Constancia Project

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  • CommodityCopper
  • LocationPeru
  • ClientHudbay Peru SAC
  • Timeframe2011 - 2015
  • Solution phaseCreate (EPCM)
  • Project valueUS$1.75b
  • ServiceEPC/EPCM

EPCM services for major copper project situated at high altitude

The Constancia deposit is a porphyry copper-molybdenum system that includes copper-bearing skarn mineralisation.The project is located in the Andes in south-eastern Peru and is positioned 4,100m above sea level.

Ausenco provided Engineering, Procurement and Construction Management (EPCM) services to design, construct, and commission a 25 Mt/y concentrator and associated infrastructure for this high-altitude project.

Constancia is a conventional surface-mining operation based on two deposits - Pampacancha and Constancia - with the processing facility located around 1 km west of the Constancia pit. The project incorporates primary crushing, twin SAG/Ball mill grinding circuit, regrind, flotation, concentrate filtration and tailings pumping capacity, as well as stand-alone molybdenum separation plant and various ancillary systems. The Pampacancha deposit is 5 km southeast of the Constancia deposit and exhibits higher grades of copper and gold. It is scheduled to enter into production in 2016.

At full production, Constancia plant throughput will average 80,000 metric tons per day (mt/d), and production of copper in concentrate will average 82,000 mt/y. Mine life is planned at 22 years (view Hudbay video).

Ausenco's knowledge of Constancia was extensive having previously delivered to Hudbay:

  • an update of the feasibility study to improve the throughput of the concentrator comminution circuit, and
  • front-end engineering design services to support development of the project including a detailed project estimate and the procurement of long lead items.

Ausenco undertook project management and engineering which was distributed across Australia, Canada and Peru. Project management commenced in Brisbane and progressively transferred to Lima as the project developed.

Highlights

  • High altitude design and construction
  • High volume low grade concentrator building on our successful development of the Lumwana and Phu Kham concentrators - design developed by adapting these successful innovative projects to suit the requirements of Constancia
  • FEED services for project completed under budget and on schedule
  • Initial concentrate production in late 2014
  • 8 million man-hours LTI free for Ausenco managed scope (October 2014)
  • Commercial production 2nd quarter 2015
  • Plant performing as designed (May 2015) with throughput occasionally exceeding design capacity due to favourable ore characteristics, with peaks of over 90,000 tonnes per day.

Ausenco’s experience on the Constancia project married with proven execution strategies and a committed partnership approach resulted in the August 2015 announcement that Ausenco would provide EPCM services for the development of Hudbay Minerals' Rosemont Project near Tucson, Arizona, USA. The Rosemont Project, when producing, is expected to be one of the largest copper mines in the United States, accounting for around 10% of the nation’s copper production.