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United States
Rosemont Project

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 Location:
41 km SE from Tucson, Arizona, United States

  Project Contacts:
Hidden Springs Rd
Vail
Arizona, United States
AZ 85641
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Overview

StatusTemporary Suspension
Mine TypeOpen Pit
Commodities
  • Copper
  • Molybdenum
  • Silver
  • Gold
Mining Method
  • Truck & Shovel / Loader
Processing
  • Dewatering
  • Flotation
Mine Life19 years (as of Jan 1, 2017)
On July 31, 2019, the U.S. District Court issued an unprecedented ruling where it vacated the U.S. Forest Service’s issuance of the Final Record of Decision, suspending construction work at Rosemont.

May 12, 2022 (GLOBE NEWSWIRE) -- Hudbay Minerals Inc. (“Hudbay” or the “company”) (TSX, NYSE: HBM) and the U.S. Department of Justice today received a split decision from the U.S. Court of Appeals for the Ninth Circuit (the “Decision”), which affirmed the U.S. District Court for the District of Arizona’s (“District Court”) decision in July 2019 relating to the Rosemont copper project in Arizona. In the Decision, the Court of Appeals agreed with the District Court’s ruling that the U.S. Forest Service relied on incorrect assumptions regarding its legal authority and the validity of Rosemont’s unpatented mining claims in the issuance of Rosemont’s Final Environmental Impact Statement.
Latest NewsThe U.S. Department of Justice and Hudbay Receive Rosemont 9th Circuit Court Ruling; Hudbay Continues to Advance Copper World     May 12, 2022


Owners

Source: p. 7
CompanyInterestOwnership
Hudbay Minerals Inc. 100 % Indirect
Hudbay Arizona Inc. 100 % Indirect
Hudbay Minerals Inc., through its subsidiaries, 100% indirectly owns Rosemont project.
Hudbay Arizona Inc., through its subsidiaries, indirectly owns 100% of Rosemont Copper Company
Rosemont Copper Company owns a 100% interest in the Rosemont project

Deposit Type

  • Porphyry
  • Skarn


Summary:

The Rosemont deposit consists of copper-molybdenum-silver-gold mineralization primarily hosted in skarn, genetically, it is a style of porphyry copper deposit, although intrusive rocks are volumetrically minor within the resource area. The skarns are formed as the result of thermal and metasomatic alteration of Paleozoic carbonate and to a lesser extent Mesozoic clastic rocks. Near surface weathering has resulted in the oxidation of the sulfides in the overlying Mesozoic units however, oxidation also occurs in the underlying Paleozoic carbonates

Garnet-diopside-wollastonite skarn, which formed in impure limestone, is the most important skarn type volumetrically. Diopside-serpentine skarn which formed in dolomitic rocks is less significant. Marble was developed in the most purest carbonate rocks, while the more siliceous, silty rocks were converted to hornfels. Both marble and hornfels are relatively poor hosts to mineralization. The main skarn minerals are accompanied by quartz, potassium feldspar, amphibole, magnetite, epidote, chlorite and clay minerals. Quartz latite to quartz monzonite intrusive rocks host strong quartzsericite-pyrite alteration with minor mineralization. Where the mineralized package of Paleozoic rocks and quartz-latite intrusive outcrop on the western side of the deposit, near surface weathering and oxidation has produced disseminated and fracture-controlled copper oxide minerals. The Mesozoic and lesser Paleozoic rocks above the LAF are propylitically altered to an assemblage including epidote, chlorite, calcite, and pyrite. Copper mineralization is irregularly developed. The rocks are commonly deeply weathered and limonitic. The original chalcopyrite is typically oxidized to chrysocolla, copper wad and copper carbonates. Supergene chalcocite is locally present.

Three mineralization domains (oxide, mixed and sulfide) were defined based on the soluble to total copper ratio (ASCu/TCu) collected in the Augusta (2005 to 2012) and Hudbay (2014 and 2015) drilling programs. The oxidation and mixed mineralization occurs mainly above a low angle fault defining the contact between the Palozoic and Mesozoic rocks as chrysocolla, copper carbonates and supergene chalcocite.

Mineralization is mostly in the form of primary (hypogene) copper, molybdenum and silver bearing sulfides, found in stockwork veinlets and disseminated in the altered host rock. Some oxidized copper mineralization is also present in the upper portion of the deposit. The oxidized mineralization is primarily hosted in Mesozoic rocks, but is also found in Paleozoic rocks on the west side of the deposit and deeper along some faults. The oxidized mineralization occurs as mixed copper oxide and copper carbonate minerals. Locally, enrichment of supergene chalcocite and associated secondary mineralization are found in and beneath the oxidized mineralization.


Mining Methods

  • Truck & Shovel / Loader


Summary:

The Rosemont deposit is a high-tonnage, skarn-hosted, porphyry-intruded, copper-molybdenum deposit located in close proximity to the surface. The Project will be a traditional open pit shovel/truck operation. It consists of open pit mining and flotation of sulfide minerals to produce commercial grade concentrates of copper and molybdenum. Payable silver and gold will report to the copper concentrate.

The proposed pit operations will be conducted from 50-foot-high benches using large-scale mine equipment, including: 10-5/8-inch-diameter rotary blast hole drills, 60 yd3 class electric mining shovels, 46 yd3 class hydraulic shovels, 25 yd3 front-end loaders, and 260-ton off-highway haul trucks.

The Rosemont final pit will measure approximately 6,000 feet east to west, 6,000 feet north to south, and will have a total depth of approximately 2,900 feet down to 3,100 feet (AMSL). There is one primary waste rock storage area (“WRSA”), which is located 1,200 feet southeast of the Rosemont final pit.

The mine phases and ultimate pit for the Project are designed for large-scale mining equipment (specifically, 60 yd3 class electric shovels and 260-ton haulage trucks) and is derived from the selected LG pit shells described in the previous section. The design process included smoothing pit walls, eliminating or rounding significant noses and notches that may affect slope stability, and providing access to working faces by developing internal ramps (including a dual ramp for the final pit). For the pit design, the targeted minimum mining width is 320 ft. and honored the wall slope design provided by Call and Nicholas, Inc. (“CNI”) and Hudbay.

Total ore reserves in the final pit are estimated to be 592 million tons. Approximately 55 million tons of medium and low grade oxide, mixed and sulfide ore will be stockpiled. This material will be reclaimed and processed during operations.


Crushing and Grinding
Flow Sheet: Source
Crusher / Mill TypeModelSizePowerQuantity
Gyratory crusher 60" x 113" 1
Pebble crusher 2
SAG mill 36' X 24' 18 MW 2
Ball mill 26' x 40.5' 16.4 MW 2
Regrind 2

Summary:

Crushing
Primary Crushing
The Primary Crusher is a 60 x 113 size Gyratory Crusher fitted with manganese steel concave and mantle liners. The primary crusher was selected based on the required mill feed rate, expected ROM feed size distribution, ore bulk density, crushing work index, stockpile capacity, and SAG feed size. The design crusher feed rate is 6,000 tons/h with a capacity of 90,000 tons/d, based on a crusher availability of 75% and a 20% catch-up capacity factor. Design parameters including the expected range of feed size distributions and crushing work indices were provided to vendors to confirm throughput performance and motor power requirements. The primary crusher dump pocket is designed to allow two trucks to dump simultaneously, one from each side. It has the capacity to hold two truckloads, approximately 520 tons in total.

A modular Crusher Control Room is located above the ROM wall to provide a direct line of sight to the dump pocket as well as the Stockpile Feed Conveyor. The Control Room includes space for crushing plant operators and two mine fleet controllers who manage the truck fleet. It is fitted with washroom and break facilities. A water spray system is fitted at each corner of the dump pocket for dust control when trucks are dumping. Dust generated in the transfer point between the Feeder and the Stockpile Feed Conveyor is captured by a dedicated Cartridge Dust Collector. Dust generated in the crusher vault is vented to the dump hopper and controlled by the water spray system.

Stockpile Feed Conveyor
Crushed ore is transferred from the Primary Crusher to the Crushed Ore Stockpile by a Stockpile Feed Conveyor. The conveyor belt is 72 inches wide and 1,014 feet in length with a 211-foot lift and has capacity to convey 6,600 tons/h of crushed feed to the stockpile (i.e. crusher capacity +10%). The conveyor is covered outside the Stockpile Dome to minimize dust emissions. The conveyor is driven by two 1,200 HP drives (one mounted on each side of the drive pulley) complete with high speed disc brake and variable speed drive for controlled start-up. The drives are located adjacent to the gravity take-up.

Coarse Ore Stockpile and Reclaim
Crushed ore for both grinding lines is stored in a single Conical Ore Stockpile. The stockpile is enclosed by a dome structure with an impervious colored fabric cover (approx. 380 feet diameter and 164 feet high).
The Stockpile Cover consists of a structural steel multi-arch frame pinned to a circular ring beam at the center of the dome and pinned at ground level to a concrete ring beam. A 20-foot-wide path around the stockpile perimeter provides access for dozer and equipment travel inside the cover. Two sets of access doors are included to allow machinery access to the stockpile area.

Live capacity of the stockpile will range between 23,000 to 51,000 tons (6 to 12 hours at full production rate and dependent on prevailing ore characteristics), representing 14% to 28% of the total stockpile capacity of 198,000 tons. Stockpile ore in dead storage can be reclaimed by heavy equipment (dozer and/or excavator) to allow for up to two additional days’ interruption of feed from the primary crusher.

Grinding
SAG and Ball Mill Grinding
The selected grinding circuit consists of two parallel SABC grinding lines, each comprising one SAG mill in closed circuit with a sizing screen and pebble crusher followed by a ball mill in closed circuit with hydrocyclones. The selected grinding mills are summarized as follows:
- SAG mills – 36 feet diameter (inside shell) x 24 feet effective grinding length (EGL) with 18 MW twin pinion drives (9 MW per pinion). Motors are controlled via an SER / hyper synchronous variable speed drive.
- Ball mills – 26 feet diameter (inside shell) x 40.5 feet effective grinding length (EGL) with 16.4 MW GMD

Mill size and power requirements were determined via Ausgrind, Ausenco’s proprietary power-based comminution calculation program using the 75th percentile values of ore parameters (ore competency and hardness). RQD was also used to adjust SAG feed size based on a correlation identified between RQD and sample depth. A +10% design factor was also added to the SAG motor specification to ensure mill power limitations would not be a significant factor for achieving throughput targets.

Pebble Crushing and Conveyor Systems
Measured ore competency shows that an SABC grinding circuit with a pebble crusher is required. Pebble crushers were selected based on crusher feed rate, ore characteristics and competency factors, pebble top size, and crusher product size. Pebble rate is expected to vary from 510 tph (15% to 25% of new SAG mill feed nominally), up to 700 tph (30% with worn SAG mill grates).

Pebbles from each SAG Mill are transferred to the Pebble Crusher Bin via the 54-inch Pebble Conveyors. Tramp metal is captured by two cross-belt self-cleaning magnets arranged in series for each crusher. The Pebble Conveyor discharges onto a diverter gate which directs the material to the Pebble Crushing Bin or allows bypass to the Pebble Conveyor Bypass Bunker or the Pebble Crusher Product Conveyor.


Processing

  • Dewatering
  • Flotation

Flow Sheet: Subscription required

Summary:

The Rosemont process plant includes the following unit processes and facilities:
- Primary crushing.
- Crushed ore stockpile and reclaim.
- Parallel SABC grinding lines with pebble crushing.
- Copper flotation comprising rougher flotation, concentrate regrind, and two stage cleaning.
- Cu-Mo concentrate thickening.
- Molybdenum flotation including roughing, concentrate regrind and five stages of cleaning.
- Molybdenum concentrate thickening, filtration and drying.
- Copper concentrate thickening and filtration.
- Copper concentrate load out and storage.
- Tailings thickening, filtration and dry stacking.
- Reagents storage and distribution (including lime slaking, flotation reagents, water treatment and flocculant).
- Grinding media storage and addition.
- Water services (including fresh water, fire water, gland water, cooling water and process water).
- Potable water treatment and distribution.
- Air services ( ........

Recoveries & Grades:

CommodityParameterAvg. LOM
Copper Recovery Rate, % 80.4
Copper Head Grade, % 0.45
Copper Concentrate Grade, % 34.3
Molybdenum Recovery Rate, % 53.4
Molybdenum Head Grade, % 0.012
Molybdenum Concentrate Grade, % 45
Silver Recovery Rate, % 74.4
Silver Head Grade, oz/ton 0.13

Projected Production:

CommodityProductUnitsAvg. AnnualLOM
Copper Payable metal k tons 2,055
Copper Metal in concentrate k tons 1122,129
Copper Concentrate kt 5,635
Molybdenum Payable metal k tons  ......  Subscription required
Molybdenum Metal in concentrate k tons  ......  Subscription required  ......  Subscription required
Molybdenum Concentrate kt  ......  Subscription required
Silver Payable metal koz  ......  Subscription required
Silver Metal in concentrate koz  ......  Subscription required  ......  Subscription required

Operational Metrics:

Metrics
Stripping / waste ratio 2 *
Daily mining capacity 90,000 tons of ore *
Annual mining capacity 32,850,000 tons of ore *
Waste tonnes, LOM 1,155 M tons *
Ore tonnes mined, LOM 592 M tons *
Daily processing capacity 90,000 tons *
Tonnes processed, LOM 592,033 k tons *
Annual processing capacity 32.8 M tons *
* According to 2017 study.

Reserves at January 1, 2021:
Mineral Reserve estimates: US$3.15 per pound copper, US$11.00 per pound molybdenum and US$18.00 per ounce of silver were used. Metallurgical recoveries of 90% copper, 63% molybdenum and 75.5% silver were applied. No metallurgical recovery of molybdenum and silver from oxide ore is projected. A $6.60 NSR cut-off grades was based on process recoveries, total processing, and general and administrative operating costs per tonne.
Mineral resources are constrained within a computer generated pit using the Lerchs-Grossman algorithm. NSR was calculated for every model block and is an estimate of recovered economic value of copper, molybdenum, and silver combined. Cut-off grades were set in terms of NSR based on current estimates of process recoveries, total processing and general and administrative operating costs of $6.10 per tonne for oxide, mixed and sulfide material.

CategoryTonnage CommodityGrade
Proven 426,100,000 t Copper 0.48 %
Proven 426,100,000 t Molybdenum 120 g/t
Proven 426,100,000 t Silver 4.96 g/t
Probable 111,000,000 t Copper 0.31 %
Probable 111,000,000 t Molybdenum 100 g/t
Probable 111,000,000 t Silver 3.09 g/t
Proven & Probable 537,100,000 t Copper 0.45 %
Proven & Probable 537,100,000 t Molybdenum 120 g/t
Proven & Probable 537,100,000 t Silver 4.58 g/t
Measured 161,300,000 t Copper 0.38 %
Measured 161,300,000 t Molybdenum 90 g/t
Measured 161,300,000 t Silver 2.72 g/t
Indicated 374,900,000 t Copper 0.25 %
Indicated 374,900,000 t Molybdenum 110 g/t
Indicated 374,900,000 t Silver 2.6 g/t
Measured & Indicated 536,200,000 t Copper 0.29 %
Measured & Indicated 536,200,000 t Molybdenum 110 g/t
Measured & Indicated 536,200,000 t Silver 2.64 g/t
Inferred 62,300,000 t Copper 0.3 %
Inferred 62,300,000 t Molybdenum 100 g/t
Inferred 62,300,000 t Silver 1.58 g/t

Commodity Production Costs:

CommodityUnitsAverage
All-in sustaining costs (AISC) Copper USD 1.65 / lb *†
C1 cash costs Copper USD 1.29 / lb *†
Assumed price Molybdenum USD 11 / lb *
Assumed price Copper USD 3 / lb *
Assumed price Silver USD 18 / oz *
* According to 2017 study / presentation.
† Net of By-Product.

Operating Costs:

Units2017
OP mining costs ($/ton milled) USD 1.95 *
Processing costs ($/ton milled) USD  ......  Subscription required
Total operating costs ($/ton milled) USD  ......  Subscription required
* According to 2017 study.
Subscription required - Subscription is required.

2017 Study Costs and Valuation Metrics :

MetricsUnitsLOM Total
Initial CapEx $M USD  ......  Subscription required
Sustaining CapEx $M USD  ......  Subscription required
Total CapEx $M USD  ......  Subscription required
OP OpEx $M USD  ......  Subscription required
Processing OpEx $M USD 2,788
G&A costs $M USD 745.9
Total OpEx $M USD  ......  Subscription required
Income Taxes $M USD  ......  Subscription required
Royalty payments $M USD  ......  Subscription required
Gross revenue (LOM) $M USD  ......  Subscription required
Net revenue (LOM) $M USD  ......  Subscription required
Pre-tax Cash Flow (LOM) $M USD  ......  Subscription required
After-tax Cash Flow (LOM) $M USD  ......  Subscription required
After-tax NPV @ 10% $M USD  ......  Subscription required
After-tax NPV @ 8% $M USD  ......  Subscription required
After-tax IRR, %  ......  Subscription required
After-tax payback period, years  ......  Subscription required
Subscription required - Subscription is required.

Proposed Heavy Mobile Equipment as of July 24, 2017:
HME TypeModelQuantity
Compactor ....................... Subscription required ....................... Subscription required
....................... Subscription required ....................... Subscription required ....................... Subscription required
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Subscription required - Subscription is required.

Mine Management:

Job TitleNameEmailProfileRef. Date
....................... Subscription required ....................... Subscription required ....................... Subscription required Subscription required Nov 4, 2021
....................... Subscription required ....................... Subscription required Subscription required Jan 4, 2022
Subscription required - Subscription is required.


Corporate Filings & Presentations:

DocumentYear
................................... Subscription required 2020
................................... Subscription required 2020
................................... Subscription required 2020
................................... Subscription required 2019
................................... Subscription required 2019
Corporate Presentation 2018
Feasibility Study Report 2017
Annual Information Form 2016
Form 40-F 2012
Feasibility Study Report 2009
Subscription required - Subscription is required.

News:

NewsDate
The U.S. Department of Justice and Hudbay Receive Rosemont 9th Circuit Court Ruling; Hudbay Continues to Advance Copper World May 12, 2022
Hudbay Announces Plans for Early Works Program at Rosemont and Provides Annual Reserve and Resource Update March 28, 2019
Hudbay Reaches Agreement To Purchase Rosemont's Minority Joint Venture Interest March 13, 2019
Hudbay Announces Receipt of Section 404 Water Permit for Rosemont March 8, 2019

Aerial view:

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