Market Survey on Copper - Indian Bureau of Mines

Market Survey on Copper - Indian Bureau of Mines Market Survey on Copper - Indian Bureau of Mines

13.02.2013 Views

Open-pit mining The Ujina and Huinquintipa zones were mined first, with a transition to the Rosario orebody completed during 2004. Stripping at Rosario began in 2002. The stripping ratio at Ujina averages 4.4:1 (waste: ore) with a 15m bench height. Huinquintipa is somewhat smaller. The design mining rate of 360,000t/d of rock was achieved in Year 1, involving the blasting of 750,000t of material every two days. In 2008, Xstrata Copper announced a 28% increase in the total estimated mineral resource at the mine, representing the equivalent of an additional 11 million tons of contained copper metal from 2007 resources. Processing The processing area consists of both oxide and sulphide plants. Oxide and mixed ores are treated by heap-leaching, solvent-extraction and electro-winning (SX- EW). Sulphide ore is crushed, ground and treated by flotation. Run-of-mine sulphide ore enters the primary gyratory crusher prior to transport to two parallel grinding circuits, each consisting of a Semi Autogenous Grinding mill and a ball mill. Secondary closed circuit grinding includes cyclone classifiers, from which the overflow feeds the flotation circuit. Flotation concentrate is thickened to 50% solids for slurry transport in a 200 km-long pipeline to Punta Patache, 65km south of Iquique, where it is thickened and filtered before shipment worldwide. An expansion to the concentrator was completed during 2004. Run-of-mine oxide ore is reduced to -10mm by three-stage crushing. The fine ore is agglomerated with sulphuric acid and water before being conveyed to the leach pads. Copper is recovered from the pregnant leach solution in the solvent-extraction plant, where the copper is stripped using organic solutions; the stripped liquor is then returned to the leach pads for re-use. The strip solution is cleaned using dilute acid and flotation, and is filtered prior to the electro-winning phase, where the copper is plated onto electrolysis cathodes. These are stripped by the Kidd process on a seven-day cycle, the cathode copper being transported by road to Iquique for export. Production In 2005, Cia Minera Doña Inés de Collahuasi produced 488,600t of copper in concentrate, plus 68,600t of cathode copper. In December 2005, the company commissioned a US$36m molybdenum recovery plant that has a capacity of 7,500t/y of contained molybdenum. In January 2008, the company announced an upgraded mineral resource of 5.19 bn tons at an average grade of 0.83% copper, including, for the first time, 746 m tons at a grade of 1.06% from the Rosario Oeste deposit. This compares to the previous mineral resource of 4.05 bn tons at an average grade of 0.80% copper. The mineral resource includes ore reserves of 2.20 bn tons at 178 Contd…..

a grade of 0.82% copper, a 25% increase in tonnage from ore reserves of 1.76 bn tons at 0.89% copper from December 2006. Environment As the environment at Collahuasi is harsh and fragile, ecological issues have a top priority. Collahuasi is a zero-discharge operation, with much of its water being recycled. An extensive environmental monitoring system is in place along with research projects in high altitude operations.Collahuasi achieved its ISO 14001 environmental management certification in 2000. 5. El Teniente Situated 44 km east of Rancagua and 75 km south of the capital, Santiago, El Teniente claims to be the largest underground copper mine in the world (see below). The El Teniente orebody has been known and worked on a small scale for many years. Work started on establishing a mine in 1905 after Government permission had been acquired but progress was slow because of difficulty of access and a hard winter climate. A small gravity plant was soon erected but it was not until 1912 that a flotation plant was erected at Sewell. Control passed to Kennecott in 1915 and it ran the mine until nationalisation in 1971. The Present Mine The porphyry orebody consists of a stockwork (a network of narrow veins) of mineralised veinlets, mainly in andesitic lavas and tonalite, superimposed by a leached zone and a substantial zone of secondary enrichment, both of very variable thickness. It surrounds a narrow, almost circular ring of tourmaline breccia which in turn surrounds the Braden Chimney, an inverted cone of breccia which was emplaced after the main mineralisation. Reserves and resources are substantial. At the end of 2007 reserves and resources in the mining plan totalled 4,204 million tonnes grading 0.91% copper or 38.3 millionn tonnes of contained copper. In addition the mine has identified additional resources of 15,827 million tonnes grading 0.46% copper or nearly 73 million tonnes of contained copper though there is no indication how much of this may prove economic. Production in 2007 was 404,728 tonnes copper and 5,053 tonnes molybdenum. Mining is gradually moving lower and removing the ore between the barren country rock and the Braden Chimney. Access is through adits (horizontal tunnels) to shafts and other services cut in the Braden Chimney. Mining methods include panel caving, panel caving with pre-undercut, and block caving, which have been adapted to overcome the serious rockburst problem which stopped mining some years ago on level 6 and threatened the future of the mine. A new level, Level 8, is now in operation and another, lower, level is being studied which will give access to 1.5 billion tonnes of ore grading 0.96% copper and extend the life of the mine by many years. 179 Contd…..

a grade <strong>of</strong> 0.82% copper, a 25% increase in t<strong>on</strong>nage from ore reserves <strong>of</strong> 1.76 bn t<strong>on</strong>s<br />

at 0.89% copper from December 2006.<br />

Envir<strong>on</strong>ment<br />

As the envir<strong>on</strong>ment at Collahuasi is harsh and fragile, ecological issues have a<br />

top priority. Collahuasi is a zero-discharge operati<strong>on</strong>, with much <strong>of</strong> its water being<br />

recycled. An extensive envir<strong>on</strong>mental m<strong>on</strong>itoring system is in place al<strong>on</strong>g with<br />

research projects in high altitude operati<strong>on</strong>s.Collahuasi achieved its ISO 14001<br />

envir<strong>on</strong>mental management certificati<strong>on</strong> in 2000.<br />

5. El Teniente<br />

Situated 44 km east <strong>of</strong> Rancagua and 75 km south <strong>of</strong> the capital, Santiago, El<br />

Teniente claims to be the largest underground copper mine in the world (see below).<br />

The El Teniente orebody has been known and worked <strong>on</strong> a small scale for many<br />

years.<br />

Work started <strong>on</strong> establishing a mine in 1905 after Government permissi<strong>on</strong> had<br />

been acquired but progress was slow because <strong>of</strong> difficulty <strong>of</strong> access and a hard winter<br />

climate. A small gravity plant was so<strong>on</strong> erected but it was not until 1912 that a<br />

flotati<strong>on</strong> plant was erected at Sewell. C<strong>on</strong>trol passed to Kennecott in 1915 and it ran<br />

the mine until nati<strong>on</strong>alisati<strong>on</strong> in 1971.<br />

The Present Mine<br />

The porphyry orebody c<strong>on</strong>sists <strong>of</strong> a stockwork (a network <strong>of</strong> narrow veins) <strong>of</strong><br />

mineralised veinlets, mainly in andesitic lavas and t<strong>on</strong>alite, superimposed by a<br />

leached z<strong>on</strong>e and a substantial z<strong>on</strong>e <strong>of</strong> sec<strong>on</strong>dary enrichment, both <strong>of</strong> very variable<br />

thickness. It surrounds a narrow, almost circular ring <strong>of</strong> tourmaline breccia which in<br />

turn surrounds the Braden Chimney, an inverted c<strong>on</strong>e <strong>of</strong> breccia which was emplaced<br />

after the main mineralisati<strong>on</strong>. Reserves and resources are substantial. At the end <strong>of</strong><br />

2007 reserves and resources in the mining plan totalled 4,204 milli<strong>on</strong> t<strong>on</strong>nes grading<br />

0.91% copper or 38.3 milli<strong>on</strong>n t<strong>on</strong>nes <strong>of</strong> c<strong>on</strong>tained copper. In additi<strong>on</strong> the mine has<br />

identified additi<strong>on</strong>al resources <strong>of</strong> 15,827 milli<strong>on</strong> t<strong>on</strong>nes grading 0.46% copper or<br />

nearly 73 milli<strong>on</strong> t<strong>on</strong>nes <strong>of</strong> c<strong>on</strong>tained copper though there is no indicati<strong>on</strong> how much<br />

<strong>of</strong> this may prove ec<strong>on</strong>omic. Producti<strong>on</strong> in 2007 was 404,728 t<strong>on</strong>nes copper and<br />

5,053 t<strong>on</strong>nes molybdenum.<br />

Mining is gradually moving lower and removing the ore between the barren<br />

country rock and the Braden Chimney. Access is through adits (horiz<strong>on</strong>tal tunnels) to<br />

shafts and other services cut in the Braden Chimney. Mining methods include panel<br />

caving, panel caving with pre-undercut, and block caving, which have been adapted to<br />

overcome the serious rockburst problem which stopped mining some years ago <strong>on</strong><br />

level 6 and threatened the future <strong>of</strong> the mine. A new level, Level 8, is now in<br />

operati<strong>on</strong> and another, lower, level is being studied which will give access to 1.5<br />

billi<strong>on</strong> t<strong>on</strong>nes <strong>of</strong> ore grading 0.96% copper and extend the life <strong>of</strong> the mine by many<br />

years.<br />

179<br />

C<strong>on</strong>td…..

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