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Delivering leading technologies and
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First Quantum Minerals Ltd. – One of the fastest
the third quarter of 2012, and commercial
growing copper producers in the world
production began on 18 August 2012 following
a rapid and successful commissioning period.
First Quantum Minerals Ltd. (FQM) is an established
and rapidly growing mining and metals company
"We have progressed according to plan
currently operating seven mines and developing five
thus far and we are confident that we can
projects worldwide. FQM currently produces copper,
go on to run the business the way that suits
nickel, gold, zinc and platinum group metals.
us best", states Anthony Mukutuma, Plant
Manager at FQM Kevitsa Mining.
The Company’s current operations are the Kansanshi
copper-gold mine, the Guelb Moghrein copper-gold
Since the development project, the major
mine, the Las Cruces copper mine, the Kevitsa nickel-
problems were solved by the eighth month of
copper-PGE mine, the Pyhäsalmi copper-zinc mine,
operations. "The equipment is running well.
the Ravensthorpe nickel-cobalt mine, and the Çayeli
We have worked with Outotec Site Account
copper-zinc mine.
Manager Hannu to resolve a number of
challenges and, at this stage, with regard
In addition, FQM is developing projects in Zambia, Peru
to Outotec equipment, we are just working
and Panama that when complete, will increase the
on the finer details of
company annual copper production capacity to more
and equipment performance optimization”,
than 1.3 million tonnes per annum. (http://www.first-
Anthony continues.
process control
quantum.com/Our-Company/overview/default.aspx)
"Overall the equipment has worked well
FQM Kevitsa:
from the start. The mills, the flotation cells
from development project to operation
and dewatering (thickeners and filters) have
all had their own challenges but Outotec
FQM Kevitsa is an open pit mine with measured and
has supported us well. One major benefit
indicated resources of 240 million tonnes grading 0.28%
has been having Outotec personnel involved
nickel sulphide and 0.41% copper; with gold and PGMs.
during
commissioning
and
ramp-up",
Frederic Wouters, Assistant Plant Manager
Kevitsa operations began in 2010 with construction of the
at FQM Kevitsa Mining.
mine site. The ramp-up progressed as planned during
Increasing Plant throughput
At the current approved throughput rate
of 5.5 Mtpa, Kevitsa is expected to produce
approximately 10,000 tonnes of nickel and
20,000 tons of copper annually. The mine is
however expected to increase throughput in
the short term.
"We are awaiting approval from authorities
on
our
environmental
assessment
and application to increase the plant
throughput rate from the current approved
5.5 million tonnes per annum up to a
maximum of 10 million tonnes per annum"
(http://www.first-quantum.com/OurBusiness/operating-mines/Kevitsa/default.
aspx)
Outotec scope in Kevitsa
The Outotec installed base in FQM Kevitsa consists of
an entire concentrate process equipment product line
including grinding mills, flotation cells, thickeners,
filters, samplers, analyzers and automation systems.
Outotec has delivered two AG Mill, one Pebble mill, 73
Outotec TankCells ranging from 20 m3 to 300m3 cells,
three High Rate Thickeners, two Outotec Larox PF 25 m2
filters (which will be expanded to 32 m2), an Outotec PSI
500 particle size analyzer for the grinding circuit, and
a Courier 6i elemental analyzer for the flotation circuit
for froth control along with 36 FrothSense imagers and
the Outotec ACT (Advanced Control Tool) for process
optimization in flotation. Outotec has also delivered the
Outotec Integrity concentrate reporting tool.
Outotec Larox PF filters have been expanded to increase
the throughput rate by 30% Outotec experts Jussi Liipo
and Tommi Lanki checking the filter together with FQM's
Anthony Mukutuma.
"Some of the equipment in the flowsheet was procured
for the duty, considering changes in treated material and
by the previous owners of the project; this included a
surges in production," Anthony explains.
number of Outotec operating units in the flowsheet.
Would we have gone with a different choice? I don't
To remove the bottlenecks, Outotec delivered two filter
think so. We have Outotec equipment on all our other
expansions to the Outotec Larox PF filters by adding plates
mine sites," reasons Anthony.
and increasing the capacity and throughput rate by almost
30%. “After the expansion, Kevitsa will be more flexible in
"Efficiency and reliability are critical when it comes to
terms of parameters and operational functions, and the
equipment selection in a process flowsheet. Inefficiency
process will not be that sensitive to changes,” states Kari
results in losses and downtimes is expensive. Although
Maalahti, Outotec Sales Manager for Service Operations.
the importance of high standards of operation and
maintenance management must not be underscored,
Outotec will also provide scales for the filters to
selecting the right equipment is a dominant key in the
enable better control. “The adjustments can be made
equation. In our case, Outotec equipment has been
automatically based on the cake weight,” explains
efficient and reliable," Anthony states.
Tommi Lanki, Outotec Sales Manager for Dewatering. “On
time weighting system indicates the solids load inside
Working together with the customer for better
the filter chambers, which allows us to control the
process results
pumping time automatically and optimize the cycle time
accordingly to get optimal capacity out of the filters. Also,
Along with the equipment deliveries, Outotec supported
an automation modification was made recently according
the FQM Kevitsa project by supervising the installation
to the customer’s needs in order to reduce the air drying
and commissioning the equipment. Outotec provided
time while still meeting the desired moisture targets.
ramp-up services, including process support and on-
This generates multiple savings for the customer. The
site expert services. These included installation support
compressed air usage can be reduced, which provides
and supervision mostly for the flotation and grinding
savings in energy usage, and also they will be able to
mills, as well as metallurgical assistance by providing
reduce the total cycle time in order to get higher capacity
the services of a process metallurgist.
out of the filters.” Tommi continues.
Prior to commissioning, it was discovered that the
The filters were optimized to run both nickel and
concentrate filters presented a potential bottleneck to the
copper to optimize availability and minimize downtime.
process. "The engineering study testwork for the filters
Accordingly, if one of the filters is out of use and nickel
was done by a third party and sizing of the filters used high
needs to be run through, either of the filters can be
specific filtration rates; the result was undersized filters
operated with that application.
“The ability to perform a crossover with the filters is an
Training the operators
important issue due to the high utilization of the nickel
filter,” states Frederic
Along
with
the
process
equipment
delivery,
commissioning, installation and ramp-up services,
“With the Larox filters we are able to achieve the
Outotec has also provided Kevitsa operators with
required moisture level, which enables us to cut costs.
equipment training.
The filters require a small floor space and operate in
short cycle times, which makes them cost effective,”
“Outotec’s
Anthony continues.
customers with a fast and effective way to train their
Virtual
Experience
Training
provides
personnel already before the production start-up phase
In addition to the challenges regarding the capacity of
and later according to individual customer needs,” says
the filters, the nickel process line was not functioning
Kai Rönnberg, team leader in product management at
as expected. After a closer look it became clear that the
Outotec.
nickel feed tank was not able to lift up the slurry. Outotec
performed auditing and conducted feed tank lab tests
“Virtual
at the Outotec Pori research and development center.
experience with operations by utilizing an advanced
Based on the lab scale studies, Outotec proposed to
training simulator developed by Outotec. In the training
Kevitsa that it change the mixer of the feed tank to an
we teach the theory of minerals processing but also
Outotec OKTOP mixer to eliminate the problem. Filters
provide simulator exercises focusing on the basic
are sensitive equipment, and even small slacks in the
operations of the equipment and process circuit and
process affect availability and product quality. By the
troubleshooting scenarios. The target of the training is
end of May 2013 - the OKTOP mixer has been installed.
to show operators how to optimize the process circuit
Experience
Training
provides
hands-on
and give advice how to maximize the recovery and profit
Outotec ACT – for optimized process results
in changing conditions,” Kai continues.
Outotec provided an ACT system with 36 FrothSense
“VEX training is a very good tool for providing operators
imagers – one imager for each TankCell to control and
with an intensive and fast way of simulating the real
optimize the process. Courier and FrothSense enable
environment and how the actions taken running the
constant froth analysis based on imagers and froth
process impact on performance (grade and recovery).
speed. The ACT system can stabilize the speed and
VEX is good package and we got the result we wanted,”
regulate the froth level and speed in different cells, as
Anthony adds.
well as run the process close to the low grade – when
the recovery improves.
“I participated in the training course, and it is a good
simulation even for experienced metallurgists to get
“Courier and FrothSense are great tools for analysis
to know the automation system before the start-up.
and control, but when combined with the ACT they
However, every process is different and you need to
enhance the concentrate and enable the operators to
make the final decisions in the control room,” says
better control and supervise the overall process while
Tomi Maksimainen, Senior Metallurgist at FQM Kevitsa
maintaining the recovery at the optimal level,” states
Mining.
Niko Koski, Project Manager for Outotec.
Service agreement aiming for higher availability
“FrothSense has worked well,” Anthony confirms. “We
have here 73 cells, and we need to make sure that all
Outotec has signed service agreements with FQM
the cells and rates are working well. With FrothSense
Kevitsa for the Outotec Analyzers, PSI 500 and Courier
imagers we get a full and continuous view. It is difficult
6i with the Advanced Control Tools (ACT) and Outotec
to predict the process, and operators can lose the edge
Integrity. The aim of these agreements is to keep the
and motivation to constantly monitor and adjust. The ACT
specialized equipment available and in good condition.
keeps us alert all the time and on top of what is happening
in the floats. FrothSense and the ACT system is like having
“The Outotec equipment has worked well. We have
an operator alert and at full attention every second.”
faced some challenges with the samplers, but these
are being solved as well. We have been able to work
Customer communication aims for better results
according to the planned maintenance, and there have
through cooperation
been no big surprises or problems. We have our own
maintenance performance reporting tool that reports on
On the large scale, for high capacity mill sites such as
safety, maintenance, quality and production throughput
FQM Kevitsa, communication with the service providers
to monitor the plant operations,” Anthony adds.
must be efficient, easy and continuous. Outotec and
Kevitsa have solved this challenge by naming one Outotec
In addition to the service agreements for the
contact person to manage the site and coordinate all the
automation, Outotec has also provided Kevitsa with
concerns and issues. Well planned monthly meetings are
mill lining services and a two year O&M (Operations
arranged by phone or personal visits with a tight agenda.
and Maintenance) agreement for the filters. The O&M
filter agreement includes an Outotec filter service
“With continuous communications we are able to listen to
representative available onsite 8 hours per day,
the customer, and with monthly well-planned meetings we
including maintenance work, working with the process
are able to meet the customer’s needs on time and improve
team at the Kevitsa plant and training the operators
their availability in terms of spare parts and maintenance,
in the filtration process. The O&M also included the
for example. By offering a single point of contact we want
start-up and basic support for mechanical, process
to make it easy for the customer to communicate with
and automation work. In addition, Outotec has a remote
us,” says Hannu Alén, Outotec’s Head of Customer Support
service available for the Kevitsa site.
Operations for Service Center Finland and Baltics.
“All the sites where I have worked have had Larox
“When communicating with large organizations, finding the
filters. It is straight forward yet sensitive equipment.
right persons to talk to can be challenging. In the beginning
We have definitely benefited from having Outotec O&M
we did have communication issues, but now with Hannu we
filter agreement. The ramp-up has been easy and, at
have found a way to work things out. Outotec provides us
the same time, we have been able to access training for
with proven technology and solutions. By communicating
our operators and maintenance personnel on the filters
and asking the right questions, Outotec can help us to get
through the Outotec filter experts stationed at the site,’
the most of our equipment and do even more clever things
Frederic says.
with it to improve our productivity,” Anthony concludes.
Outotec provides leading technologies and services for the sustainable use of Earth’s natural
resources. As the global leader in minerals and metals processing technology, Outotec
has developed over decades many breakthrough technologies. The company also provides
innovative solutions for industrial water treatment, the utilization of alternative energy
sources and the chemical industry. Outotec shares are listed on NASDAQ OMX Helsinki.
info@outotec.com
www.outotec.com