Toromocho copper, molybdenum and silver mine

Toromocho copper, molybdenum and silver mine

Toromocho mine is located at an altitude of 4,480 to 5,000 meters above sea level in Morococha, Yauli province in Peru. Under the original EPC design, the facility is capable of treating 117,200 tons of ore per day and producing in excess of 210,000 tons of copper annually, plus byproducts of silver and molybdenum.

Minera Chinalco Perú S.A., a subsidiary of Chinalco Mining Corporation International (CMC) is boosting the mine's productivity with a new production line. Through the expansion of the mine and the resulting increase of the mining volume Toromocho sets to become the most productive mine in Peru.

Situated in the ore-rich Morococha mining district of the western Andes, Toromocho contains an estimated 7.3 million tons of copper and 4.7 million tons of molybdenum, silver and other metals.

Milestones

  • 2013

    Mining plan approval

  • 2013

    Authorization to start exploitation activities

  • 2011

    Mining plan approval

  • 2010

    EIA approval

Siemens
2014
US$ 4.5M

Gearless Mill Drive systems (GMDs)

Siemens

Siemens delivers two gearless mill drives and Sinamics cycloconverters to Minera Chinalco Perú S.A.

The Siemens Drive Technologies Division is delivering an Integrated Drive System for two new mills for the Toromocho mine in the Peruvian province of Yauli. In future, two gearless mill drives and water-cooled Sinamics cycloconverters will be used in the new production line with one SAG mill and one ball mill. Thus, 1 million tons of copper concentrate, 10,000 tons of molybdenum and four million ounces of silver oxide can be mined annually – even at an altitude of around 4,600 meters above mean sea level.

In future, the 36-foot SAG mill of the new production line will be operated with a 13.5-megawatt drive. A further gearless mill drive with 22 megawatt output will ensure equally efficient and reliable driving of a ball mill with an inner diameter of 28 foot.

Source: Siemens

Project control support

GMI Ingenieros Consultores

Consulting services and project control support for Toromocho mining operation.

Source: GMI S.A. Ingenieros Consultores
Jacobs Engineering Group
2013
US$ 108K

Feasibility studies

Jacobs Engineering Group

Perform a feasibility study for the expansion of Toromocho copper mining facilities. Project is expected to be executed out of Jacobs Lima-Peru office with assistance from its Santiago, Chile and Tucson, Ariz., US offices.

Major equipment required for the proposed capacity expansion includes apron feeders, a conveyor system for mill feed, a semi-autogenous grinding (SAG) mill, a ball mill and cyclones, flotation cells, a tailings thickener, and all associated equipment. The existing plant layout allows for the integration of new equipment required for the current expansion.

Source: Jacobs Engineering Group Inc.
Techint Engineering & Construction
2013

Hydrometallurgical plant

Techint Engineering & Construction

The project includes the construction, installation and implementation of an hydrometallurgical plant and molybdenum filter. The expected duration of the works is 14 months.

The main equipment to install are: Filtering units of compression copper concentrate (56.2tn at 10m high), 65t3/day oxygen plant, 22 tn oxygen compressor, 10 m3/h ACD concentration filters (45.3tn at 7m high), 20 m3/h reverse osmosis plant, 1.8 t/h ADM rotary calciner and automated equipment for molybdenum oxide packetization.

Source: Techint Engineering & Construction
San Martin
2013
US$ 465.5K

Civil works

San Martin

Construction of platforms (45ha), conveyor belt corridor, main road and access rodas, execution of earthwork necessary for future processing areas and infrastructure project.

The main activities of the project include: Earth-moving, excavation of coverage soil and common material, rock excavation, rock excavation by drilling and blasting methods, mass fills, structural fills and placement of base material as well as civil works on platforms, macaferry walls, gabions, tunnels.

Source: San Martín
3.5Man-Hours (Million)
C2 Mining
2012
US$ 1.6M

MESH Networks

C2 Mining

Development of engineering, procurement, construction, commissioning support of wireless communications system for voice, data and video transmision services at Toromocho project.

Activities included installation of communication equipment linked to heavy fleet (drills, shovels, loaders, trucks, and excavators) and integration with the ministar system.

Source: C2 Mining

Budget and Cost Engineering

GMI Ingenieros Consultores

Pre-investment and investment studies for the rehabilitation and improvement of Cut Off - Yauli highway.

Source: GMI S.A. Ingenieros Consultores
Cosapi Ingeniería y Construcción
2012
US$ 1.1M

Civil, structural and mechanical frameworks

Cosapi Ingeniería y Construcción

A consortium comprised by Cosapi and GyM was hired to implement structures assembly, piping and wet area equipments on Toromocho concentrator plant project.

The consortium installed 01 SAG mill (40'x26'), 02 ball mills (28'x44'), 2 vibrating screens (14'x28') and 28 Rougher flotation cells (Diameter 9m H= 7m, V= 300m3)

Source: Cosapi Ingeniería y Construcción

Assembly of steel structures

GyM

Assembly of steel structures, mechanical equipment and pipelines for the wet area of the concentrator plant.

Includes the erection of two ball mills and one SAG mill, in addition to functional testing and pre-commissioning of all equipment. Associated works.

Source: GyM
Swisscontact
2012

Capacity building of local businesses

Swisscontact

Commissioned by Minera Chinalco Peru SA , Swisscontact runs this project with the aim of improving the skills and competences of local businesses within the new town of Morococha (Junín) in order to to strengthen its management, increase sales and achieve greater market competitiveness locally.

In ordert o achive these goals, Swisscontact is training traders on issues about formalization, implementation of good practices, promotion and marketing, among others.

Source: Swisscontact
Nexans
2011

Electricity Procurement

Nexans

Cosapi Ingeniería y Construcción
2011
US$ 465.5K

Civil works

Cosapi Ingeniería y Construcción

The civil works correspond to the so-called "Wet Area" project which is related to the concentrator areas where grinding and flotation would be executed. Civil works also includes tasks for compressor and fun buildings, foundations for tanks & power rooms as well as service pipes.

Source: Cosapi Ingeniería y Construcción
Walsh Peru S.A
2011
US$ 84K

Closure plan preparation

Walsh Peru S.A

The mine closure plan (MCP) provides activities related to temporary closure, progressive closure as well as final closure of the mining project Toromocho.

Decommissioning activities of processing facilities as well as facilities for waste management, water management and hosting services for workers are also mentioned. Additional tasks of demolition, salvage and disposal are also included within the MCP.

According to directorial resolution Nº434-2012-MEM/AAM given on December 21st 2012, the mine closure plan for Toromocho Project was approved meeting the technical requirements for the Peruvian Ministry of Energy and Mines.

Source: Peruvian Ministry of Energy and Mines

Earthworks

Stracon GyM

From April 2011 to August 2013, STRACON GyM undertook the earthworks for the construction of the Tailings Storage Facilities (TSF) and associated structures. These works included the building of access roads, diversion channels, dams and sediment ponds, placing geomembrane, concrete preparation, as well as the development and operation of quarries.

The total scope included 7.5 million m3 of earthworks, placing 120,000 m2 of geomembranes and 30,000 m3 of concrete. The work was conducted in partnership.

Source: Stracon GyM S.A.
7.5Earthworks (million m3)30000Concrete poured (m3)120000Geomembranes placed (m2)
Tecno Fast
2011

Camps and field offices development

Tecno Fast

The Tunshuruco camp is located on the Chinalco property near the town of Pachachaca. Mining believe this project generates a considerable improvement in the quality of life of local people.

For the achievement of the above, Tecno Fast was chosen for the construction of this new project, currently the most important one in Peru project. The project consists of 28 buildings, four of which are one-story and 14 three.

Source: Tecno Fast
32034Surface Area (m2)3864People Capacity
Abeinsa Ingeniería y Construcción Industrial
2011

Engineering, Procurement and Construction (EPC)

Abeinsa Ingeniería y Construcción Industrial

Engineering, procurement and construction EPC covering civil and electromechanical work of the 220 kV Pomacocha-Toromocho transmission line, the 23 kV Toromocho-Kingsmill distribution line and upgrades to the Pomacocha substation.

Source: Abeinsa Ingeniería y Construcción Industrial
ABB
2010

Extended Automation

ABB

ABB has won an order from Minera Chinalco Peru S.A. to supply electrification and automation systems for a new copper mine and concentrator plant.

ABB will engineer and supply the 23 kV (kilovolt) main switchgear, unit substations and distribution transformers, prefabricated electrical rooms containing medium- and low-voltage switchgear, variable-speed drives and motor control centers, as well as a plant-wide process automation system using ABB’s Extended Automation System 800xA.

Source: ABB
FLSmidth  Minerals
2009
US$ 302.8K

Conveyor Belt System

FLSmidth Minerals

FLSmidth has signed a contract with Chinese-owned Minera Chinalco Peru for equipment for its Toromocho copper mine.

FLSmidth is to provide detailed engineering and design, as well as manufacture and delivery of equipment, including two overland conveyors. The overland conveyor will be one of the most complex conveyors in the world, it will be 5.2 kilometres in length and have 9 MW of installed power. The conveyor will have complex vertical and horizontal curves and can demand or regenerate power depending on loading conditions.

Source: FLSmidth Minerals
5.2Length (km)9000Rated power (KW)
FLSmidth  Minerals
2009
US$ 30M

Engineering and Design

FLSmidth Minerals

FLSmidth is to provide detailed engineering and design, as well as manufacture and delivery of equipment, including two overland conveyors, seven in-plant conveyors, and two belt feeders.

The conveyor solution included in this order consists of cutting-edge technology and know-how - making it one of the most complex conveyors.

Source: FLSmidth Minerals
Knight Piésold
2009
US$ 160.7K

Environmental Impact Assessment (EIA)

Knight Piésold

The EIA details the Delimitation of Direct Influence Area (AID) as well as Indirect Influence Area (AII) of the project. Areas of socioeconomic influence and additional coverage of geographical, environmental, social and human interest features are also included.

Project components are also detailed considering infrastructure, manpower requirement. Potential environmental and social impacts, prevention, control and mitigation as well as abstract of social baseline and summary of community relations plan are also analyzed.

According to directorial resolution Nº411-2010-MEM/AAM given on December 14th 2010, the Toromocho Exploration EIA study was approved meeting the technical requirements for the Peruvian Ministry of Energy and Mines and the environmental local regulations.

Source: Peruvian Ministry of Energy and Mines
Aker Solutions
2009
US$ 143M

Engineering, procurement and construction management (EPCM)

Aker Solutions

Aker Solutions has been awarded the detailed engineering, procurement, and construction management (EPCM) services on the Toromocho Project for Minera Chinalco Peru S.A.

Resources and expertise from the Aker Solutions offices in Tucson, Arizona, USA; Santiago, Chile; Lima, Peru; and Shanghai / Beijing, China, will be involved in delivering this project.

Source: Aker Solutions
117200Daily Ore Input tn/day1642Area of Mine (ha)2160Project Capital ($mil)
ABB
2009
US$ 4.5M

Gearless Mill Drive systems (GMDs)

ABB

ABB’s scope of supply includes three complete gearless mill drive (GMD) systems. The gearless mill drive systems shall grind the mineral ore into smaller pieces prior to further processing. These GMDs will be the largest such systems operating anywhere in the world and at the highest altitude.

One system will be installed on a 40-foot SAG (semi-autogenous) mill with a power rating of 28 megawatts (MW), the other two will drive 28-foot ball mills with power ratings of 22 MW. This is not only going to be the largest GMD, but at 4,600 meters above sea level in the Andes will be the first GMD at this altitude.

Source: ABB
28000Mill rated power (KW)

Construction Management (CM)

GMI Ingenieros Consultores

Construction management of Kingsmill tunnel acid water treatment plant.

The Kingsmill tunnel was built in 1934 to drain tailings from mining operations in Morococha and it has two objectives: Yauli river decontamination and viability of the Toromocho mining project.

The HDS (High Density Sludge) process was selected for the water treatment because it represents the best conventional technology available to produce a high quality effluent and minimum volumes of chemically stable sludge at the lowest possible cost.

The plant is at 4,200 masl on the river bank, opposite to the tunnel intake. It has a 68m diameter clarifier, feed tanks and reactors, lime silo and a whitewash tank, located next to a building that will house a lime system, the replacement system of the flocculants polymer dry storage, compressors and blowers, maintenance area and spare parts, electrical control room and the laboratory area, offices and services.

Source: GMI S.A. Ingenieros Consultores
30.782Engineering man hours (K)

Engineering, Procurement and Construction (EPC)

Cosapi Ingeniería y Construcción

Project developed by Minera Chinalco in order to remedy the pollution of Yauli river waters before having Toromocho project executed.

Cosapi was in charge of design, procurement, construction, equipping and commissioning of civil and electromechanical works for the Acid Water Treatment Plant Kingsmill Tunnel, which consists of a clarifier, a feed tank, tank reactors, pools sludge, a pool of emergency, a building process, adduction line and a transmission line .

Source: Cosapi Ingeniería y Construcción
Vargas Pareja Abogados & Consultores
2008

Energy, Mining & Infrastructure Legal Services

Vargas Pareja Abogados & Consultores

Vargas Pareja since 2008 is involved in the resettlement process of Morococha city in order to develop Toromocho Project. Successful participation in the purchase of land, identification of cadastral areas and enumeration of each of the owners, tenants and occupants of the city, supporting community relations as well as in the process of resettlement.

Source: Vargas Pareja Abogados & Consultores
Social Capital Group
2006

Population resettlement

Social Capital Group

Oversee Community Relations Program and train community relations staff for the population resettlement project.

A community relations program has been established considering the follow items: Create a vision of the future that incorporates the communities impacted by the project. Promote collaboration, trust and respect between the mining company and the communities. Establish an effective two-way dialogue and good relations with all the communities. Assist in the promotion of sustainable development in the communities.

Additional items include: Keep the communities continually informed of the advances and status of the project. Receive information from the communities with respect to their concerns about the project. Promote community participation in the decision making processes where the community is impacted. Create and execute a plan for the relocation of those living within the immediate impact area of the project.

Source: Social Capital Group and USA Securities and Exchange Commision
5000Number of people resettled

Basic Engineering Design (BED)

Anddes Asociados

Process engineering, metallurgical testing program and sampling of ore in the pit. Tradeoff for leaching heaps location, crusher and SX-EW plant.

Conceptual design of: ROM and crushed ore leaching heaps, ore transport conveyor belts, pumping system, irrigation system. Capex and Opex estimation.

Source: Anddes Asociados
Confidential
US$ 1.6M

Tailing dam construction

Confidential

2.8Storage Capacity (Mt)

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

Snapshot

Capital Expenditure
US$ 3.5B
Project Status
Expansion
Production starting date
January 2013
Daily Ore Output in Tonnes
117200
Mine Type
Open pit
Mineral reserves (Million Tonnes)
1526
Metals mined
Copper, Silver, Molybdenum
Life of Mine LoM (Years)
36
Copper Annual Output (Tonnes)
275000
Copper Mineral Reserves
0.48%
Molybdenum Mineral Reserves
0.019%
legal.unidad
TOROMOCHO
Electricity Requirement (MW)
165

Top Contractors

Aker Solutions
FLSmidth Minerals
Stracon GyM
ABB
Siemens

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