Market Survey on Copper - Indian Bureau of Mines
Market Survey on Copper - Indian Bureau of Mines Market Survey on Copper - Indian Bureau of Mines
One of the first of the recent series of major investments was an in-pit, semimobile gyratory crushing unit linked to the Copperton Concentrator by an 8km conveyor system. This reduced haulage distances from the working faces substantially but even so the mine needs a large fleet of Caterpillar mechanical drive and Komatsu electric-drive trucks, mostly of 218t-capacity, to service ten P&H electric rope shovels. Dispatching is by the Modular Mining computerised system and Bingham also utilises Thunderbird Pacific's drill monitoring and logging systems. Both GPS and Glonass are used for precise drill positioning. Germany's MAN Takraf has upgraded and relocated the semi-mobile in-pit crushing plant and conveyor system to keep trucking distances down. Processing The Copperton concentrator was expanded in 1992 and fitted with some of the world’s largest SAG and ball mills, and large flotation cells. There are four grinding and flotation lines, sequentially yielding a copper and molybdenum concentrate. The copper concentrate is piped about 27km to the smelter. Until its closure in mid-2001, the older North plant supplied about 20% of the copper concentrate for smelting. Rio produces approximately 8% of the world's molybdenum. The current smelting facilities are the result of major investment, comprising a new primary flash smelter and flash converter system, designed by Outokumpu with input from Kennecott, plus a slag treatment plant. The converter treats matte that has been granulated and powdered. The 98.6% copper from the new converter is refined to 99.5% copper in two anode furnaces. Cast anodes are railed about 3km to the refinery’s electrolytic tankhouse, where marketable high-purity copper is produced and the gold and silver content of the concentrate is also recovered. Production Having been regarded as a minor contributor to income at Bingham Canyon, increased world demand for molybdenum has now made it very important. Income from moly sales was just $30m in 2002, but rose to $700m in 2005. The 2008 mine plan was modified to include areas of higher moly content, even at the expense of copper, while the concentrator has also been fine-tuned to optimise moly recoveries, with a second expansion of the moly-recovery circuit commissioned in mid-2006. Rio produces approximately 8% of the world's molybdenum and expects to produce 60 million pounds by 2015. In order to improve efficiency, it is constructing an autoclave process in Magna to produce molybdenum instead of outsourcing. The plant is estimated to cost $340m and is scheduled to be completed by 2012. Operations are expected to begin in 2013. 188 Contd…..
Concld….. 10. Andina Copper Mine, Chile Situated some 50 km northeast of the capital, Santiago, the Andina mine was discovered in 1920 but production did not start until 1970. It consists of the Rio Blanco underground (block cave) mine and the Sur Sur open pit and an underground concentrator. Unlike other Codelco mines, it does not have its own smelter. Geologically it consists of about half the Los Bronces-Rio Blanco complex of mineralised breccias, the other half being owned and mined by the Los Bronces mine of Compania Minera Disputada de la Condes which is in turn owned by Anglo American. Originally owned by the American Cerro De Pasco Corporation, who brought the mine to production, it has been gradually built up by Codelco and is now the subject of a major expansion scheme. At the end of 2007, reserves and resources in the mining plan totalled 5,698 million tonnes grading 0.78% copper containing 44.3 million tonnes of metal and additional identified resources of 11,342 tonnes grading 0.52% copper containing 59.6 million tonnes of metal. The orebodies are at considerable heights, between 3,000 and 4,200 metres and operations can be severely affected by the weather. Originally the mine was only the underground block cave and an underground concentrator with an 'hotel'/bunkhouse where the workers live when the Rio Blanco valley is impassable in the winter. Now the Sur Sur and Don Luis breccias above and to the south of the underground mine are being worked as open pits. Production in 2007 was 218,322 tonnes of extractable copper and 2,525 tonnes molybdenum in concentrate from the 72,000 tonnes per day concentrator. Work is now under way on the Andina Phase I Development Project which aims to raise mill capacity to 92,000 tonnes per day and is expected to be complete by November 2009. Pre feasibility studies on raising mill capacity to over 200,000 tonnes per day by 2014 should be complete this year. Deep drilling to prove up resources to sustain such a production rate continues. No estimates of the likely copper output at a milling rate of 200,000 tonnes per day have been given and cannot be until the deep drilling campaign is complete. One of the mysteries of Andina is why it did not buy Compania Minera Disputada de las Condes when Peñarroya was prepared to sell it for a very low price in 1972. It went to Enami who subsequently sold it for a handsome profit to Exxon Minerals for US$97 million. It would have given Codelco complete control of the district. When Exxon finally did decide to sell in 2002, Codelco expressed interest but were not prepared to match the US$1.3 billion that Anglo American were prepared to give for it Rock glaciers have been seriously intervened by Andina since the late 1980s, when it started to deposit several million tons of waste rock on top of rock glaciers, resulting in their acceleration and partial destabilisation. Since then, 2.1 km 2 of rock glaciers with a water equivalent of more than 15 million cubic metres have been affected by Andina, including the partial removal of rock glaciers. 189
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C<strong>on</strong>cld…..<br />
10. Andina <strong>Copper</strong> Mine, Chile<br />
Situated some 50 km northeast <strong>of</strong> the capital, Santiago, the Andina mine was<br />
discovered in 1920 but producti<strong>on</strong> did not start until 1970. It c<strong>on</strong>sists <strong>of</strong> the Rio<br />
Blanco underground (block cave) mine and the Sur Sur open pit and an underground<br />
c<strong>on</strong>centrator. Unlike other Codelco mines, it does not have its own smelter.<br />
Geologically it c<strong>on</strong>sists <strong>of</strong> about half the Los Br<strong>on</strong>ces-Rio Blanco complex <strong>of</strong><br />
mineralised breccias, the other half being owned and mined by the Los Br<strong>on</strong>ces mine<br />
<strong>of</strong> Compania Minera Disputada de la C<strong>on</strong>des which is in turn owned by Anglo<br />
American.<br />
Originally owned by the American Cerro De Pasco Corporati<strong>on</strong>, who brought the<br />
mine to producti<strong>on</strong>, it has been gradually built up by Codelco and is now the subject <strong>of</strong> a<br />
major expansi<strong>on</strong> scheme. At the end <strong>of</strong> 2007, reserves and resources in the mining plan<br />
totalled 5,698 milli<strong>on</strong> t<strong>on</strong>nes grading 0.78% copper c<strong>on</strong>taining 44.3 milli<strong>on</strong> t<strong>on</strong>nes <strong>of</strong> metal<br />
and additi<strong>on</strong>al identified resources <strong>of</strong> 11,342 t<strong>on</strong>nes grading 0.52% copper c<strong>on</strong>taining 59.6<br />
milli<strong>on</strong> t<strong>on</strong>nes <strong>of</strong> metal.<br />
The orebodies are at c<strong>on</strong>siderable heights, between 3,000 and 4,200 metres and<br />
operati<strong>on</strong>s can be severely affected by the weather. Originally the mine was <strong>on</strong>ly the<br />
underground block cave and an underground c<strong>on</strong>centrator with an 'hotel'/bunkhouse where the<br />
workers live when the Rio Blanco valley is impassable in the winter. Now the Sur Sur and<br />
D<strong>on</strong> Luis breccias above and to the south <strong>of</strong> the underground mine are being worked as open<br />
pits. Producti<strong>on</strong> in 2007 was 218,322 t<strong>on</strong>nes <strong>of</strong> extractable copper and 2,525 t<strong>on</strong>nes<br />
molybdenum in c<strong>on</strong>centrate from the 72,000 t<strong>on</strong>nes per day c<strong>on</strong>centrator.<br />
Work is now under way <strong>on</strong> the Andina Phase I Development Project which aims to<br />
raise mill capacity to 92,000 t<strong>on</strong>nes per day and is expected to be complete by November<br />
2009.<br />
Pre feasibility studies <strong>on</strong> raising mill capacity to over 200,000 t<strong>on</strong>nes per day by 2014<br />
should be complete this year. Deep drilling to prove up resources to sustain such a producti<strong>on</strong><br />
rate c<strong>on</strong>tinues. No estimates <strong>of</strong> the likely copper output at a milling rate <strong>of</strong> 200,000 t<strong>on</strong>nes per<br />
day have been given and cannot be until the deep drilling campaign is complete.<br />
One <strong>of</strong> the mysteries <strong>of</strong> Andina is why it did not buy Compania Minera Disputada de<br />
las C<strong>on</strong>des when Peñarroya was prepared to sell it for a very low price in 1972. It went to<br />
Enami who subsequently sold it for a handsome pr<strong>of</strong>it to Exx<strong>on</strong> Minerals for US$97 milli<strong>on</strong>.<br />
It would have given Codelco complete c<strong>on</strong>trol <strong>of</strong> the district. When Exx<strong>on</strong> finally did decide<br />
to sell in 2002, Codelco expressed interest but were not prepared to match the US$1.3 billi<strong>on</strong><br />
that Anglo American were prepared to give for it<br />
Rock glaciers have been seriously intervened by Andina since the late 1980s,<br />
when it started to deposit several milli<strong>on</strong> t<strong>on</strong>s <strong>of</strong> waste rock <strong>on</strong> top <strong>of</strong> rock glaciers,<br />
resulting in their accelerati<strong>on</strong> and partial destabilisati<strong>on</strong>. Since then, 2.1 km 2 <strong>of</strong> rock<br />
glaciers with a water equivalent <strong>of</strong> more than 15 milli<strong>on</strong> cubic metres have been<br />
affected by Andina, including the partial removal <strong>of</strong> rock glaciers.<br />
189