Tag Archives: copper

Adelaide Brighton cements contract extension with OZ Minerals at Prominent Hill

Base metals, Mine operation news, Mining consumables, Mining services, Precious metals, , , , , , , ,

ASX-listed Adelaide Brighton has announced the signing of a contract with OZ Minerals for the continuation of cement supply to the Prominent Hill copper-gold operation in South Australia.

The contract period is for a five-year term with options to extend, Adelaide Brighton said.

In addition to the supply of cement, Adelaide Brighton will also supply aggregate and sand from the company’s Sellicks Hill Quarry and Price sand operation as well as auxiliary logistics services, it said.

Adelaide Brighton CEO, Nick Miller, said: “The contract, which now also includes aggregate and sand supply for the Prominent Hill operation, reflects the company’s competitive offering of a broad range of products in the South Australian market.”

Prominent Hill is a copper-gold mining operation in northern South Australia, which is made up of the Malu open-pit mine – which concluded operations last year – the Ankata and Malu underground deposits and a conventional crushing, grinding and flotation processing plant.

Pleuger pumped up with Collahuasi copper mine contract win

Base metals, Comminution of minerals, Mine operation news, Mineral processing, Mining equipment, Mining services, Water management, , , , ,

Germany’s Pleuger Industries has installed six robust high-performance pumps at the Anglo American- and Glencore-owned Collahuasi copper mine in Chile, helping the operation continue to produce more than 5,000 tonnes of fine copper every year.

At Collahuasi, two open-pit mines, Rosario and Ujina, provide the necessary copper ores, which are smelted on site into copper concentrate and cathodes. Pleuger’s 10 in pumps come in during the flotation process at Collahuasi, where they help dewater the copper sludge for copper concentrate extraction.

The acceptance of the six pumps, for which the technical management of the mine together with the pump distributor Wellford had travelled from Chile to Hamburg, took a week. “This is not unusual when one considers the significance of the new submersible motor pumps for the processing of copper sulphide,” Pleuger said. “If the pumps fail, the production process comes to a standstill until the pumps are repaired. Reliability, therefore, has top priority.

“The decision in favour of a pump manufacturer is, therefore, less a question of one-time costs than of confidence in the technical know-how of the engineers.”

Wellford, from Chile, Collahuasi’s pump supplier, brought Pleuger into play because the German pump manufacturer has decades of experience in designing pump units for the special requirements of the mining sector, the Germany-based company said. “Pleuger’s engineers have acquired their expertise in various customising projects around the globe, which the Hamburg-based company continuously uses in the construction of its engines.”

Process pumps like the ones used at Collahuasi are placed under extreme operating conditions, Pleuger said.

“Copper… quickly oxidises the materials from which pumps are usually made. In order to counteract this process, the engineers at Pleuger Industries rely on a corrosion protection concept specially adapted to the customer when designing the pumps,” the company said.

“In addition, the new pump systems must be energy-efficient, because Collahuasi’s copper production follows an energy management system based on international standards.”

Belzona reinforces crusher foundations at Brazil copper mine

Base metals, Equipment maintenance, Mineral processing, Mining equipment, Mining maintenance, Mining services, , , , , , , , ,

Belzona has used its own concrete repair and rebuild composite to keep a primary crusher operational at a copper mine in Brazil.

A common cause of wear in the mining industry can be vibration. This can cause eventual fatigue, resulting in cracks and a loss of material in operational equipment. It can also lead to premature failures in areas such as concrete foundations and their anchoring systems.

“Generally speaking, concrete can be considered too brittle and weak to absorb such constant impact and vibration transferred from the equipment,” Belzona said. “Once the concrete has failed, anchor bolts in the foundations can loosen, further aggravating the effects of the vibration on the foundation.”

A copper mine in Marabá, Brazil, found this to be the case with its primary crusher, according to the company, with the base of the primary crusher needing to be rebuilt due to weakening caused by vibration. The 3,000 t/h primary crusher weighs 336 t, is 9.5 m high and 5.6 m wide, contributing further to the amount of stress being put on the foundations, Belzona said.

“Being one of the biggest copper crushers in South America, and with copper being traded at around $6,000/t, every hour of shutdown can result in a loss of almost $20 million,” the company said.

A solution was required that could rebuild the foundation and bases of the primary crusher, while being able to withstand high dynamic and impact loads without shattering and breaking, according to Belzona. “Excellent mechanical properties and a fast curing time were also critical in ensuring the primary crusher would return back to service in as little time as possible.”

The solution used was Belzona 4111 (Magma Quartz), a high-performance concrete repair and rebuild composite.

Using an impact hammer drill, the first two layers of concrete were removed to reach the steel reinforcement structure.

“Particularly with concrete repairs, surface preparation is critical in its success,” Belzona said. ”The substrate needs to be free from contamination, free from excess moisture and any loose material needs to be removed.”

The area was cleaned and degreased with solvent and compressed air was used to remove the entire repair area of loose debris and dust. A conditioner was then applied to ensure an optimum bond between the substrate and repair materials.

The perimeter of the repair area was initially built up, later acting as a mould for a slurry mix of Belzona 4111. The material was able to level evenly to recreate a foundation at the base of the primary crusher, according to Belzona.

“The implemented solution offered resistance to high vibrations and dynamic loads due to its high mechanical strength. The system adhered to both metal and old concrete allowing for a homogeneous load distribution, without weak spots during the anchoring/grouting procedure and service,” the company said.

The assembly of the machine to the structure commenced in as little as four to six hours after application, according to Belzona, with a full return to service possible in some 16 hours.

“The fast turnaround time allowed the copper mine to continue its processes without a majorly disruptive or costly downtime,” the company concluded.

Specialising in erosion, corrosion and chemical protection, Belzona calls itself a world leader in the design and manufacture of repair composite materials and protective coatings for machinery, equipment, buildings and structures.

Heron concentrates on 1.5 Mt/y production goal at Woodlawn zinc-copper mine

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Heron Resources says it has successfully commenced processing activities at its Woodlawn zinc-copper mine in New South Wales, Australia.

Reclaimed tailings from hydraulic mining operations are now being processed in the new flotation treatment facility; a significant milestone that marks the start of full production activities, the company said.

Attention has now turned to the ramp-up program with a focus on increasing throughput to nameplate capacity of 1.5 Mt/y, achieving design recoveries and meeting product quality specifications for the three base metal concentrates to be produced at Woodlawn.

In addition, preparation for the first processing campaign of high-grade underground ore is well advanced and will proceed following the current ramp-up program, Heron said.

“Underground mining continues to perform well, with production in the last three months exceeding plans, and development ore from the G2 Lens stockpiled at the crushing circuit in readiness for processing,” the company said.

Based on the current ore reserves mine plan, the project is expected to produce three concentrates at an average annualised gross production rate at steady-state of 40,000 t zinc, 10,000 t copper, 12,000 t lead, 900,000 oz silver and 4,000 oz gold over an initial mine life of 9.3 years. The company says there is significant potential for mine life extensions through the conversion of high-grade underground resources and further exploration success.

Heron’s Managing Director and CEO, Wayne Taylor, said: “We are excited to have now achieved this significant milestone in the transition from explorer to producer with the processing of the first reclaimed tailing through the Woodlawn plant. Commencing operations is timely, and we look forward to taking advantage of continuing favourable conditions in base metals markets as we ramp-up our operations.”

The feasibility study for the “starter case” at Woodlawn contemplated campaign treatment processing of 1-1.5 Mt/y from two separate production sources – underground and tailings.

The company kicked off commissioning at Woodlawn back in December.

 

RCT brings automation to MATSA underground operations in Spain

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RCT says it has finalised a major automation project at MATSA’s Aguas Teñidas and Magdalena mines in the Huelva province of Spain.

The project involved installing ControlMaster® Guidance Automation on four CAT R2900G underground LHDs and one Automation Centre Surface Control Station at MATSA’s Aguas Teñidas copper-lead-zinc mine.

MATSA is a jointly-owned company by Mubadala Investment Co and Trafigura. It owns and operates three mines in the Huelva, including Aguas Teñidas, Magdalena and Sotiel, on top of a 4.4 Mt/y copper and polymetallic processing plant.

RCT’s automation centre at Aguas Teñidas is fitted out with RCT’s Multiple Machine Control feature enabling a single operator to remotely control multiple machines at the same time via the mine’s digital communications network.

RCT also commissioned two Sandvik LH621 underground LHDs with ControlMaster Guidance Automation at the nearby Magdalena copper mine. These Sandvik LHDs can operate on a digital network via RCT’s Area Access Cabinets which act as an extension of the automation centre and interfaces between the work areas and the machines.

This instalment builds on a previous project to mount ControlMaster Teleremote and Guidance Automation solutions on three of the site’s CAT R2900G LHDs, which operated on an analogue network via two surface control stations, according to RCT.

Guidance Automation allows machines to tram between two predetermined points on a mine site with the push of a button by operators who also receive real-time information including machine speed, rpm, direction, pitch and roll, RCT said.

“The automation centre consists of an ergonomically designed operators chair facing up from screens, which feed real-time information from sensors and machine-mounted cameras to the operator,” the company added. Teleremote, meanwhile, enables the operator to remotely manage the machine from a control station in real time.

A MATSA spokesperson said: “This system not only allows us to operate in hazardous conditions safely from the surface, but also increases productivity by permitting us to operate during shift change and smoke clearing. We also have the capability to simultaneously operate more than one piece of equipment with the same teleremote operator.”

RCT Account Manager, Shane Smith, said the Guidance Automation products would provide solid benefits for MATSA. “ControlMaster Guidance Automation has a proven track record of improving operator safety in a traditionally hazardous working environment by removing them from the mine face,” he said.

“The faster tramming speeds will also help to boost site productivity on site and limit unplanned machine downtime due to repairs from machinery accidents while the new automation centre will reduce operator fatigue due to improved comfort and ease-of-access on the mine’s surface.”

Canada Cobalt Works moves to protect Re-2OX process following SGS testing

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Canada Cobalt Works says it has made important breakthroughs in its proprietary and environmentally green Re-2OX process for the recovery of cobalt, precious metals and base metals, and will look to submit a patent application to protect the technology.

New testing using SGS Lakefield in Peterborough, Ontario, Canada, has highlighted further optimisation of Re-2OX can allow the recovery of silver and copper for the first time, while also increasing the recovery rates for cobalt and nickel.

“In refining the Re-2OX process through a one-step leach extraction, overseen by Canada Cobalt adviser Dr Ron Molnar, SGS has recovered >99% cobalt, >99% silver, 99% nickel and 99% copper while removing 99% of arsenic from a composite of gravity concentrates,” the company said.

The gravity concentrates tested at SGS were from the historic Castle mine, in Ontario, classified as waste material and grading 10.2% Co, 11,000 g/t Ag, 0.26% Cu, 1.49% Ni and 45.1% arsenic.

Re-2OX skips the normal smelting process to create battery-grade cobalt sulphate, according to Canada Cobalt Works. The company said nickel-manganese-cobalt (NMC) battery-grade formulations are also in the pipeline.

“In addition, the ability of Re-2OX to achieve exceptionally high recovery rates for both cobalt and silver, plus nickel and copper, while also removing 99% of arsenic, expands the potential of the Castle mine given Phase 1 underground results released February 19, 2019, and a second phase starting soon,” the company said. “Furthermore, Re-2OX is a value-driver for the company’s planned tailings programs at Castle and elsewhere in the district, and will also be used by Canada Cobalt to immediately build a new model of ‘streaming’ opportunities for the company with respect to other battery metal projects while protecting the process.”

Given the current optimisation level of Re-2OX, and the growing importance of this hydrometallurgical process to Canada Cobalt and its shareholders, the company has now initiated the process of submitting a patent application for this proprietary metal extraction method.

Frank J Basa, Canada Cobalt President and CEO, said: “The fact that SGS has demonstrated that Re-2OX can very efficiently recover a broad set of metals from arsenic-rich material, ranging from low grade to high grade, further de-risks the Castle mine project and expands opportunities to build shareholder value. Further Re-2OX optimisation will target the recovery of gold.”

Metso books comminution equipment order from Codelco at El Teniente

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Metso says it has been awarded a contract to supply crushing and material handling equipment for the first stage of Codelco’s El Teniente copper mine expansion project in central Chile.

The order was booked in Metso’s March quarter 2019 orders and will see the company deliver, among other elements, primary gyratory crushing equipment with apron feeders and conveyer belts as well as related services.

El Teniente is the world’s largest underground copper mine as well as the largest operation of the Chile state-owned copper mining company Codelco. The expansion project, called El Teniente New Mine Level, is expected to add 50 years to the life of the mine, with the first stage expected to start up in 2023.

Once completed, the full expansion will allow El Teniente to maintain its current output of around 450,000 t/y of refined copper, Metso said.

Victor Tapia, President, Mining Equipment Business Area at Metso, said: “We are proud of being part of this landmark project in which we will utilise our process and product knowledge gathered over 150 years of experience.

“In a landscape where challenges are continuously evolving, we are fully committed to keep developing solutions that help our customers to secure sustainable productivity and long-term success.”

Most of the equipment deliveries to El Teniente are scheduled for 2021, while services will be carried out between 2022 and 2023, according to Metso.

“Metso in Chile and Codelco have a long history of cooperation. This order confirms once again our expertise and our position as a leading equipment supplier for underground mining and as a key equipment a supplier for Codelco,” Tapia said.

“Going forward, we’ll focus on providing El Teniente with a high level of performance, reliability and best-in-class support service throughout the project life cycle,” he added.

GIW pumped with Anglo American Quellaveco copper project order

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GIW Industries says it is to deliver four MDX 600 cyclone feed pumps to Anglo American’s Quellaveco copper project in Peru.

GIW, a subsidiary of KSB, won the order based on the reputation of its centrifugal slurry pumps and the firm’s commitment to customer support, it said. “Decades of experience in slurry transport means GIW is in the perfect position to partner with Quellaveco.”

Anglo American plans on first copper production coming out of Quellaveco in 2022, which, with a reserve of 1,300 Mt at 0.58% Cu, is expected to have a 30-year mine life at an average production capacity of 127,500 t/d. This could see the mine produce around 300,000 t/y of copper.

The Quellaveco project marks a significant milestone for GIW as it continues to invest in the region, the company said. In 2018, it expanded its service capabilities in South America to meet the needs of current and future customers.

Local GIW technicians will be on-site to assist Quellaveco for the installation, commissioning, and start-up of the four MDX 600 cyclone feed pumps, according to the company.

“The MDX pump was selected for the Quellaveco project because of its success in copper and gold applications around the world,” GIW said. “The MDX product line has undergone extensive development; in fact, the latest technology features a remotely adjusted mechanical suction liner.

“The pumps for Quellaveco are specially designed to operate in the most extreme duty conditions. Critical wear parts are made of GIW’s proprietary white-iron alloy, Endurasite. This material extends wear life and optimises pump performance.

“These features combined have a direct impact on Quellaveco’s total cost of ownership – proving the MDX is the most reliable pump on the market.”

Hernan Palavecino, South America Region Manager for GIW, said economic stability and continuous growth in the country have facilitated the investment of new mining projects in Peru, with the country, over recent years, becoming a key player in the global market.

“GIW recognises the importance of the Quellaveco mine to the region,” he said. “The greenfield project solidifies Peru’s position as a substantial player in the South American and global mining markets. The award is a result of GIW’s drive for continuous improvements in slurry technologies. We are committed to offering high-quality service while building a long-term partnership with Quellaveco.”

Sandvik to automate and digitalise Codelco’s Chuquicamata underground mine

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Sandvik says it will automate and digitalise Codelco’s underground copper operation at Chuquicamata, in Chile, creating one of the “most efficient and advanced underground mines in the world”.

Sandvik’s AutoMine® and OptiMine® solutions will allow Codelco to operate its new fleet of Sandvik LH621 loaders in fully autonomous mode, the mining equipment maker said.

Codelco is converting Chuquicamata from an open pit to underground mine as part of a 10-year strategic project to prolong its existing operations. It is due to start up in 2019.

Sandvik said: “The open system integrates manual operations and autonomous equipment into one powerful solution with AutoMine and OptiMine, enabling full transparency and real-time control over the parallel production and mine development activities.”

Andrés Avendaño, Operations Manager, Chuquicamata Underground, said: “Using our mines to full effect is part of our focus on sustainability and a key driver for our business. Automation and optimisation are critical to getting the most from our mines and keeping our people safe while we do it.”

Sandvik and Codelco started their automation journeys together with the first-ever AutoMine loading system installation at Codelco’s El Teniente copper mine, in 2004, Sandvik said.

Riku Pulli, Vice President, Automation, Sandvik Mining and Rock Technology, said: “Codelco has been an important partner for us from the beginning. It’s fantastic to continue the partnership as our visions are well aligned. We look forward to working with Codelco to deliver even smarter, safer, more productive mining through digitalisation.”

Codelco is the number one copper producer in the world and is owned by the Chile government. It controls about 19% of the world’s copper reserves and is also the second producer of molybdenum worldwide, with 24,000 t produced in 2018.

Sandvik’s digital solutions, including AutoMine, OptiMine and “My Sandvik” are working in hundreds of mines around the world.

The AutoMine product family allows customers to scale up automation at their own pace, covering all aspects of automation, from remote and autonomous operation of a single piece of equipment to multi-machine control and full-fleet automation using automatic mission and traffic control capabilities. AutoMine installations have logged more than 2.5 million hours with zero lost time injuries, according to the company.

OptiMine, meanwhile, is a suite of digital tools for analysing and optimising mining production and processes. It integrates all relevant data into one source, delivering both real-time and predictive insights to improve operations, Sandvik said. OptiMine is open and scalable, giving customers the flexibility to build at their own speed and incorporate other equipment, systems and networks.

ALTA retains metallurgical innovation focus for 2019 event

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The organisers of ALTA are gearing up to welcome the international metallurgical community to Perth, Western Australia, with the annual conference now just a month away.

ALTA has developed a reputation as a leading technical metallurgical-oriented event, attracting senior industry representatives from around the globe. The conference had a record attendance last year and is hoping to hit new heights in 2019.

ALTA 2019, to be held on May 18-25 at the Pan Pacific Perth, promises to continue the tradition of delivering high-quality technical content for professionals from the metallurgical and related sectors, the organisers said.

Conference Founder and Chair, Metallurgical Consultant Alan Taylor, said: “For the past 23 years, this event has provided a dynamic forum for sharing ideas, innovations, technologies and projects. Both ALTA and the industry have come a long way since our first conference in 1995, but our focus on the importance of metallurgical innovation remains the same.”

The emphasis of the program is practical rather than academic, and the themes running through the conference are the various aspects of technology and project development. “Each session has been carefully crafted to provide the best value for delegates and includes an insightful and authoritative keynote address,” the organisers said.

Taylor said: “Over many years, the conference has evolved to meet the demands of the industry. For example, in recent years, the program has been expanded to include the current hot topics of lithium processing, and in-situ recovery (ISR) and to reflect the rapidly developing field of battery metals.”

The event now incorporates separate dedicated sessions for nickel-cobalt-copper, uranium-rare earths, gold-precious metals, ISR and lithium processing.

The organisers said: “Panel discussions and Q&A are a major highlight of ALTA events, providing a unique opportunity for knowledge sharing, discussion and debate with highly-experienced professionals. Following the conference, detailed notes are published for the benefit of the wider industry and are provided via the ALTA Free Library.”

The signature nickel-cobalt-copper combined sessions are spread over three days, encompassing segments on battery metals, laterite processing, leaching process development and other key topics. The highlight of the sessions is the Pressure Acid Leaching (PAL) Forum and Panel Q&A, which acknowledges the 20th anniversary of the commissioning of the landmark Bulong, Cawse, and Murrin Murrin nickel-cobalt PAL projects, according to the organisers.

The uranium-REE sessions, organised in co-operation with the International Atomic Energy Agency (Austria), for the fifth year, are held on May 23. They feature a Developments in IX Forum and Panel Q&A.

ALTA has partnered with Curtin Gold Technology Group (Perth) for the Gold-PM sessions, also on May 23, with The Forum and Panel Q&A focussed on fit-for purpose leaching systems, ALTA’s organisers said.

On the final day of the conference, the ISR sessions will run in parallel with the lithium processing sessions, each offering its own panel discussion, “providing a rare opportunity for open discussion and debate”.

The ISR sessions are organised in partnership with CSIRO (Perth), which will lead the Forum and Panel discussion on Enhancing ISR Permeability. The Novel Lithium Processes Forum and Panel Q&A is already attracting international interest, according to organisers.

By popular demand, this year’s ALTA will also introduce additional flexibility for attendees by including single-day and corporate shared registrations options, the organisers said, on top of a short course program. The latter three practically-oriented short courses are presented by Alan Taylor, who draws from his extensive first-hand experience gained in 40-plus years with major engineering firms and as an independent consultant.

“The courses, a valuable introduction for newcomers and a useful refresher for old hands, typically attract a highly-international audience,” the organisers said, adding that the 2019 courses cover nickel-cobalt laterites, copper SX/EW and heap leaching of copper, gold, uranium and nickel.

The organisers said this year’s exhibition area has been expanded to meet increased demand, with the floor boasting Australia and international exhibitors.