Mass Balance
GWP / LCA
TEA
Process Mass Flows
NCL Wet Feed
480
kg/h
NCL Dry (Raw Material)
360
kg/h
Bulk Coarse Laterite
340
kg/h
Bulk Fine Laterite
20
kg/h
Mn Oxides Concentrate
2.400
kg/h
BCL to Storage
268
kg/h
BCL Size Fractionation
| Stream | Flow (kg/h) | Formula basis |
|---|---|---|
| BCL to attrition & wet sieving | 72.00 | 72/360 × NCL |
| BCL fine fraction (<0.1 mm) | 69.00 | 69/360 × NCL |
| BCL to Mozley separation (0.1–0.4 mm) | 1.700 | 1.7/360 × NCL |
| Heavy & mixed fraction | 0.600 | 0.6/360 × NCL |
| Mn oxides concentrate = Attrition − Fine − Heavy | 2.400 | mass balance |
Process Flow — Mass Balance Diagram (bar width ∝ mass flow)
Mn Oxides Concentrate — Bioleaching Material Flows
| Metal | wt% in conc. | Recovery % | kg rec./kg conc. | kg/h recovered |
|---|
Bulk Fine Laterite — Bioleaching Material Flows
| Metal | wt% in BFL | Recovery % | kg rec./kg BFL | kg/h recovered |
|---|
Source: Energy GWP-MnO (w allocation) worksheet · Mass allocation applied to MnO proportion only ·
Co-product GWP distributed by dividing by 3 across Mn, Ni and Co (cells C43, C46, C47)
Energy Inventory — Mn Oxides Concentrate Processing
Total Oven Dry Heat (B9)
383.95
MJ/h
Electricity — Mn ox. conc. allocated (B27)
2.0659
MJ/h
Bioleaching volume — Mn ox. conc. (B29)
36.00
L/h leaching solution
FeSO₄ — Mn ox. conc. (B31)
0.9000
kg/h
GWP Contributors — Mn Oxides Concentrate Bioleaching (B33–B36)
| Contributor | kg CO₂e/h | Emission factor | Unit |
|---|---|---|---|
| Ferrous sulfate — Mn ox. conc. (B33) | 0.15332 | 0.17036 | kg CO₂e/kg |
| Electricity allocated (B34) | 0.11879 | 0.0575 | kg CO₂e/MJ |
| Heating to 46°C — bioleaching (B35) | 0.23011 | 0.07579 | kg CO₂e/MJ |
| Nutrient (basal salt) medium (B36) | 0.037799 | 0.001050 | kg CO₂e/L |
| Total GWP (B37) | — | per kg NCL | kg CO₂e/kg NCL |
| Total GWP per kg metal (B38) | — | B37÷B49×NCL | kg CO₂e/kg metal |
GWP Allocated to Co-Products (C43, C46, C47) — B38 × B49 ÷ B_metal ÷ 3
Mn Oxides Concentrate — Metal Recoveries (B40–B49)
| Metal | kg/h recovered | GWP allocated (kg CO₂e/kg metal) |
|---|---|---|
| Mn | — | — (C43) |
| Ni | — | — (C46) |
| Co | — | — (C47) |
| Al | — | — |
| Total (B49) | — | — |
Source: TEA-price MnO BFL worksheet · Lang factor = 3 (TCI/delivered cost) ·
CEPCIcurrent = 820 · 290 operating days/year (6,960 h/y)
Capital Cost Estimation — Six-Tenths Rule (Lang Method)
| Unit (rows 4–11) | Base cost M$ | Scale n | Current size | Cost M$ (H4–H11) |
|---|
Delivered Equipment Cost (H12)
—
million $
Total Capital Investment H13 = H12 × 3
—
million $
Annual Operating Costs (rows 16–36)
| Cost Item | Quantity | Unit | Price | Unit | M$/y |
|---|
Product Value (G24)
—
million $/y
Product Value − Total Cost (B36)
—
million $/y
Total Opex (B33)
—
million $/y
Total Cost — Annual Capex + Opex (B34)
—
million $/y
Net Present Value Profile — 10 Years (rows E27–G37)
Cumulative NPV & Discounted Cash Flow (million $)
NPV Schedule
| Year (col E) | Discounted CF — col F (M$/y) | Cumulative NPV — col G (M$) |
|---|