A bright future for Alacer
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WRITTEN BY
DAN BRIGHTMORE PRODUCED BY
RICHARD DEANE
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ALACER GOLD
The construction of the Çöpler Sulfide Plant is a game-changer for intermediate gold producer Alacer
T
he Çöpler Sulfide Expansion Project (CSEP) was completed on time and ~10% under its projected budget of $744mn.
The project was delivered 13 million hours Lost Time Injury (LTI) free, and with a Total Recordable Injury Frequency Rate (TRIFR) of 1.84 per million hours – a record that Chief Operating Officer 04
Stewart Beckman describes as a “stellar” achievement for the more than 3,000-strong team responsible for construction and the operations team, who are responsible for ramping up and running the new plant. The successful completion of the CSEP, combined with its operational oxide plant, will provide Alacer’s Çöpler Gold Mine with a strong foundation for at least the next 20 years. “For approximately 10 years we have produced gold by processing oxide ore through our heap leach plant. Underneath the oxide ores are sulfide ores that also contain gold, but gold that cannot be recovered by simple leaching. Nature converted the top of the deposit to oxide ore by slowly oxidising the sulfide ores. The construction of the Çöpler Sulfide Plant gives us the ability to accelerate the process and rapidly
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WINNING THE GOLD METAL !
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It‘s the teamwork that leads a project to success! Our expertise for your success in: Process studies Process related developments Finite element calculations Hardware solutions
EKATO Rühr- und Mischtechnik GmbH | Hohe-Flum-Str. 37 | 79650 Schopfheim | Germany | +49 7622 29-0 | info@ekato.com
Close collaboration with EKATO for the Çöpler Sulfide Expansion Project As for many other mineral processing projects, EKATO accompanied the Çöpler gold project over the last years. Already in the early design stages an intensive exchange and discussions between the end customer, engineering company and the equipment suppliers like EKATO took place. As the experience with other similar projects has shown in the past, this collaboration is increasingly limited to not just the equipment but to an extended scope of supply, which is appreciated by customers. In these cases, EKATO, with more than 85 years of experience in mixing technology and state-of-the-art testing equipment in its technical center, offers much more than just agitators. This additional scope can be quite extensive and cover all types of agitated applications in the plant flowsheet. For Anagold’s Çöpler Sulfide Expansion Project, EKATO designed and delivered agitators for all large agitated applications including the POX autoclaves‘ agitators. EKATO also performed several studies in its technical center. One of these series of tests was related to the optimum feed pipe locations and geometries in the first autoclave compartment. These tests in the model scale were then backed up by CFD (Computational Fluid Dynamics) studies which were carried out in-house as well. Other services included the assessment of slurry rheology data, supplied by other parties. The consideration of the appropriate slurry rheology is crucial for the proper operation of the agitators, especially for the large atmospheric tanks with capacities up to several thousand cubic meters. For this particular project, additional CFD simulations were prepared to double-check the designs of these tanks. EKATO’s capabilities also allow to extend this scope, provided during the design and construction phase, to the start-up and operation of the plant.
3D model of a world scale POX autoclave
Of course EKATO’s solutions are not limited to process related issues. The reliable mechanical design of the agitators, including the in-house manufactured mechanical seals and supply systems, ensures a maximum life time of the equipment with longest service intervals. This overall reliability has not only been proven in this particular project but in many other projects in mineral processing.
Pilot autoclaves in EKATO‘s R&D Center
www.ekato.com
ALACER GOLD
“ A “stellar”achievement for the more than 3,000-strong team responsible for construction and the operations team, who are responsible for ramping up and running the new plant”
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— Stewart Beckman, Chief Operating Officer, Alacer Gold
oxidise the sulfide ores, enabling us to recover the considerable gold value that was previously trapped,” explains Beckman. “The oxide ore in the original mining area was depleting and so, without the CSEP, the Çöpler Mine would have been facing declining production and the prospect of winding down operations. However, the CSEP now gives the operations ~20 years of life. In addition, recent discoveries of new oxide ore deposits around the original Çöpler deposit now provide the prospect of extending the
CLICK TO WATCH : ‘ALACER GOLD: EMPOWERING EMPLOYEES AND TRANSFORMING THE FUTURE WITH SAP S/4HANA®’ 09 life of the oxide ore processing well into the future. We have gone from the prospect of declining operations at Çöpler to now having a very bright future, with both the oxide plant and the sulfide plant running. This is a great outcome for our business, our employees and the communities that are supported by the mine’s operations”. In 2019, Çöpler is expected to produce 355-415 koz at an AISC range of $675-725/oz from both the oxides and sulfides. Project Director John Ebbett oversaw the design and build of the CSEP, explaining that the construction of the w w w.a l a c e rgold . com
No Margin for Error Congratulations to Alacer Gold and the Wood Group, we look forward to our continued working relationship at this site and other potential projects in the future. Koch Knight, LLC is a leader in acid proof and corrosion solutions with capabilities in construction, engineering and services, working with state-of-the-art ceramics and plastic materials. Koch Knight manufactures ceramic products which include, brick, proprietary mortars and membranes highly suited for the mining industry. Koch Knight provides responsive, customer-focused solutions. Our products and services are available worldwide through our global network of manufacturing and outsourcing ceramic and plastic facilities. Whether it is a revamp or new construction, from start to finish, Koch Knight will assist you with every step to ensure speedy completion and successful results.
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new plant utilised an Integrated Project
behaviours, while also remaining
Management Team (IPMT) model to
involved throughout the project by
successfully break down inter-company
performing organisational health
barriers, increase transparency and
checks and assisting with change as
drive individual accountability. “This
the project progressed through its
allowed project issues to be highlighted
execution stages.”
and dealt with in a timely manner,”
Ebbett’s teams were able to take
he says. “Early in the development of
advantage of existing infrastructure on
the IPMT, 4Points were engaged to
site and built additional accommodation
develop a structured programme that
for the 3,000 temporary workers “at
would instill the desired culture and
well above the typical local standards
E XE CU T I VE PRO FI LE
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John Ebbett John Ebbett spent almost five years as Project Director at Alacer Gold throughout the construction process on the company’s Çöpler Sulfide Expansion Project (CSEP). Previously, he spent over four years working as Project Manager for Newcrest in Indonesia and Papua New Guinea. Managing the portfolio of capital works at the Lihir Gold Mine, he ensured that capital use was efficient and aligned with Newcrest’s short- and long-term strategic plans. The projects delivered during this time included optimising the process plant following the MOPU project, community infrastructure and refurbishment of process plant facilities. Prior to this he was a Senior Mechanical Engineer at Ausenco, where he has now returned to take up the role of Vice President, Global Project Delivery.
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ALACER GOLD
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“ The construction of the Çöpler Sulfide Plant gives us the ability to accelerate the process and rapidly oxidise the sulfide ores, enabling us to recover the considerable gold value that was previously trapped” — Stewart Beckman, Chief Operating Officer, Alacer Gold
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for a construction site”, along with
sections of scope: the process plant,
more than 100 apartments, including
tailings storage facility and support
three-bed family units, for the ongoing
infrastructure. The tailings storage
operations team. “Compared to some
facility is a fully lined, downstream
of the projects I have completed
impoundment with both under and over
elsewhere in the world, the infrastruc-
drain systems. The embankment is a
ture in eastern Turkey is fantastic. We
mass wall, with phase one constructed
had a great road to the mine site, a
during the CSEP construction,
50MW hydro power station 5km away
containing 3.5 million m3 of structural
(connected to the national grid) and
rock fill. The construction of the TSF
other hydro power stations in the area.”
was delivered using the current mining
The CSEP comprised of three major
contractor, Çiftay, with Golder providing w w w.a l a c e rgold . com
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construction quality control.
The process plant scope included
The infrastructure scope included
crushing, grinding, acidulation,
upgraded access roads, accommoda-
pressure oxidation, iron/arsenic
tion apartments for staff, an upgraded
precipitation, counter current decanta-
water supply system and other site
tion, leach, carbon in pulp, elution,
facilities. The bulk of this infrastructure
electrowinning, detox/neutralisation
was delivered by local contractors from
and tailings pumping. “A key feature of
within the Çöpler District, resulting in a
the process plant is the twin autoclave
significant level of community involve-
circuits that, due to transport con-
ment. The CSEP was an opportunity to
straints, required vessels to undergo
further develop local contractor
final assembly and post-weld heat
capability and assist with Alacer’s goal
treatment on site,” reveals Ebbett of
of creating a sustainable operation and
this industry-leading approach. “We
surrounding community.
looked at the best way we could get
E XE CU T I VE PRO FI LE
Stewart Beckman Mr. Beckman joined Alacer Gold in June 2016. He has 30 years of experience in the mining and minerals processing industry. Prior to joining Alacer, Mr. Beckman spent 19 years with Rio Tinto, working across a number of product groups in senior leadership, minerals processing, mining operations and project development roles. His most recent roles were Global Lead for Group Working Capital Reduction and Senior Vice President Operations and Technical Development for Turquoise Hill Resources and Director Oyu Tolgoi Expansion. Prior to joining Rio Tinto, he spent seven years in a variety of operational roles at Placer Dome.
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Courage, firm steps, innovation, and common sense. Result: Success More than 130 successfully completed projects on three different continents. Ranking in ENR’s “Top Contractors League” Since 2006. Logistics power extending over three continents. 22 million accident free man/hours.
As a prestigious contracting company preferred in infrastructure, substructure, housing and industrial plant projects, G İnşaat is a leading, innovative, and environment-friendly solution partner, which has adopted the principle of making maximum use of modern technology. GAP has undertaken the whole scope of Civil Works, Steel Structure, Equipment Installation, Lifting, Piping, Carbon Steel, Stainless Steel and Super Duplex Tanks installation, Electrical and Instrumentation Works and Scaffolding Works at ÇÖPLER PROJECT .
LEARN MORE
CONTACT US
www.gapinsaat.com | www.calik.com HQ (0 212) 306 50 00
the autoclaves to site in sections within
flexibility are also provided by matching
the tight transport limits in terms of
the twin horizontal autoclave configura-
both size and weight. Transporting the
tion to the twin train oxygen plant
autoclave to site in sections allowed us
(supplied by Air Liquide under a build
to balance the operational benefits of
own operating agreement).
horizontal autoclaves, and to minimise
Ebbett recalls the unity of the
the potential construction issues by
various branches of the contracted
only having to weld autoclaves sections
Engineering, Construction & Project
together on site rather than site
Management (EPCM) team: “Some-
fabricating the complete vessels.�
times owners can get in the way of the
Increased availability and operational
EPCM being effective; with an integrated
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ALACER GOLD
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“ Sometimes owners can get in the way of the EPCM being effective; with an integrated owner’s team and no positions duplicated we were able to meet challenges with quick decision making” — John Ebbett, Project Director, Alacer Gold
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Industry leading severe service innovations More than ever before, autoclave operations require commissioning of process sites as quickly and efficiently as possible. Thereafter, the focus shifts to sustainability and reliability, where it becomes critical to extend the production time between major shutdowns. Extreme processing conditions require high-integrity valve designs with the most advanced coatings. For over forty years, MOGAS has invested in surface engineering development, culminating in the latest and most advanced coating technologies. Our breakthrough ML-381 metallurgically bonded weld overlay has been proven to substantially increase the time of plant operations between shutdowns. When profitability and efficiency are key, MOGAS valves outperform the competition time and time again.
www.mogas.com
The Çöpler Gold Mine Alacer continues to pursue opportunities to further expand its current operating base to become a sustainable multimine producer with a focus on Turkey. The Çöpler Gold Mine is located in east-central Turkey in the Erzincan Province, approximately 1,100km east of Istanbul and 550km east of Ankara, Turkey’s capital city. The mine processes ore through two producing plants. With the recent completion
of the new sulfide plant, the Çöpler Mine will produce over 3.5 million ounces at first quartile All-in Sustaining Costs, generating robust free cash f low for approximately the next 20 years. Commercial production at the sulfide plant was declared in May 2019 and the bank completion test passed in August 2019. The ramp up continues and the plant design is proving to be robust with good upside potential.
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ALACER GOLD
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owner’s team and no positions duplicated, we were able to meet challenges with quick decision making.” Wood provided engineering procurement and construction management services; Carpenteria Corsi delivered POX circuit vessels, while Ekato brought mixing and agitation technologies. “The IPMT structure drove a high level of collaboration and ensured nothing fell through the cracks in terms of information shared,” adds Ebbett. Turkish contractor GAP İnşaat (a subsidiary of Çalik group, which is Alacer’s Turkish partner and 20% owner of the Çöpler Gold Mine) was the general contractor for the process plant scope of the project, working closely as part of the IPMT. “GAP was C OM PA N Y S TAT S
Çöpler Sulfide Expansion Project (CSEP) by numbers
key for us to effectively manage and work with our Turkish subcontractors,” he confirms. Ebbett maintains completion of the
• 40,363 m3 concrete
project on time and under budget was
• 8,751 tonnes steel
achieved by “getting the basics right”
• 1,164 mechanical items
and following best practice rather than
• 85km piping
taking risks with new innovations. “One
• 885km cable
of the key achievements was that we were well advanced on the engineering when the Alacer board approved the w w w.a l a c e rgold . com
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project,” he says. “Some resource
make sure we could get the process
projects tend to miss cost and schedule
and performance requirements Wood
targets when they’ve been approved
was specifying.”
with insufficient engineering and project definition.” Wood’s strong engineering expertise
Elsewhere on the project, MOGAS provided all of the severe service valves needed around the POX
is recognised by the project director.
(pressure oxidation) circuit. “There
“They provided the bulk of our person-
are only a few manufacturers in the
nel and worked with other key partners.
business capable of delivering the
Carpentiria Corsi fabricated the
valves required and their performance
pressure vehicles (certified under
is important for plant reliability,” says
the European Pressure Equipment
Ebbett. “Koch Knight was another vital
Directive) and also completed the site
partner, brought on board to provide
assembly, working in unison with us to
the lining of the vessels with the use of w w w.a l a c e rgold . com
ALACER GOLD
3 MAJOR COMPANIES, 10 MAJOR CONTRACTORS, 3000+ PEOPLE AND 30+ CULTURES...
See how we solved the Integration challenge on the CSEP. DISCOVER HOW
A WORLD FIRST PROGRAM FOR MINING, CONSTRUCTION AND INFRASTRUCTURE PROJECTS. INTEGRATE.4POINTS.COM.AU
29 tailored acid and corrosion resistant
in the future operation of the Çöpler
materials. Also working with us was
Gold Mine and its plants was a
Weir, which supplied the specific
consideration throughout the CSEP.
equipment required (for the POX feed
“We have included the ability to take
pumps) with an elegant design and
it further,” confirms Ebbett. “The full
proven technology to function at the
control system across the plant is
high POX feed temperatures present
state-of-the-art, along with the ability
at Çöpler.” Importantly, along with
to collect and utilise data.” The new
specialist international suppliers, the
plant also has a high level of digitisation
tanks, piping and structural steel
laying the groundwork for advanced
fabrication and prefabricated electrical
analysis. “Nothing is set in stone,” he
rooms were all sourced from within
adds. “These plants are complex to run
Turkey, resulting in a high portion of
and optimise, with the operators
in-country spend.
managing many input and control
The role that technology would play
variables such as the sulfide in the ore, w w w.a l a c e rgold . com
ALACER GOLD
“ There’s plenty of options to accommodate growth, and different ore characteristics through the sulfide plant.We’ve got flexibility in the process plant for the future” — John Ebbett, Project Director, Alacer Gold
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oxygen consumption, oxygen efficiency, carbonates in the ore, the amount of acid being generated, etc. The ability to leverage simulators and high-powered tools will help the plant keep delivering to the highest standards in the future.” Beckman is proud of the speed at which the plant has been ramped up. “We fully expect the CSEP to have the capacity to perform beyond its nameplate design,” he says. “We’re
already working on options to make
ore characteristics through the sulfide
minor modifications to the plant to
plant. We’ve got flexibility in the
improve operations and increase
process plant for the future.”
production. Concurrently we’ve got significant exploration adjacent to the mine, so we aim to continue the oxide plant running in parallel to the sulfide plant and to increase the amount of ore available to the sulfide plant.” Ebbett concurs: “There’s plenty of options to accommodate growth, and different
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www.alacergold.com