Tag Archives: Stuart McDonald

Taseko Mines using innovation to increase production and efficiencies

The Taseko Mines story is indicative of the current environment miners find themselves in – maximise productivity to grow margins at existing operations or invest in innovative new methods of extracting critical metals that come with a reduced footprint.

The Vancouver-based company is pursuing both options at the two main assets on its books – the Gibraltar copper mine in British Columbia, Canada, and its Florence Copper project in Arizona, USA.

Gibraltar, owned 75% by Taseko, initially started up in 1972 as a 36,000 t/d operation. It was shut down in 1998 due to low copper prices before Taseko restarted it in 2004. In the years since, the company has invested over $800 million in the mine, increasing the throughput rate to 85,000 tons per day (77,111 t/d), where it’s been operating at since 2014.

The asset now sits as the second largest open-pit copper mine in Canada – with life of mine average annual production of 130 MIb (59,000 t) of copper and 2.5 MIb of molybdenum.

Stuart McDonald, President and CEO of the company, says the company continues to work on the trade-off of upping throughput – potentially past the nameplate capacity – and improving metallurgical recoveries at the operation.

This became apparent in the latest quarterly results, when Taseko reported an average daily throughput of 89,400 tons/d over the three-month period alongside “higher than normal” mining dilution.

The company believes Gibraltar can improve on both counts – mill throughput and mining dilution.

“We were optimistic coming into the new pit (Gibraltar Pit) that, based on the historical data, we could go above 85,000 tons/d as we got settled in and mined the softer ore,” McDonald told IM. “We still believe there are opportunities to go beyond that level, but, at some point, it becomes an optimisation and trade-off between throughput and recoveries.

“In our business, we’re not interested in maximising mill throughput; we’re interested in maximising copper production.”

On the dilution front, McDonald believes the problem will lessen as the mining moves to deeper benches in the Gibraltar Pit.

“As we go deeper, the ore continuity improves, so we hope the dilution effect will continue to improve too,” he said.

“The dilution rate is still not quite where we want it to be, so it’s a matter of looking at our operating practices carefully and following through a grade reconciliation process from our geological model through to assays from our blast holes, assays into the shovel bucket and all the way through to the mill.”

‘Assays into the shovel bucket’?

McDonald explained: “We do use ShovelSense® technology on two of our shovels, so that helps us assess the grade of the material in the shovel bucket.”

To this point, the company has leveraged most value from this XRF-based technology, developed by MineSense, when deployed on shovels situated in the boundaries between ore and waste. This offers the potential to reclassify material deemed to be ‘waste’ in the block model as ‘ore’ and vice versa, improving the grade of the material going to the mill and reducing processing of waste.

ShovelSense has been successful in carrying out this process with accuracy at other copper mines in British Columbia, including Teck Resources’ Highland Valley Copper operations and Copper Mountain Mining’s namesake operation.

McDonald concluded on this grade reconciliation process: “We just have to make sure we are tracing the material through all of those steps and not losing anything along the way. Gibraltar is a big earthmoving operation, so we must continue to keep the material flowing as well as look at the head grade.”

A different type of recovery

In Arizona at Florence Copper, Taseko has a different proposition on its hands.

Florence is a project that, when fully ramped up, could produce 40,000 t of high-quality copper cathode annually for the US domestic market.

It will do this by using a metal extraction and recovery method rarely seen in the copper space – in-situ recovery (ISR).

The planned ISR facility consists of an array of injection and recovery wells that will be used to inject a weak acid solution (raffinate – 99.5% water, 0.5% acid) into copper oxide ore and recover the copper-laden solution (pregnant leach solution) for processing into pure copper cathode sheets. The mine design is based on the use of five spot well patterns, with each pattern consisting of four extraction wells in a 100 ft (30.5 m) grid plus a central injection well. This mine outline and associated infrastructure comes with a modest capital expenditure figure of $230 million.

The company has been testing the ISR technology at Florence to ensure the recovery process works and the integrity of the wells remains intact.

Since acquiring Florence Copper in November 2014, Taseko has advanced the project through the permitting, construction and operating phase of the Phase 1 Production Test Facility (PTF). The PTF, a $25 million test facility, consists of 24 wells and the SX/EW plant. It commenced operations in December 2018.

Over the course of 18 months, Taseko evaluated the operational data, confirmed project economics and demonstrated the ability to produce high-quality copper cathode with stringent environmental guidelines at the PTF, the company says.

McDonald reflected: “We produced over 1 MIb [of copper] over this timeframe and then switched over from a copper production cycle into testing our ability to rinse the orebody and restore the mining area back to the permitted conditions.

“We’re proving our ability to do the mining and the reclamation, which we think is a critical de-risking step for the project.”

Over an 18-month period, Taseko produced 1 MIb from the ISR test facility at Florence

Taseko says Florence Copper is expected to have the lowest energy and greenhouse gas-intensity (GHG) of any copper producer in North America, with McDonald saying the operation’s carbon footprint will mostly be tied to the electricity consumption required.

“Our base case is to use electricity from the Arizona grid, which has a combination of renewables, nuclear and gas-fired power plants,” he said. “In the longer-term, there are opportunities at Florence to switch to completely 100% renewable sources, with the most likely candidate being solar power.

“At that point, with renewable energy powering our plant, we could be producing a copper product with close to zero carbon associated with it.”

Gibraltar has also been labelled as a “low carbon intensity operation” by Skarn Associates who, in a 2020 report, said the operation ranked in the lowest quartile compared with other copper mines throughout the world when it comes to Scope 1 and 2 emissions.

When it comes to the question of when Florence could start producing, Taseko is able to reflect on recent successful permitting activities.

In December 2020, the company received the Aquifer Protection Permit from the Arizona Department of Environmental Quality, with the only other permit required prior to construction being the Underground Injection Control (UIC) permit from the US Environmental Protection Agency (EPA).

On September 29, the EPA concluded its public comment period on the draft UIC it issued following a virtual public hearing that, according to Taseko, demonstrated strong support for the Florence Copper project among local residents, business organisations, community leaders and state-wide organisations. Taseko says it has reviewed all the submitted comments and is confident they will be fully addressed by the EPA during its review, prior to issuing the final UIC permit.

Future improvements

In tandem with its focus on permitting and construction at Florence, and upping performance at Gibraltar, the company has longer-term aims for its operations.

For instance, the inclusion of more renewables to get Florence’s copper production to carbon-neutral status could allow the company to benefit from an expected uptick in demand for a product with such credentials. If the demand side requirements for copper continue to evolve in the expected manner, it is easy to see Taseko receiving a premium for its low- or no-carbon product over the 20-year mine life.

At Gibraltar, it is also pursuing a copper cathode strategy that could lead to the re-start of its SX-EW plant. In the past, this facility processed leachate from oxide waste dumps at the operation.

“As we get into 2024, we see some additional oxide ore coming out of the Connector Pit, which gives us the opportunity to restart that leach operation and have some additional pounds coming out of the mine,” McDonald said.

Alongside this, the company is thinking about leaching other ore types at Gibraltar.

“There are new technologies coming to the market in terms of providing mines with the opportunity to leach sulphides as well as oxides,” McDonald said. “We’re in the early stages of that work, but we have lots of waste rock at the property and, if there is a potential revenue stream for it, we will look at leveraging that.”

Metso Outotec VSFX solvent extraction tech set for Taseko’s Florence Copper Project

Metso Outotec has signed an agreement with Florence Copper Inc, a subsidiary of Taseko Mines Ltd, to supply copper solvent extraction and electrowinning technology for a plant to be built in Arizona, USA.

The order, exceeding €20 million ($24 million), has been booked in the Metals’ segment September quarter orders received.

The Metso Outotec delivery includes the modular VSF®X solvent extraction plant and the main process equipment for the electrowinning plant.

“We are very excited to have purchased the key SX/EW process equipment from Metso Outotec, a world leader in mineral processing and hydrometallurgical technologies,” Stuart McDonald, President and CEO of Taseko Mines, says. “The VSFX technology is ideally suited for our Florence Copper Project, which is set to become one of the most energy-efficient and low-carbon copper producers in the world. The modular nature of the equipment will reduce construction time and allow Florence to commence copper production quicker than with other technologies available.”

Back in February, Taseko, having just completed a $400 million bond refinancing and fundraising program, said it was moving forward with developing a commercial operation at its Florence in-situ recovery project.

Jari Ålgars, President of the Metals business area at Metso Outotec, says: “We are looking forward to working with Taseko Mines on the Florence Copper Project. The energy-efficient VSFX solvent extraction plant, which is part of our Planet Positive product range, reduces emissions and is safe to operate. The Florence Copper Project will become an important new reference for Metso Outotec in the US copper market as a supplier of a complete production plant that uses solvent extraction and electrowinning technology for copper recovery.”

Taseko Mines starts commercial construction move at Florence ISR copper project

Taseko Mines, having just completed a $400 million bond refinancing and fundraising program, is moving forward with developing a commercial operation at its Florence in-situ recovery (ISR) copper project in Arizona, USA.

Capital requirements for the commercial production facility at Florence, which followed an ISR pilot project, are estimated at $230 million.

Pending final regulatory approvals and financing, Taseko has previously stated it could start construction of the commercial operation this year, with first production in late 2022.

Stuart McDonald, President of Taseko, said: “With the majority of the required funding for our Florence Copper project now in hand, we are moving forward with final design engineering of the commercial production facility as well as procurement of certain critical components.”

McDonald said the company is continuing to advance discussions with potential joint venture partners at Florence, but its strong cash balance and improved Gibraltar mine cash flows from copper prices currently over $3.70/Ib ($8,159/t) means it has “numerous options available” to obtain the remaining funding.

Russell Hallbauer, CEO of Taseko, added on Florence: “Florence is one of the least capital-intensive copper production facilities in the world and, when fully ramped up, will produce 40,000 t of high-quality cathode copper annually for the US domestic market.

“It is a green project, with carbon emissions and water and energy consumption all dramatically lower than a conventional mine, and, with C1 operating costs of $0.90/Ib of copper, it will also be in the lowest quartile of the global cost curve.”

Taseko Mines’ Gibraltar operation honoured at BC Mine Reclamation Awards

Taseko Mines’s Gibraltar copper-molybdenum operation has been awarded the prestigious Jake McDonald Annual Award for Metal Mine Reclamation from the British Columbia Technical and Research Committee on Reclamation (TRCR).

TRCR’s annual BC Mine Reclamation Awards, which recognises outstanding achievement in mine reclamation in British Columbia, was held on September 23, 2020.

The aim of Gibraltar’s reclamation research program is continual improvement by identifying and introducing leading-edge ideas within the field of environmental science in mine reclamation, it says. With this goal in mind, projects at Gibraltar include:

  • Sampling of salmon from the Fraser River in partnerships with the Xatśūll First Nations and the North Shuswap Tribal Council to provide information to local Indigenous communities regarding the safety of consuming salmon captured at traditional fishing sites;
  • Studying and using innovative technologies to determine how reclamation activities promote the development and recovery of biological communities; and
  • Supporting BCIT, SFU, and Mitacs master’s students in a trial research program to expedite the development of soil microbial crust, specifically at the tailings storage facility.

Stuart McDonald, President of Taseko, said: “The Jake McDonald Award is the top mine reclamation award in British Columbia, a province that has a large mining industry. This achievement reflects the hard work of many talented people and we are honoured to have been chosen as this year’s recipient. The award adds to our track record of achievement which includes other recognition awards for employee safety and community service.”

Russell Hallbauer, CEO and Director of Taseko, added: “Gibraltar has been operating for nearly 50 years, generating opportunity for people and economic benefit for communities in the Cariboo. The efforts of our Gibraltar employees continue to be rewarded by achievements like this high-profile award. It is gratifying to see their talent and ingenuity being recognised at the highest levels. Gibraltar is proof of mining sustainability in action.

“We would specifically like to acknowledge the local Xatśūll First Nations and the North Shuswap Tribal Council Fisheries Department for their partnership and traditional knowledge in the annual Fraser River salmon sampling program. As well as a thank you to the Xatśūll First Nations reclamation crew, whose participation has contributed to the success of Gibraltar’s reclamation program.”

Xatśūll First Nations Chief, Sheri Sellars, said: “I am proud of the work Xatśūll First Nation community members have done in partnership with Taseko-Gibraltar. The fish sampling program and the reclamation work have been award-winning successes. Our members have also benefitted from employment opportunities and educational initiatives which stem from our relationship with Gibraltar.”

Taseko, the 75% owner of Gibraltar, restarted the operation in 2004. It is the second largest open-pit copper mine in Canada and the largest employer in the Cariboo region, according to the company.

Taseko Mines’s Florence ISR trial copper mine reaches commercial level ahead of time

Taseko Mines says it has reached “commercial grade levels” at its Florence in-situ copper test mine in Arizona, USA, less than six months after well field operations commenced.

The company cannot yet say it is a ‘commercial mine’, but it is well on the way to being able to with permits amendment applications to transfer the test facility into a commercial operation being delivered and financing arrangements being made.

On the former, Taseko said the Aquifer Protection Permit (APP) amendment application for Florence was now on its way to the Arizona Department of Environmental Quality (ADEQ). “The APP is one of two key permit amendments which are required for commercial production at the company’s Florence copper project,” Taseko said, adding that the permit amendment application for the Underground Injection Control Permit will be made to the US Environmental Protection Agency in the coming weeks.

Russell Hallbauer, Chief Executive Officer of Taseko, provided the update on operations at Florence. “This past week, after roughly six months of operating the test facility, the leach solution reached commercial grade levels, well in advance of our anticipated timeframe,” he said.

“Based on previous bench-scale testing, we expected it would take upwards of a year to reach target solution grade, so we are obviously extremely pleased to have achieved this milestone after such a short period of time.”

Hallbauer said the grade of the leach solution coming from Florence’s main recovery well is around 1,600 parts per million (ppm) of copper in solution and would be comparable to a typical open pit, low cost heap leach operation.

“The main difference between Florence Copper and other leach operations is that we have no mining costs associated with our in-situ leach process, making Florence Copper, when in commercial operation, one of the lowest cost operations globally,” he said.

The main focus of the Florence test facility, beyond ensuring the company achieves all the technical targets of its feasibility study, will be building the company’s on-the-ground operational experience to streamline the transition to commercial production, according to Halllbauer.

“Based on the knowledge we have gained in the last six months, the benefits of the two phase approach (production test facility followed by the commercial facility) will significantly improve the ramp up of the final commercial scale operation,” he said.

Stuart McDonald, President of Taseko, said financing for the commercial production facility is progressing with multiple options continuing to be pursued.

“We have initiated discussions with potential lenders and financing partners and we remain on track to have a plan formalised in the coming months,” he said.

“We now have the three key initiatives – technical, permitting and financing – all aligned for our project to be construction-ready in the first half of 2020.”

The commercial Florence mine is expected to produce copper at average operating costs of $1.10/Ib ($2,425/t), come with a capital cost intensity of $5,200/t of copper capacity and yield a pre-tax net present value of $920 million. It also has a slated copper production capacity of 85 MIb/y (38,555 t/y) and a 21-year mine life.