Overview
Stage | Production |
Mine Type | Open Pit |
Commodities |
- Copper
- Molybdenum
- Silver
- Gold
|
Mining Method |
|
Processing |
- Crush & Screen plant
- Sulfuric acid (reagent)
- Flotation
- Heap leach
- Dewatering
- Filter press
- Solvent Extraction & Electrowinning
|
On-Site Camp |
4,150 people Source: |
Production Start | 2015 |
Mine Life | 2047 |
Aktogay is a large scale, low cost open pit mine. The annual sulphide processing design capacity was doubled to 50 million tonnes following the commissioning of the second sulphide concentrator in October 2021, which ramped up during 2022.
Aktogay is competitively positioned on the global cost curve and is expected to produce an average of 170 kt of copper per year from 2022 to 2027. |
Source:
p. 2
Company | Interest | Ownership |
Nova Resources B.V.
|
100 %
|
Indirect
|
KAZ Minerals Aktogay LLC
(operator)
|
100 %
|
Direct
|
KAZ Minerals has been wholly acquired by Nova Resources BV to support the Company’s pursuit of a capital-intensive strategy focused on long-term growth.
KAZ Minerals Limited is a high growth copper company focused on large scale, low cost, open pit mining in Kazakhstan. It operates the Aktogay and Bozshakol open pit copper mines in the Abay and Pavlodar regions of Kazakhstan, three underground mines and associated concentrators in the Abay and East regions of Kazakhstan and the Bozymchak copper-gold mine in Kyrgyzstan.
Contractors
Contractor | Contract | Description | Ref. Date | Expiry | Source |
unawarded or unknown
|
Power supply
|
220kv connection to Karaganda power station.
|
Dec 31, 2023
|
|
|
Source:
Summary:
Copper mineralisation at Aktogay consists predominantly of chalcopyrite and occurs in quartz-carbonate filled stockwork fractures and as disseminations. It forms a compact body shaped like a flattened goblet within the rocks of the first intrusive phase and the volcanogenic sedimentary rocks of the Keregetas formation. The copper mineralisation is spatially associated with small stocks and dykes of porphyritic granodiorites and later granodiorite porphyries.
The deposition of copper and associated minerals was structurally controlled by faulting. About 70% of the copper-molybdenum mineralisation is hosted by intrusive rocks, mainly diorites and granodiorites, and about 30% by volcanogenic-sedimentary rocks of the Keregetas Formation.
The stockwork and disseminated copper mineralisation with average grade in excess of 0.2% Cu was delineated by trenching and drilling over an area of 2.1 km by 1.6 km and to a depth of 600 m to 860 m. The vertical extent of the mineralisation at a 0.15% threshold is at least 1,000 m. The copper mineralisation is accompanied by molybdenite and low but recoverable quantities of gold, silver, rhenium and selenium.
The thickness of the oxide capping is variable, the average being 18 m and maximum about 60 m. There is a general tendency for the oxide capping to thicken eastwards. The base of oxidation was defined visually during core logging. In some drillholes it was also defined by a phase analysis. The visually determined base is on average 1.8 m lower than the base defined from a phase analysis.
The oxide zone passes downwards into a weak supergene sulphide enrichment zone. Secondary copper sulphide minerals – bornite, chalcocite and covelline – are accompanied by chalcopyrite and other primary copper and by some cuprite and native copper.
Source:
Summary:
Aktogay is a large scale, open pit mine with a remaining mine life of around 25 years (including the expansion project) at an average copper grade of 0.35% (oxide) and 0.33% (sulphide).
Source:
Source:
- subscription is required.
Processing
- Crush & Screen plant
- Sulfuric acid (reagent)
- Flotation
- Heap leach
- Dewatering
- Filter press
- Solvent Extraction & Electrowinning
Flow Sheet:
Source:
Summary:
The Aktogay open pit, sulphide concentrator and oxide plant located in the east of Kazakhstan.
The sulphide concentrator was commissioned in the final quarter of 2016. The capacity of the existing concentrating plant for processing sulfide copper-molybdenum ores is 25.0 million tons of ore per year.
The smaller oxide plant was commissioned in the fourth quarter of 2015 and produces copper cathode. The oxide plant is included in the Aktogay operating segment due to the sharing of infrastructure, its relatively small size and to reflect the Group’s management structure.
An expansion of the sulphide processing facilities at Aktogay was announced in December 2017. The expansion project envisages an increase in processing up from 25 to 50 million tons per year.
Copper cathode production from oxide ore at Aktogay will be unchanged at the current level of around 20,000 t/y for the remaining eight year life of the oxide deposit.
The Aktogay expansion project to double sulphide processing capacity at the mine was officially opened in October 2021, with first shipments to customers dispatched in December 2021.
Ore processing technology includes the following operations:
- the rougher, scavenger and three recleaner operations of bulk floatation;
- thickening of the bulk concentrate;
- two stages of slurry (pulp) agitation of the bulk concentrate;
- roughing and 4 recleaner operations of molybdenum floatation;
- thickening and filtration of molybdenum and copper concentrates;
- thickening of tailings.
The flow process involves the use of the following reagents:
- lime;
- Sodium isobutyl xanthate;
- methylisobutylcarbinol;
- sodium sulfide and sodium hydrosulfide;
- pine oil;
- molybden collector;
- flocculant.
The concentration under the said flowsheet of the original ore with a copper and molybdenum content of 0,361% and 0,009%, respectively, allows the following technological parameters to be achieved:
- copper content in copper concentrate 24,3%;
- content of molybdenum in molybdenum concentrate is 46,3%;
- extraction of copper into copper concentrate 83,8%;
- extraction of molybdenum into molybdenum concentrate 75,0%;
- content of copper in the tailings 0,059%;
- content of molybdenum in the tailings of 0,002%.
Process Description
The hydrocyclone overflow of the grinding stage II enters the chambers of floatation machines of the rougher bulk floatation. The concentrate of the rougher bulk floatation enters the regrinding mill operating in a closed cycle with a battery of hydrocyclones. The hydrocyclone overflow goes through the 2nd recleaner.
The tailings of the bulk rougher flotation enter the chambers of flotation machines of the scavenger bulk floatation. The concentrate of the scavenger bulk floatation is re-grinded in a mill operating in a closed cycle with hydrocyclones. The hydrocyclone overflow enters the cells of flotation machines of the scavenger bulk flotation I, the concentrate of which is sent to recleaner III.
Tailings of the recleaner I are sent to the control recleaner flotation, the concentrate of which is returned to the cycle of the re-grinding cycle of the concentrate of control flotation.
Concentrate of the recleaners II and III, which is a bulk copper-molybdenum concentrate, is condensed in a thickener to remove the parts of the reagents with an overflow, which is returned to the process as recycled water.
The thickened bulk concentrate is agitated with sodium hydrosulfide in a mixture with sodium sulfide in two agitators and enters the flotation machine of the rougher molybdenum flotation. The concentrate of the rougher molybdenum flotation is subjected to recleaner I. The froth product of the sixth molybdenum recleaner enters the molybdenum regrinding mill, working in a closed cycle with a battery of hydrocyclones. The hydrocyclone overflow is sent to the II clean-up molybdenum flotation, the tailings of which are returned to the molybdenum recleaner- I. And the concentrate is subjected to two consecutive recleaners. The froth product of the fourth molybdenum recleaner is a finished molybdenum concentrate. The flotation product of the rougher molybdenum flotation is a finished copper concentrate.
Molybdenum and copper concentrates are thickened in their respective thickeners, the overflows of which are returned to the process as recycled water. The thickened products are sent to the appropriate press filters of the filter area with a warehouse of concentrates.
Copper concentrate after filtration on two parallel operating filter presses is stored in stockpiles. The copper concentrate from the warehouse is shipped by the loader to the railway cars.
The molybdenum concentrate after filtration on a filter press is packed in big bags and sent to consumers.
Tailings of the scavenger bulk and recleaner flotations are the waste tailings, which by gravity are transported to the tailings sump and then pumped to the tailings thickeners. The thickened tailings are pumped to the tailings pond (under the project of the second phase of construction of he tailings storage).
Processing of ores is envisaged under the scheme of circulating water supply. Thickener drains are returned to the process as recycled water.
Filter press
The Larox® PF plate pack expansion increased concentrate production by 25% at KAZ Minerals’ Aktogay Concentrator Plant in Kazakhstan. The PF expansion is a cost-efficient way to rapidly increase filter capacity, increase production and gain maximum benefit from your current filtration equipment.
KAZ Minerals planned to increase copper concentrate production at its greenfield project Aktogay plant by increasing the filtration capacity by 25%.
The solution avoided large investment costs by avoiding having to purchase additional filters to expand the capacity of the existing filtration area. Both filters were expanded from 72 m2 up to 96 m2 by installing 4 additional plates to each filter.
Recoveries & Grades:
Commodity | Parameter | 2020 | 2019 | 2018 | 2017 | 2016 | 2015 |
Copper
|
Recovery Rate, %
| 85 | 88 | 87 | 80 | | |
Copper
|
Head Grade, %
| 0.56 | 0.58 | 0.61 | 0.66 | 0.41 | 0.37 |
Copper
|
Concentrate Grade, %
| 23.4 | 23.4 | 21.9 | 22.8 | | |
Pipelines and Water Supply
Source:
- subscription is required.
Production:
Operational Metrics:
Metrics | 2023 | 2022 | 2021 | 2020 | 2019 | 2018 |
Annual processing capacity
| 50 Mt of ore (in concentrator) | 50 Mt of ore (in concentrator) | | | | |
Ore tonnes mined
| 77,331 kt | 69,505 kt | 54,944 kt | 41,246 kt | 55,134 kt | 41,911 kt |
Tonnes processed
| 54,358 kt of ore (in concentrator) | 50,423 kt of ore (in concentrator) | 27,959 kt of ore (in concentrator) | 24,138 kt of ore (in concentrator) | | |
Tonnes processed
| 18,694 kt of ore (in heap leach) | 15,355 kt of ore (in heap leach) | 20,655 kt of ore (in heap leach) | 10,577 kt of ore (in heap leach) | | |
Waste
| | 4.4 Mt | 6.8 Mt | 8.6 Mt | 3.3 Mt | 0.5 Mt |
Total tonnes mined
| | | 61,744,000 t | 49,846,000 t | | |
Stripping / waste ratio
| | | | | | 0.2 |
Reserves at December 31, 2021:
Category | OreType | Tonnage | Commodity | Grade |
Measured
|
Sulphide
|
809.9 Mt
|
Copper
|
0.35 %
|
Measured
|
Oxide
|
28.9 Mt
|
Copper
|
0.26 %
|
Measured
|
Total
|
838.8 Mt
|
Copper
|
0.35 %
|
Measured
|
Sulphide
|
809.9 Mt
|
Molybdenum
|
0.009 %
|
Indicated
|
Sulphide
|
1,036 Mt
|
Copper
|
0.32 %
|
Indicated
|
Sulphide
|
1,036 Mt
|
Molybdenum
|
0.007 %
|
Measured & Indicated
|
Sulphide
|
1,846 Mt
|
Copper
|
0.33 %
|
Measured & Indicated
|
Oxide
|
28.9 Mt
|
Copper
|
0.26 %
|
Measured & Indicated
|
Total
|
1,875 Mt
|
Copper
|
0.33 %
|
Measured & Indicated
|
Sulphide
|
1,846 Mt
|
Molybdenum
|
0.008 %
|
Inferred
|
Sulphide
|
98.8 Mt
|
Copper
|
0.28 %
|
Inferred
|
Sulphide
|
98.8 Mt
|
Molybdenum
|
0.007 %
|
Commodity Production Costs:
| Commodity | Units | 2022 | 2021 | 2020 | 2019 | 2018 | 2017 |
Cash costs
|
Copper
|
USD
|
|
|
1.21 / lb
|
1.02 / lb
|
1.06 / lb
|
1 / lb
|
Cash costs
|
Copper
|
USD
|
1.14 / lb†
|
1.08 / lb†
|
1.16 / lb†
|
0.98 / lb†
|
1.03 / lb†
|
0.98 / lb†
|
† Net of By-Product.
Financials:
| Units | 2022 | 2021 | 2020 | 2019 | 2018 | 2017 |
Sustaining costs
|
M USD
| | | 46 |
44
|
20
|
|
Capital expenditures
|
M USD
| | | 297 |
553
|
514
|
27
|
Revenue
|
M USD
| | | 806 |
863
|
775
|
276
|
Operating Income
|
M USD
| | | 309 |
381
|
350
|
126
|
EBITDA
|
M USD
| 1,329 | 806 | 476 |
564
|
530
|
189
|
Heavy Mobile Equipment as of March 13, 2023:
HME Type | Model |
Dozer (crawler)
|
Caterpillar D11T
|
Dozer (crawler)
|
Caterpillar D10T
|
Dozer (crawler)
|
Caterpillar D9R
|
Dozer (crawler)
|
Komatsu D375A
|
Dozer (rubber tire)
|
Caterpillar 844K
|
Dozer (rubber tire)
|
Caterpillar 834K
|
Drill (blasthole)
|
Sandvik D55SP
|
Drill (blasthole)
|
Epiroc D65
|
Excavator
|
Hitachi EX5600
|
Excavator
|
Hitachi EX3600
|
Grader
|
Caterpillar 16H/M
|
Loader
|
Caterpillar 994 K
|
Loader
|
Caterpillar 993K
|
Truck (haul)
|
Caterpillar 785C
|
Truck (haul)
|
Caterpillar 793D
|
Truck (haul)
|
Caterpillar 777D
|
Mine Management:
Job Title | Name | Profile | Ref. Date |
Concentrator Manager
|
Aizharyk Berdaliyev
|
|
Mar 3, 2024
|
General Director
|
Tony Todd
|
|
Mar 3, 2024
|
Maintenance Manager
|
Anton Khoroshev
|
|
Mar 3, 2024
|
Maintenance Manager
|
Yegor Melnichenko
|
|
Mar 3, 2024
|
Maintenance Planner
|
Baurzhan Dyussembekov
|
|
Mar 3, 2024
|
Maintenance Planning Superintendent
|
Timur Kabdushev
|
|
Mar 3, 2024
|
Project Director
|
Andrew Batteson
|
|
Mar 3, 2024
|
Technical Director
|
Johan Barnard
|
|
Mar 3, 2024
|
Technical Services Manager
|
Emmanuel Obeng
|
|
Mar 3, 2024
|
Staff:
Employees | Year |
5,031
|
2020
|
4,166
|
2019
|
2,107
|
2018
|
1,490
|
2017
|
992
|
2016
|
386
|
2015
|
Corporate Filings & Presentations: