WELCOME TO MINERAÇÃO PARAGOMINAS - … · WELCOME TO MINERAÇÃO PARAGOMINAS (2) ... SAG mill,...

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José Flávio Alves - General Manager of Operational Support November 7, 2012 WELCOME TO MINERAÇÃO PARAGOMINAS

Transcript of WELCOME TO MINERAÇÃO PARAGOMINAS - … · WELCOME TO MINERAÇÃO PARAGOMINAS (2) ... SAG mill,...

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José Flávio Alves - General Manager of Operational Support

November 7, 2012

WELCOME TO MINERAÇÃO PARAGOMINAS

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What is bauxite?

• Rock composed mainly of aluminum oxide and aluminum hydroxide minerals

• Other materials: iron hydroxides, clay, silt and free silica

• 3 main mineralogy’s

1. Gibbsite Al(OH)3

2. Boehmite AlO(OH)

3. Diaspore AlO(OH)

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Bauxite - where do we find the different mineralogy's?

Diaspore AlO(OH) � China and Russia � High Pressure and Temperature Bayer Process at Higher Cost, � 250 Celsius;Gibbsite Al(OH)3

� Paragominas and Trombetas � Low Pressure and Temperature Bayer Process, � 145 Celsius

Boehmite AlO(OH) � Austrália and Guinea � High Pressure and Temperature Bayer Process, � 250 Celsius

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Bauxite mining in Paragominas

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19721972

Beginning of geological research

20072007

Start-up operation

1980 1980 --19901990 20022002

Beginning of the Paragominas Bauxite Project

20082008

Consecutive production records

20112011

Hydro acquires Paragominas Mining

20122012

Beneficiation plant - Expansion

More explorationand new studies

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Bauxite mining in Paragominas

•Exploration, geological survey

•Deforestation and Use of Wood

•Top Soil Removal & Reuse, Overburden Removal: Yellow Clay,

Nodular Bauxite & Ferruginous Laterite

•Bauxite Ripping

•Bauxite Excavation & Transportation

•Recovery of Terrain and Reforestation

• Infrastructure: Access Roads, Drainage, Dust Control, Safety & Environment

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Bauxite mining in Paragominas

• Mines: Two Mines in One Plateau called M3 with 9,9 Mtpy capacity

• Expansion: A Third Mine could be opened in Plateau M5 with 4,85 Mtpy capacity

• Mine Planing: Short, Medium & Long Term (LOMP)

• Mining Concept: Conventional (Smaller Equipment's and Manpower Intensive - Lower Productivity and Higher Cost) & Continuous Mining (Higher Productivity and Lower Cost)

• Actual Mining Fleet: 186 Equipment's & 972 FTE's (Operation & Maintenance)

• New Technologies: Surface Miner (bauxite excavation); BWE & XPS (overburden); LDCB (bauxite transportation); Bigger Trucks (bauxite short distance transportation)

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Vegetation removal

Stripping

Conventional mining method Ripping – Loading - Transport

Prepare for rehabilitation

Reforestation area

1

2

3

Mining method using the surface minerBauxite excavation/loading - transport4

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Mine process

Vegetation removal

Removal and stocking of the timber

Top soil removal

Stripping

Ripping or excavation using the surface miner

Grading the box

Loading

Transport

Regularizing the land for planting

Reforestation

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Equipments and training

Surface Miner

Compactor roll Motor grader

Auxiliary truck - Dolly

Off road truck

Righway truck

Water truck Tire Dozer

D11 Bulldozer

Hydraulic Excavator 4,5m³

Hydraulic Excavator 18m³

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From conventional to continuous mining?

• Traditional technology

• Smaller equipment

• More manpower intensive

• Lower productivity

• Higher cost

• Actual mining fleet:

• 186 trucks, excavators etc,

• 972 FTE's (Operation & Maintenance)

• New Technologies

• Surface Miner (bauxite excavation)

• BWE & XPS (overburden)

• LDCB (bauxite transportation)

• Bigger Trucks (short distance transportation)

• Higher productivity

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Surface mining

Beyond this, it has almost the double of the hydraulic excavator productivity

and can work with bigger trucks (60m³ a 80m³) reducing the mining costs.

The ore control process is better, since the terrain shape left by the surface

miner is more regular.

The Surface Mining SM

2500 has replaced the

operations performed

by bulldozers, hydraulic

excavators and graders

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Bauxite physical beneficiation

• Concept: remove clay from the ore (30 to 40%) & grinding the final product to pipeline transportation (100% below 0,3 mm);

• Economics: improve the available alumina from 38-40% to 47-48% and reduce reactive sílica from 9-10% to 4,5-5%;

• Grinding (coarse fraction): SAG mill, terciary crusher & ball mill;

• Classification (fines, ultrafines & clay): hydrociclones 26" and 10";

• Thickeners (water recirculation & solids concentration): product & tailings;

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Bauxite physical beneficiation

•Actual installations: two beneficiation plants (each with capacity of 4,85 mtpy);

•Relevant points

•Water

• Electric energy

•Tailings disposal system, located at valley

• Structure: four dikes to disposal tailings, one dike to preserve natural water, one dike to return clean used water to natural drainage and channel for safety in case of long run heavy rainfall

• The dikes are being raised every year and will be depleted in 2015

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Pipeline

•Concept: Transport slurry to refineries with 50% solids, transport capacity 14,85 Mtpy

• Pump Stations

• PS1 at M3 with 6 pumps

• PS2 at Tomé-Açú with 6 pumps (being Installed and start-up scheduled to 2013/2014)

•Tanks and valves at Barcarena: receive the slurry and adjust solids content to delivery to Alunorte's dewatering filters

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Competent and enthusiastic local employees

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Yearly Production

We are improving but need to stabilize

9.900kt

8.1

50

7.5

24

6.2

03

4.4

03

1.8

91

0 kt

2.000 kt

4.000 kt

6.000 kt

8.000 kt

10.000 kt

2007_R 2008_R 2009_R 2010_R 2011_R 2012_P

9.200–9.300

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Steps to leverage the business value

• Economy of scale: pursue gains

• Product: improve the quality

• Reduce costs: mining, beneficiation, pipeline and dewatering

• Project MAIS

• People: attract, retain and continuous training

• HSE: improve the management

• Housekeeping: Hydro Way

• BABS – Bauxite and Alumina Business System

• Certifications: ISO 9 000 and 14 000, OHSAS 8 000

• Maintenance: high level system and skilled people

• Procurement and warehouse; to improve efficiency and reliability

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