Optimised maintenance strategies for copper concentrator assets

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Xstrata Mount Isa Mines operates mining and processing streams for copper and zinclead- silver. The copper operations include two underground copper mines from which 6.2 M/ty of ore is mined, a concentrator with 7.2 Mt/y capacity and a copper smelter. 

Ausenco Rylson was engaged to carry out a risk based criticality analysis and facilitate a PM Optimisation (PMO) program of all copper concentrator assets. 

The project objectives were: 

  • To review the existing plant hierarchy in Ellipse for completeness and accuracy 
  • To conduct a comprehensive criticality analysis of the plant and equipment 
  • To optimise the maintenance strategies for the plant and equipment removing duplication of effort and ensuring all maintenance is value-adding. 


The work completed by Ausenco Rylson at Xstrata’s copper concentrator at Mount Isa yielded the following results:

  • A number of assets were identifi ed as missing from the CMMS (Computerised Maintenance Management System) 
  • A significant number of assets had their details modified to bring them up-to-date in the CMMS 
  • All copper concentrator assets went through a structured PMO process to refine and optimise the maintenance being carried out 
  • Standard Jobs and Maintenance Scheduled Tasks (MST) were developed for all concentrator assets for implementation into the CMMS.

Project details

Asset management
Queensland, Australia
Xstrata Mount Isa Mines
Solution phase