Mineral Sands Projects

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Toliara Sands Project

Client
World Titanium Resources
Location
Toliara, Madagascar
Products
Ilmenite, Zircon and Rutile Concentrate
Project Capital Value
$190M (ref Scoping Study Report 426/523)
Project Summary
The Toliara Sands Project is a large mineral sands deposit located in the southwest of Madagascar. The project is being developed by World Titanium Resources (WTR). EPMS was engaged by WTR to provide design and engineering services for their Feasibility Study considering a process to produce 400,000 tonnes per annum of ilmenite and 43,000 tonnes per annum of a zircon rich concentrate.

The scope of the engineering was for the design of In-pit Feed Preparation Plant, Primary Wet Concentrator Plant, Mineral Separation Plant, and associated infrastructure.
Scope
Development of Process Flow Diagrams
Development of Mass Balance and Process
Design Criteria
Options Study
Process Plant and Associated Infrastructure

Design, which included:
In-Pit Feed Preparation Plant
Primary Wet Concentrator
Transfer Station
Slurry Pipeline
Mineral Separation Plant
Product Handling, Storage and Loadout Facilities
Tails Handling
Plant Infrastructure and Services
Equipment Sizing and Selection
Preparation of Equipment Datasheets and Specifications
Detailed General Arrangement Drawings
Compilation of Capital Cost Estimate
Basis of Estimate Report
Project Achievements
EPMS was able to provide high quality robust deliverables for inclusion into the Feasibility Study report and the Capital Cost Estimate provided was to a level of accuracy that exceeded the industry standard for this stage of study. EPMS’s involvement with similar projects in the past ensured the work for this project was completed efficiently and within the client’s extremely tight timeframe.

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South Mine Expansion

Client
Tiwest JV
Location
South Mine, Cooljarloo, WA
Products
HMC
Project Capital Value
Confidential
Project Summary
Cooljarloo, Tiwest’s mineral sands mining operation, located 170 km north of Perth, Western Australia, is made up of two mines. The Cooljarloo South Mine, the principal mine is a dredging operation.


EPMS was engaged by Tiwest to undertake a Pre-feasibility Study and Detailed Feasibility Study to consider requirements for a throughput upgrade of Cooljarloo South Mine. To facilitate the increase in capacity of 2400 t/h up to 3600 t/h, upgrades were required to Tiwest’s primary and secondary mining dredges, the feed preparation plant and concentrator.
Scope
Dredge Capability Analysis

Pump and Piping Calculations

Process Simulations using LIMN

Load Study

Cyclone Evaluations and Selections

Trommel and Boilbox Design

Slimes and Water Balance

Development of Preliminary Designs

Structural Integrity Checks

Stability and Buoyancy Analysis for Dredge and SMC

Development of Specs, Datasheets and Scopes of Work

Development of Capital Cost Estimate for Upgrade

Determination of Refurbishment Costs and Upgrade Requirements for Second-hand Dredge

PFS and DFS Reports
Project Achievements
EPMS delivered robust PFS and DFS reports within the client’s required timeframe and budget. Subsequently the upgrade works were undertaken by Tiwest and desired throughput targets were met and in some cases exceeded.

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Dongara Dredge Mining Pre-feasibility Study

Client
Tronox
Location
Dongara, WA
Products
Heavy Mineral Concentrate
Project Capital Value
Confidential
Project Summary
The Dongara Project, owned by Tronox, is located approximately 28 km south-east from the coastal town of Port Denison and some 370 km north of Perth in Western Australia. Following a successful Dredge Proof of Concept study, EPMS was again engaged by Tronox to undertake a Pre-feasibility Study for the project, considering a 1500 t/h dredge mining operation. The dredgable deposits will be mined this way after completing the dry mining of the first deposit. A feed preparation unit and pre-concentrator would be included in the dredging operation to upgrade the mined ore prior to pumping to the relocated North Mine Concentrator from Cooljarloo.
Scope
Specify and conduct vendor enquiries for a suitable mining dredge

Prepare site layout plans for dredge mining activities

Design and cost a floating pre-concentrator plant

Develop plans for the upgrading of the existing Dry Mining equipment to that required for dredging operations

Determine if an SPQ upgrade is required and develop the plans and cost to achieve this if required

Detailed process flow sheets and mass balances

Detailed P&IDs

Preliminary power reticulation designs

Update the capital cost estimate to the required accuracy (±30%)

Report written in conjunction with Tronox to cover all engineering input on this project

Preliminary plans for the change over from dry to dredge mining

Prepare a preliminary Gantt
Project Achievements
EPMS successfully worked with Tronox to execute the study and prepare the report. The project was completed within the short time frame allowed and on budget.

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Dongara Dry Mining DFS

Client
Tronox
Location
Dongara and Muchea WA
Products
Heavy Mineral Concentrate
Project Capital Value
Confidential
Project Summary
The Dongara Project, owned by Tronox, is located approximately 28 km south-east from the coastal town of Port Denison and some 370 km north of Perth in Western Australia. EPMS was engaged by Tronox to undertake a Definitive Feasibility Study for the project considering a 600 t/h dry mining operation using the relocated North Mine Concentrator from Tronox’s existing operations at Cooljarloo.


The study also included identifying methods of coatings removal from the mineral grains and design of a 50 t/h attritioning plant, to enable the Dongara HMC to be successfully processed through Tronox’s existing Dry Mill and SR kiln at Chandala, WA.
Scope
Testwork co-ordination and supervision of bulk sample spiral and coatings removal applications

Detailed flowsheets, general arrangement drawings, mass and water balances for the Dongara wet plant and new attritioning circuit

Infrastructure specifications and design for the new Dongara site including water, power, gas, communications, roads, offices and accommodation

Site layouts for both the Dongara mine site and attritioning plant at Chandala

Determine the equipment requirements for all the pumping of sand tails, concentrate and slime slurry at Dongara

Enquiries into Shire approval procedures for both construction camp and single persons’ quarters

Development of detailed cost estimates, at an accuracy of ±10%, for all designs.

Create a cashflow forecast for the execute Phase of the project.

Define a Project Execution Plan and create a project Gantt Chart for the Execute Phase of the project

Report on all outcomes and phases of work completed by EPMS
Project Achievements
EPMS worked successfully with Tronox to carry out the study and finalise the report. The project was completed within the short time frame allowed and on budget.

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Cooljarloo West Pre-feasibility Study: Engineering

Client
Tronox
Location
Cooljarloo, WA
Products
Heavy Mineral Concentrate
Project Capital Value
Confidential
Project Summary
Exploration leases owned by Tronox to the west of their current mine at Cooljarloo contain three resources collectively referred to as Cooljarloo West.



As part of a Pre-feasibility Study conducted by Tronox, EPMS was contracted to supply engineering services to examine a number of options to relocate the mining equipment from Cooljarloo to the Cooljarloo West leases.
Scope
Option analysis on alternatives for the relocation of the mining activities from Cooljarloo to Cooljarloo West


Options risk analysis


Capital cost estimates and schedules prepared for client’s preferred option


Review of transportation routes


Preparation of site layouts with transportation routes


Water requirement calculations


Bulk earth works calculations


3D modelling of canal and lock routes
Project Achievements
EPMS was able to clearly identify the best option from a cost and schedule perspective. This allows Tronox to progress the project by focussing on the best method of relocation. Report was submitted as required on time and within budget.

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