Tag Archives: Capstone Copper

RIINO expands consortium as it heads into engineering phase

The RIINO system, a zero-emission material movement solution leveraging technology influences from monorails, subway systems and the mechanised raise climber, is now officially in the engineering and development stage, with an expanded consortium advancing the technology’s development.

Having completed an in-depth, four-month scoping study backed by Agnico Eagle Mines and Vale Base Metals, utilising a consortium approach, supported by the Canada Mining Innovation Council (CMIC), the company has now moved into this phase, President and CEO, Aaron Lambert, told IM recently.

“Having been in early-stage development since 2020, we’re excited to move into this new phase and engage directly with all parts of the mining ecosystem,” Lambert said, adding that the consortium RIINO is assembling covers not only mining companies, but also fabricators and constructors. “Our aim is to build a consortium that goes across the value chain, we want to support the technology from the beginning to the end.”

In addition to the previously mentioned mining companies, Lambert announced that several more industry leaders have joined the consortium, including mining company Capstone Copper and mining and forestry equipment service company Soudure Dufer. This expansion, RIINO says, highlights the consortium’s growing strength with each new member.

“We’re open to inviting more members into this consortium as we advance the technology and build the demonstration system.” Lambert said. “All of these companies are incentivised by the same thing: to come up with an alternative to the mine haulage status quo that is cost effective, sustainable and flexible.”

RIINO is described as an innovative monorail haulage system targeting the reduction of the industry’s carbon emissions and achieving net-zero goals. It is designed to receive its power from the electrical grid which drives the internal, train-mounted motors as well as auxiliary on-board batteries for a complete electric and automated operation.

The RIINO concept originated out of Lambert’s experience as a contract miner in Sudbury – a role that saw him interact and engage with many different technologies. He has been working on RIINO for several years, with the initial plan to produce a system that is both capex- and opex-efficient. The headline number associated with this is a targeted 50-90% reduction in haulage operating costs.

The zero-emission element has created a further selling point for RIINO, encouraging mining companies to consider its use alongside a host of other haulage alternatives to the standard diesel-powered truck and shovel fleet.

To this point, the power requirements for RIINO have been based off existing specifications for both open-pit and underground mines. The standard 120-t (18% grade) or 400-t payload numbers have also been influenced by existing underground or open-pit mining profiles.

Each RIINO locomotive, part of an integrated system, is equipped with internal, train-mounted motors to provide optimal driveline power. The unique design of these locomotives includes wheels that are fully attached to the rails, similar to a rollercoaster, which effectively eliminates the risk of derailments. According to Lambert, this feature not only enhances safety but also prevents production losses.

Furthermore, the RIINO locomotives offer significant environmental and operational advantages. They play a crucial role in the decarbonisation of mining operations, achieving zero emissions, the company says. The advanced technology used in these locomotives results in reduced energy consumption and lower greenhouse gas emissions. This contributes to decreased environmental risks and liabilities, as well as a reduced overall mining footprint.

The inclusion of a Busbar able to provide 750 V of DC power comes out of the subway and surface transit space, meanwhile. On top of this, the system’s auxiliary on-board batteries eliminate a significant amount of electrical infrastructure such as power cables and additional sub-stations.

The company has partnered with Rainbow Concrete Industries to provide a demonstration site for a prototype system in Sudbury. This site will validate the technology in real-life scenarios. Once testing is completed in December 2025, the site will be open to the public for learning and community engagement.

Capstone Copper eyes ore recovery boost at Mantos Blancos from ShovelSense use

Capstone Copper has announced the implementation of ShovelSense® sensor technology at its Mantos Blancos operation, in Chile.

MineSense’s ShovelSense system uses X-ray Fluorescence based sensing technology that is mounted directly to digging equipment such as front-end loaders and shovels to accurately characterise and grade with each bucket, and differentiate between low, medium and high grade mineralised material.

This tool, Capstone Copper says, allows it to detect the characteristics of the extracted ore early, optimising operations and improving ore recovery by up to 36%. Tests on the use of these sensors have shown a potential increase in fine copper production, making it a key technology for this year, the company added.

“We are grateful for the collaborative work of the superintendencies ofgeology, maintenance, operations and planning, which were decisive throughout the implementation process,” the company added.

Mantos Blancos is an open-pit mine in the Antofagasta region of Chile. The operation currently mines and processes both sulphide and oxide ores.

Following the completion and current ramp up of the Mantos Blancos Concentrator Debottlenecking Development Project (MBCDP, or Mantos Blancos Expansion), the mine will primarily treat sulphide ore in an expanded concentrator. It has a plant capacity of 7.3 Mt/y.

Komatsu P&H 4100XPC electric rope shovels reduce truck waiting times at Capstone Mantoverde

The recent arrival of two Komatsu P&H 4100XPC electric rope shovels at Capstone Copper’s Mantoverde operation in Chile is significantly reducing waiting time for haul trucks at the open-pit mine, the company says in its latest sustainability report.

These large buckets – two of four that the company committed to purchasing in 2022 – are able to move approximately 4,000 t/h of material per hour, and require not only operators in the cab, but also personnel to move the medium-voltage (7.2 kV) cables that supply power to the shovels, to accommodate the needs of the shovel operators.

The nominal payload of the P&H 4100 XPC is 108.9 t, making it ideal for loading 218 t to 363 t haul trucks and high capacity (8,000 t/h-plus) in-pit crusher-conveyor systems, Komatsu says.

Jamie Figueroa, an experienced operator with both diesel and electric shovels, said: “The electric shovel makes our jobs much more productive. It makes much less noise than a diesel shovel and has no emissions. It is a win-win on all fronts.”

Last year, Mantoverde received 13 Komatsu 830E haul trucks as part of its Mantoverde Development Project (MVDP). These trucks come with a 230-t capacity and are powered by a Cummins QSK60 diesel engine. Mantoverde also uses a conveyor system to stack and remove ore for heap leaching, reducing its truck haulage needs.

The MVDP is expected to enable the company to process 235 Mt of copper sulphide reserves over a 20-year expected mine life, in addition to the operation’s existing oxide reserves. It involves the addition of a sulphide concentrator (12.3 Mt/y) and tailings storage facility, and the expansion of the existing desalination plant. This is expected to see production at Mantoverde increase from around 49,000 t of copper (cathodes only) in 2021 to approximately 120,000 t of copper (copper concentrate and cathodes) post project completion in 2024. The mine will also benefit from the production of approximately 31,000 oz/y of gold.

Freeport furthers its leading copper leaching excellence

Among the new applications, technologies and data analytics Freeport-McMoRan is advancing as part of a plan to improve copper recovery from its leach processes in North and South America is Jetti Resources’ patented catalytic technology, the company has confirmed to IM.

In its December quarter and 2022 annual results, released late last month, the leading copper miner said it believed the leach innovation initiatives it was pursuing provided potential opportunities to produce incremental copper from its large existing leach stockpiles and lower-grade material currently classified as waste.

The company has been exploring the potential for incremental low-cost additions to its production and reserve profile for some time, saying in the latest results release that it had identified opportunities to achieve an annual run rate of 200 MIb/y (90,718 t/y) of copper through these initiatives by the end of 2023.

Freeport has a long history of copper leaching production with its Americas division, which includes assets such as Morenci and Cerro Verde, having developed and implemented industry-leading technologies for leaching of oxide ores.

The company has been pursuing internal and external initiatives to expand this leading position, focusing on traditional ores and sulphide orebodies that have been typically considered difficult to leach, like chalcopyrite.

This is where Jetti’s technology comes in.

The Colorado-based company has developed catalytic technology to allow for the efficient and effective heap and stockpile leach extraction of copper. This bolts onto existing solvent extraction/electrowinning (SX/EW) leaching plants so it can be deployed rapidly with limited capital expenditure and, because it uses no heating or grinding, has low operational costs. In addition, there are huge environmental benefits from using leaching over pyrometallurgy, according to Jetti.

A Freeport spokesperson confirmed to IM that the company was in a trial of the Jetti technology through “a commercial installation” at its Bagdad mine in Arizona, USA. This mine is one of its major leaching test hubs, with the company targeting over 3 MIb/y of incremental copper cathode production from the open-pit copper mine through this work.

Bagdad has a 77,100 t/d concentrator that produces copper and molybdenum concentrate, an SX/EW plant that can produce approximately 6 MIb/y of copper cathode from solution generated by low-grade stockpile leaching, and a pressure-leach plant to process molybdenum concentrate.

The spokesperson added: “There is potential to expand production via the treatment of additional stockpiles at Bagdad in the future based on results.”

The use of Jetti’s technology is one of several leaching initiatives the company is pursuing – some with outside vendors, some using its own technology and some with joint venture partners.

All of these are focused on not only adding low-cost production to Freeport’s large production base, but also achieving a lower carbon footprint.

Jetti, which Freeport is an investor in, has been conducting a carbon footprint study and Life Cycle Assessment (LCA) of its technology, with the LCA including analyses of typical copper mining operations without Jetti’s technology and a mining operation with Jetti’s technology installed. The LCA is being conducted in conformance with the ISO 14040/44 standard and will be critically reviewed by an independent expert.

Jetti Resources has developed catalytic technology to allow for the efficient and effective heap and stockpile leach extraction of copper

Jetti has also committed to starting to track water usage and waste at all its operations and sites, which includes the installation it has at Capstone Copper’s Pinto Valley operation, also in Arizona.

At Capstone’s operation, Jetti technology is being used extensively as part of a plan to recover up to 350 MIb of cathode copper over the next two decades from historic and new mineralised waste piles.

Teck Resources has also taken an interest in Jetti’s technology having signed an agreement for the evaluation of the solution at a number of Teck’s assets with potential copper resources outside of existing mine plans. BHP, through its BHP Ventures arm, is also an investor in Jetti.

As to Freeport’s wider leaching plans, it said it was looking to use data analytics to provide new insights to drive additional value, while new applications to retain the heat in the stockpiles were “yielding results”.

The company has assessed that it has some 38,000 MIb of contained copper in leach stockpiles deemed “unrecoverable” by traditional leach methods. Of this amount, about 50% is from the massive Morenci mine, which already has leaching production capacity of 900 MIb/y of copper.

Komatsu 830Es arrive at Capstone Copper’s Mantoverde Development Project

Capstone Copper’s Mantoverde copper operation in Chile received 13 Komatsu 830E haul trucks in the March quarter in a sign of construction progress on its Mantoverde Development Project (MVDP).

The company said the MVDP at the existing Mantoverde (oxide) operation in Chile continued to progress, having, as of April 30, 2022, achieved overall progress of 49% and construction progress of 14% with the schedule remaining intact and construction completion targeted for late 2023.

Komatsu’s latest 830E, the 830E-5, comes with a 230-t capacity and is powered by a Cummins QSK60 diesel engine rated at a standard 2,500 hp (gross).

A 2021 technical report on the MVDP said the haulage fleet would mainly consist of Komatsu 830E trucks and a fleet of Cat 785s to re-handle oxide material. It said the peak required trucks will be between 2026 and 2029 with a requirement of 50 units.

The MVDP is expected to enable the company to process 235 Mt of copper sulphide reserves over a 20-year expected mine life, in addition to the operation’s existing oxide reserves. It involves the addition of a sulphide concentrator (12.3 Mt/y) and tailings storage facility, and the expansion of the existing desalination plant. This is expected to see production at Mantoverde increase from around 49,000 t of copper (cathodes only) in 2021 to approximately 120,000 t of copper (copper concentrate and cathodes) post project completion in 2024. The mine will also benefit from the production of approximately 31,000 oz/y of gold.

Work completed in the March quarter included the bulk earthworks for the primary crusher and grinding area platforms; bypass water pipeline with the internal lining, trench excavation and pipeline installation in the trench; drilling for all pumping and monitoring wells at the tailings storage facility (TSF) allowing for the commencement of the major TSF construction activities; and and the construction camp.

The MVDP is being progressed under a lump-sum turn-key engineering, procurement and construction (EPC) arrangement with Ausenco. The execution plan includes a Capstone Copper owner’s team working with the contractors during the execution phase.

FLSmidth has been selected by Ausenco to supply most of the key mineral processing technologies for the MVDP. The range of equipment and technologies includes the primary gyratory crusher, SAG mill, ball mill, traditional flotation cells, column cells, thickeners, cyclones and pumps.

The total project capital budget is now estimated to be $825 million and spend to date totals $338 million. The EPC contract total budget is approximately $525 million of which $220 million has been spent to date. The total project costs have increased slightly from $787 million to $825 million due to diesel price impact on pre-stripping costs of $23 million plus additional contingency of $15 million. The majority of the capital costs are fixed due to the nature of the lump sum turn-key contract with Ausenco of $525 million, or 67% of the original capital. Major mining equipment was price fixed prior to the current inflationary environment for approximately $140 million or 18% of the total original capital.

In the March quarter, Capstone Copper merged with Mantos Copper, a transaction that brought the MVDP into the Capstone asset base.