At Mipac, the automation of copper processing plants is more than just a specialty—it’s in our DNA. Since our first project 27 years ago, we have been on-site at copper plants worldwide. We know the daily challenges the plants face, from fluctuating ore grades to the demands of modern production. With this deep process knowledge and a best-practice approach to technology, we’ve provided tailored automation and digitalization solutions to address some of the industry’s toughest challenges. We always aim to ensure our clients’ operations are efficient and resilient.
This article discusses a series of projects we’ve worked on – demonstrating our capability to enhance copper mining operations globally and showing that copper processing is indeed embedded in our DNA.
Our Global Expertise in Copper Processing Automation and Optimization
With a global footprint that spans continents, Mipac has worked in some of the most challenging environments, from Australia to Zambia, Alaska to Peru, and beyond. Our international experience is coupled with deep partnerships with industry leaders like First Quantum Minerals, Freeport McMoRan, and Anglo-American. These relationships have allowed us to consistently deliver automation solutions that address each site’s unique needs, whether starting up a new operation or optimising an existing one.
Tackling the Complexities of Copper Processing
Copper processing presents complex challenges, including aging infrastructure, declining ore grades, and the need for continuous improvement. At Mipac we are on a mission to help plants navigate these obstacles through advanced automation and process control.
Our work at the Glencore Kamoto Copper Company (KCC) in the Democratic Republic of Congo is a prime example. Faced with significant control challenges and the need for process optimization, we improved the control system logic for grinding mills and the Counter-Current Decantation (CCD) circuit.
The result? Reduced downtime and increased throughput, demonstrating our ability to modernise and optimise operations.
Optimized grinding mills and CCD circuits, reducing downtime and increasing throughput.
In another major project, we were tasked with the startup of First Quantum Minerals’ Cobre Panama project—one of the largest new copper mines to come online in recent years. As the main automation control partner, we successfully managed the entire project under an extremely fast ramp-up time. We ensured a seamless transition to full operation through a modular design, configuration and commissioning approach, highlighting our ability to manage complex greenfield projects.
Greenfield automation project with fast ramp-up to target production.
Our involvement in Anglo-American’s Quellaveco project further underscores our expertise. Quellaveco was Peru’s first large mining project to adopt Siemens PCS7, and more on-site experience with this system was needed. Mipac stepped in to provide critical support in resolving the design and configuration issues with the control system, offering training, remote commissioning, and ongoing operational support. This project is a testament to our ability to overcome technical challenges and ensure the successful implementation of advanced control systems.
Resolved design and configuration issues and improved plant process control strategies.
Modernizing and Optimizing Copper Plants
Modernization is critical to improving efficiency in aging copper plants. At Mipac, we specialize in upgrading outdated control systems, integrating modern technologies, and bringing plants into the future.
For instance, the First Quantum Minerals Kansanshi Smelter upgrade project in Zambia saw us upgrade the Siemens PCS7-based control system from V8.0 SP2 to V9.1. The challenge came from the highly aggressive cutover timeline of just eight weeks from project order to site execution.
Our work enabled the smelter to operate at peak efficiency, showcasing our capability to modernize and optimize even the most complex operations.
Upgrade executed in 3 month window, bringing plant online with no outage after startup
Similarly, our work at CMOC’s Northparkes Mine (now owned by Evolution) in Australia involved implementing advanced grinding mill and flotation control strategies. These control system modifications improved stability and recovery rates, highlighting how targeted upgrades can lead to significant performance improvements.
Enhanced grinding mill and flotation control, improving stability and recovery rates.
At Ok Tedi Mining Limited in Papua New Guinea, we developed a comprehensive automation roadmap. This long-term plan included upgrades to existing systems and the integration of new technologies to improve overall operational efficiency. Our approach helped Ok Tedi navigate the challenges of aging infrastructure while laying the groundwork for sustained future success.
Developed an automation roadmap to upgrade aging systems and integrate new technologies.
The Glencore Mount Isa Mines copper project in Australia is another example of how our advanced control strategies can transform operations. By implementing best practice control strategies over the past 27 years, we’ve continued to help stabilize production and allow the plant to operate consistently at optimum capacity. This project underscores our ability to deliver results that improve both efficiency and output.
Implemented advanced control strategies, stabilising production and optimising capacity.
Remote Support and Training: Empowering Operations
In today’s interconnected world, remote support has become crucial for maintaining efficient operations. Our work at KCC is a shining example of how we leverage remote capabilities to achieve success, even in the most challenging circumstances. During the COVID-19 pandemic, travel restrictions posed significant challenges, but our remote commissioning and support services allowed us to continue delivering results without onsite presence. This not only saved time and resources but also ensured that the project remained on track.
Training is another cornerstone of our approach. We empower your team with the knowledge and skills needed to operate and maintain the systems we implement. Our comprehensive training programs ensure that the improvements we introduce are sustainable and that your team can continue to achieve peak performance long after the initial implementation.
Case Studies for Efficient, Resilient and Sustainable Operations
The successes at these copper processing plants are more than isolated incidents—they are a testament to our ongoing commitment to excellence in copper processing.
- Kamoto Copper Company: Optimized grinding mills and CCD circuits, reducing downtime and increasing throughput.
- Cobre Panama: Successfully managed a fast-paced greenfield project, ensuring smooth operation through modular design and commissioning.
- Quellaveco: Overcame technical challenges with Siemens PCS7, providing critical startup and operational support.
- Kansanshi Smelter: Upgraded control systems to enable efficient operation of a large-scale copper smelter.
- Northparkes Mine: Enhanced grinding mill and flotation control, improving stability and recovery rates.
- Ok Tedi Mining: Developed an automation roadmap to upgrade aging systems and integrate new technologies.
- Glencore Mount Isa Mines: Implemented advanced control strategies, stabilizing production and optimizing capacity.
These case studies underscore our ability to deliver tangible outcomes that go beyond mere adaptation to diverse environments and project requirements. Through our efforts, we’ve ensured that these sites are not only running more efficiently but are also more resilient and better equipped to support their ESG goals.
By optimizing operations and enhancing sustainability, we help our clients meet their environmental and social responsibilities, creating mining operations that are both profitable and aligned with a sustainable future.
Mipac: Your Trusted Partner in Automation of Copper Processing Plants
At Mipac, our deep expertise, innovative solutions, and collaborative approach make us an invaluable partner in copper processing. We understand the challenges you face because we’ve worked side by side with you to solve problems and deliver results. Whether you’re modernizing an existing plant, starting up a new operation, or looking to optimize your processes, we have the experience and solutions to help you achieve your goals.
Let’s work together to ensure your copper processing operations survive and thrive. Contact us today to discuss how we can help you overcome your unique challenges and drive your operations to new heights.
Catch up on other projects and insights from our team
Mipac has been chosen, over several competitors, to deliver the plantwide process control system (PWCS) for Arafura Rare Earths Limited’s Nolans Project in the Northern Territory, solidifying Mipac’s reputation and ability to deliver next-generation projects.
Mipac has been chosen, over several competitors, to deliver the plantwide process control system (PWCS) for Arafura Rare Earths Limited’s Nolans Project in the Northern Territory, solidifying Mipac’s reputation and ability to deliver next-generation projects.
4 minute read It’s been six months since Process Engineer Andrew Yang made the move from Townsville to Brisbane to join Mipac’s …
