Tag Archives: copper

Anax Metals brings Gekko in for process plant design at Whim Creek copper mine

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Anax Metals Limited has appointed Gekko Systems as process plant design consultant to assist with the design process of a polymetallic sulphide concentrator plant at the Whim Creek copper mine in Western Australia, Gekko says.

The concentrator plant will be designed to process approximately 320,000 t/y of pre-concentrate, with feedstock for the concentrator consisting of primary sorted ore and upgraded fines from the gravity circuit.

Anax plans to design the process plant and associated infrastructure such that it may be fabricated and assembled on skids, in a factory, prior to transportation and installation on site. This strategy delivers many significant benefits and reduces site related construction risks.

Anax’s Managing Director, Geoff Laing, said: “We are very pleased to be working with the Gekko team and look forward to delivering a cost-effective modular plant for Whim Creek. Modularisation is a key element of the ‘Anax Blueprint’ which is expected to deliver leveraged outcomes to our projects.”

PolyMet heralds positive permit news at NorthMet copper-nickel-palladium project

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The Minnesota Court of Appeals has affirmed nearly all aspects of the water discharge permit for the NorthMet project, overruling six of the seven challenges to the permit made by mining opponents and paving the way for the “reactivation” of this key permit, according to Poly Met Mining Corp Chairman, President and CEO, Jon Cherry.

The Court of Appeals affirmed virtually every aspect of PolyMet’s permit at issue. In particular, the court endorsed the district court’s factual findings regarding the Minnesota Pollution Control Agency’s (MPCA) and the Environmental Protection Agency’s interactions during the permitting process; agreed with MPCA’s application of state law governing groundwater discharges; upheld the agency’s conclusion that PolyMet’s project has no reasonable potential to violate water quality standards; agreed with MPCA’s finding that PolyMet’s project will not violate the Fond du Lac Band’s water quality standards; and affirmed the agency’s denial of mining opponents’ requests for a contested case hearing, the company said.

In its decision the panel concluded that the MPCA should still consider whether “any discharges to groundwater will be the functional equivalent of a discharge to navigable waters, and thus, whether the Clean Water Act applies to those discharges”. The court remanded the permit to the MPCA to conduct this functional-equivalence analysis, which the US Supreme Court established in County of Maui vs Hawaii Wildlife Fund, a new precedent set more than a year after PolyMet’s permit was issued.

PolyMet is a mine development company that owns 100% of the NorthMet project in the Mesabi Iron Range, the first large-scale project to be permitted within the Duluth Complex in north-eastern Minnesota. NorthMet has significant proven and probable reserves of copper, nickel and palladium, in addition to marketable reserves of cobalt, platinum and gold. When operational, NorthMet will become one of the leading producers of nickel, palladium and cobalt in the US.

The NorthMet deposit will be mined by open-pit methods to a depth of approximately 700 ft below surface. It is also reusing existing infrastructure of the former LTV Steel taconite processing site. It is expected to produce up to 57.7 Mlbs of copper, 8.7 Mlbs of nickel, 311,000 lbs of cobalt, 14,000 oz of platinum, 59,000 oz of palladium, 4,000 oz of gold and 48,000 oz of silver annually over an estimated mine life of 20 years.

According to a Reuters story, PolyMet received a state permit to discharge water from its proposed mine site in late 2018. Shortly after that, three environmental groups sued to challenge the permit. The case wound its way through the court system before this week’s ruling at the appeals court, which sits below the state supreme court.

“We are pleased that we have prevailed on the majority of the issues and the court has narrowed the case to just this single issue regarding Maui, where considerable scientific data already exists,” Cherry said. “MPCA has already determined there is not a permittable discharge to groundwater and we are optimistic the agency will reach the same conclusion from the Maui test. This will mean a little more process, but it gives us a clear roadmap to the reactivation of this permit.”

Howden to supply complete mine cooling system for OZ Minerals’ Prominent Hill mine

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Howden says it has won a contract to supply a cooling system for the expansion of OZ Minerals’ Prominent Hill mine in South Australia.

The solution provided by Howden will be for the complete mine cooling system, with Howden’s equipment ensuring safe productive outcomes at depth and additional efficiencies to reduce environmental impact for current and future carbon footprint compliance.

Howden will focus on sustainability and the solution will include closed circuitry on both condenser and evaporator circuits and R717 (Ammonia) compressors which emit no harmful CO2 or HFCs, the company said. The system consumes no water, using the ambient air as the cooling medium and Howden will supply chillers, air cooled condensers, bulk air coolers, pumps, electronic controls and hydraulic design.

Camille Levy, President of Howden APAC, said: “Howden works in partnership with customers to create solutions for their needs which are of the highest functionality, while supporting their net zero targets. This project is no exception. Our unique combination of manufacturing excellence, technical and project deliverables, and our global experience, also contributes to the reduction of carbon impact of operations.”

The use of Howden refrigeration screw compressor technology coupled with supplies of condenser coolers and bulk air coolers were other supporting factors in the successful offer which will be delivered by the Howden team in China, the company said.

The OZ Minerals Board approved construction of a hoisting shaft at the Prominent Hill copper-gold mine in South Australia last year, paving the way for a mine life extension and throughput expansion.

Rio, TRQ and Mongolia agree on Oyu Tolgoi Underground development path

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Rio Tinto, Turquoise Hill Resources (TRQ) and the Government of Mongolia have reached an agreement that, Rio says, will move the Oyu Tolgoi (OT) project forward, resetting the relationship between the partners and increasing the value the project delivers for Mongolia.

As a result, the OT Board, comprised of representatives of Rio Tinto, TRQ and Erdenes Oyu Tolgoi (EOT), the latter of which is wholly owned by the Government of Mongolia, has unanimously approved commencement of underground operations. This step unlocks the most valuable part of the mine and is expected to begin in the coming days, with first sustainable production expected in the first half of 2023, according to Rio Tinto.

As part of a comprehensive package, TRQ will waive the $2.4 billion EOT carry account loan in full, comprising the amount of common share investments in OT LLC funded by TRQ on behalf of EOT to build the project to date, plus accrued interest.

The Parliament of Mongolia has approved a resolution (Resolution 103) that resolves the outstanding issues that have been subject to negotiations with the Government of Mongolia over the last two years in relation to addressing Parliament Resolution 92 (December 2019).

With this approval, the Parliament of Mongolia has required that certain measures be completed in order for Resolution 92 to be considered formally implemented. Among the measures already addressed are improved cooperation with EOT, implementation of measures to monitor OT underground development financing mechanisms and enhance ESG matters and the approval of the Electricity Supply Agreement.

Rio says it is continuing to work with the Government of Mongolia and TRQ to finalise the remaining outstanding measures of Resolution 92, namely the formal termination of the Oyu Tolgoi Mine Development and Financing Plan (UDP) and resolution of the outstanding OT LLC tax arbitration.

An updated funding plan has been agreed to address TRQ’s current estimated remaining funding requirement for the OT Underground Project. Until sustainable underground production is achieved, OT will be funded by cash on hand and rescheduling of existing debt repayments, together with a pre-paid copper concentrate sales agreement with TRQ. This is in line with restrictions on debt financing contained in Resolution 103, passed on December 30, 2021.

Rio Tinto and TRQ have amended the Heads of Agreement signed in April 2021 to ensure they appropriately fund OT. The capital forecast for the project is $6.925 billion, including $175 million of known COVID-19 impacts to the end of 2021. Forecasted remaining underground capital expenditure is approximately $1.8 billion. A reforecast will be undertaken during the first half of this year to determine a revised cost and schedule estimate that will reflect:

  • Any further COVID-19 impacts;
  • Any additional time-based impacts and market price escalation arising from resequencing due to 2021 budget constraints (as a result of the OT Board not approving the capital budget uplift at the time the Definitive Estimate was finalised); and
  • Updated risk ranging reflecting the latest project execution risks.

The key elements under the amended Heads of Agreement include:

  • Pursuing the rescheduling of principal repayments of existing OT project finance to potentially reduce the OT funding requirement by up to $1.7 billion;
  • Seeking to raise up to $500 million of senior supplemental debt at OT from selected international financial institutions which could be put in place after sustainable underground production is achieved;
  • Rio Tinto providing a co-lending project finance facility to OT of up to $750 million to be made available after sustainable underground production is achieved (with up to $300 million of such amount being available under a short-term secured advance directly to TRQ pending such co-lending); and
  • TRQ agreeing to conduct equity or rights offerings of up to $1.5 billion (with an initial offering of at least $650 million by no later than August 31, 2022).

The re-profiling of the existing OT project finance and any additional senior supplemental debt at OT will be subject to availability and terms and conditions being acceptable to Rio Tinto and TRQ, according to the company.

The OT Board has also approved the signing of an Electricity Supply Agreement to provide OT with a long-term source of power from the Mongolian grid, under terms already agreed with the Government of Mongolia. In meeting OT’s commitment to sourcing power domestically, Rio Tinto will work with the Government to support long-term renewable energy generation in support of the Mongolian grid. The Government of Mongolia and OT are in constructive discussions with the Inner Mongolia Power International Cooperation Company (IMPIC) for an extension of current power import arrangements beyond the current agreement of July 2023. IMPIC has indicated its support for an extension and commercial terms are being finalised.

Luvsannamsrain Oyun-Erdene, the Prime Minister of Mongolia, said: “The commencement of Oyu Tolgoi underground mining operations demonstrates to the world that Mongolia can work together with investors in a sustainable manner and become a trusted partner. As part of our ‘New Recovery Policy’, I am happy to express Mongolia’s readiness to work actively and mutually beneficially with global investors and partners.”

Rio Tinto Chief Executive, Jakob Stausholm, said: “We would like to thank the Government of Mongolia for their commitment to working productively with Rio Tinto and TRQ to reach this crucial agreement that will see one of the world’s largest copper growth projects move forward and firmly establish Mongolia as a global investment destination. This agreement represents a reset of our relationship and resolves historical issues between the OT project partners. We strongly believe in the future of this country and I am personally committed to ensuring that the people of Mongolia benefit strongly from OT along with our shareholders.

“I have visited Mongolia twice in the last few months and I cannot help but be proud of what has been achieved by our workforce, hand-in-hand with communities, suppliers and other partners. I would like to thank the many thousands of people involved for what they have achieved.

“The OT underground development will consolidate Rio Tinto’s position as a leading global supplier of copper at a time when demand is increasing, driven by its role in enabling decarbonisation and electrification in the race to net zero. We will also explore additional opportunities to decarbonise the OT operations, including sourcing renewable power.”

Steve Thibeault, Interim Chief Executive Officer of Turquoise Hill Resources, added: “Today is a landmark day for Turquoise Hill and a major milestone in the development of the Oyu Tolgoi underground development project. We are very excited to be starting work on the undercut, which is critical to unlocking the immense potential of this world-class, high-grade deposit for the benefit of all stakeholders. Following the agreements with the Government of Mongolia and the Amended Heads of Agreement with Rio Tinto being put in place, we now have greater certainty and confidence to complete construction of this once-in-a-generation mine that, when finished, is expected to be one of the largest copper producing mines in the world and a generator of vast economic value and employment in Mongolia and of returns for our shareholders for years to come. I want to thank the Government of Mongolia for its commitment to securing a balanced agreement that helps to advance the project while ensuring that all stakeholders including the people of Mongolia truly benefit from the development of this resource. This agreement says a lot about the positive environment for foreign investment in the country.”

By 2030 OT is expected to be the fourth largest copper mine in the world. It is a complex greenfield project comprising an underground block cave mine and copper concentrator as well as an open-pit mine which has been successfully operating for almost 10 years. It is also one of the most modern, safe, sustainable and water-efficient operations globally, with a workforce which is more than 96% Mongolian. Since 2010, OT has spent a total of $13.4 billion in-country, including $3.6 billion of taxes, fees and other payments to the state budget. The size and quality of this Tier 1 asset provides additional expansion options, which could see production sustained for many decades.

At peak production, OT is expected to produce around 500,000 t/y of copper on average from 2028 to 2036 from the open pit and underground, and an average of around 350,000 t for a further five years, compared with 163,000 t in 2021. The underground Ore Reserve has an average copper grade of 1.52%, which is more than three times higher than the open pit reserve, and contains 0.31 g/t Au.

Hudbay’s Constancia continuous improvement quest leads to MineSense XRF trial

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Hudbay Minerals has one of the lowest cost per tonne copper sulphide operations in Peru on its hands at Constancia, but it is intent on continuously improving the mine’s margins and environmental performance through a commitment to continuous improvement. This has recently led it to exploring the potential of sensor-based ore sorting.

Hudbay’s operations at Constancia include the Constancia and Pampacancha pits, an 86,000 t/d ore processing plant, a waste rock facility, a tailings management facility and other ancillary facilities that support the operations.

The company increased reserves at the mine, located in the Cusco department, by 33 Mt at a grade of 0.48% Cu and 0.115 g/t Au last year – an increase of approximately 11% in contained copper and 12% in contained gold over the prior year’s reserves.

With the incorporation of Pampacancha and Constancia North, annual production at Constancia is expected to average approximately 102,000 t of copper and 58,000 oz of gold from 2021 to 2028, an increase of 40% and 367%, respectively, from 2020 levels, which were partially impacted by an eight-week temporary mine interruption related to a government-declared state of emergency.

Constancia now has a 16-year mine life (to 2037) ahead of it, but the company thinks there is a lot more value it can leverage from this long-life asset and it has been looking at incorporating the latest technology to prove this.

In recent years it has, for instance, worked with Metso Outotec to improve rougher flotation performance at Constancia using Center Launders in four e300 TankCells and installed a private LTE network to digitise and modernise its open-pit operations.

Peter Amelunxen, Vice President of Technical Services at Hudbay, said the Constancia ore sorting project – which has seen Hudbay partner with MineSense on a plan to trial the Vancouver-based cleantech company’s ShovelSense X-ray Fluorescence (XRF)-based sorting technology – was one of many initiatives underway to further improve the operating efficiency at Constancia.

“The ore sorting program is separate from the recovery uplift program at Constancia,” Amelunxen said, referring to a “potentially high-return, low capital opportunity” that could boost milled copper recovery by 2-3%.

He added: “The ore sorting program is expected to yield positive results at the mining phase of the operation and is expected to increase the mill head grade and reduce metal loss to the waste rock storage facility.”

Back in April 2021 during a virtual site visit, Hudbay revealed it was trialling bulk sorting at Constancia as one of its “optimisation opportunities”, with Amelunxen updating IM in mid-January on progress.

Hudbay has previously evaluated particle sorting at its Snow Lake operations in Manitoba – with the benefits outlined in a desktop study “muted” given “bottlenecks and constraints”, Amelunxen said – but, at Constancia, it considered XRF sorting from the onset for copper-grade only pre-concentration, due to its perception that this application came with the lowest potential risk and highest probability of success.

The company has a three-phase evaluation process running to prove this, with phase one involving a “bulk sorting amenability study”, phase two moving up to laboratory-scale testing and phase three seeing trials in the field.

The “bulk sorting amenability study” looked at downhole grade heterogeneity to estimate curves of sortability versus unit volume, Amelunxen detailed. Laboratory testing of drill core samples to evaluate the sensor effectiveness was then carried out before an economic analysis and long-range-plan modelling was conducted.

With the concept and application of bulk sorting having cleared all these stage gates, Hudbay, in November, started pilot testing of XRF sensors on a loader. This involved fitting a ShovelSense unit onto the 19 cu.m bucket of a Cat 994H wheel loader, with around 20 small stockpiles of “known grades” loaded onto the bucket and dispatched into a feeder and sampling system (pictured below, credit: Engels Trejo, Manager Technical Services, Hudbay Peru). With this process completed, the company is now awaiting the results.

At a similar time, the company moved onto demonstration trials of a “production” ShovelSense sensor unit on the 27 cu.m bucket of a Hitachi ECX5600-6 shovel operating in one of the pits. It has collected the raw spectral data coming off this unit since the end of November, with plans to keep receiving and analysing sensor data through to next month.

“We should have the finalised XRF calibration in February, at which time we’ll process the raw data collected during the three-month trial period and compare it with the short-term mine plan (ie grades of ore shipped),” Amelunxen said. “So, by the end of February or early March, we’ll be able to validate or finetune the economic model.”

Should the results look favourable, Amelunxen is confident that leasing additional sensors and installing them on the other two Hitachi ECX5600-6 shovels will not take long.

Credit: Engels Trejo, Manager Technical Services, Hudbay Peru

“Plans may change somewhat as the program unfolds,” he said. “For example, we may have success sorting ore, but feel additional calibration is required for waste sorting at Pampacancha, in which case we may install production sensors on Constancia ores while doing another trial program at Pampacancha.

“It all depends on the precision of the XRF calibration.”

Higher head grades and potentially higher copper recoveries may be the headline benefits of using ore sorting technology, but Hudbay is equally focused on obtaining several key environmental benefits, including reduced consumption of energy and water.

On the latter, Amelunxen said: “This is expected due to the processing of less ‘waste’ by removing uneconomic material earlier in the process and reducing the hauling and processing costs of the uneconomic material.”

Looking even further forward – past a potential commercial implementation of XRF-based ore sorting at Constancia – the company plans to evaluate the application of other sensors, too.

“For our future development copper project in Arizona, we plan to look at other sensors as well,” Amelunxen said, referencing the company’s Rosemont asset.

This ore sorting project is not the only project the processing team at Constancia are examining, as Amelunxen already hinted at.

As part of the recovery uplift project, it is installing equipment that will allow the operation to increase the overall mass recovery of the roughers, which is currently constrained by the downstream pumps and cleaning circuit.

“This will allow us to achieve an expected 2-3% increase in copper recoveries without impacting concentrate grade,” Amelunxen said.

It has various initiatives underway under the “Moly plant improvement projects” banner, too. This includes flowsheet optimisation, pH control in the cleaners and pH reduction in the bulk cleaners.

“This project has been in the works since late 2019, and the new mechanical agitator installation in the cleaning cells was completed during the August 2021 schedule mill maintenance shutdown and the new nitrogen plant was commissioned in the second half of the year,” Amelunxen explained. “The next steps are pH control in the cleaners (with CO2), water balance optimisation and potentially installing a Jameson flotation cell as a pre-rougher (the cell is already on site and not in use, it will be repurposed pending results of the pH trials).”

A flotation reagent optimisation study is also on the cards, aimed at reducing zinc and lead contamination in the copper concentrate.

“A depressant addition system is on the way to site and should be installed in February, with plant trials commencing in March,” Amelunxen said, explaining that this followed laboratory test work completed in 2021.

Bartram comes back to TOMRA Mining ready for sensor-based sorting demand uptick

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Having left TOMRA Mining more than a decade ago only to return to the Germany-based company in November, Kai Bartram’s re-arrival at the sensor-based sorting firm represents a good time to take stock and reflect on how far the mining sector has come with its understanding and acceptance of this type of pre-concentration technology.

Bartram, now Global Sales Director of TOMRA Mining and a member of TOMRA’s Mining Management Team, was happy to answer some of IM’s questions after getting his feet back under the table in the company’s offices in Wedel, Germany.

IM: How has the mining industry’s appreciation of the benefits of sensor-based ore sorting changed since you left TOMRA in 2010? What trends have led to a wider take up of the technology?

KB: In 2010, sensor-based sorting (SBS) was still seen as a niche technology in the mining industry. Some smaller, more innovative mining companies had seen the potential and effectively implemented SBS, but the mining industry, as such, had not accepted the technology. While in the industrial minerals sector several optical sorters – and, in the diamond industry, mainly X-ray luminescence machines – were operating, the rest of the industry was cautious about integrating sorters into their flowsheets.

That changed slowly with the introduction of Dual Energy X-ray technology. The technology is so robust and perfectly suited to the harsh environment of the mining industry that the economic benefits of pre-concentration became obvious. Another point that has strongly supported the adoption of sorting technology is the fact that average ore grades keep decreasing while energy costs keep increasing.

IM: Diamond and industrial mineral operations were typically the first adopters in the mining sector; what commodity sectors do you expect to see dominate demand for sensor-based ore sorting systems into 2030? What changes to the technology or wider industry understanding have led to this belief?

KB: In the beginning, sorters were seen as small machines, which would never meet the capacity requirements of large hard-rock mineral processing circuits. Therefore, only small mines saw the opportunity to implement sorting as a pre-concentration step in their process. Today, we see that our 2.4-m-wide flagship sorter, TOMRA COM XRT 2.0, can process up to 500 t/h, so that large operations can also implement the technology. An example of such a trend is the Ma’aden Phosphate Umm Wu’al processing plant, where 2,000 t/h are processed with TOMRA XRT sorters.

I am sure we will see more of these bigger projects in many different commodities. Of course, the current market trend is towards ores that are required for the electric revolution, like lithium, copper, cobalt and rare earth elements. TOMRA has proven that we have the right solution to upgrade those ores efficiently and can contribute to more economical output. So, I expect to see more installations in the future.

The TOMRA COM XRT 2.0 units can process up to 500 t/h

IM: Are there any regions more willing to apply these solutions than others? Why is this the case?

KB: If you look at our global reference list, you can see that the larger installed base resides in Europe, Africa and the Americas. The Asian markets are a little behind, but this is easily explained by history. As a European company, we focused more on the better known and established markets. In general, the mining market is a very global industry with big players active in all continents.
I do not believe there are regions more willing to apply the technology than others. It is just a matter of supporting all regions in the same way. TOMRA is investing heavily to ensure we have a good global support network, to be there for and with our clients.

IM: Do you expect to see more collaboration with OEMs over the next decade when it comes to implementing ore sorting solutions with process flowsheets? How do you see the input of both TOMRA and OEMs benefitting the wider mining industry?

KB: Collaboration is essential in any industry. We need specialists who are experts in their field, and TOMRA is one of the global leaders in sensor-based sorting. In order to achieve the best results in one field, one must focus. Therefore, big projects can only be undertaken by a group of companies or experts who collaboratively work together. We, as a solution provider, are very dependent on well-engineered and integrated plant designs and believe we have to collaborate and have close relationships with plant builders to ensure the best possible solution for our clients.

BHP backs Kabanga Nickel mine development and refinery plan

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BHP has invested $40 million in Tanzania-focused Kabanga Nickel, in addition to backing Lifezone Limited and its patented hydrometallurgical technology with a $10 million investment.

Kabanga Nickel Limited says its share of the cash will be used to accelerate the development of the Kabanga nickel project in Tanzania, which it claims is the world’s largest development-ready nickel sulphide deposit.

Lifezone, meanwhile, will use the funds to advance the roll-out of its technologies. The owner of the hydrometallurgy technology that will be used to build and operate the planned nickel refinery in Tanzania, Lifezone claims this technology is more cost efficient than smelting, has a significantly lower environmental impact, and will ensure that finished Class 1 battery-grade nickel, copper and cobalt will be produced in Tanzania.

Chris Showalter, Kabanga Nickel CEO, said: “BHP is the ideal partner for Kabanga Nickel, bringing significant advantages and expertise that will enable us to move ahead with the project.

“BHP’s investment reflects the project’s strong ESG credentials and its role in improving environmental performance throughout the nickel value chain. In addition, BHP’s funding support of Lifezone’s hydromet technology – the future of sustainable metals processing – will drive progress towards a greener world. Through development of Kabanga and Lifezone hydromet, Tanzania will have a growing role in the supply of the battery metals needed to move to a global low carbon economy.”

The Kabanga nickel project has had more than $290 million spent on it by previous owners such as Barrick and Glencore between 2005 and 2014, including 587,000 m of drilling. The outcome of this previous investment is an in-situ mineral resource of 58 Mt at 2.62% Ni, containing more than 1.52 Mt of nickel, 190,000 t of copper and 120,000 t of cobalt. The Barrick-Glencore joint venture also outlined a mine plan in a draft feasibility study that looked to recover 49.3 Mt of ore at 2.69% nickel equivalent from the two primary orebodies – North and Tembo. Kabanga is in the process of updating this plan.

While the BHP transaction is for a total consideration of $50 million, with investments in both Kabanga Nickel ($40 million) and Lifezone ($10 million), future investment tranches in Kabanga Nickel have been agreed subject to certain conditions. This includes a second tranche of $50 million and the right for BHP to make a further investment in Kabanga Nickel subject to achieving certain agreed milestones.

The first tranche of $40 million will convert into an 8.9% equity stake in Kabanga Nickel (7.5% see-through interest in Tembo Nickel Corp) once approvals and conditions are met. Once invested and on conversion, the second tranche of $50 million will increase BHP’s equity stake in Kabanga Nickel to 17.8% (15% see-through interest in Tembo), thereby valuing the project at $658 million, post-money. Tembo Nickel is the joint venture owner of the project, owned 84% by Kabanga Nickel and 16% by the Government of Tanzania, set to undertake mining, processing and refining to Class 1 nickel with cobalt and copper co-products near the asset.

The investment into Kabanga Nickel from BHP will support an acceleration in the mine’s development, including an enhanced metallurgical drilling program (which has already started) to enable update of the definitive feasibility study and support the construction plans for the hydromet refinery. These studies are expected to be completed by the end of 2022. Site and infrastructure development is already underway. The investment will also support hiring and training of local Tanzanian talent.

The investment into Lifezone allows for new patent applications as well as R&D work that will further commercialise the Lifezone hydrometallurgical technology. Lifezone currently has patents granted in over 150 countries.

The current project development timeline anticipates first production in 2025. Output will ramp up to target a minimum annual production of 40,000 t of nickel, 6,000 t of copper and 3,000 t of cobalt.

Atalaya Mining approves construction of E-LIX-backed processing plant at Riotinto

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Atalaya Mining has, following a feasibility study, approved the construction of the first phase of an industrial-scale plant using the E-LIX System to produce high value copper and zinc metals from the complex sulphide concentrates sourced from Proyecto Riotinto (pictured) in Spain.

Following its announcement on October 28, 2020, Atalaya concluded the study, which evaluated the technical and economic viability of producing cathodes from complex sulphide concentrates by applying E-LIX, a new, patented electrochemical extraction process developed and owned by Lain Technologies Ltd.

Relative to conventional flotation techniques, the value creation potential of E-LIX offers a unique opportunity for Atalaya, it said. As a result – and as previously disclosed – the company secured certain terms of exclusivity with Lain Tech for the use of E-LIX within the Iberian Pyrite Belt.

The E-LIX plant will dissolve the valuable metals contained within the concentrates. The test work and system design allows for the dissolution of chalcopyrite while avoiding the passivation of particles. After copper or other metals are brought into solution, they can be recovered by conventional precipitation or solvent extraction followed by electrowinning (SX-EW).

Phase I plant capacity has been designed to produce between 3,000-10,000 t of copper or zinc metal per year depending on the ratio of copper to zinc in the concentrate feed.

The estimated capex for Phase I is €12 million ($13.6 million) and the design allows for unlimited capacity expansion through the addition of multiple lines in parallel. Atalaya will start the construction of the plant in the coming weeks and it is expected to be operational in 2022, including commissioning.

The decision to approve and construct the Phase I industrial-sized plant follows over six years of evaluation and de-risking work including continuous tests at the laboratory, a small pilot plant and finally a semi-industrial pilot plant, Atalaya explained.

A semi-industrial E-LIX pilot plant was constructed in late 2019 and has operated during 2020 and 2021, despite the challenges of the COVID-19 outbreak. The results of the pilot tests were included in the feasibility study and successive optimisation work. The long run continuous tests demonstrated the feasibility of leaching complex polymetallic concentrates with global recoveries of over 95% for copper and zinc while producing clean metal precipitates and/or high purity metals.

Atalaya said the use of the E-LIX System has shown the potential to unlock the significant value from the polymetallic sulphides contained within Atalaya’s mineral resources, including:

  • The polymetallic deposits of San Dionisio, San Antonio, Masa Valverde and Majadales, all of which are located in the Iberian Pyrite Belt and within trucking distance of Proyecto Riotinto’s  15 Mt/y processing facility;
  • The significant contained metal within these historical drilled resources from San Dionisio and Masa Valverde contain over 1.1 Mt of copper, 2.4 Mt of zinc, 1.7 Moz of gold, over 110 Moz of silver as well as additional lead resources. These figures are in addition to the over 1 Mt of copper reserve at Proyecto Riotinto’s Cerro Colorado orebody and at Proyecto Touro; and
  • Historical applications of differential flotation within the Iberian Pyrite Belt in Spain and Portugal have typically resulted in recoveries of 60-80% into concentrates for complex copper-zinc polymetallic sulphides, with even lower recoveries historically reported for lead, silver and gold. The use of hydrometallurgical systems, such as E-LIX, has demonstrated that base metal recoveries of over 90% can be achieved.

E-LIX is, Atalaya said, also expected to reduce Atalaya’s carbon footprint. By producing high-purity metals on-site, Atalaya can reduce the transportation costs associated with delivering concentrates to smelters, avoid treatment and refining charges associated with converting concentrates into metal and eliminate penalties associated with deleterious elements often contained within concentrates produced in the Iberian Pyrite Belt and elsewhere. The E-LIX plant is also expected to use the renewable energy that will be produced by Proyecto Riotinto’s planned solar plant.

Alberto Lavandeira, Atalaya CEO, said: “The E-LIX System offers Atalaya a unique opportunity to unlock significant value from its portfolio of deposits that contain complex polymetallic mineralisation. Atalaya has worked together with Lain Technologies for many years in order to test, refine and demonstrate the E-LIX process, providing the company with confidence in its potential. In addition to enhancing recoveries, E-LIX will eliminate penalties associated with deleterious elements and reduce the costs of transportation and energy, thereby improving the company’s carbon footprint.”

Resolution Copper, Stantec leverage hydropanel tech to provide new clean water source for locals

Base metals, Environmental, Mineral project development, Mining services, Water management, , , , , , , , , ,

Native American communities in eastern Arizona, USA, look set to benefit from a new source of clean drinking water through a project sponsored by Resolution Copper and Stantec to deploy innovative renewable “hydropanel” technology, the mine developer says.

Resolution Copper and Stantec are partnering with White Mountain Apache community members to provide 64 hydropanels on the Fort Apache Reservation and supporting hydropanel installation programs in other Native American communities.

White Mountain Apache Tribe District II Councilman, Jerold Altaha, said: “Water is valuable; it’s the life force of humanity. Thanks to this wonderful opportunity with Resolution Copper, our community of Carrizo will have access to safe, clean drinking water. Due to high levels of manganese in the main water wells, our community has had to depend on portable water tanks as a means to obtain drinking/cooking water for years. The hydropanels will now enable us to draw water from the air which will provide up to 10 litres of water or about 20 16 oz bottles a day, at no cost to the family. We are grateful for these opportunities which continue to make a difference in everyday life for our people and community.”

Stantec Water Business Operating Unit Leader, John Take, added: “We are proud to be a part of this effort to provide safe, reliable drinking water to the Native American communities in eastern Arizona. Innovative and renewable methods such as the hydropanel technology are playing an increased role in helping solve these complex problems in a sustainable manner.”

Hydropanels are a one-of-a-kind renewable water technology that uses the solar energy to provide a safe and consistent supply of drinking water by drawing pure, constantly replenished water vapour out of the sky, according to Resolution Copper. The self-contained system converts water molecules in the air into liquid water, which is collected and mineralised in a reservoir inside the panel, creating high-quality drinking water that can be delivered directly to homes, businesses, and community distribution centres.

Resolution Copper Project Director, Andrew Lye, said: “Water is a fundamental resource, and many members of our neighbouring Tribes do not have reliable access to safe drinking water. Projects like the hydropanel deployment will help alleviate some of the burden, and make a difference where it matters most. Resolution Copper continues to look for ways in which we can work in partnership to be part of the solution and support the communities around us.”

So far, Resolution Copper has invested nearly $2.8 million through partnerships and donations to projects with Native American Tribes and other communities in the Copper Corridor in 2021.

The Resolution Copper project is a proposed underground mine 96 km east of Phoenix, Arizona, near the town of Superior. The project is a joint venture owned by Rio Tinto (55%) and BHP (45%).

To date, more than $2 billion has been spent to develop and permit the project, including reclamation of the historic Magma Copper Mine site, sinking a second shaft to mining depth, rehabilitating an existing shaft and deepening to mining depth, extensive drilling and orebody testing, and the federal approval and public engagement process.

Sandvik receives record AutoMine order from Codelco’s El Teniente mine

Automation, Base metals, IoT, Mine operation news, Mining equipment, Mining services, , , , , , , , , , , , ,

Sandvik Mining and Rock Solutions says it has received a major order for the AutoMine® load and haul automation system valued at about SEK 250 million ($28 million) from Chile’s Codelco to be used in the El Teniente mine.

In addition, a connected load and haul equipment order, with an initial value of SEK 150 million, was received, bringing the total value of the orders to SEK 400 million, Sandvik said.

The contract will run from 2022 through 2027 at the Andes Norte block cave.

Since the first AutoMine system was commissioned in El Teniente’s Pipa Norte mine in 2004, Sandvik has supplied several intelligent load and haul equipment fleets as well as AutoMine and OptiMine solutions to Codelco mines.

The new order will be supplied in two phases. During 2022 and 2023, Codelco will receive two Toro™ TH663i trucks and two Sandvik LH514 loaders, as well as an AutoMine Fleet system capable of being scaled to support up to 16 machines and AutoMine production area hardware for future expansions over several years.

The first phase of the order, which also includes support contracts for the equipment and AutoMine system, will initially be used by Codelco Andes Norte in a new block caving area in El Teniente that is expected to commence production between mid-2022 and early 2023.

From 2023 through 2027, Sandvik will deliver six more Toro TH663i trucks, six Sandvik LH514 loaders and an additional AutoMine Fleet system.

Emilio Vega, Business Line Manager for Automation, Sales Area Andean & South Cone at Sandvik Mining and Rock Solutions, said: “Codelco selected Sandvik’s solutions based on our proven technology, capable of fulfilling requirements for safety, reliability and productivity. Furthermore, we have competent staff capable of serving and supporting the organisation’s existing systems. This provides value-added services that enable optimised productivity in order to meet the customer’s production performance.”

AutoMine underground for loading and hauling is an automation system for autonomous and tele-remote operation of a wide range of Sandvik loaders and trucks. The scalable solution can provide tele-remote to fully autonomous operation for a single machine or multiple machines, including full fleet automation with automatic mission and traffic control capability, according to Sandvik.

Patricio Apablaza, Vice President Sales South Cone & Andean at Sandvik Mining and Rock Solutions, added: “Codelco’s objective is to continue implementing automation and digitalisation solutions in its mining operations. We have a great opportunity, as a key supplier, to be part of this change by supporting Codelco with high-end technology and providing key support to its operations to help our customer succeed in this journey.”

The AutoMine Fleet system is a highly advanced automation system for a fleet of Sandvik underground loaders and trucks sharing the same automated production area. It provides advanced traffic control capabilities, as well as a wide range of interfaces for infrastructure integration to allow for complex automation applications in challenging environments.

Pablo Gandara, Project Portfolio Manager, El Teniente Mine, explained: “For Codelco and, in particular, for El Teniente mine, it is a goal to continue being the largest underground mine in the world. This purpose also needs to be accompanied by other attributes that are key today to continue being leaders in the mining business, such as safety, environmental sustainability, and productivity.

“Considering all these elements, we have come to the conclusion that to operate our mines we require companies that have the same values, and that is how we came to define that the Sandvik AutoMine product satisfies all our needs. In addition to show best practice of a real partnership is the cooperation that began many years ago between Codelco and Sandvik in the first automated project for El Teniente, which was the Pipa Norte sector in 2004. From there we have built a relationship between two companies, we understand each other very well, and we trust in the joint capacities that we have developed.”

David Hallett, Vice President, Automation at Sandvik Mining and Rock Solutions, said: “We are excited to continue our journey in automation and digitalisation at Codelco’s El Teniente mine to help increase safety and productivity for their operations. This order will be delivered as a turnkey solution composed of all elements of Sandvik Mining and Rock Solutions’ offering for equipment, digital technologies and aftermarket. Sandvik strives to be the number one productivity partner for our customers and this order and delivery will embody all elements of this.”

Back in February 2021, Sandvik said it would deliver its AutoMine Fleet system to automate a new fleet of Sandvik LHDs running at Codelco’s Pacifico Superior and Pilar Norte GTI operations, part of the El Teniente underground mine.