A THREE-PHASE PLAN BUILDS BRITISH COLUMBIA OPERATION INTO CANADA’S SECOND-LARGEST OPEN-PIT COPPER MINE

For about 30 years, the Gibraltar mine in south-central British Columbia generally operated at its design capacity of 36,000 tonnes of ore a day producing on average 60 million pounds of copper annually. Commercial production at the mine began in 1972, but by 1999, it was shut down due to low metal prices.

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That’s when Taseko Mines acquired the copper-molybdenum mine located at McLeese Lake. For five years, it sat under the Taseko wing with minimal activity at the site, but that changed considerably in 2004.

“Copper prices began to rise, and we believed that trend could be long-term, so Taseko began putting resources back into production,” explained Dave Rouleau, Vice President of Operations for Taseko and General Manager of Gibraltar. “Originally, the plan was for 40 months. During that time frame, we put a considerable amount of time and effort into defining the ore body, which included extensive exploration. It turns out, the property has about 900 million tonnes of reserves, so we put a multiphase plan in place for sustained operations.”

The three-phase plan began in earnest with construction of a 34-foot, semi-autogenous grinding (SAG) mill; conversion of existing rod mills to ball mills; replacement of the floatation recovery system with modern float cells; and additional mining equipment. Phase One concluded in 2008, increasing the concentrator capacity to 46,000 tonnes of ore per day.

A year later, Taseko commenced Phase Two: a $224-million investment in a new in-pit crusher and conveying system, an increased regrind and cleaner floatation capacity, the installation of a tailings pumping system, more mining equipment, and a new coarse-ore stockpile and SAG direct-feed system. The two-year phase bumped capacity to 55,000 tonnes per day.

The final phase, completed in 2013, brought a second independent crushing facility into the mix, with a new concentrator and an even more substantial upgrade of the mining fleet. With the three-phase plan complete and a production capacity of 85,000 tonnes per day, Taseko’s Gibraltar Mine is now the second-largest open-pit copper mine in Canada and the fourth-largest in North America. Taseko’s total investment in the mine upgrade topped $700 million.

“One of the goals was to lower risks involved with up and down cycles of the markets,” said Rouleau. “Adding the second mill helped with this because with two we’ll never flat line, as we now have the capability to produce much more. We’re producing some of the best copper concentrate in the global market. Customers like it, so there’s a great demand, and we believe that further sets us up for long-term success.”

Now the region’s largest employer

Taseko’s Gibraltar Mine is now the largest employer in the Cariboo Region with a staff of about 670. During the seven-year process of ramping up production, the mine added about 500 people. Key mine personnel include Manager, Mine Operations Kelly Parker; General Superintendent, Mine Engineering Michael Blusson; and General Foreman, Mine Operations Bob Dunn.

“Growing capacity meant we had to make a substantial push in hiring new people, but even with adding that much new staff, our experience level remains very high,” Rouleau pointed out. “Our average age is about 42 years, so we believe we have a very nice mix of veteran, intermediate and less-experienced personnel, which sets us up well for the present and the future. And, we offer a great future by providing advancement opportunities. Someone who’s starting as a labourer could move into an operator’s position or beyond, based on their desire. We also offer an apprenticeship program. Taseko’s commitment to advancement opportunity, along with a solid pay structure, has helped us build the area’s strongest and most dedicated work force.”

It’s also a very safe one. “Our safety record is very positive, and that’s due to a focus on making it our highest priority,” said Rouleau. “We want to ensure our workers are taken care of, and that they, in turn, look out for each other. It has always been, and remains the goal of Taseko’s Gibraltar Mine and of our workers to have zero lost-time accidents.”

Komatsu 930Es ramp up production

Even with the additional upgrades, one thing hasn’t changed at Taseko’s Gibraltar Mine: the way ore is mined. “We’re still a conventional truck-and-shovel operation,” stated Kelly Parker, Manager, Mine Operations. “Ore is loaded on trucks in the mine and delivered to crushers. That’s obviously equipment-intensive, so part of the ramp-up efforts involved a considerable investment in acquiring machinery that would meet the challenge with maximum availability and the lowest per-tonne costs.”

Included in the mine’s equipment acquisition were 18 new Komatsu 930E electric mining trucks that feature a 320-tonne payload capacity, augmenting a fleet that already included 830Es.

“I came on board at Gibraltar about a year ago from another mine that uses 930Es,” noted Parker. “At the other mine, the haul involves trucks going downhill loaded, whereas at Gibraltar, trucks have an uphill climb on a 10-percent grade. The Komatsu 930Es handle both situations well, due in large part to the AC-drive, which provides excellent power for the climb. It also provides a comfortable ride for the operators, and they really appreciate that. At the same time, we appreciate the availability we’re getting. It’s more than 90 percent, and that’s outstanding.

“Dynamic electric retarding is another standout feature,” added Parker. “It saves brake wear and tear, so the 930Es have an extended life compared to mechanical-drive trucks, which use traditional braking systems. That improves maintenance costs considerably.”

Taseko’s Gibraltar Mine also runs Komatsu WA700 and WA800 wheel loaders. “We’ve found the loaders give us more flexibility and efficiency compared to dozers, especially working the piles that build up as shovels are pulling material from the face,” Parker reported. “With a dozer, we can only push a pile, and that can take considerable movement and time. Using loaders, we can pick up material and move it much more quickly. As a result, the shovels have to move less, which saves time and increases production.”

To improve its maintenance capabilities, Taseko’s Gibraltar Mine built a new six-bay, state-of-the-art shop big enough to service large mining equipment, including the 930Es. The company tracks hours and other critical machine data through Komatsu’s KOMTRAX Plus, and works closely with SMS Equipment personnel, including Mining Equipment Sales Rep Jason McCleery, Product Support Sales Representative Jamin Price and Operations Manager Richard Roberts.

“SMS has provided terrific support every step of the way, including modifications that meet our specifications, and operator and technician training,” said Rouleau. “They showed us how to best utilize our resources so we’re getting the most production and efficiency out of our equipment. SMS has technicians dedicated to the mine, and we continue to hold monthly meetings to talk about anything that needs to be addressed. Part of any equipment-buying decision is factoring in the relationship with the dealer, and we’ve built one with SMS Equipment that we believe is very solid, and we’re very happy with it.”

Plans from start to finish

The companies are currently testing lighter-weight dump bodies on two 930E trucks in an effort to maximize payload and reduce fuel costs and tire wear. Rouleau notes it’s part of a strategy to maximize long-term assets.

“Based on our history with Komatsu trucks and an aggressive maintenance approach, as well as a fleet-rotation plan, we expect them to be part of our operations for a long time to come,” said Parker. “The original 40-month plan for this mine has been extended to an anticipated lifespan of up to 25 years, so we have plenty of time and production left at Gibraltar.”

“We’re still operating under the original permit for the mine, so we’re updating with additional environmental plans for air and water quality,” added Rouleau. “The company has always been very environmentally conscious, including performing reclamation as we progress through the mine. We already are developing plans for capping areas as they’re closed for use, sloping the ground and planting appropriate trees and grass. We have plans for each new area of development that takes it from start to finish.”