general overview of the infrastructures for a large mining project in panama - john whitaker
TRANSCRIPT
Minera Panamá
General Overview of the Infrastructures for a large
Mining Project in Panama
Cobre Panama Project
By: John Whitaker/Jose Garcia
April 18, 2012
TABLE OF CONTENT
• Project History
• Project Overview
• Port Infrastructure
• Main project infrastructures: General Plan
• Design and construction challenges
• Tailings Management Facility
• Port Facility
• Dams
• Concluding remarks
• Acknowledgements
2
Project Background and History
Project has been known and studied for 44 Years • Potential of the Mina de Cobre Panamá project investigated since 1968.
• 1977 Preliminary feasibility report prepared by Panamá Mineral Resources Development
Co. Ltd. in - updated 1979.
• 1994 Prefeasibility study issued for Adrian Resources Ltd and updated in 1995
• 1996 Feasibility study for Teck Corporation - update 1998.
• 1998, Document was submitted to Dirección General de Recursos Minerales (DGRM) and
accepted as the official Feasibility Study to satisfy concession law requirements
• 1997 The Petaquilla (Mina de Cobre Panamá) concession rights granted to Minera
Petaquilla, S.A., now Minera Panamá, S.A. (MPSA), under Panamanian Law No. 9.
• 2008 Inmet acquired Petaquilla Copper Ltd., and Inmet Teck Cominco’s remaining share
in MPSA, taking Inmet to a 100% interest in MPSA.
• 2007 Draft Interim FEED Report (AMEC, 2008) commenced, to bring the Mina de Cobre
Panamá project (then known as the Petaquilla project) to full feasibility level
3
Project Background and History
Project has a 44 year history. (Cont)
• The project name was changed to Mina de Cobre Panamá in 2009.
• FEED Study issued April 2010 followed on from the Draft Interim FEED Report.
• Basic engineering commences November 2011ESIA
• Work commenced in 2008.
• ESIA approval granted by ANAM Dec 2011
• Basic Engineering completed March 2012
• Early works are underway to:
– Upgrade site access from Llano Grande to site
– Construction of bypass road around Petaquilla Gold operations
– Construct a pioneer road to the NE corner of the tailings dam for early access
– Establish and open-up the principal site quarry for construction material
– Establish initial construction camps onsite
4
Project Background and History
Project has a 44 year history – Site Activity
5
1967–1969 United Nations Development Program (UNDP) identified deposit
1970–1976 Panamá Mineral Resources Development (PMRD (Japanese
Consortium) carried out additional site investigations
1992–1995 Adrian with Minnova and Teck undertook extensive site exploration
including extensive airborne geophysical investigations
1996–1997 Teck undertook additional exploration
2006–2008 Petaquilla Copper continued additional exploration and Geophysics
2008–20012 MPSA Continued extensive resource definition and geotechnical
drilling
Drill Programs
Since 1968 a total of 307,075 m have been drilled in 1577 holes define the resource
and characterize ground conditions
MINERA PANAMA FACTS
Production Summary 30 year Mine Life.
• Mill initially throughput -150,000 t/d ore @ up to 0.7% Cu & 0.013% Mo
• From Year 10, throughput increased by 50%, to a nominal 225,000 t/d, to
maintain production despite a falling head grade.
• Total tonnes scheduled to be mined 3,681 Mt
• Total tonnes scheduled to be milled 2,319 Mt
• Metallurgical test work - conventional flow sheet of crushing, grinding, differential
flotation.
• LOM total of 27.289 M dmt Cu cons @ 28% Cu, containing
• 7.641 Mt Cu, 2.690 M troy oz Au, 45.228 M troy oz of Ag
• 185,648 dmt Mo cons @ 52%, containing 96,537 tonnes of Mo
• Mo cons will also contain 520 g/t of rhenium..
6
PROJECT LOCATION
7
PROJECT
Panamerican Highway
Port Site
Transmission
Line
Coast Road
Tailings
Management
Facility
2km
Project Infrastructure
8
There are distinct and separate
construction areas all projects within their
own right.
• Port Marine development and logistics
infrastructure
• Port Concentrate dewatering infrastructure
• 300 MW power plant
• Process plant site and ancillary infrastructure
• Botija pit prestrip and development
• Tailings management facility and associated
infrastructure
• 230 kV overhead power line & Llano Sanchez
Substation
• Coast Road and pipelines.
• Eastern Infrastructure
Process Plant
Plant Site
Facilities
Mine Pits
Waste Storage
Facilities
Power Plant
Project Overview
Four major ports:
▪ 3 – Colon (1,2,3)
▪ 1 - Panamá City (4)
Punta Rincón 90 km Port of Colon by sea
1,2,3
4
Road
Panamerican highway:
▪ Project is 215km by road from Panama City via
Penonome on existing road infrastructure.
▪ Existing 46km gravel road Llano Grande to Site being
upgraded.
230 kV Power
National Power Grid parallels the Panamerican highway
Cobre
Panama
Existing Infrastructure
10
Environmental issues
• High Rainfall 4500 – 5000 mm/y
• Saprolitic soils – Ave depth 22 m
• Stringent enforcement of BMP to
manage erosion and sediment
control
• Difficult access – helicopter only
• .
11
Fresh rock
Saprolite oxidized (0-40 m)
Saprock (weathered rock)
Residual soil (<1 m)
Water table
Saprolite reduced
(limited)
Rock sources initially limited
Saprolite Profile
Environmental issues
Flora and Fauna Rescue and Clearing
12
• Stringent commitments to managing the
rescue and relocation of flora and fauna
• Stringent Project and ESIA commitments
relating to Flora and Fauna rescue and
relocation
• Partnering arrangements with prestigious
institutions
– Smithsonian Tropical Research Institute
(STRI)
– Missouri Botanical Gardens
– Kew gardens
– and other international experts to identify
SoC and rescue and relocation protocols.
• Clearing rates of up to 4 ha will be required
to achieve project development
C1002A – Port Site Earthworks, 6.6 / 0.3 C1002B – Port Off-Shore, 0.0 / 0.33 C9007 – Aggregate Supply (Port), 1.3 / 0.0
C1003 – Plant Site Mass Earthworks, 7.1 / 5.0 C9007 – Aggregate Supply (Mine), 4.0 / 0.0 Mine Prestrip total 65.4 Mm3 by contractor and owner
Notes: 1) Volumes - Cut / Fill (Million m3) 2) C9007 – Quantity shown only for overburden removal. 3) Quantities calculated by JVP as of January 12, 2012
EARTHWORKS
PACKAGES OVERVIEW
C1004A – Eastern Access Road, 0.6 / 0.5 C1004B – Coast Access Road, 3.3 / 5.1 C1010A – Tailings Dam Mass Earthworks, 2.7 / 8.7
Earthworks
Earthworks Summary
• Clearing and Grubbing
• Stripping: 2,7 million m3
• Excavation:
• Mass
• Saprolite
• SapRock
• Rock Excavation
• Backfilling:
• General
• Rip Rap
• Total Earthworks: 104.4 million m3 (Incl. Owner’s Pre-strip)
• Concrete: 160,000 m3(not including Power Plant)
Earthworks
Major Equipment
• Hydraulic Excavators: 20T – 300 T
• Rigid Trucks: 60T – 200T
• Articulated Trucks: 25T – 40T
• Mack Trucks: 15T
• Bulldozer: Caterpillar D5 – D9T
• Compactor: 5T – 10T
• Grader: Caterpillar 140 / 160
• Crusher: 350 T / hour and 1000 T / hour
• Mobile Crusher: 250 T / hour
• Hydraulic Drills: 3” – 9” 7/8 Diameter
• Maintenance Vehicles
• Bulk Explosive Trucks
• Water Tanker Trucks (5, 000 – 10,000 gallons)
• Mobile Light Plants
• Generators
CAT 789C – 200T Capacity
Typical Mine Pre-Stripping Equipment
Project Overview - Port Site Current
Rio Caimito village
Punta Rincon Rio Caimito village
Port
17
Punta Rincon area is currently
assessable only by sea or helicopter
Facilities to be established include
• Port Marine development and logistics
infrastructure
• Port Concentrate dewatering
infrastructure
• 300 MW power plant
Construction will need to be serviced
from sea (Colon) until road constructed
to Mine.
Construction camp for up to 4000.
Port Facilities overlay on Existing
Topography
Port Layout
Overall Port Facilities 3D Model
19
Power Station
Coal Yard
Barge Berth
Bulk Berth
Cons. Storage
Filter Plant
Port Layout
Overall Port Facilities 3D Model
20
Concentrate Dewatering Facility
21
• Concentrate received as slurry from Plant to max 230 tpy
• Dewatered by three pressure filters to nominal 9% moisture.
• Filtered concentrate transported by conveyor into concentrate
storage shed (nominal 100,000 t capacity) for load out to export
ships.
Power Plant Overview
2 x 150 MW gross (136.9 MW net) Pulverized Coal-fired power plant
• Design fuel is sub-bituminous coal from Colombia
• Emissions controls – Low NOx burners, SCR, baghouse and seawater
FGD scrubber.
• Condenser cooling – seawater, design inlet temp is 30C, delta T is 7C for
condenser, 2C for FGD, total 9C
• CCW flow approx. 50,000 M3/hr
Project Power Demand
Year 1-9
− Peak load range is 226 to 257 MW , Running load range is 206 to 233 MW
− Years 1-9 Will have about 40 MW available for export
Year 10 onwards (after addition of 3rd mill)
− Peak load range is 338 to 343 MW, Running load range is 307 to 312 MW
− Use grid power when units not available
− Years 10-30, when 3rd line is installed, import power
230 kV Power line
23
▪ Power Station
▪ Route 123km
– 96km, Llano Sanchez – Minesite
– 4.5 km Minesite Sub – Plant
– 24km Minesite – Power Station
▪ Minesite Substation
▪ Plant Site
▪ Line Details
– Double Circuit
– Cond. ACM 1024 518 mm2
– OPGW 58 mm2
– Integral 48 fibre FO for SCADA
– Construction Land/Helicopter
▪ Llano Sanchez Substation
National Grid
Coast Road
• Road to be constructed to connect the port at Punta Rincón on the Caribbean Sea
with the mine/plant site.
• Approximately 30 km long
• Designed for the transport of freight and equipment, including all oversized
equipment, needed for construction and operation of the mine/plant facilities.
• Max Gradient 10%, 8m pavement, 1.5 m shoulders
• Two significant bridges over Rio Uvero and Medio
• The Road will incorporate pipeline right-of-way for three buried pipelines concentrate,
diesel fuel, filtrate water return that will run between the two project sites.
24
• Concentrate Pipeline 291 mm dia (8.625”) X427.92 mm wall, HDPE liner
• Diesel Pipeline 114 mm dia X52 • Filtrate return line 291 mm dia (8.625”) X52
Project Overview - Mine Site Current
MPSA camp
Botija camp
Petaquilla Peak
Botija Pit
MPSA camp Colina camp
Petaquilla Peak
Botija Pit
0 kilometres 2
Mine Infrastructure Layout LOM
26
Colina pit
Botija pit
Valle Grande pit
Plant
LG Stkpile
Botija South Dump
Saprolite Dump
Colina WRSF
Botija West Dump
Southwest WRSF
Botija Crusher
Colina Crusher
Tailings Facility
Mining Sequence - Year 0 (Start-up)
27
Mining Sequence - Year 5
28
Mining Sequence - Year 10
29
Mining Sequence - Year 15
30
Mining Sequence - Year 20
31
Mining sequence - Year 25
32
Mining sequence - Year 30
33
PP-2 PP-1 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y11-15 Y16-20 Y21-25y26-30*
Waste 46 65 40 25 35 31 40 52 61 57 54 59 54 27 5
Ore to Stockpile 11 20 24 23 21 22 10 17 7 8 5 1 2 0 0
Ore to Mill 0 1 42 58 57 57 56 57 57 57 55 80 83 84 74 73
-
20
40
60
80
100
120
140
160
Tonnes(millions)
Mining Schedule
Mine Plan (Mt/y)
• overall mining rates 100-130 mtpy for 9 yrs
• peak rates of 140 mtpy yr 10 to 20
• about 20 mtpy to stockpile to year 4
Process overview
35
• 2 Gyratory Crushers 60in X 110in, 1,200 kW drive
• Crushing Rate max 220,000 tpd. P80 75 ~ 125 mm
• Overland conveyors 2.134 m wide, 4.5 m/s, 10,115 tph
• 2 SAG mills, 12.2m x 7.3m, 28 MW, P80 4.9 mm
• 4 Ball mills, 7.9m x 12.8m, 16.5 MW, P80 180 μm
• Rougher flotation, 4 banks of seven 300 m³ cells
• Re-grind, two banks of eight 100 m³ cells,
• Two stages column cells
• Molybdenum separation
• Concentrate pumping and
• Pipeline to port, 34 km long, 290 mm dia.
• Pressure filters, concentrate storage facility 100 kt capacity
• Filtrate return line
Crushing
Dewatering
and storage
for shipping
Grinding
Flotation
Mill Process Flow
36
From bulk concentrate thickener
PROCESS FLOW - Molybdenum
37
Mine / Plant Layout
Overall Process Plant 3D Model
38
Tailings Storage Facility
Colina WRSF
Valle Grange Pit
Cilina Pit
South West WRSF
Eastern Infrastructure
(Construction and Permanent Camps)
Process Plant
Botija South WRSF
Crushing Station
Botija Pit
Botija West WRSF
& LGO Stockpile
Mine / Plant Layout
Overall Process Plant 3D Model (close-up)
39
Process Plant
Botija South WRSF
Crushing Station
Botija Pit
Botija West WRSF
& LGO Stockpile
Truck Shop
Major Facilities Plant Site
40
655 m
Coarse Ore Stockpile
(450,000 t)
Process Plant
Mine Substation
655 m
Truck Shop
Crusher
Process Plant Layout
41
Mine Substation
Grinding
Flotation
Concentrate
Thickening
Mill Workshop Regrind
Moly Plant
Coarse Ore Stockpile
Project Overview - TMF Site current
Starter Dam
East Abutmen
t
N
East Dam Alignment
East Infrastructur
e Plant Site
Starter Dam
East Abutment
N
North Starter Dam Alignment
TMF Construction
Tailings Basin Schematic – Year Zero
43
Tailings Dam
• Ultimate surface area ~2500 ha
• Starter Dams 38 m high
• Site specific Seismic study
undertaken to establish design
Seismic design criteria
(applicable for all site facilities)
• Detailed diversion work required
to divert existing streams to
enable construction
• Total 11.4 M m3 material to be
handled to complete construction
• Borrow area established within
the TMF for requires material
• Total of 1300 ha required cleared
of Flora and Fauna and trees
felled
• 137 ha requires to be fully
grubbed for construction
2 km
TMF Underdrainage Design Update
North Dam – Drain Details
44
Drain Elevated
Overall Slope – 1% min
TMF Sand Dam Construction
North Starter Cross Section
45
TMF Tailings Basin Schematic – Year 22
• Final surface area 2500 ha
• Final wall height 100 m
• Total contained tailings 1.3 Bt
• Total Volume cycloned sand
used for downstream wall
construction 200 Mt
TMF Sand Dam Construction
Staged Dam Raises
47
10. Sand Dam Construction
Upstream Sand Dam Construction
48
Eastern Infrastucture and Support Facilities
• Camps
– Construction camps will be constructed for a minesite workforce of 4500
persons
– Permanent Operations camp for 2100 persons
• Security Facilities
• Panamanian Police station
• Hospital clinic for site workforce medical treatments and emergency
stabilization prior to medivac
• Potable water facilities
• Sewerage treatment Waste handling (landfill, incineration, hazardous
materials)
• Heliport
• Bus terminals
• Site Power generation
• Fuel storage and distribution facilities
• Blasting Agent Magazines
49
Project Execution Challenges
• Health & Safety Culture
• Environmental challenges
• Flora & Fauna Rescue & Relocation
• Erosion and Sediment Control
• Climatic Conditions
• Heavy Rainfall
• Port Site Access
• Equipment & Materials
• Manpower
• Timing & Availability (Beach landing and Construction Wharf)
• Logistics
Execution Challenges
• Seismicity
• Site readiness - Facilities (e.g. accommodations)
• Aggregates
• Lack of skilled in-country construction resources
(Local Resource Development Initiative)
• Labour Productivity