Canada – Consultec

Gold Mine – Brownfield EP

Challenge

A Brownfield project to recommission a 2500 t/d gold concentrator in a remote location in Northern Canada with extreme winter conditions and accessibility challenges.

Process

Process areas included Coarse Stockpile Feed, SAG and Ball Mills, Gravity Concentrator, CIL, Electrowinning, CN Destruct, Tailings Thickening, Reagents, Goldroom.

Delivery

After completion of Basic Engineering, Consultec performed equipment and bulk procurement as well as detail engineering. Extensive refurbishment of existing structures and equipment was required.

An open pit expansion to two underground mines, required a new paste backfill system to produce a cemented backfill used to fill underground stopes. The paste backfill is composed of dewatered mill tailings and slag/cement binder mix that is pumped or allowed to flow by gravity. This part of Canada is both a severe cold climate and remote location for such a project requiring specific design consideration including: precast concrete work, modular design based on shipping dimensions, heat tracing and insulation of piping and bins, building and entry space heating.

Process

The facility included a 360 t/h paste plant, booster station and binder storage facility.

Delivery

Consultec, in partnership with an equipment supplier, designed the plant and procured the process equipment, plant services/utilities, electrical equipment and construction bulk materials.

Cogeneration Plant – Biomass

Challenge

To serve the growing demand for Renewable Energy, this 25 MW cogeneration power plant was constructed on the premises of a saw mill in Alberta, Canada to take advantage of the abundant waste wood that was previously burned as waste.

Process

The extreme cold climate and difficult-to-handle wood fuel provided abundant design challenges.

Delivery

Consultec was responsible for equipment procurement, mechanical, electrical and civil design.

Slag Grinding Mill

Challenge

This global cement producer has a policy of maximizing cement replacement materials in order to minimize the carbon footprint of the end product and to reduce production costs. Ground slag can substitute up to 30% of the ordinary portland cement used in the making of concrete This was in fact the first vertical mill for slag grinding in Canada and one of the first in the world.

Process

Although vertical grinding is a very energy efficient technology, the supporting equipment and controls is complex and confined to a small area. Further complicating the design, the system was to be designed to grind future materials such as clinker so the overall capacity varied from 60 t/h to 100 t/h.

Delivery

Consultec was the overall engineering integrator for this project. Responsible for balance of plant equipment, mechanical, civil, structural and electrical design as well as construction supervision.

New Kiln Line

Challenge

Design and construction supervision of a 5600 mtpd clinker kiln line from raw material storage and handling, raw grinding, pyro-processing through clinker storage.

Process

5600 t/d Clinker production line (increased to 6300 t/d with process improvements)

Delivery

St. Marys Cement replaced 2 existing wet klins with one 5 stage, double string new kiln line with a capacity of 5,600 tpd. In 1999 Consultec engineered modifications to increase clinker production capacity to 6,400 mtpd. Projects included a new downcomer, ID Fan, indirect kiln coal firing system, dust collection, upgrades, cooler enlargement and new tertiary air duct.

Country: Canada

Gold Mine – Brownfield EP

Mine Paste Fill

Cogeneration Plant – Biomass

Slag Grinding Mill

New Kiln Line