nordic operations focus accurate exploration automated mineralogy optimisation atlas copco's bob ...

80 Pages·2012·9.51 MB·English

www.im-mining.com FEBRUARY 2012
Informed and in-depth editorial on the world mining industry
NORDIC
OPERATIONS
FOCUS
Orivesi gold and
AUTOMATED
Kaunisvaara iron
MINERALOGY
OPTIMISATION
ACCURATE
EXPLORATION
ATLAS COPCO'S
Advanced
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technologies
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CONTENTS
88
FEBRUARY 2012
8 OPERATION FOCUS – Kaunisvaara
Northern Sweden has a long iron ore tradition.
John Chadwickrecently visited the latest project
there – Northland Resources’ Kaunisvaara iron ore,
for which Metso is providing major process solutions
18 OPERATION FOCUS –Orivesi
“Production, cashflow, growth” is the operating
principle Dragon Mining has employed for its
gold operations in Sweden and Finland. John
Chadwick visited the Orivesi mine recently
3322
1188 26 GREAT MINES – Zinkgruvan
In our penultimate Great Mines series on Lundin
Mining, Paul Moorelooks at the Zinkgruvan
operation, which literally means ‘zinc mine’,
2266
outlines the paste tailings project at Neves Corvo
and provides a brief update on the winding down
4444 Galmoy and soon to be reopened Aguablanca mines
44 MINERAL EXPLORATION
32 AUTOMATED MINERALOGY With an uncertain economic future, ever more
remote deposits in operationally challenging
John Chadwick looks at some of the
countries, as well as more interest in other
new developments in XRD and XRF
mined products from potash to rare earths and
analysers including handheld and
lithium – Paul Moorereports that the
lab-based solutions
importance of the most accurate exploration
methods with the most advanced technology
70 HIGH PROFILE: Atlas Copco
and equipment continues to increase
Paul Mooreinterviewed Atlas
6600
Copco’s new Business Area 60 EMISSION CONTROL
President for Mining and Rock John Chadwicklooks at improving some of the
Excavation Technique, Bob Fassl, in fluids used in mining machines, noise reduction,
gases and dust. Water is considered separately,
late 2011 about the positioning and
next month
strategy for the company’s mining
assets -94 MINING TECHNOLOGY UPDATES
Every month, IMposts around 100 news items to
its website, mainly technology related. Here are
7700
some recent highlights
COVER: SRK Exploration www.im-mining.com
FEBRUARY 2012
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an independent mineral exploration consultancy and service provider, working ATLABSO CBO FPACSOS'LS
worldwide on a wide variety of commodities and at all stages of project COENMTIRSOSLIOLINNSG
development. For more details, email [email protected],
call [phone] or visit the website. www.srkexploration.com
Photo: Daniel Marsh, Exploration Geophysicist, SRK ES
AROUND THE WORLD 3 The Leader 4 World Prospects 75 Classifieds 76 Forthcoming events
FEBRUARY 2012| International Mining 1
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THE LEADER
VOLUME 8 • NUMBER 2
IPCC 2012…and Rapid Development 2013!
Publisher
John Chadwick
International Mining has great pleasure in tonne of total material
Email: [email protected]
announcing the confirmation of two new moved by using the IPCC
Editor
Paul Moore focussed conferences for 2012 and early 2013. system instead of a large
Email: [email protected]
The first is In-Pit Crushing & Conveying (IPCC) truck fleet is in the order
Associate Editor
Chris Cann 2012, which will be held in the Grand Hyatt Bali, of $0.25/t or
Email: [email protected] Indonesia from 24th to 26th October, and follows approximately $0.80/t
Editorial Board
on from the highly successful IPCC 2011 event in ore mined. In addition to
Professor Malcolm Scoble
Robert E. Hallbauer Belo Horizonte in Brazil, which was a who’s who of the operational savings,
Chair in Mining
Engineering., mining groups considering and implementing IPCC Exeter estimates an initial and sustainable capital
University of BC, systems, along with key consultants, contracting saving of approximately $1 billion by building the
Vancouver
groups, equipment OEMs and component tailings dam wall largely from a conveyor-stacker
Jeff Roschyk
Vice President of suppliers involved in IPCC. More information can system rather than using conventional truck
Product Management
& Marketing, P&H Mining, USA be found on page 31 of this issue, but Indonesia haulage for material movement. The waste dump
Peter Knights was chosen due to its geographical location would form the backbone of an engineered tailings
BMA Chair & Prof. of Mining
EngineeringUniversity between Australia and mainland Asia; but also the dam face and provide a significant margin of safety
of Queensland massive domestic potential for IPCC with a huge in the event of an earthquake or other event.
Stephen Stone
and growing surface coal industry. Themes to be covered at IPCC 2012 include:
West One Management
Perth, Western Australia And IPCC continues to gather momentum. One mine planning, and truck-shovel versus IPCC;
Dr. Andrew M. Robertson
of the key speakers at the IPCC 2011 event in Belo design criteria for IPCC; fully mobile and semi-
President, Robertson
GeoConsultants Horizonte, Brazil, was Consulting Mining Engineer mobile IPCC; conveyor systems for waste handling;
Vancouver, Canada.
and former Sandvik VP Technical Mining Services, real mine case studies; relocation of IPC and
Ed McCord
Project Consultant Phil Morriss, who gave an in-depth review of the conveyor systems and a consideration of other
Caterpillar Global Mining, USA
Exeter Resource Caspiche project in northern Chile, alternatives – surface miners, bucketweel systems,
Jason Nitz
Mining Systems Strategist a significant project in that it is set to produce etc. By late 2012, several very large new IPCC
Newcrest Mining Ltd, Australia
696,000 oz/y of gold, 844,000 oz/y of silver and systems will have been put in place globally, which
Dr Terry Mudder
Managing Director 244 Mlb/y of copper over a 19 year mine life. But will provide new avenues for discussion.
TIMES Ltd, USA
its significance also lies in the fact that it is a major Finally, we also are very proud to be launching a
Simon Tarbutt
Consultant, Santiago, Chile hard rock metallic operation that will incorporate completely new conference – Rapid Development –
Dr. Mike Daniel IPCC; joining the club of majors already utilising or which will be held from 23rd to 25th January 2013
Comminution Process Consultant
developing high tonnage IPCC systems for waste in the Sydney Harbour Marriott Hotel. Why this
Ausenco Minerals & Metals, Australia
rock – this includes Chuquicamata, Antamina, subject and why Australia? It is increasingly clear
Editorial Enquiries:
Tel: [phone] Collahuasi and Escondida. The company provided that with the number of large open pit to
Fax [phone]
an update on 17th January 2012, when it was underground projects as well as new block caves
Advertising Sales:
announced that the Prefeasibility Study (PFS) for coming onstream in the next 10-15 years, that the
Phil Playle
Email: [email protected] Caspiche had indicated average operating costs of industry needed a meeting that is both technical
[phone]
$606 per oz gold equivalent. However, the gold and commercial to look at this topic. Everything
Advertising Production
Emma Smith production cost drops to $18 per oz when copper from rapid shaft sinking techniques to the
Email: [email protected] and silver by-product credits are considered. application of TBMs and new mobile continuous
Publishing Consultant Proven and probable gold reserves stand at 19.3 mining machines for horizontal development in
Robin Peach
Moz and 4.6 billion pounds for copper. hard rock will be covered; as will new approaches
Design & Production
Trevor Sheldon The PFS was completed by Aker Solutions (now to longhole drilling, underground material
Email: [email protected]
Jacobs Engineering), and evaluated three mining movement and rock support. Australia is the
Website: and processing options. A key component of the location for much of the technology advancement
www.im-mining.com
PFS is the inclusion of high tonnage IPCC systems and testing in these areas. To offer potential
Annual Subscription Enquiries:
Emma Smith for the movement of waste rock. This achieves papers, find out about sponsorship opportunities,
Email: [email protected]
greater efficiencies in the movement of the pit or for any other queries on either theIPCC 2012or
Annual Subscription
overburden, not only to address rising operating Rapid Develoment 2013events, please contact me.
UK and Europe £160, E230
Rest of the world US$270 costs for mining waste, but also the capital and
International Mining is published operating costs involved in the construction of
monthly by Team Publishing Ltd,
tailings dam walls using conventional methods.
2 Claridge Court, Lower Kings Road
Berkhamsted, Herts. HP4 2AF, UK The early implementation of IPCC allowed the open
Printed by The Manson Group, St Albans pit development to be tailored to the needs of the
© Team Publishing Ltd 2012 system and has resulted in significant reduction in Paul Moore
ISSN 1747 -146X
projected mining costs. NCL, Exeter’s mining Editor and IM Events Conference Director
consultants, estimated that the cost saving per [email protected]
FEBRUARY 2012| International Mining 3
WORLD PROSPECTS
Hillgrove Resources progressing well at Kanmantoo copper mine
Hillgrove Resources recently commissioned process plant and
the Kanmantoo mine located less than associated
55km from Adelaide in South Australia. It equipment and
is an open-pit mine, ramping up over the first buildings for
half of 2012 to an initial throughput of 2.4 Mt/y, Kanmantoo. Pillara,
producing approximately 80,000 t/y of located 375 km
concentrate. During December 2011: east of Broome in
■154,000 t (dry) crushed and milled, Western Australia,
representing 77% of annual throughput rate was established by
of 200,000 t/month, and above plan for this Western Metals
stage of ramp-up Limited in 1998 as
■Average crushing rate achieved was 387 t/h a lead/zinc mine. It
(dry), representing 94% of design of 411 t/h was shut down in
■Average milling rate achieved was 259 t/h September 2008.
(dry), representing 83% of design throughput The purchase
of 311 t/h comprised the float
■2,159 t (dry) of copper concentrate produced, plant, which
grading 30% Cu and 5.3 g/t Au, both above included a ball mill and SAG mill, office In November 2010 the final approvals were
plan of 26% Cu and 2.6 g/t Au buildings, crusher, plant spares and received and the 12-month construction period
■Some 1,615 t of concentrate transported to consumables, workshops, warehouse building, commenced with Abesque once again
storage at Port Adelaide, with about 810 t in sample preparation facility, laboratory, fuel farm contracted to undertake the A$121 million
the concentrate shed at Kanmantoo and product storage buildings. The purchase construction project through to commissioning
■Average copper recovery of 70%, reflecting provided a number of advantages, which of the plant in November 2011.
some oxide and transitional material in the included: In association with the construction program,
early stage, low grade, commissioning ore ■A reduction in capital expenditure and mining activities centred on providing sufficient
feed to the mill. Recovery steadily increased reduced possibility of cost blow outs by using waste material to undertake the groundworks
over the month, and is now running at a second hand plant rather than buying required for the Tailing Storage Facility (TSF)
approximately 85% everything new embankment, the establishment of haul roads
■Close-off of additions of exploration drilling ■Increased certainty of meeting the 12-month linking areas of the mine, as well as hard-stand
data to the Kanmantoo resource database construction target as not waiting for long laydown areas for the mining contractor, Exact
occurred, with work commencing on a new lead time items Mining’s workshop and go-line area. Over 1
resource estimate, with results expected in ■A number of items excess to our million m3(bank) of material (ore and waste)
Q2, 2012. requirements were able to be sold, including were moved in the process, all requiring drilling
The project currently hosts 2.3 Mt of Proven the smaller Outotec SAG mill already ordered, and blasting.
ore reserves at 0.87% Cu, 0.13 g/t Au and 3.2 reducing the expected capital outlay. To maintain best practice environmental
g/t Ag, with a Probable reserve of 12.5 Mt at Abesque Engineering undertook the guidelines, the TSF required a clay liner,
0.84% Cu, 0.18 g/t Au and 3.1 g/t Ag, for a total dismantling and transport of the plant. The installation of drainage networks and decant
of 14.8 Mt at 0.85%, 0.17 g/t and 3.1 g/t, individual plant components were carefully pipework, and then a High Density Poly-
respectively. Total Measured, Indicated and itemised and numbered before being sent in Ethylene (HDPE) lining. The first stage of the
Inferred resources total 32,192 Mt at 0.9% 0.2 batches by truck. A total of 293 truck-loads were TSF was approved for use in October 2011 and
g/t and 3.2 g/t, respectively. involved – a major logistics exercise by any will be extended according to the Mining and
In August 2009 Hillgrove entered into a measure. They were then laid out at Kanmantoo Rehabilitation Plan (MARP) approvals as
purchase agreement with Lennard Shelf (Teck ready for refurbishment if required and required over the life of the mine.
Resources/Xstrata) to acquire the Pillara mine’s reassembly. www.hillgroveresources.com.au
Lynas forging ahead with Australian/Malaysian rare earths production
Lynas owns the richest known deposit of ratio for the pit (4.6:1). Due to the high ore recovery of 64% at the end of Q3 2011, which
rare earths, also known as Lanthanides, in grades, the ore production level is forecast to be compares to a target final concentrate grade of
the world at Mount Weld, near Laverton in relatively small. For example, production of 37% REO and recovery of 58% in the planned
Western Australia. The company's strategy is 11,000 t REO in the first year of operation will ramp-up schedule for the same period.
"to create a reliable, fully integrated source of require 121,000 t of ore to be processed. Based The detailed feasibility study was completed
rare earths supply from the mine through to on proposed ore treatment options, current for an expansion of the plant to double its
customers in the global rare earths industry. The reserves were calculated by AMDAD in 2003 as capacity. At the end of last year a letter of award
project embraces the mine and concentration 2.1 Mt @ 15.5% REO containing 321,000 t REO. was issued to Abesque Engineering for the EPCC
plant at Mount Weld and the Lynas Advanced Lynas expects that further metallurgical test contract for Phase 2 of the plant. The letter of
Materials Plant (LAMP) in Malaysia. work and inclusion of lower grade ore will result award is for a lump sum contract in the amount
Australian Mine Design and Development in a mine life in excess of 20 years. of approximately A$36 million.
prepared preliminary pit optimisations, pit Following the commissioning of the The concentrate produced by the plant is
designs and mine schedules over the central concentration plant in May 2011, it continued to shipped in sea containers and transported by
part of the Central Lanthanide Deposit (CLD). ramp up and is performing ahead of road and ship to the east coast of Malaysia to
The work confirmed the simplicity and low risk expectations. It achieved a final concentrate the LAMP within the Gebeng Industrial Estate,
of a mining operation, and the low overall strip grade of 36.8% Rare Earths Oxide (REO) and a Kuantan, Pahang, Malaysia, to process the ▲
4International Mining| FEBRUARY 2012
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WORLD PROSPECTS
concentrate through to separated rare put in place a comprehensive process
earths products. It will also produce to monitor and evaluate our
three synthetic mineral products; compliance with the highest
synthetic gypsum, magnesium-rich international standards and our
gypsum, and iron-phospho gypsum. responsibility to operate the plant in a
On January 3, the Malaysian Atomic safe and sustainable manner. Lynas
Energy Licensing Board (AELB) provided maintains a deep commitment to the
hardcopy documents relating to the communities in which it operates as
LAMP temporary license application for well as ongoing communication with
public comment. In accordance with the interested parties to reinforce the facts
recommendations of the International about the safety of the LAMP.”
Atomic Energy Agency review of LAMP The LAMP is being built in Malaysia
of June 2011, these application due to the readily available industrial
documents include a detailed waste infrastructure, including industrial land,
management plan and safety case. Leaching, up and downstream separation and sources of gas, water and electricity, reagents
product finishing workshops at the LAMP
The Malaysian Ministry of International Trade from local suppliers and a port that can manage
and Industry indicated that the AELB will meet container, chemical and bulk shipments. The
on January 30, 2012 for a decision on the Lynas products. A temporary license has duration of area where the plant is being built also offers
temporary license. two years. If the temporary license is granted, much knowledge infrastructure, such as
A temporary license will allow Lynas to and if Lynas complies with the requirements of technical and trade skills and chemical industry
commission the LAMP and, subject to the temporary license, a permanent operating experience. The government infrastructure is in
continuous oversight by the Malaysian license can be issued within the two years place and provides accountable regulators, clear
regulatory authorities, progressively ramp up Lynas Executive Chairman, Nicholas Curtis, legal frameworks and FDI incentives.
the plant to nameplate capacity and sell its said “The Malaysian regulatory authorities have www.lynascorp.com
Good progress with development of Vlakfontein coal mine
Concor Opencast Mining says it has made
excellent progress with the establishment
of the new Vlakfontein coal mine near Ogies
in Mpumalanga, South Africa, since moving onto
the greenfields site in February 2011. Under the
contract awarded by African Exploration Mining
and Finance Corp (AEMFC), Concor is required to
clear the 16.25 ha site, strip overburden, drilling
and blast and provide a constant supply of coal
at a rate of 70,000 t/month.
Ivan Robinson, contract manager Concor
Opencast Mining, says that mining work
commenced in March 2011 after stripping of
268,000 m³of top soil and the development of a
box cut 640 m long by 60 m wide. “There are
two coal seams, the seam four is 6.5 m thick
and the seam two is 7.2 m thick, separated by
interburden. To get to the upper coal seam
(seam four), we removed 279,000 m³of soft
material in an 8 m thick layer and 592,000 m³of
sandstone, also 8 m thick.’ period the N12 is temporarily closed. Both Concor Robinson equates the increased production
Product from the two seams will be and Transnet monitor the blasts for vibration. to 1.32 Mt/y of coal compared with the original
stockpiled separately. A total of 1.2 million m³of Robinson estimates that steady state mining tender amount of 800,000 t. “We started the
interburden between the two coal seams will be will be achieved by a projected March 2012. contract with two Hitachi 32 t excavators and 12
removed over the 36 month contract period. The Mashudu Netshipale, Vlakfontein Mine Manager, Bell B20 and B25 ADTs. We have expanded the
contract includes transporting coal to a coal says coal from the mine has been sold to fleet by adding two Liebherr 55 t excavators and
crusher, currently a high volume portable Eskom’s Tatuka power station and subsequently a 60 t Komatsu, seven 35 t Volvo ADTs and four
machine, on mine property. Thereafter, to the nearby Kendal power station as well as to 40 t Volvos ADTs. Additional equipment on site
Vlakfontein mine is responsible for other domestic customers. “Our objective is to included three dozers - a Cat D6, a Bell 850 and
transportation of product to various customers. become a contracted mine to Eskom. We will a Komatsu 375 - two 18,000-litre Bell water
B&E International is currently constructing a continue to sell coal for blending to domestic tankers, a Cat 140H grader and a pneumatic
permanent coal crushing plant on site. customers, mostly other mines.” breaker. About 70% of the fleet is Concor
The blasting of overburden and the coal seam Netshipale says that at the end of October, Opencast Mining equipment while the balance
is a delicate process because of the proximity of AEMFC requested Concor Opencast Mining to comprises hired equipment, including operators.”
the mine to the N12 freeway and Transnet’s oil increase on-site resources in order to ramp up Pit life in phase one at current take-off rates is an
pipeline. Blasting is carried out twice a week the monthly coaling volume from 70,000 t to estimated five years. Phase two, comprising mining
and Concor Opencast Mining is given a 10 110,000 t/month. He estimates life of mine as 20 of the entire 587 ha project area and including the
minute window by the South African National years, which aligns with the company’s mining central and northern reserve, extendslife of mine
Roads Agency to carry out the blast, during which licence. to the stipulated 20 years. www.concor.co.za
6 International Mining| FEBRUARY 2012
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OPERATION FOCUS
More Norbotten
iron
Northern Sweden has a long iron ore
tradition. John Chadwick recently visited
the latest project there – Northland
Resources’ Kaunisvaara iron ore, for which
Metso is providing major process solutions
On site at the beginning of November, Building capacity from the surrounding bog by a dike. Eventually
offices stood empty, work continued on Current material movement is restricted to the pit will be 2.6 km long, 750 m wide and 350
the shell of the massive process plant quarrying for rock to build infrastructure and m deep.
and at the Tapuli open pit, prestripping was prestripping of the Tapuli pit. All this is being Sahavaara’s dimensions will be 2.1 km x 750
rapidly exposing the ore. On November 10, the undertaken by Peab using a fleet of Volvo ADTs m x 360 m. However, it is open at depth and the
offices were occupied and in that manner (A40s), wheel loaders and hydraulic excavators. ore quality gets better with depth. This mine
another major step forward was taken in the Some 10-12 m of swampy overburden (peat and could eventually go underground. Beyond that,
development of this high-grade iron ore till/moraine) is being dewatered (5,000 m3of Northland has identified about 30 mineralised
concentrate project. water pumped out daily) and removed at a rate prospects on its tenements that will all be
To start with Northland will mine the Tapuli of about 20,000 m3/d to expose the Tapuli ore. explored in more detail in due course.
and Sahavaara deposits in northern Sweden, All the overburden will have been stripped by The schedule has been designed to ensure
about 100 km north of the Arctic Circle in the autumn 2012. Tapuli will have to be isolated mine production is not affected by the
municipality of Pajala and near the village of
Kaunisvaara. The Sahavaara deposit is located
close to the centre of the Kaunisvaara village
and Tapuli is some 4 km to the north of
Sahavaara. There is also the Pellivuoma deposit
about 15 km from Kaunisvaara, which should
extend the life of the Kaunisvaara area.
The plan is for Kaunisvaara to begin
production first, at 5 Mt/y and a second (2 Mt/y)
mining operation will be developed across the
border in Finland at the brownfield site of
Hannukainen. A DFS is to be completed in this
first quarter of 2012. Mining of Tapuli ore will
start in the fourth quarter of 2012, with the first
shipment from of concentrate from the Port of
Narvik in the first quarter of 2013.
8International Mining| FEBRUARY 2012