22.11. Codelco El Teniente PDF

El Teniente overview
November, 2010
Copyrights 2008 CODELCO-CHILE. Todos los Derechos Reservados./Copyrights 2008 by CODELCO-CHILE. All Rights Reserved.
Copper production
6000
5000
kton Cu
4000
Privates
3000
Codelco
2000
1000
2008
2007
2006
2005
2004
2003
2002
2001
2000
1999
1998
1997
1996
Codelco - overview
Geological Resources: more than 307 million tonnes of fine copper.
Ore Reserves: 113 millions tonnes of fine copper.
Six operative divisions: Codelco Norte, Gaby, Salvador, Andina, Teniente and
Ventanas (Smelter).
Copper and Molybdenum
Production - 2009
Copper:
Molybdenum:
1.7 millions metric tonnes fine copper per year

21 thousand metric tonnes per year
Cash Cost- 2009
93.9 dollars cent per pound
Profits 2009
4,069 millions dollars
Workers-2009
19,335 Company employees

22,386 Contractors employees
Safety-2009
2.42 Frequency rate index

120 Severity rate index
El Teniente
El Teniente Iocation
El Teniente - overview
One of the largest copper deposits: more than 111 million tonnes of fine copper in
geological resources
The biggest underground copper mine, In operation since 1906
An integrated complex: mine-plant-smelter facilities
Copper , molybdenum and sulfuric acid producer
Current capacities
Mine-Plant:
Smelter:
131,000 tonnes per day ore

1.3 Mt/year concentrate
Production - 2009
Copper:
Molybdenum:
Sulfuric acid:
404,035 fine metric tonnes per year

5,179 metric tonnes per year
1.1 million tonnes per year
Cash Cost- 2009
81.8 dollars cent per pound
Workers - 2009
Safety-2009
5,152 Company employees

6,291 Contractor companies employees
2.33 Frequency rate index
152 Severity rate index
El Teniente history - highlights
Inicia sus
operaciones la
Fundicin Caletones
Comienza
explotacin Sector
Fortuna
1905
1914
1922
Al antiguo
Establecimiento se le
bautiza como Sewell
1967
Se pone en
marcha el Plan
280 tmf/a
1968
Comienza la
ejecucin del
PDT
Desarrollo del
Convertidor
Teniente
Comienza la
Construccin
del nivel
Teniente 8
1970
Comienza a operar
el concentrador
Coln
1975
1978
Entran los
primeros LHD a
la mina.
Produccin
131.000 tpd.
1998
2010
Comienza la
Construccin
del Proyecto
Nuevo Nivel Mina
Business description
UG MINE
COLON PROCESSING PLANT
CALETONES SMELTER
SAN ANTONIO
PORT
BALL
MILL
SAG
BLOCK/PANEL CAVING
MINING METHOD
COMMINUTION & FLOTATION
PRODUCTS
SX-EW PLANT
COPPER CONCENTRATE TO
MARKET
ACID WATER
FUSION AND CONVERSION
MOLYBDENUM
CONCENTRATE TO MARKET
ANODES
FIRE REFINED COPPER
PRODUCTS
CATHODES
SULFURIC ACID
WATER SUPPLY
POWER SUPPLY
ROAD INFRASTRUCTURE
EL COBRE HIGHWAY
TAILINGS DISPOSAL SYSTEM

LAUNDER (CONCRETE CHANNEL)
CAREN TAILINGS DISPOSAL
Geology
The southern and newest Porphyry Cooper

Deposit in South America (4 to 7 My)
Ore control for copper and molybdenum is

related to porphyry intrusions and
hydrothermal breccias
Upper secondary enriched ore mined out
High grade in Primary ore (compared to other

porphyry copper deposits)
Smooth vertical variations, high homogeneity of

copper grade around 0.9 % CuT
Copper grades remain approximately constant

even down to depths of 1,600 masl.
Mineralogically not complex, mainly

chalcopyrite as main copper sulphide
Resources & reserves
10
Mining
Mining Method
Caving
Caving Process
Process
Mine
Development
Undercutting
Undercutting
Extraction
Extraction
By:
11
Mining method
Isometric view
12
Mining
Mine description
Mechanized Panel Caving method
Hard rock mining under high stress conditions
Massive mining of Primary ore since 1980s
Today six sectors running simultaneously allow El Teniente to
reach an overall production of 131 kt/d
Material handling through combinations of LHDs, TrucksTrains-Crushers-Conveyors-Ore Pass to a main haulage
system (Teniente 8 Railway haulage level)
13
Mine plan
Run off mine production
PLAN MIXTO
ktpd
%Cu
Cuf
Mina Subterrnea: Sectores Actuales y Proyectos (P)

T4 Sur
Esmeralda
Diablo Regimiento
Pipa Norte

Reservas Norte
Pilar Norte
Dacita Project
Pacifico Project
Rajos Project
Nuevo Nivel Mina (incluye opcin a 180 ktpd en PND)

Proyecto Estructural del Plan de Negocio
Soporta la competitividad y continuidad operacional
de DET en el largo plazo
Inicio Produccin: 2017
CopyrightsCODELCO
2008 CODELCO-CHILE.
Todos
los Derechos
Reservados./Copyrights
2008 by CODELCO-CHILE.
Rights Reserved.
CHILE / DIVISIN
CODELCO
ELCHILE
TENIENTE
/ DIVISIN
Copyrights
EL TENIENTE
2008 CODELCO-CHILE.
Todos los DerechosAll
Reservados
14
Production areas
Sur Andes Pipa
Reservas Norte
Ao 2009
Total rea abierta 289.500 m2
Esmeralda
Pipa Norte
Total rea nueva 2009
Teniente 4 Sur
Diablo Regimiento
15
El Teniente - development activities
16
Main projects-mining
Rajo Sur
Project
Dacita
Project
Pacifico
Project
Rajo Norte
Project
New Mine Level
Project
17
Plant process - Coln facilities
VOLVER
18
Plant process
SAG Grinding
and Flotation
SX/EW PLANT
Administration
Offices
FFC
C Te
nien
te
8
Coln Facilities
Unitary
Grinding and
Flotation
Minero Power
subsub-station
ch
an
ne
l
Crushing
Plant
Thickeners
Ta
ili
ng
El
Co
br
eR
oa
d
Unitary
Grinding
Source: Fly Top-Eye, february, 2005
Flotation concentration process

Two Primary crushers
Two SAG mills 12 lines of standard ball mills
Collective & selective Flotation
Tailings transported by an 80km tailings channel to the Carn dam in the Alhue Valley
Copper Concentrate transported by pipeline to Caletones and by trucks to Ventanas
19
Caletones smelter
General Description
Smelting capacity ~ 1.3 Mt/y of copper concentrate
Refined copper production:

Anodes (60% of total)
Clients: Ventanas, Codelco Norte Division, El Paso, Mexicana
Fire Refined Copper (RAF) (40% of total)

European market
By-product: Sulfuric acid

Mine activities in Northern Chile
Internal use
Fulfillment of environmental regulations
Teniente Converter (CT): Technological Innovation used in

Codelco Smelters. Exported to Thailand, Peru and Zambia
20
Caletones smelter process

Copper Concentrate
Acid Plant
(2)
SO2
Dryer
(2)
Sulfuric Acid
Slag
TENIENTE
CONVERTER (2)
...............
White Metal
SLAG CLEANING
FURNACE (4)
Slag to Disposal
CPS CONVERTER
(4)
....
....
..............
BLISTER COPPER
99.3 % Cu
ANODE
FURNACE (2)
ANODES
99,7 % Cu
FIRE.. REFINING
FURNACE (3)
RAF COPPER
99.9 % Cu
21
Power supply
Candelaria
N
SING
Minero Substation
SIC
Transfer
Station
Los Lirios
COLON
PLANT
CALETONES
SMELTER
El Teniente
..
.
.
.
Sewell
EL TENIENTE
MINE
RANCAGUA
Coya
Pangal
Long Term Contract Supply 260 MW Colbun

Demand 245 MW
22
Rive
TTE
Coya
Dam Sapos
5.5 Mm3
Riv
er
Water supply
SEWELL
1,2
00
L/
s
COLON
r
Fl
or
es
Bl
an
co
250 L
/s
Coy
a Ri
ver
(125 L/s)
iv
e
CALETONES
New Plant
Ri
ve
r
(1.260 L/s)
Paredes River
Ca
ch
a
po
al
R
iv
e
COYA
Pangal River
Ca
ch
ap
oa
lR
ive
r
Water Supply
(Average Annual; 95% Exceeding Probability)
Hydrologic Potential: 13,300 L/s

Main Water Rights: 5,500 L/s (Consumables)
Main Sources
- Ro Blanco: 1,200 L/s
- Coya System: 500 L/s
Main Rivers
Consumption Centers
Pump System
Main Aduction Systems
Main Pick Up Points
- Drainages Mine: 300 L/s
Consumption: Actual 1,425 L/s, Projected:1,.800 L/s
Mine Drainages
23
Technological achievements
Mine
Controlled mining
Pre and Advanced undercutting
Preconditioning
Remote controlled operations
Semi-autonomous LHDs
Automated railway haulage system
Smelter
Teniente Converter
24
Safety Health & Quality

Management
Health and Safety:
OHSAS 18000 Certificate
Reduction of global D-40 rate
National Safety Council awards
Quality:
ISO 9001 Certificate in smelting and
concentrating processes (2002)
National Quality Award
25
Environmental Management and

Community relationship
Environment:
ISO 14001 Certificate
Gas emissions:
Achievement of SO2, dust (pm10) and As
regulations
Solid Waste:
Centralized solid waste, and slag handling
facilities
Liquid Waste
Compliance with national regulations planned in
2006
Community:
Pro OHiggins regional development Corporation
26
Main milestones
PRODUCTION
At
131 kt/d
2005
2006
2007
2008
2009
2010
2011
MINE
MINE
PILAR NORTE
PROJECT
START-UP
RAJO SUR
PROJECT
START-UP
2012
2013
SMELTING
MINE
INCREASED CAPACITY
100% WHITE METAL
PRODUCTION
NLM
PROJECT
START-UP
2014
2015
2017
2023
NEW PLANT
MINE
CONCENTRATOR
START-UP
NLM PROJECT at
180 kt/d
2024
MINE
MINE
DACITA PROJECT
START-UP
PACIFICO PROJECT
START-UP
2025
2026
2027
2028
27
El Teniente Capex
2010 - 2034
28
Critical Factors of Success

Business
Prices evolution of critical supplies and services
Impact in mine plan for present especial copper prices.
Technical
Rock-Mechanics issues (Rockbursts & collapses)
Strong rock mechanics team knowledge / Prevention
through seismic monitoring / Planning parameters and
production/cave management
Environmental
More strict environmental regulations
Environmental planning / Work with the environmental
authorities and local communities
29
End
El Teniente Overview
November, 2010
Proyecto Rajo Sur

Descripcin General
Explotacin por rajo abierto de las reservas
ubicadas en la naciente de la Quebrada
Diablo, al sureste del yacimiento y de la
cavidad El Teniente, entre la cotas 2.720 y
3.140 msnm.
Mtodo : Rajo abierto y procesamiento en plantas
Sewell y Coln
Reservas: 33,2 Mt @ 0,69% CuT (LC 0,4%CuT)
Cobre fino: 224 ktmf
Tipo mineral: 100% secundario
Inversin total estimada: MUS$ 215,2
Estado Actual: Etapa prefactibilidad terminada y

aprobada inversin obras tempranas.
Hitos Principales
(OOCC 2011, versin mayo 2010)

Inicio obras tempranas: Ao 2010
Inicio produccin: Ao 2012
Capacidad diseo: 20 ktpd
DIA con RCA autorizada
Cierre Fase
Aprobacin
Inicio
Pre-factibilidad
API Inversional
Produccin
JUN 09
ABR 11
DIC 09
ABR 10
SEP 10
MAR 12
NOV 11
Aprobacin Item 1
Hito de Control
Inicio Construccin
Inicio
API Factibilidad
API Obras Tempranas
Obras Tempranas
Pre-Stripping
Proyecto Dacita
Descripcin General
Proyecto
de
Explotacin
que
considera
la
incorporacin del sector Dacita a partir del ao

2014, ubicado al norte de la Pipa Braden y
caracterizado por roca primaria del tipo prfido
dactico.
Reservas Conocidas: 37,6 millones ton.

Ley media: 1,20% Cu / 0,017% Mo
Tipo Mineral: 100% primario
Produccin en Rgimen: 20.000 tpd
rea a Hundir: 106.550 m2
Cota Piso Hundimiento: 2.120 msnm
Dimensiones Aprox.: 200(a) x 500 (l) m2
Etapa Actual: Trmino Perfil
Inversin Estimada: U$ 104 millones
Pacifico superior project

RAJO NORTE
EL PROYECTO PACIFICO SUPERIOR EN SU

ETAPA DE PREFACTIBILIDAD CONSIDERA
DOS
OPCIONES
DE
PACIFICO
SUPERIOR
EXPLOTACIN
EXCLUYENTES ENTRE SI:
RAJO ABIERTO.
SUBTERRNEA EN COTA UCL 2320
RAJO SUR
ESTAS OPCIONES ENTREGAN TONELAJE QUE

PERMITE DAR FLEXIBILIDAD AL PND.
EL PERODO DE EXPLOTACIN CONSIDERA 7
AOS
RAJO
PACIFICO
(2015 2021).
DESTINO DE MINERAL A PLANTA COLON VIA
FFCC TEN 8.
PROYECTO PACIFICO
SUPERIOR
API CODELCO-CHILE.
T09E204
Copyrights
2008
Todos los Derechos Reservados./Copyrights 33
2008 by CODELCO-CHILE. All Rights Reserved.
Pacifico Superior Open pit option

CAMION (91 t) / CARGADOR FRONTAL (17 yd3)
LASTRE
RAJO
MINERAL
PLATAFORMA.
COTA 2350
MARTILLO
PICADOR
COTA PISO 2380
PIQUE TRASPASO
3m
CAMION 50 t
semiautomtico
140.0
BOTADERO
BUZON
Nv. ACARREO.
COTA 2210
PLANTA COLON
227.0
OP 13 15 - 16
A SUPERFICIE
NIVEL TRANSPORTE PRINCIPAL FFCC TEN 8
COTA 1983
PROYECTO PACIFICO
SUPERIOR
API CODELCO-CHILE.
T09E204
Copyrights
2008
Pacifico Superior underground option

Nv. FORZAMIENTO.
CARGADOR LHD
PERFORADORA
JUMBO DE AVANCE
COTA 2440
140.0
AREA FORZAMIENTO
JUMBO DE AVANCE
COTA 2320
JUMBO
CARGADOR LHD MINI
MARTILLO
REDUCCION
CARGADOR PICADOR
7 yd3
Nv. PRODUCCION
COTA 2304
CHIMENEA
VENTILACION
12.0
JUMBO
EMPERNADOR
JUMBO RADIAL
CHIMENEA
VENTILACION
SNV. INY / EXT.

COTA 2292
VENTILADOR
INYECTOR
VENTILADOR
EXTRACTOR
CAMION 50 t
semiautomtico
PIQUE TRASPASO
32.0
CARGADOR LHD
16.0
Nv. HUNDIMIENTO.
BUZON
Nv. ACARREO.
COTA 2260
PLANTA COLON
277.0
OP 13 15 - 16
A SUPERFICIE
NIVEL TRANSPORTE PRINCIPAL FFCC TEN 8
COTA 1983
PROYECTO PACIFICO
SUPERIOR
API CODELCO-CHILE.
T09E204
Copyrights
2008
Proyecto Rajo Norte

Descripcin General
PROYECTO EXPLOTACIN SECTOR NORTE
Descripcin: Considera la Explotacin de las reservas ubicadas

en la Quebrada Teniente, al Norte del yacimiento, entre la
coordenadas 1.200 Norte y 2.000 Norte. Como parte del Estudio
de Prefactibilidad se identificar, evaluar y recomendar la mejor
alternativa de beneficio para ser desarrollada en la Factibilidad.
Reservas: 87 millones ton.
Ley media: 0,62% Cu / 0,013% Mo
Produccin en Rgimen: Hasta 35.000 tpd
Estado Actual: En proceso de emisin de API para Prefactibilidad.
Inversin Estimada
KUS$
Inicio Produccin
255.189
Mar 2016
Hitos Principales
Aprobacin API
Prefactibilidad
Aprobacin API
Factibilidad
MAR 11
Sw
OCT 12
JUL 12
Inicio
Produccin
Aprobacin API
Inversional
MAR 2016
MAR 14
DIC 13
NOV 14
Trmino
Factibilidad
Inicio
Construccin
Coln
Kt/d
%CuT
Emisin API
para Factibilidad
Inversin en MP 2010
Proyecto Rajo Norte

Descripcin General
New Mine Level project
TTE 4 Sur
Cota 2372
TTE 8 FFCC
Cota 1980
Esmeralda
Cota 2210
Nuevo Nivel Mina

Cota 1880
Nivel Profundo
Diablo
Regimiento Cota
2210
Cota 1480
38
New Level Mine Project

Objective:
Assure continuity of mine operations in the
long run, replacing sectors above Teniente 8
level
Description:
UCL elevation at 1.880 masl, 100 m below Teniente
8 Railroad level
Panel Caving method
Reserves: 1,645 Mt @ 0.91%Cu
Steady production: 180.000 t/d
Expected Life time: 37 years
Main haulage by conveyor belts
CAPEX 1,520 MUS$
Impact of the Project

Increase of capacity (131 to 180 kt/d)
Increase life mine (2035 a 2052)
with NML
less NML
200 000
200 000
1.20
1.20
1.00
1.00
150 000
150 000
0.80
100 000
0.60
0.40
50 000
%Cu
0.60
t/d
100 000
%Cu
t/d
0.80
0.40
50 000
0.20
0
0.00
06
11
16
21
26
t/d
31
36
%Cu
41
46
51
0.20
0
0.00
06
11
16
21
26
t/d
31
36
41
46
51
%Cu
39
AREA PREACONDICIONADA
O FR
AC
T. HID
RTIRA
ULICO
Perfil esquemtico Cota 1.880
NIVEL PREACONDICIONAMIENTO
JUMBO DE AVANCE
Nv. HUNDIMIENTO.
COTA 1880
JUMBO DE AVANCE
20.0
JUMBO RADIAL
Nv. PRODUCCION
CARGADOR LHD
MINICARGADOR
COTA 1860
MARTILLO
PICADOR
CHIMENEA
VENTILACION
CHIMENEA
VENTILACION
20.0
JUMBO
REDUCCION
ESTACION
DE VACIADO
SNV. INYECCION.
COTA 1840
VENTILADOR
INYECTOR
20.0
PIQUE TRASPASO
SNV. EXTRACCION.
COTA 1820
20.0
VENTILADOR
EXTRACTOR
BUZON
Nv. ACARREO.
COTA 1800
20
CAMION SUPRA
AC
ONC
E
Nv. DRENAJE.
CHANCADOR
GIRATORIO
NTR
A DO
RC
OLO
N
COTA 11780
87.0
JUMBO
EMPERNADOR
PORTAL
A CONFLUENCIA
BUZON
TUNEL CORREA TRANSPORTE PRINCIPAL
COTA 1713
Tneles Principales
Caractersticas Principales
2 Tneles de 8,9 Km de longitud, seccin de 9.4m de dimetro, pendiente 2,0% aprox.
Rampa Salida de Emergencia
TTE. 7 CONEXION OP 20-21 Cota 2042
OP 17 HW
TTE. 8 Cota 1980
RAMPA SALIDA DE EMERGENCIA
NNM Nv. Hdto.- Cota 1880

NNM Nv. Prod. Cota 1860
NNM SNV
PNNM
DESARROLLOS HORIZONTALES
DESCRIPCIN
UNIDAD
CANTIDAD
Accesos
ml
16.389
Rampa de Acceso Interior Mina (P&T)
ml
2.520
Tnel de Acceso de Personal
ml
8.969
Conexiones (Tneles de Acceso y Correa)
ml
900
Tnel Curvo
ml
4.000
Manejo de Materiales
ml
9.420
Tnel de Transporte de Mineral
ml
8.870
Tnel entre Confluencia y Stock Pile
ml
550
Ventilacin
ml
4.600
Adits de Ventilacin Inyecc. y Extracc.
ml
4.600
Preparacin Minera (1 Bajada)
ml
34.965
Nivel de Hundimiento (UCL)
ml
11.679
Nivel de Produccin
ml
10.423
Subniveles de Ventilacin
ml
6.742
Nivel Transporte Intermedio
ml
6.121
TOTAL
ml
65.374
Proyecto Nuevo Nivel Mina
PNNM
DESARROLLOS VERTICALES
DESCRIPCIN
UNIDAD
CANT.
Ventilacin
ml
2.200
Chimeneas Adits de Ventilacin (4)
ml
1.340
Chimeneas de Ventilacin Tneles TBM (2)
ml
860
Preparacin Minera
ml
3.860
Piques de Traspaso (41)
ml
2.460
Chimeneas de Ventilacin Niveles (48)
ml
1.400
TOTAL
ml
6.060
PNNM
OTRAS EXCAVACIONES
DESCRIPCIN
UNIDAD
CANT.
Superficie
m3
2.594.229
Plataformas
m3
1.308.000
Zanjas de Galeras y Caeras
m3
112.613
Caminos
m3
1.173.616
Interior Mina
m3
231.104
Sistema de Chancado
m3
61.010
Desarenadores
m3
17.686
Talleres y Barrios Cvicos
m3
142.231
Otros Suministros
m3
10.187
TOTAL
m3
2.825.333

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El Teniente overview

Geological Resources: more than 307 million tonnes of fine copper.

Ore Reserves: 113 millions tonnes of fine copper.

Copper and Molybdenum

1.7 millions metric tonnes fine copper per year

Cash Cost- 2009

93.9 dollars cent per pound

4,069 millions dollars

19,335 Company employees

2.42 Frequency rate index

The biggest underground copper mine, In operation since 1906

An integrated complex: mine-plant-smelter facilities

Copper , molybdenum and sulfuric acid producer

131,000 tonnes per day ore

404,035 fine metric tonnes per year

Cash Cost- 2009

81.8 dollars cent per pound

5,152 Company employees

El Teniente history - highlights

COLON PROCESSING PLANT

COMMINUTION & FLOTATION

FUSION AND CONVERSION

TAILINGS DISPOSAL SYSTEM

The southern and newest Porphyry Cooper

Ore control for copper and molybdenum is

Upper secondary enriched ore mined out

High grade in Primary ore (compared to other

Smooth vertical variations, high homogeneity of

Copper grades remain approximately constant

Mineralogically not complex, mainly

Resources & reserves

Mina Subterrnea: Sectores Actuales y Proyectos (P)

Nuevo Nivel Mina (incluye opcin a 180 ktpd en PND)

Total rea nueva 2009

El Teniente - development activities

Plant process - Coln facilities

Source: Fly Top-Eye, february, 2005

Flotation concentration process

Smelting capacity ~ 1.3 Mt/y of copper concentrate

Refined copper production:

Fire Refined Copper (RAF) (40% of total)

By-product: Sulfuric acid

Fulfillment of environmental regulations

Teniente Converter (CT): Technological Innovation used in

Caletones smelter process

Long Term Contract Supply 260 MW Colbun

Hydrologic Potential: 13,300 L/s

- Drainages Mine: 300 L/s

Consumption: Actual 1,425 L/s, Projected:1,.800 L/s

Safety Health & Quality

Environmental Management and

Critical Factors of Success

Proyecto Rajo Sur

Estado Actual: Etapa prefactibilidad terminada y

(OOCC 2011, versin mayo 2010)

API Obras Tempranas

incorporacin del sector Dacita a partir del ao

Reservas Conocidas: 37,6 millones ton.

Pacifico superior project

EL PROYECTO PACIFICO SUPERIOR EN SU

EXCLUYENTES ENTRE SI:

SUBTERRNEA EN COTA UCL 2320