Copper Plant-Tanzania
Neptune Sator engaged in reconfiguration and optimization of a copper plant in Tanzania Matomondo region.We also offered process management services on going to the client.The plant flow sheet included gravity circuits of spirals and shaking tables .
Client:
Kisma Copper tx Limited
Completed:
August 2026
Status:
Completed
Project Summary: Copper Beneficiation Facility Optimization and Process Management
Client / Location: Copper Beneficiation Facility, Matomondo Region, Tanzania
Engineering Partner: Neptune Sator
Scope of Metallurgical Engineering & Reconfiguration
Neptune Sator executed a comprehensive plant audit, retrofit, and circuit optimization for a primary copper beneficiation facility in the Matomondo region of Tanzania. The intervention aimed to maximize metallurgical recovery, improve concentrate grade, and eliminate operational bottlenecks within the existing processing plant.
Key engineering deliverables included:
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Flowsheet Redesign & Debottlenecking: Restructured the mineral processing circuit to enhance liberation and streamline material handling from run-of-mine (ROM) preparation to final product filtering.
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Grade-Recovery Optimization: Adjusted operational parameters across classification and separation stages to balance mass pull with high-purity copper mineral recovery.
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Equipment Retrofitting: Integrated upgraded mechanical handling and sizing units to stabilize throughput and reduce unscheduled downtime.
Beneficiation Flowsheet & Gravity Separation Circuitry
To efficiently process the complex mineralogy of the Matomondo deposit, Neptune Sator engineered and integrated a robust multi-stage gravity concentration circuit tailored for density-based separation:
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Spiral Concentrators: Deployed in the primary rougher circuit to capitalize on density differentials, effectively processing intermediate-to-coarse size fractions, rejecting barren gangue material early in the flowsheet, and reducing the mass load on downstream units.
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Shaking Tables: Implemented in the secondary/cleaning stage to maximize the recovery of high-density fine-grained copper-bearing minerals through asymmetric deck motion and stratification, ensuring a high-grade final concentrate.
Ongoing Process Management & Operational Support
Beyond the initial plant reconfiguration, Neptune Sator provided comprehensive, long-term metallurgical management and technical governance to ensure sustained operational excellence:
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Continuous Metallurgical Accounting: Implemented rigorous mass-balancing protocols, daily feed-grade monitoring, and recovery tracking to audit plant performance.
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Operational Readiness & Quality Assurance: Provided hands-on technical oversight for plant operators, fine-tuning cut points, wash-water rates, and feed densities in real-time.
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Continuous Improvement Initiatives: Delivered data-driven recommendations to stabilize circuit kinetics, reduce reagent and energy footprints, and consistently meet target commercial specifications.
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