Minerals

Galaxy Lithium

GALAXY, MT CATTLIN PROJECT
CONSTRUCTION, COMMISSIONING AND MAINTENANCE WORKS

End Client Galaxy Resources
Location Ravensthorp, Western Australia
Commodity Lithium
Project Value $26M+ | Primero Scope $4.3M
Solution Provided

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Galaxy’s Mt Cattlin mines were placed into care and maintenance in 2013 due to poor market conditions. In 2016 Galaxy commenced upgrades to modify the existing circuit to improve product recoveries and increase the annual production of the plant. After a number of project set back and delays, Primero were engaged in late August 2016 by the Galaxy Board to manage the completion of the works and bring the plant back into operation.

Primero were responsible for the finalisation of design, procurement, construction, commissioning and operation of the plant until the end of December 2016 when control of the plant was handed back to the client. Primero remained on site assisting Galaxy to meet the plant throughput to nameplate including maintenance of the plant.

With Primero’s experienced lithium team, we were able to support Galaxy from the process design through to commissioning and operation and ultimately enable galaxy to ship 10,000t of product by the end of 2016.

PROJECT HIGHLIGHTS:
+ Implementation of strategy and site team within 48hrs of contract award
+ 50,000 site man-hours with no medical treatments
+ Project key milestones were achieved and Lithium produced ahead of schedule and on specification
+ Seamless integration from Construction to commissioning and operation
+ Implementation of critical maintenance systems and scheduling of plant shutdowns

With a strong background in engineering and delivering complex mineral processing project, the Primero team were able to turn around a difficult project and exceed the clients expectations.


Tawana Bald Hill

TAWANA BALD HILL
LITHIUM MINE EARLY WORKS

End Client Tawana Resources NL
Location 50km South East of Kambalda, Western Australia
Commodity Lithium
Project Value $30M
Solution Provided

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Tawana (in conjunction with AMAL) has engaged Primero to commence works on a 1.2Mtpa front end spodumene concentrator utilising dense medium separation to produce a coarse (+1mm) spodumene product of 6.0% Li2O. The -1mm material from this new concentrator will be stockpiled for future processing. All secondary DMS floats material (+1mm) will be stockpiled for future consideration.

Primero has been engaged to complete the detailed design and to order long lead capital items including parts of the DMS plant and tails thickener. These items represent key components in the process flowsheet for the spodumene concentrator.

The engineering, procurement, and construction (EPC) contract is being finalised and is expected to be awarded in early June 2017. This project has been fast tracked from an initial concept in December 2016. Primero completed a detailed feasability study in the first quarter of 2017 with detailed design and procurement in May 2017.

Primero has achieved this aggressive timeline by utilising its expertise in the lithium space to deliver a functional design that meets Tawana’s needs. Primero has recently completed and commissioned a DMS lithium plant in Western Australia and is currently involved in several significant lithium projects within Australia and overseas.


Tujuh Bukit

TUJUH BUKIT
HEAP LEACH GOLD ORE PREPARATION PLANT

End Client PT Bumi Suksesindo (BSI)
Location East Java Province, Indonesia
Commodity Gold
Project Value $2M+
Solution Provided

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Primero was engaged by PT Bumi Suksesindo (BSI) to complete the detailed design and procurement for the Ore Preparation portion of the Tujuh Bukit Heap Leach Gold Plant. The plant is located in Indonesia, specifically Banyuwangi Kabupaten in the province of East Java and consists of a 4Mtpa heap leach pad and processing facility to produce gold and silver.

The ore preparation plant process consists of a two-stage open circuit crushing plant and agglomeration circuit. Stockpiled agglomerated ore is reclaimed and loaded into haulage trucks for delivery to the heap leach pad. The plant is located on the side of a steep embankment with a total fall of 65m over a linear distance of only 240m. This challenging terrain created a unique set of difficulties requiring an innovative design approach. Primero’s solution consisted of ten cascading process pad areas following the natural ground contours.

The resulting pads limited the amount of earthworks and provided an optimised process layout. The project scope included civil, structural, mechanical, electrical and control systems design in addition to vendor procurement and management.

Primero utilised a 3D Building Information Modelling (BIM) design process to streamline the flow of information from Primero to local installation contractor. A hybrid system of smart 3D models in conjunction with traditional 2D drawings were transferred to the local contractor to compress the design schedule, reduce the number of design hours and decrease the chance of errors between design and construction.

Innovation through engineering process improvement and industry leading Safety in Design resulted in a successful multi-discipline design delivery.



WINDIMURRA VANADIUM
BENEFICIATION PLANT UPGRADE

End Client Atlantic Resources
Location Mt Magnet, Australia
Commodity Vanadium
Project Value $15m+
Solution Provided Turnkey Upgrade

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Windimurra Vanadium is located near Mount Magnet in Western Australia. The vanadium processing plant is operated by Midwest Vanadium (MVPL) which is 100% owned by Atlantic Limited.

The plant consists of a crushing, high pressure grinding, beneficiation, roasting and refinery stages. The front end of the plant was suffering from a large amount of fines in the circuit. MVPL planned to add additional screening capacity to the existing crushing circuit, Primero took the concept and turned it into an operating screening plant.

The turnkey project involved the design, construction and commissioning of multiple pieces of machinery including magnetic separators, conveyors, double deck screens, vibrating feeders and pumps.

Primero completed civil, structural, mechanical, piping and electrical design works as well as procurement, fabrication and site installation.

The project works commenced in February 2012 with successful commissioning of the works completed in July 2012.


WINDIMURRA VANADIUM BENEFICIATION PLANT

WINDIMURRA VANADIUM
BENEFICIATION PROCESS IMPROVEMENTS

End Client Atlantic Resources
Location Mt Magnet, Australia
Commodity Vanadium
Project Value $15m+
Solution Provided Turnkey Upgrade

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After Primero’s successful completion of the Dry Screening Plant at Windimurra Vanadium in 2012, a new evolving project scope was triggered in March 2013 to push the front end beneficiation plant into sustainable production.

Primero spearhead the developing projects and formulate solutions with a fast track, low cost approach. Solutions were implemented within weeks to allow major process changes to take effect and prove the concept for the permanent solution expenditure. Highlights included the installation of a mobile stacker conveyor and chutes to remove the HPGR product from the plant feed repulper and redirected to the dry screening plant. Following this, a 29m conveyor and chutes were designed and installed in place of the stacker within six weeks.

Another major installation was the design and install of a 20m conveyor to take all oversize material from two wet screens direct to the ball mill and removing the wet recirculating material from the dry crushing circuit completely. This was designed and installed within four weeks.

Since March 2013, Primero have undertaken civil, structural, mechanical, piping and electrical design works as well as procurement, fabrication and site installation for over 80 projects, site wide and continue to meet budgets and schedules. A permanent team has been based on site since April 2013 and Primero have supplied large shutdown teams to deliver installations on schedule.



CITIC PACIFIC MINING
SINO IRON CYCLONE UNDERFLOW

End Client CITIC Pacific Mining
Location Karratha, Australia
Commodity Iron Ore
Project Value $1m+
Solution Provided Detailed Design

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Sino Iron (CITIC Pacific Mining) have been sustaining extensive wear within the grinding circuit during their ramp-up phase resulting in significant downtime. Primero Group were engaged to formulate a solution with an intensive fast track, low cost approach.

The first item to be redesigned was the train 1 cyclone underflow line, which is a combination of rubber lined carbon steel and mining hose, returning oversize material to the AG Mill. The high volume and high line velocity are the major causes of the wear in the pipe and the resulting slurry trajectory causing high wear upon entry to the mill feed launder.

Designing a large volume launder arrangement for a very restricted space, Primero used a series of adjustable weir gates to slow the material velocity as much as possible whilst falling several meters. The design will allow the material to enter the mill feed launder at an acceptable velocity to impact the existing wear panels.

Primero has used three dimensional modelling and animations to optimise the design for installation during a tight shutdown timeframe. The modified design will dramatically reduce wear and the ongoing maintenance required to the chute.


GREENBUSHES PLARECOMMENCEMENT STUDY

GREENBUSHES
PLANT RECOMMENCEMENT STUDY

End Client Global Advanced Metals
Location Greenbushes, Australia
Commodity Tantalum
Project Value $200k+
Solution Provided Feasibility and CAPEX

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Red Gully Greenbushes is located in the south-west of Western Australia, approximately 250km from Perth and contains one of the world’s largest hard rock tantalum resources.

The operation comprises open cut and underground mines, crusher, a primary processing plant, as well as the secondary processing plant that can treat the primary tantalum concentrate from both Wodgina and Greenbushes.

The operation currently has the capacity to produce about 1.0 million pounds of tantalum pentoxide per annum.

Primero Group was engaged by Global Advanced Metals Greenbushes to review the Tantalum Primary processing facility to define the required capital expenditure to re-start within a 12 month period.
In addition for the re-commencement of operations, environmental aspects of the plant required review and change to enable re-start.

Primero Group completed a systematic review of the plant to develop the restart CAPEX. In addition Primero also finished a new drainage design to meet the site environmental requirements.


WODGINA PROCESS OPTIMISATION STUDY

WODGINA PROCESS
OPTIMISATION STUDY

End Client Global Advanced Metals
Location Port Hedland, Australia
Commodity Tantalum
Project Value $15m+
Solution Provided Optimisation Study

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Wodgina is a tantalum mine located near Port Hedland in Western Australia. The mine is owned and operated by Global Advanced Metals. The processing plant consists of crushing, milling and various mineral sand separation stages.

Primero Group was engaged to assist Global Advanced Metals in developing the capital cost requirement for various upgrade works to areas of the processing plant. Primero completed preliminary engineering and design to produce a feasibility level cost estimate.

Primero’s involvement included site visits to verify brownfield interfaces, design layout drawings as well as structural design works.

This allowed the design to be optimised, providing the basis for more accurate quantities and development of the capital cost estimate.