resources (was Mod Resources)

LOCATION: Botswana

COMMODITY: Copper 

SERVICES: Metallurgical Testwork Management | Subject Matter Expert 

copper processing optimisation

COPPER OUTPUT

>58,000t CuEq (FY25)

copper processing optimisation

PROCESSING THROUGHPUT

5.5 Mt/a (FY25)

copper processing optimisation

KEY OUTCOMES

93% Cu recovery, 30% Cu con grade (FY25)

Project Background

The Motheo Copper Operations in Botswana commenced processing the T3 deposit in May 2023, producing high-quality copper concentrate (containing a silver by-product) for sale to international smelters.  

Chemech's Contribution

In 2018, Chemech were engaged to assist Sandfire (was Mod Resources at that time) with an independent review of the metallurgy and processing component of their T3 PFS. The goals of the review were to: identify any fatal flaws; assess potential opportunities to reduce capital and operating costs; provide opportunities to improve operability and maintainability; and make recommendations for further testwork. In addition to identifying a number of potential design improvements, many of which were incorporated into the design, Chemech also made recommendations regarding comminution and flotation variability sampling for the DFS testwork program. 

Sandfire subsequently engaged Chemech to support the T3 DFS metallurgical testwork program including: 

  • Assistance with development of the testwork program scope. 

  • Development and issuance of requests for quotation (RFQs) for the testwork program. 

  • Adjudication of the testwork proposals and laboratory recommendation. 

  • Technical support to ensure correct sample generation, which was complex due to the number of samples required to provide grade, spatial and lithological representation. 

  • Ongoing technical support throughput the testwork program. 

  • Assistance with the development of the Net Smelter Return for the concentrate. 

 

On the back of a successful T3 testwork program, Sandfire engaged Chemech to assist with the program for the newly identified A4 deposit in 2021. This program focused on confirming the A4 ore’s metallurgical response using the Motheo process flowsheet and conditions, as well as providing sufficient testwork data to support the A4 DFS. The A4 program included specific testwork targeting the separation of copper and molybdenum to investigate the opportunity for separate molybdenum production, and the separation of copper and bismuth to improve the copper concentrate quality.  

Final Outcome

The Motheo plant went into production in May 2023 processing T3 ore at a rate of 3.2 Mt/a.  In 2024, the plant was expanded to 5.2 Mt/a to treat A4 ore. The expanded Motheo plant achieved an annualised processing rate of 5.6Mt/a for H1 FY25, reaching a CuEq production record of 16.4kt in Q4 FY25. 

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