Toquepala Copper-Molybdenum Mine

Toquepala Copper-Molybdenum Mine

Toquepala operations consist of an open-pit copper mine and a concentrator. Copper is refined at the SX/EW facility through a leaching process. The concentrator has a milling capacity of 60,000 tons per day and uses an state of the art computering monitoring system in order to coordinate inflows and optimize operations.

The SX/EW facility has a production capacity of 56,000 tons per year of LME grade A copper cathodes of 99.99% purity from solutions obtained by leaching low-grade ore stored at the Toquepala and Cuajone Mines. The Toquepala concentrator expansion, for which Environmental Impact Assessment (EIA) studies were recently approved, will increase annual production capacity by 100,000 tons of copper and 3,100 tons of molybdenum at a total capital cost of approximately $1.2 billion.

Toquepala is located in southern Peru, 30 kilometers from Cuajone and 870 kilometers from Lima. Overburden removal commenced in 1957 and ore production commenced in 1960. Toquepala operations utilizes a conventional open-pit mining method to collect copper ore for further processing in the respective concentrator.

Milestones

  • 2014

    EIA Approved for plant concentration and tailings deposit expansion

  • 2002

    Expansion to 63000 t/d

  • Expansion to 43000 t/d

  • Construction at 39000 t/d

ABB
2016
US$ 4.5M

Gearless Mill Drive systems (GMDs)

ABB

Provisioning variable-speed drive systems as part of SPCC brownfield optimization and expansion projects. For the expansion project, which aims to double the mine’s concentrator milling capacity from 60,000 to 120,000 tons per day, ABB is supplying two 25-foot gearless mill drive systems (GMD) of 15MW.

The GMD systems by removing critical mechanical components like ring-gear, pinion and gearbox, are about 4% more energy efficient than traditional fixed-speed mill drives.

Source: ABB
15000Mill rated power (KW)
ABB
2016

High Pressure Grinding Roll (HPGR) Drive System

ABB

Provisioning variable-speed drive systems as part of SPCC brownfield optimization and expansion projects. For the expansion project, which aims to double the mine’s concentrator milling capacity from 60,000 to 120,000 tons per day, ABB is supplying two complete high pressure grinding rolls (HPGR) drive systems of 2 x 2,650 kW.

The HPGR drive systems feature the RollXtend technology, aimed to extend the rollers’ overall life time.

Source: ABB
2650Mill rated power (KW)

Geotechnical studies

Anddes Asociados

Geotechnical studies for the optimización High Pressure Grinding Roll (HPGR) Drive System provisioning project.

Source: Anddes Asociados

Detailed engineering

GMI Ingenieros Consultores

Detailed engineering and procurement of the new workshops for light and medium equipment tractors.

Source: GMI Ingenieros Consultores

Hydrological studies

Geoservice Ingeniería

Consultancy services on the preparation of studies on surface, underground water resources and hydraulic infrastructure link to the basin river Locumba water resources usage plan.

Southern Peru is working with the authorities of the Candarave province following the June 2013 signed agreements between the National Water Authority, local authorities and the Candarave Board of Water Users in regards to the hydrogeological study of the Locumba river in order to improve the water utilization in the province.

Source: Southern Cooper Corporation and Geoservice Ingenería
Walsh Peru S.A
2014
US$ 160.7K

Environmental Impact Assessment (EIA)

Walsh Peru S.A

Walsh was in charge of the Environmental and Social Impact Assessment (ESIA) studies providing adequate information to existing features of the areas of influence of the Toquepala project to expand the concentrator plant capacity to a level of 100,000 TMD.

The scope of the project was to determine the likely and actual impacts of the project on environmental resources and social issues, a cost/benefit of the project and specific contingency plan to address environmental risks were also included .

According to directorial resolution Nº611-2014-MEM/DGAAM given on Dec 17th 2014, the EIA study for plant concentration and tailings deposit expansion were approved Peruvian Ministry of Energy and Mines.

Source: Walsh Peru S.A
Itasca S.A.
2013

Drilling

Itasca S.A.

Program of oriented geotechnical drilling, totaling 20,000 meters, was executed at the Toquepala mine. This program, which began in May 2013, is part of the slope stability upgrade study and it is being executed by the team of mining consultants, including Itasca S.A., Stacey Mining Geotechnical Ltd. and Piteau Associates.

During the execution of this program additional instrumentation has been implemented, including eight vibrating wire piezometers. The study report will include slope stability appraisals, evaluation of the numerical modeling, slope performance and inter-ramp angle design and evaluation of hydrogeological conditions.

Source: Southern Copper Corporation
20000Drill Depth (m)

Stability analysis studies

ZER Geosystem Perú

Analysis of the physical stability of reinforced soil retaining wall located in the area of ​​primary crusher within the Toquepala project.

The analysis of the physical stability is based on information from results of laboratory tests made by JJC General Contractors SA and parameter information of the wall by Freyssinet Tierra Armada Peru SAC who undertook the analysis and design of the wall of reinforced soil.

The present study aims to verify the physical stability of reinforced soil wall and the stresses and strains that occur in the soil foundation, for this purpose a Geotechnical finite elements algorithm was used.

Source: ZER Geosystem Perú S.A.C
Arcadis Peru SAC
2012
US$ 73.2K

Engineering and Design

Arcadis Peru SAC

Study and development of engineering as well as procurement service in order to perform system optimization water pumping at Quebrada Honda.

Source: Arcadis Peru SAC

Geophysical survey

ZER Geosystem Perú

Technological improvements in ore transport system to Toquepala concentrator plant and new mine workshops. Geophysical exploration by seismic refraction methods Multichannel Analysis of Surface Waves (MASW).

Source: ZER Geosystem Perú S.A.C
JJC Contratistas Generales S.A. (JJC)
2012
US$ 465.5K

Civil works

JJC Contratistas Generales S.A. (JJC)

Civil works on crushing building , tunnel and intermediate stack for technology improvement project on Toquepala mine operations.

Source: JJC Contratistas Generales S.A.
Buenaventura Ingenieros S. A. (BISA)
2012

Engineering and procurement

Buenaventura Ingenieros S. A. (BISA)

Basic engineering, detailed engineering and procurement services for new maintenance workshops on Toquepala mine equipment.

The activities were executed covering areas of civil, structural, architecture, mechanical, piping, instrumentation and procurement.

Source: Buenaventura Ingenieros

Advertising clothing

Industrial Textil Runa

Supply of advertising clothes and personal uniforms. Delivered products included round necked jersey t-shirts.

Source: Industrial Textil Runa
Hatch Ltd.
2008

Engineering, Procurement and Construction (EPC)

Hatch Ltd.

Hatch has been retained by Southern Peru Copper Corporation (SPCC) to provide engineering and procurement services for the Toquepala Expansion Project, located in Peru.

SPCC is undertaking a project at the Toquepala open-pit copper-molybdenum mine to expand the capacity to 100,000 tpd. Hatch will provide engineering and procurement services covering the feasibility study, basic and detailed engineering, and procurement phases of the project. Hatch Santiago and Hatch Lima are undertaking the assignment.

Source: Hatch
Tenova TAKRAF
2005
US$ 302.8K

Conveyor Belt System

Tenova TAKRAF

Tenova TAKRAF designed and supplied a conveyor bridge for the Toquepala porphyry copper mine, an open-pit mine producing copper, molybdenum, rhenium and silver with minor gold and zinc.

The conveyor bridge has a lift height of 12m, conveying capacity of 8,350 t/h, height of 15.6m, total length of 150m, outreach boom length of 33.5m, span width of 115m, belt width of 1.828m, belt speed of 4.4 m/s.

Source: Tenova TAKRAF
0.150Length (km)8350Transport Capacity (t/h)4.4Belt Speed (m/s)1828Belt Width (mm)
Cosapi Ingeniería y Construcción
2004
US$ 9.7M

Civil works

Cosapi Ingeniería y Construcción

The scope of work includes the construction of a grinding system, transport and stacking of ore for leaching. It includes the construction of fixed crushing system to then transport the ore by a combined system of belt conveyors. Stacking and distribution is made towards two streams where low grade sulfide ore deposits are formed to then be leached.

Its includes the building construction that will house the crusher, excavations with a volume of 80,000 m3 and fillings with a volume of 30,000 m3 were performed for such construction.

320,000 m3 volumen of earthmoving works are executed for the installation of a conveyor belt. Excavations were carried by a volume de 75,000 m3 for the construction of a transfer tower which starts the mineral stacking system.

Source: Cosapi Ingeniería y Construcción
0.32Earthworks (million m3)155Excavations (miles m3)

Belt Rip Detection

Kingdom Solutions

Commissioning of 01 equipment Master BPS-A2-M2G y 01 equipment Slave BPS-A1-S to protect 2.5km of conveyor belt located in Toquepala concentration plant.

Source: Kingdom Solutions
2.5Length (km)
Equipos de Detección de Corte Coal Control de Kingdom Solutions – Ventajas y características-18_4

Belt Rip Detection

Kingdom Solutions

Commissioning of 01 equipment Master BPS-A1-M2G y 01 equipment Slave BPS-A1-S to protect the conveyor belt CV-017 on the leach deposit plant.

Due to an special connection between a belt with shape 8 antennas and another one, of different brand, with 0 shape antennas in the aforementioned plant, it was necessary to use Coal Control GmbH equipment as other equipments were not able to detect said antenna configuration.

Source: kingdom Solutions
Equipos de Detección de Corte Coal Control de Kingdom Solutions – Ventajas y características-15_4
Cesel Ingenieros
US$ 139.5K

Detailed engineering

Cesel Ingenieros

New copper concentrator plant of 40.000 t/day separated from the current one. Including a moly and filter plant, with contact's points to existing concentrator facilities. Including tailings conveyance and concentrate shipment facilities.

Design of primary crushing and a 2,3 km tunnel, with a belt conveyor for transportation of the crushed ore to the coarse ore stockpile; molybdenum flotation plant, concentrate and tailings thickeners, filtration plant of copper and molybdenum concentrates; electrical and water supply systems, access roads and auxiliary facilities.

Source: Cesel S.A.
Ulma Construction
US$ 465.5K

Civil works

Ulma Construction

The Leachable Deposits Formation Project is part of the Toquepala mine modernization plan. The primary structure is the Crushing Building, which has the mission of crushing the large volumes of minerals hauled to the building.

The Primary Crushing building stands 41 m tall and covers a surface area of 390 m2. The crushing building was divided into two zones: the primary zone includes the main slabs (three total) and is divided into four levels, while the secondary zone includes the auxiliary slabs (four total) and is divided into four levels.

The Primary Crusher also included the 41 m high cut-off wall construction with total slurry wall surface area of 1,800 m2. Approximately 7,000 m3 of concrete was poured in the crusher building.

Source: Ulma Construction
1800Slurry wall surface area (m2)7000Concrete poured (m3)

More contracts, contractors and photos are included in the PDF.

Snapshot

Capital Expenditure
US$ 1.1B
Project Status
Expansión
Environment Impact Study Approval Date
December 2014
Mine Type
Open pit
Metals mined
Copper, Molybdenum
Type of Ore Body
Porphyry system
Concentrator facilities (tpd)
60000
legal.unidad
ACUMULACION TOQUEPALA
Electricity Requirement (MW)
80

Top Contractors

Southern Peru Copper Corporation Sucursal Del Peru
Cosapi Ingeniería y Construcción
ABB
JJC Contratistas Generales S.A. (JJC)
ZER Geosystem Perú

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