Tag Archives: lead

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

Base metals, Environmental, Metallurgy, Mine operation news, Mineral processing, Mining services, Sustainable mining, , , , , , , , , , , , , ,

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.”

Wagners to haul McArthur River zinc-lead concentrate for Glencore

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

Following the completion of a competitive tender process, Wagners says it has secured a new haulage services contract with McArthur River Mining Pty Ltd (MRM), a subsidiary of Glencore, for the haulage of zinc and lead concentrate from McArthur River Mine, in Queensland, Australia, to the Bing Bong Loading Facility and the Mount Isa Mines metal processing facility.

Glencore owns and operates combined surface mining, underground mining, processing and smelting operations in Queensland and Northern Territory for the production of zinc, lead and copper concentrate. This includes the mine which is operated by MRM.

Wagners’ scope of works will include the loading of the zinc and lead concentrate at the mine and its haulage to both the Bing Bong Loading Facility and the processing facility in Mount Isa. The haulage services will operate 24 hours a day, seven days a week throughout the term with haulage services planned to commence in December 2021.

Based on forecast haulage requirements, the contribution to the company’s revenue over the contract term is expected to be in the vicinity of A$33 million ($24 million), Wagners said. This will remain subject to the mine’s production and ability to make the required volume of material available to meet the haulage tonnage forecast.

Wagners’ Chief Executive Officer, Cameron Coleman, said: “Wagners has a long-standing relationship with Glencore and is very grateful to be provided with the opportunity to service the McArthur River Mine operations in the delivery of these haulage services, which is a new project for us. This project will provide many employment opportunities throughout both the Northern Territory and Queensland and will require substantial capital investment to increase our haulage fleet, demonstrating Wagners’ commitment to this area of our business and the resources sector.”

Metarock set to leverage competitive contractor advantage

Automation, Base metals, Careers in mining, Coal technology, Communications in mining, IoT, Mining equipment, Mining mergers and acquisitions, Mining services, Mining software, Precious metals, Steel and iron ore, , , , , , , , , , , , , , , ,

Mastermyne’s contract mining growth ambitions became very clear in September when it proposed a buyout of contractor PYBAR Mining Services in a deal valuing PYBAR equity at A$47 million ($35 million).

The deal, which has just completed, sees Mastermyne, up until this point a company focused on the Australian coal sector, expand into the domestic hard-rock space through exposure to PYBAR’s gold, copper, zinc and lead-related revenues. In the process, it has been restructured under Metarock Group Limited.

The transaction is expected to create a leading Australia-based diversified mining services business with material scale, Mastermyne said, adding that the combined group will have a A$1.7 billion-plus order book and an active tender pipeline of A$2.7 billion-plus after completion. PYBAR will continue to operate as an independent business unit within the group with the existing management team.

Tony Caruso, Managing Director of Metarock (pictured), said the company had identified some time ago the need to diversify into “adjacent markets” to ensure its business retained “resilient and sustained earnings”.

“To be clear, we are very supportive of the coal industry, and we will continue to grow our coal business,” he told IM. “What we do know from 30 years of experience of operating in this market is it is very cyclic.”

When coal prices are strong, it is a great market to be a contractor, Caruso explained. Yet, when prices come down, contractor workforces or scope reductions often follow as mine owners look to cut their “flex costs”.

A diversified Metarock would be able to better cope with such a market dip.

“The theory (behind the PYBAR acquisition) is that when coal is down, other commodities will be up,” Caruso said.

In addition to increased commodity diversity, there are also a huge number of synergies that could be realised with the combination of the two companies.

PYBAR offers raiseboring services that can be used in coal, while Mastermyne offers ground support services (through its recently acquired Wilson Mining business) that can be used in the hard-rock space.

Both have registered training organisations that could share industry best practice across sectors, too.

What Mastermyne learned in the coal boom when it developed the “clean skin” training program, using a simulated underground coal mine with a bespoke program to train people for working in an underground coal mine, may have relevance in the hard-rock sector given the recent ‘boom’ perceptions, according to Caruso.

There are also more specific technology synergies that could benefit both hard-rock and soft-rock customers.

PYBAR has embraced automation and digitalisation with, for example, teleremote loading operations at the Dargues gold mine in Western Australia (pictured below, credit: PYBAR) and the use of Digital Terrain’s Simbio data entry and processing solution on its mining fleet.

Mastermyne has been running a similar project where real-time data is “taken off” machinery and, through proprietary software, converted into real-time dashboards for the operators to track performance against operational targets. Mastermyne used such a system with great success at the Narrabri underground operation, owned by Whitehaven Coal.

Caruso said on the latter: “We were looking at building out that software into other areas of our business – we used that in our production machines when we were cutting coal, but we were starting to look at bringing that across to a lot of the other support services we provide to customers as well.”

Should PYBAR come on board, Simbio could end up being used on its coal development machines, according to Caruso.

It works the other way round, too, with Mastermyne’s proximity detection expertise in coal having applications in the hard-rock space.

“Not only are these solutions OEM-agnostic; they are sector-agnostic,” Caruso said. “The same technology is applicable for coal and metalliferous markets.”

The benefits of the business combination do not stop here.

Growth in the coal space has mostly been tied to sustaining capital projects – the overall production levels have remained flat, if slightly increased – whereas, in the hard-rock sector, brownfield and greenfield projects have been the order of the day, catalysed by higher prices and projections of increased demand.

This means the pressure dynamics around skilled labour are slightly different between the two.

Mastermyne has, to this point, benefitted from the ongoing trend of majors exiting their thermal coal businesses to deliver on ambitious ESG targets, with smaller companies taking on these assets and outsourcing work to contractors. Mining contracts at Crinum (Sojitz Blue Pty Ltd) and Cook (QCoal) in Queensland are two examples of the company taking advantage of this trend.

This type of sustaining growth capital expenditure in the coal sector is very different to the greenfield growth witnessed in 2010-2012, Caruso said. “The significant volume increase in greenfield expansion, which drove real pressure on labour, is not there,” he said.

In the hard-rock space, the dynamic is much more reminiscent of that boom a decade ago.

“There are a lot of new projects in Western Australia opening up so there is a lot more pressure on resources because the demand is far outstripping the supply in the hard-rock labour pool,” he said.

While there has not, typically, been a transfer of labour between the coal and hard-rock contracting sectors, if Metarock is able to facilitate such a shift, it could gain a competitive advantage over peers scrabbling for talent that are focused wholly on the hard-rock mining space.

“We have a workforce of 2,000-2,500 people at the moment, and we want to have a fluid workforce that can move across sectors,” Caruso said. “This will enable us to send our best people to projects to make sure we replicate good performance at these operations, regardless of where they are, geographically, or what type of work they are doing.”

Not only could this provide Metarock with the ability to shift employees between sectors, but it could also allow them to offer employees long-term security beyond the current Australian coal demand horizon.

Redpath to take on underground mining work at Aurelia’s Hera operation

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

Redpath Australia has been awarded the underground mining services contract at Aurelia Metals’ Hera gold-lead-zinc mine in New South Wales.

The project will see production activities continue at Hera from January 2022 with a primarily NSW-based workforce.

While Hera produced 4,650 oz of gold in the September quarter, Aurelia is working on a feasibility study at the Hera-Federation Complex (including Hera and the Federation discovery), due in mid-2022, that could see production increase.

Redpath Australia has also been selected as the contractor for the exploration decline at this project.

APA Group to deliver solar power to MMG’s Dugald River mine

Base metals, Environmental, Mine operation news, Mining services, Power supply for mines, , , , , , , , , ,

Stage one of APA Group’s plan to build an 88 MW solar farm in Mount Isa, Queensland, Australia, has got underway with a Final Investment Decision to construct 44 MW of capacity to serve MMG’s Dugald River zinc-lead mine in the state.

The investment of more than A$80 million ($60 million) will see APA Group provide solar power to the mine as part of a 15-year offtake agreement.

APA also entered into a 32-year lease agreement with the Queensland Government to locate the solar farm on a site near APA’s Diamantina Power Station Complex. The first stage of the solar farm is expected to be operational by the March quarter of 2023, while APA says it is in advanced discussions with a number of customers to commit to the development of stage two, reaching 88 MW.

APA CEO and Managing Director, Rob Wheals, said the Mica Creek Solar Farm will deliver lower emissions power underpinned by the reliability of APA’s gas-fired power, while reducing the average cost and emissions of power across Mount Isa.

MMG, meanwhile, said the solar agreement will supply Dugald River with renewable energy to reduce its carbon footprint and provide immediate energy cost savings once operational in early 2023.

“The new agreement further supports MMG’s commitment to supporting the global transition to a low carbon economy with the company’s key products, copper and zinc, playing a critical role in the development of sustainable technologies such as solar panels, wind turbines, electric vehicles and batteries,” it added.

Boliden invests $160 million in leaching plant, underground repository at Rönnskär

Base metals, Environmental, Mineral processing, Precious metals, Sustainable mining, , , , , , , ,

Boliden has opened a new leaching plant and underground repository at its Rönnskär operations in Sweden as it looks to extract additional metal from residual materials at the smelter and store any remaining waste in a sustainable way.

For many years, residual materials from smelting processes containing copper, zinc and lead, among other elements, have been stored temporarily at the Rönnskär site.

These residual materials, together with future residues from production, will from this point pass through the newly built leaching plant where further metal extraction will take place. The remaining material will then be transported straight down to the underground repository, which is located about 350 m below the site.

This will see Rönnskär become the only copper smelter in the world with a long-term, sustainable on-site storage solution, according to Boliden.

Investments in the two facilities have amounted to SEK 1.4 billion ($160 million), Boliden says.

Daniel Peltonen, President Boliden Smelters, says: “Our aim is to extract as much metal as possible from our raw materials while ensuring the best achievable environmental and climate performance. The investments we have now made represent a new chapter in Rönnskär’s history in both of these areas.”

Rönnskär produced 226,000 t of copper, along with 33,000 of zinc clinker, 28,000 t of lead, 506,000 t of sulphuric acid, 524,000 kg of silver and 14,000 kg of gold last year, according to Boliden.

GR Engineering captures A$90 million of EPC contracts from Galena Mining

Base metals, Mineral processing, Mineral project development, Mining services, , , , , , , ,

GR Engineering Services has been given the notice to proceed with the engineering, procurement and construction (EPC) of a 1.2 Mt/y lead sulphide flotation processing plant at Galena Mining Limited’s majority-owned Abra base metals project in Western Australia.

The contract, which follows a conditional agreement from February 2020, comes with a value of A$79.5 million ($59 million) to be realised predominantly in GR Engineering’s 2022 financial year.

In addition, Abra Mining has also awarded GR Engineering an EPC contract to relocate, refurbish and commission the Abra Mining-owned Higginsville paste plant. The value of this contract is a further A$10 million.

Geoff Jones, Managing Director, said: “GR Engineering looks forward to continuing its solid working relationship with the Abra Mining team on the delivery of the project and supporting Abra Mining as it becomes the next Australian base metals producer.”

Mastermyne looks for hard-rock exposure with PYBAR Mining buy

Automation, Base metals, Mining mergers and acquisitions, Mining services, Precious metals, , , , , ,

Mastermyne has accelerated its hard-rock mining strategy with an agreement to acquire PYBAR Mining Services in a cash and share deal that comes with an expected equity purchase price of A$47 million ($35 million).

The acquisition for PYBAR Holdings, owner of PYBAR Mining Services, will see Mastermyne, a metallurgical coal-focused contractor, exposed to PYBAR’s gold, copper, zinc and lead-related revenues, it said.

The deal is expected to create a leading Australia-based diversified mining services business with material scale, it said, adding that the combined group will have a A$1.7 billion-plus order book and an active tender pipeline of A$2.7 billion-plus after completion.

To reflect the changing make up of revenues, Mastermyne is proposing to change its name to Metarock Group Ltd.

Mastermyne MD and CEO, Tony Caruso, said: “The PYBAR acquisition is highly complementary to Mastermyne’s existing underground business and expands the combined group’s addressable markets to support ongoing growth, in addition to increasing the earnings resilience of the group by diversifying our commodity exposure.”

PYBAR Mining Services was established in 1993 and has gone on to become one of Australia’s largest underground mining contractors, serving the likes of Glencore (Black Rock mine), Diversified Minerals (Dargues gold mine), Gold Fields (Hamlet North mine), Evolution Mining (Cowal gold mine), OZ Minerals (Carrapateena) and more.

It has a large fleet of equipment, which includes Sandvik DD421 and DD421i series drills, a fleet of Cat R1300, R1700, R2900 and Sandvik LH621i LHDs, Cat AD45V-AD60 sized trucks and several Sandvik TH663s haul trucks. It provides services such as mine development, raiseboring, mine production, shotcreting, cable bolting and production drilling.

Mastermyne says PYBAR will continue to operate as an independent business unit within the group with the existing management team should the deal go through.

Subject to Mastermyne shareholder approval and the satisfaction or waiver of other conditions associated with the transaction, Mastermyne anticipates the deal completing by the end of the year.

PYBAR sets records at Glencore’s Black Rock mine with Sandvik DL432i longhole drill

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

The introduction of PYBAR’s new Sandvik DL432i longhole drill in October 2020 has led to month-on-month improvements in drilling productivity at the Black Rock copper-lead-zinc mine, in Queensland, Australia.

Versatile and compact, the Sandvik DL432i is a fully mechanised electro-hydraulic top hammer longhole drill, designed for large-scale mining. The Sandvik iSOLO drilling control system allows the client (Glencore in this case) to provide electronic drill plans on a USB, which is plugged straight into the drill. The operator then lines the drill up on the survey markings and selects the required drill design, with the remainder of the drilling taken care of by the iSOLO software.

Since arriving on site, a specialised pump has been installed on the DL432i, allowing AMC (a subsidiary of IMDEX) to add a Bore Hole Stabiliser™ to the water circuit while drilling to improve hole integrity in the soft ground conditions. This technology, combined with Sandvik’s iSOLO drilling control software, has been key to PYBAR’s production success at Black Rock to date, the contractor said.

“The ground conditions at Black Rock have put Sandvik’s iSOLO drilling control system to the test, and the technology has proven itself with flying colours,” PYBAR said. “After several months of on-site refinement of the automated drilling system, the drill can now operate with minimal operator input.”

This has led to month-on-month increases in production drilling rates with a record month in March, closely matched in April, according to PYBAR. This, in turn, has meant a significant increase in available production fronts resulting in increased tonnes and improved overall project performance.

Trials of automated drilling for complete firing patterns will begin shortly at Black Rock to enable drilling to take place during firing and shift change, as well as free up the operator to assist with other tasks around the mine, PYBAR said.

The transition to further automation has the potential to significantly maximise both productive drilling time and overall performance for the project, it added.

Trevali to test out FLSmidth’s Rapid Oxidative Leach tech on Caribou material

Base metals, Metallurgy, Mine operation news, Mineral processing, Mining services, Precious metals, Sustainable mining, , , , , , , , , , , , ,

Trevali Mining has announced the commencement of a pilot plant testing program using Caribou run-of-mine and milled material at FLSmidth’s Rapid Oxidative Leach (ROL) process testing facility in Salt Lake City, Utah.

The program expands on previous laboratory test work and is aimed at demonstrating the potential to recover zinc, lead, copper, gold and silver as a precipitate or metal and additional zinc and lead from Caribou ore and mill tailings.

The leach test program is targeting an improvement to zinc, lead, copper, gold and silver metal recoveries, the potential to produce a precipitate or metal on site replacing the current ore concentrate that is produced at Caribou – which, if implemented, would lead to savings on transport costs and offsite treatment costs – and the opportunity to process historic mill tailings, which include gold and copper metals, in addition to run of mine ore. The latter would increase revenues and reduce closure liabilities, Trevali said.

Trevali says the use of FLSmidth’s ROL technology also provides the potential to reduce Trevali’s carbon footprint at Caribou and extend Caribou’s mine life and treat lower-grade deposits in the Bathurst camp of Canada.

FLSmidth says ROL leaches 97-99% of copper directly on-site in six to eight hours, from concentrates as low as 5% Cu. In gold, ROL has the potential to unlock the value of undeveloped refractory gold deposits with less than 3 g/t gold head grade, it says.

Unlike other refractory processing techniques, the ROL process uses the application of mechanical energy coupled with oxidation under atmospheric conditions. The process relies on stirred media reactors to accelerate the oxidation of sulphide minerals. This eliminates the need for ultrafine grinding, high temperatures and high pressure which makes it energy saving and very cost-effective, according to the mining OEM.

Trevali said a successful pilot plant test program using ROL may allow Trevali to replace the existing flotation circuit at Caribou with atmospheric leach vessels and potentially an SX/EW train, introducing the possibility of producing base and precious metals on-site and thereby save transport costs and offsite treatment costs.

Conceptual objectives of the program include:

  • Recovery of metals/minerals that are not recoverable using the current technology at Caribou (precious metals and magnetite); and
  • Improved payables/selectivity of the traditional flotation process using new and emerging technologies.

Ricus Grimbeek, President and Chief Executive Officer of Trevali, said: “FLSmidth’s ROL metallurgical technology has the potential to transform the Caribou mine and the wider Bathurst Mining Camp.

“This next phase of the testing program is an essential step in evaluating the suitability and economic viability of a processing solution with the potential to enhance the value of the in-situ material and tailings at Caribou as well as the surrounding deposits in the Bathurst region. The positive results to date support further study and analysis given the potential implications for the Bathurst Mining Camp in general and Trevali in particular.”

Beyond quantifying the ability to recover additional metal values, the objective for the pilot plant test program is to determine the various kinetic factors, mass and energy balance and engineering data to support future engineering on a preliminary economic assessment for potential processing of the Trevali mill feed and mill tailings and produce metal on site.

Continuous pilot plant trials commenced in June 2021 (Phase 1) to tune the pilot plant and provide material for precious metal leach tests in late July, followed by a test program at the Caribou Mine site that is planned for September 2021 (Phase 2). Leach data and results are expected to verify that batch testing results can be achieved in a continuous operation.