Table of Contents - RTB Bor · Table of Contents 3.0 CURRENT COPPER ... RTB BOR ... Table 3.2.1 Overview of processing ore from the open pit\Veliki Krivelj in the period 2005-2009

$Page 1: Table of Contents - RTB Bor · Table of Contents 3.0 CURRENT COPPER ... RTB BOR ... Table 3.2.1 Overview of processing ore from the open pit\Veliki Krivelj in the period 2005-2009$
EIA Study – New Smelter and Sulphuric Acid Plant Project

University of Belgrade Faculty of Metallurgy

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Table of Contents

3.0 CURRENT COPPER PRODUCTION – RTB BOR .................................................. 1 3.1 Historical Perspective – Local Copper Production In Bor......................................... 1 3.2 Current Production In Rtb Bor .................................................................................. 1

3.2.1 Flotation Plant Veliki Kirvelj ............................................................................. 2 3.2.2 Flotation Plant Bor (Processing Of Pit Ore)..................................................... 9 3.2.3 The Flotation Plant Bor (Slag Processing) .................................................... 15 3.2.4 Plant PMS Cerovo and Flotation Bor (Cerovo Ore Processing).................... 21 3.2.5 Flotation Plant Majdanpek............................................................................. 27

3.3 Rtb Bor Strategic Plan For Copper Concentrate Production.................................. 29 3.3.1 Strategic Plan Development.......................................................................... 29 3.3.2 Future Strategic Production Plan In Rtb Bor Company................................. 30 3.3.3 Transportation Plan for RTB Bor’s Future Production................................... 37

List of Tables

Table 3.2.1 Overview of processing ore from the open pit\Veliki Krivelj in the period

2005-2009. ................................................................................................... 7 Table 3.2.2 Overview of Ore Processing from Jama Bor Mine in the Period 2005-2009........................................................................................................................................ 14 Table 3.2.3 Overview of slag processing in the period 2005-2009 ................................ 20 Table 3.2.4 Overview of Cerovo Ore Processing in the period 2005-2009.................... 25 Table 3.2.5 Summary of Majdanpek Ore Processing in the Period 2005-2009 ............. 28 Table 3.3.1 The Planned Schedule of Production in RBB Bor (Mining)......................... 31 Table 3.3.2 The Planned Schedule of Production in RTB Bor (The Pit) ........................ 32 Table 3.3.3 The planned schedule of production in RBM, total production in RBB-Bor

and total production in RTB-Bor ................................................................. 33 Table 3.3.4 The Planned Schedule of the Concentrate Production in Mines Separately

and/in Total for RTB-Bor............................................................................. 34 Table 3.3.5 The Planned Schedule of the Concentrate Production in Mines Separately

and/in Total for RTB-Bor............................................................................. 35 Table 3.3.6 Identifying the Concentrate Transport Movements for the Floatation

Facilities......................................................................................................... 39



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List of Figures

Figure 3.2.1 Overview of Facilities and Systems of Exploitation and Processing in RTB Bor ................................................................................................................ 3

Figure 3.2.2 Veliki Krivelji Production Area ...................................................................... 4 Figure 3.2.3 Technological scheme of flotation plant Veliki Krivelj .................................. 5 Figure 3.2.4 The volume of produced wet and dry concentrate in the 2005-2009 period

2005-2009 (blue-wet concentrate, red-dry concentrate). ............................. 8 Figure 3.2.5 BOR Complex ............................................................................................ 10 Figure 3.2.6 The Technological Scheme of Primary, Secondary and Tertiary Crushing in

Plant Jama Bor ........................................................................................... 11 Figure 3.2.7 Technological Scheme of the Milling and Flotation in Flotation Plant Bor . 12 Figure 3.2.8 The volume of produced humid and dry concentrate in the period 2005-

2009 (blue-wet concentrate, red-dry concentrate)......................................... 15 Figure 3.2.9 The Technological Scheme of Transport, Crushing and Sieving of Furnace

Slag in the Flotation Plant Bor .................................................................... 18 Figure 3.2.10 Technological Scheme of Milling and Flotation of Slag in Blast Furnace in

the Flotation Plant in Bor ............................................................................... 19 Figure 3.2.11 The volume of produced wet and dry concentrate in the period 2005-2009

(blue-wet concentrate, red-dry concentrate)............................................... 21 Figure 3.2.12 Cerovo Mine and Mill Site ........................................................................ 23 Figure 3.2.13 The volume of produced wet and dry concentrate in the period .............. 26 Figure 3.2.14 The volume of produced humid and dry concentrate in the period.......... 28 Figure 3.3.1 The planned schedule of the concentrate production in mines separately

and total in RTB-Bor (Y axes-production....................................................... 36 Figure 3.2.2 Identifying the Concentrate Transport Movements for the Floatation

Facilities......................................................................................................... 42



Section 3

SECTION 3

CURRENT AND FUTURE COPPER PRODUCTION



Section 3

Page 1

3.0 CURRENT COPPER PRODUCTION – RTB BOR

3.1 Historical Perspective – Local Copper Production In Bor

The company named the French Society of the Bor mines, concession St. George, began the exploitation of copper ore 1904th, when the 5500 tones of ore was found and produced 495 tons of copper. The company was 65.5% owned by French company Mirabeau, Pierari and companies.

Between 1904 and 1929 the ore mined from the Bor Mines had a copper content of between 15-20% and was directly transported to metallurgical processing plant. The first pilot plant for the preparation and concentrate was commissioned in 1929 with a processing capacity of 25-30 tons per day.

Copper production took place during and between the two world wars, with production depending on the environment under which the company operated. After the Second World War, the Bor mine became a state company in which intensive restructuring of equipment and production facilities.

In 1951 a new company was formed under the name Mine Smelting Complex Bor as a large economic system and it still operates under that name as a business entity today. RTB Bor during 1960's and 1970's went through two development stages and achieved a copper production capacity of more than 150 thousand tons per year.

RTB Bor now consists of 4 companies:

• Base company; • Bor Copper Mine (RBB); • Copper Mine Majdanpek (RBM); and • Smelting and refining of copper (TIR).

The current annual production capacity of RTB Bor is about 15 million tons. The mining equipment is worn out and technologically outdated, with low production efficiency and with great operating costs.

3.2 Current Production In Rtb Bor

The following provides a brief description of the mining operations and processing facilities for RTB Bor, Figure 3.2.1 presents a location distribution of the various facilities that are described further below.



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3.2.1 Flotation Plant Veliki Kirvelj

Mine Veliki Krivelj consists of large open pit mine Kirvelj (position 1, on Figure 3.2.1) and flotation Veliki Kirvelj (position 2, on Figure 3.2.1). Mine facilities are located approximately 4 km from the Town of Bor (position 12). Figure 3.2.2 shows a more detailed aerial view of the Veliki Krivelj facilities.

The mine can be reached by two roads, a regional road approximately 7 km in length (position 11) and internal transportation road connecting (position 10). The internal road is approximately 12 km in length and serves as a bypass to the Town of Bor connecting directly to the complex RTB Bor.

Description of the production process and product

Flotation Veliki Krivelj processing facilities deals with the preparation and concentration of copper minerals from the ore pit Veliki Krivelj. The processing and concentration of copper minerals consist of following phases:

• Primary crushing; • Secondary and tertiary crushing with sieving; • Milling and grading; • Flotation concentration of copper minerals, basic flotation and purification of

copper concentration; • Drainage of final copper concentrate, which takes place in two phases:

o Thickening of the final copper concentrate o Filtering of the final copper concentrate

• Transport and final disposal of waste at barren Veliki Kirvelj (position 3), with the process of returning of technological water in the process.

All these segments of the process are closely related and together transform copper minerals from ore to a final concentrate containing about 20% Cu which is suitable for further metallurgical treatment. Figure 3.2.3 provides a schematic description of the production process at the Veliki Krivelj processing facilities.



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Figure 3.2.1 Overview of Facilities and Systems of Exploitation and Processing in RTB Bor



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Figure 3.2.2 Veliki Krivelji Production Area

Krivelji



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Figure 3.2.3 Technological scheme of flotation plant Veliki Krivelj



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Product Description

Final copper concentrate has the following physical-chemical characteristics:

• moisture concentrates: 10% • density of solid phase: 4t/m3 • chemical analysis of final concentrate:

Elements KCu Elements KCu % Cu 19,880 % Zn 0,097 % Cu-ox 0,286 % Se 0,0170 % Cu-suf 19,594 % Mo 0,030 % S 36,68 % Co <0,0030 % SiO2 6,80 % TiO2 0,13 % Fe 31,34 % Ge <0,0010 % Fe3O4 / % Sn 0,0022 % Al2O3 2,38 % Sb 0,0067 % CaO 0,71 % Bi <0,0030 % MgO 0,36 g/t Rh <1,0 % As 0,0200 g/t Pt <1,0 % Na2O 0,14 % V2O5 <0,0050 % K2O 0,51 g/t Ag 16,30 % Pb <0,01 g/t Au 1,30

Estimated production

Restrictions of production capacities of flotation plant Veliki Krivelj are related to capacities of equipment itself. The Veliki Krivelj flotation facility has an installed the equipment capacity for an annual processing capacity of 10.6 Mt of ore.



Section 3

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Table 3.2.1 Overview of processing ore from the open pit\Veliki Krivelj in the period 2005-2009.

No. Name unit. 2005 2006 2007 2008 2009

1. Wet ore t 4328697 3759496 4293724 5793176 5615034

2. Dry ore t 4148259 3608695 4128484 5560339 5440768

3. Cu in wet ore % 0,241 0,271 0,258 0,250 0,227

4. Cu in dry ore % 0,251 0,282 0,268 0,260 0,234

5. Cu in ore t 10415 10183 11073 14485 12749

6. Au in ore kg 716,6953 606,5413 514,0321 1008,2526 781

7. Ag in ore kg 10615,044 9587,007 9449,846 12299,421 9466

8. Moisture in conc. t 51878 48091 54532 78524 68931

9. Dry conc. t 46457 42520 48836 70804 61248

10. Cu in conc. t 7843,351 7939,650 8591,975 10538,408 9.502,322

11. Au in conc. kg 57,8558 86,2327 137,5772 130,2131 101,9304

12. Ag in conc. kg 640,053 753,918 1019,285 945,846 818,405

13. Cu yield % 75,31 77,97 77,59 72,76 74,54



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Figure 3.2.4 The volume of produced wet and dry concentrate in the 2005-2009 period 2005-2009 (blue-wet concentrate, red-dry concentrate).

Transportation of Concentrate

The transport of concentrate from the flotation plant Veliki Krivelj to smelter in Bor is via

an asphalt road (position 10) that goes around the town of Bor and into the RTB Bor

Complex from the industrial side. The wet concentrate from the flotation plant Veliki

Kirvelj is transferred to the smelter in Bor (12 km away) using trucks carrying 22 ton

loads. The road for transportation of the concentrate goes through an uninhabited part of

the Town of Bor. The amount of concentrate, which is driven, depends on the daily

production and the need for smelting. The truck traffic in the 2005-2009 period has

generally ranged between 6-10 trucks per day.



Section 3

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3.2.2 Flotation Plant Bor (Processing Of Pit Ore)

Bor flotation plant (position 5) is located in the complex RTB Bor. It was built in 1933 and it’s the oldest facility for preparation and concentration. Bor flotation plant facilities are located close to rest of metallurgical facilities.

Description of the production process and product

Bor flotation plant deals with the preparation and concentration of copper minerals from the ore mines Jama Bor.

The process of preparation and concentration of copper minerals consist of the following phases:

• Primary crushing; • Secondary and tertiary crushing with sieving (see Figure 3.2.6); • Milling and grading (see Figure 3.2.7); • Flotation concentration of copper minerals (see Figure 3.2.7); • Drainage of final copper concentrate, which takes place in two phases: • Thickening of the final copper concentrate • Filtering of the final copper concentrate • Transport and final disposal of waste. Condensed mullock with pumps and pipes is

transported to the barren RTH (position 6) for disposal.

All these steps in the process are closely related and together transform copper minerals from ore to the finished product of flotation concentration to yield the final concentrate containing about 20% Cu suitable for further metallurgical treatment.

BOR COMPLEX

BOR

FIGURE 3.2.5 THE BOR COMMUNITY AND THE BOR MINING COMPLEX

N



Section 3 Page 11

Figure 3.2.6 The Technological Scheme of Primary, Secondary and Tertiary Crushing in Plant Jama Bor



Section 3 Page 12

Figure 3.2.7 Technological Scheme of the Milling and Flotation in Flotation Plant Bor

Ulaz

2040

2090

2050

2070

2060 2080

Ulaz

3040

3090

3080

3070

1210 2210 3210

103302450 3450 1230 2230 3230

435

345

2240

3240

12702270 3270

430

271

2410

110

3410

2320 3320

23303330

421

420280A,B,C

3241

ka filtraži

jalovina

290



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Product Description


• moisture concentrates: 10% • density of solid phase: 3,4t/m3 • chemical analysis of final concentrate:

Elements KCu Elements KCu

% Cu 18,58 % Zn 0,063

% Cu-ox 0,346 % Se <0,0040

% Cu-suf 18,234 % Mo <0,010

% S 39,50 % Co <0,0030

% SiO2 9,86 % TiO2 0,057

% Fe 27,70 % Ge <0,0010

% Fe3O4 0,05 % Sn 0,0050

% Al2O3 3,51 % Sb 0,0075

% CaO 0,51 % Bi /

% MgO 0,049 g/t Rh /

% As 0,64 g/t Pt <1,0

% Na2O 0,15 % V2O5 0,035

% K2O 0,31 g/t Ag 14,6

% Pb / g/t Au 2,6

Realized production

Production capacity constraints of the flotation plant Bor are linked to the capacity of the equipment itself. The installed equipment in flotation plant Bor is processing capacity of 2.5 Mt per year.



Section 3

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Table 3.2.2 Overview of Ore Processing from Jama Bor Mine in the Period 2005-2009

No. Name Un. 2005 2006 2007 2008 2009

1. - Excavations t 440105 296375 141822 156893 208254

- Ore-humid t 440105 296375 141822 156893 208254

2. - Dry-ore t 432135 291147 138939 151936 202771

3. Cu content in o.h. % 0,664 0,668 0,935 0,921 0,806

4. Cu content in d.o. % 0,676 0,680 0,954 0,952 0,827

5. Cu in ore t 2922 1979 1325 1446 1678

6. Au in ore kg 121,7828 75,7733 33,6178 65,8718 284,1197

7. Ag in ore kg 1419,368 854,058 373,334 607,693 2211,027

8. Humid concentrate t 14559 10863 8073 8363 10672

9. Dry concentrate t 12435 9525 7108 7312 9247

10. Cu in conc. t 2249,897 1604,193 1075 1054 1394

11. Au in conc. kg 28,1378 25,1319 18,8793 23,3124 74,9684

12. Ag in conc. kg 173,645 177,19 155,942 173,638 557,047

13. Cu gain % 77,01 81,04 81,13 72,92 83,11



Section 3

Page 15

Figure 3.2.8 The volume of produced humid and dry concentrate in the period 2005-2009 (blue-wet concentrate, red-dry concentrate).

Concentrate Transportation

Wet concentrate from the flotation plant Bor (position 5) was transported to the metallurgical facility RTB Bor, the Smelter at Bor, 200 m away, by trucks carrying 22 tons.

Trucks with wet concentrate from the flotation plant Bor were driven on asphalt road that goes from copper filtration in the flotation plant Bor to Beding, ie. entrance to the plant Bor Smelter. The road that the trucks transported the concentrate from the flotation plant Bor to plant Bor Smelter was in an industrial area, that is, in the complex of metallurgical facility RTB Bor. The amount of concentrates, which was driven, depended on the daily production and the need of smelter and was 1-2 trucks per day in average.

3.2.3 The Flotation Plant Bor (Slag Processing)

Description of production and product

Bor flotation plant, beside the preparation and concentration of copper minerals from the ore from Jama Bor mine, is also engaged in the preparation and concentration of copper from raw furnace slag that represents waste from the process of metallurgical copper concentrate processing in Bor Smelter.

The process of preparation and concentration of copper is carried out in the following phases:



Section 3

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preparing and loading the slag from the slag bearing Depot 1 (position 7, figure 3.2.1),

secondary and ternary crushing with sieving (see Figure 3.2.9);

• milling and grading,

• concentration of copper minerals by flotation (see Figure 3.2.10),

• drainage of final copper concentrate, is conducted in two phases:

o thickening the final copper concentrate,

o filtering the final copper concentrate,

• transport and disposal of the final tailings. Condensed mullock is transported with pumps and pipes to the barren RTH (position 6, figure 3.2.1) where is left.

Product Description


• moisture of concentrate: 13%

• density of the solid phase: 4.4 t/m3

• chemical analysis of the final concentrate:


% Cu 10,81 % Zn 1,22

% Cu-ox 0,041 % Se 0,0071

% Cu-suf 10,77 % Mo 0,045

% S 8,61 % Co 0,0050

% SiO2 34,16 % TiO2 0,080

% Fe 33,19 % Ge 0,0025

% Fe3O4 9,88 % Sn 0,0061

% Al2O3 4,25 % Sb <0,0050

% CaO 3,26 % Bi /



Section 3

Page 17


% MgO 0,68 g/t Rh /

% As 0,061 g/t Pt /

% Na2O 0,30 % V2O5 0,0084

% K2O 0,93 g/t Ag 25,0

% Pb 0,23 g/t Au 3,3



Section 3 Page 18

Figure 3.2.9 The Technological Scheme of Transport, Crushing and Sieving of Furnace Slag in the Flotation Plant Bor

Mlevenje

Šljakište

500 t01

TO204

TO3

05

2.0

2.1 2.2

2.3 2.4

3.0 4.0

T8

T10

T11

T12B

2 500 t

T3010

Legenda:01 -

TO2 -TO3 -

04 -05 -

2.0 -2.1 -2.2 -2.3 -2.4 -3.0 -4.0 -T8 -

T10 -T11 -T12 -

B -T3010-

prihvatni bunker sa stacionarnom rešetkomplocasti dodavactraka za hranjenje drobilicešutšutsekundarna drobilica "Symons"traka za prihvat ruderazdeoni šutsito - vibracionosito - vibracionotercijalna drobilica "Symons"tercijalna drobilica "Symons"prihvatna traka za drobljen proizvodtrakatrakatrakabunker za izdrobljenu šljakutraka za mlina



Section 3 Page 19

Figure 3.2.10 Technological Scheme of Milling and Flotation of Slag in Blast Furnace in the Flotation Plant in Bor

3010 3020

H2OCa(OH)2

3040H2O H2O

3070

3080H2O

3090

3270

280

3241C

2330 3330

420 421

2210

A B 1230

22403240

340

Zgušnjivaci 6 i 7

10330

345Ka filtraži Cu



Section 3

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Realized production

Production capacity constraints of the flotation plant Bor for blast furnace slag processing, are connected to the capacity of the equipment itself. The installed equipment in flotation plant Bor can meet the annual processing capacity of 900,000 tons of slag.

Table 3.2.3 Overview of slag processing in the period 2005-2009

No. Name Un. 2005 2006 2007 2008 2009

1. Slag-wet t 138963 388874 703107 933522 935459

2. Dry-slag t 137783 385988 698035 924314 927799

3. Cu in wet slag % 0,785 0,711 0,701 0,651 0,709

4. Cu in dry slag % 0,792 0,716 0,706 0,658 0,715

5. Cu in slag t 1091 2764 4930 6081 6636

6. Au in slag kg 26,5680 100,2105 155,5015 308,7311 219,8588

7. Ag in slag kg 404,31 1364,12 1862,39 2503,08 1698,49

8. Wet concentrate t 3670, 8952 19414 22126 22006


10. Cu in conc. t 399,012 1000,606 1918,128 2196,633 2100,856

11. Au in conc. kg 6,8273 21,1403 44,4806 60,1070 50,5553

12. Ag in conc. kg 43,343 155,055 366,987 447,591 375,441

13. Cu gain % 36,57 36,20 38,90 36,12 31,66



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Figure 3.2.11 The volume of produced wet and dry concentrate in the period 2005-2009 (blue-wet concentrate, red-dry concentrate).


Wet concentrate from the flotation plant Bor (position 5) was transported to the metallurgical facility RTB Bor, the Smelter at Bor, 200 m away, by trucks carrying 22 tons loads. Trucks with wet concentrate from the flotation plant Veliki Krivelj are driven on asphalt road that goes from copper filtration in the flotation plant Bor to Beding, (ie. entrance of the plant Bor Smelter). The road that the trucks transported the concentrate from the flotation plant Bor to plant Bor Smelter was in an industrial area, that is, in the complex of metallurgical facility RTB Bor. The amount of concentrates, which was driven, depended on the daily production and the need of smelter and was 1-2 trucks per day in average.

3.2.4 Plant PMS Cerovo and Flotation Bor (Cerovo Ore Processing)

Description of Production

Plant for raw material preparation (PMS) Cerovo (position 9, as shown on Figure 3.2.1) was actively mined during the 1993-2002 period. Since 2002 production at this location has been under temporary suspension due to the completion of the pit surface exploitation and the inability to open another functional pit area during this time period. In plant PMS Cerovo preparation of copper ore from the ore pit Cerovo was carried out at the PMS Plant and the prepared pulp was then transferred by hydrotransport to the flotation plant Bor for further processing.



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Figure 3.2.12 presents an aerial overview of the currently non-operating Cerovo Mine Pit and Ore Processing Plant.

The process of copper minerals preparation and concentration is done in the following phases:

primary crushing;

• secondary and ternary crushing with sieving;

• milling and grading;

pulp containing 65-70% -0.074 mm fraction and corresponding density, was hydro-transported by pumps and pipelines to the flotation plant Bor for further treatment;

• concentration of minerals copper by flotation;

• drainage of final copper concentrate, in two phases:

o thickening the final copper concentrate,

o filtering the final copper concentrate; and

• treatment of tailings, transport and disposal at barren RTH (position 6, as shown on Figure 3.2.1).

All of these process phases were closely related and together had a function to produce the final product with flotation concentration from copper ore, also the product with the final concentrate, which contains about 20% Cu and was suitable for further metallurgical treatment.

Figure 3.2.12

Cerovo

Mine and Mill Site



Section 3Page 24

Product Description

Plant PMS Cerovo had few intermediate and one final product, the final copper concentrate.


• concentrate moisture: 10%

• density of the solid phase: 4 t/m3

• chemical analysis of the final concentrate:


% Cu 14,18 % Zn 0,23

% Cu-ox 0,813 % Se <0,0040

% Cu-suf 13,367 % Mo <0,010

% S 37,96 % Co 0,0070

% SiO2 10,04 % TiO2 0,057

% Fe 33,51 % Ge <0,0010

% Fe3O4 0,84 % Sn /

% Al2O3 2,51 % Sb <0,0050

% CaO 0,71 % Bi <0,0030

% MgO 0,81 g/t Rh <1,0

% As / g/t Pt <1,0

% Na2O 0,41 % V2O5 <0,0050

% K2O 0,49 g/t Ag 12,9

% Pb 0,04 g/t Au 1,8



Section 3Page 25

Realized production

Production capacity constraints of the flotation plant Bor are linked to the capacity of the equipment itself. The installed equipment in flotation plant Bor is processing capacity of 5.0 Mt per year.

Table 3.2.4 Overview of Cerovo Ore Processing in the period 2005-2009.

No. Name Un. 2005 2006 2007 2008 2009

1. Ore-wet t 2553991 2180159 2104232 1429828 1202230

2. Dry-ore t 2400707 2079308 2002859 1374261 1170751

3. Cu in wet ore % 0,626 0,520 0,348 0,323 0,343

4. Cu in dry ore % 0,666 0,545 0,366 0,336 0,352

5. Cu in ore t 15991 11342 7325 4615 4125

6. Au in ore kg 392 395 293 176 192

7. Ag in ore kg 5106 4807 4694 2569 2317

8. Wet concentrate t 87287 61579 40086 26826 24633


10. Cu in conc. t 13342 9567 5626 3320 3037

11. Au in conc. kg 169,8341 122,0243 76,3455 47,3682 54,9547

12. Ag in conc. kg 1211,449 903,944 581,788 399,208 412,721

13. Cu gain % 83,44 84,35 76,80 71,93 73,62



Section 3Page 26

Figure 3.2.13 The volume of produced wet and dry concentrate in the period

1998-2002 (blue-wet concentrate, red-dry concentrate).


Wet concentrate from the flotation plant Bor was transported to the metallurgical facility RTB Bor, the Smelter at Bor, 200 m away, by trucks carrying 22 tons. Trucks with wet concentrate from the flotation plant Veliki Krivelj were driven on asphalt road that goes from copper filtration in the flotation plant Bor to Beding, ie. entrance of the plant Bor Smelter. The road that the trucks transported the concentrate from the flotation plant Bor to plant Bor Smelter was in an industrial area, that is, in the complex of metallurgical facility RTB Bor. The amount of concentrates, which was driven, depended on the daily production and the need of smelter and was 1-3 trucks per day in average.



Section 3Page 27

3.2.5 Flotation Plant Majdanpek

Flotation plant Majdanpek is located in the complex of Majdanpek mine, RBM, near open pits, and near the Town of Majdanpek. The Majdanpek mine is located approximately 72 km by main road away from the Town of Bor and the RTB Complex.

The Majdanpek Mine operates fully independent preparation and concentration facilities from those associated with the RTB Bor Complex.

Figure 3.2.13 shows the location of the Majdanpek mine in relation to the other RTB Bor facilities.

Description of production and product

Plant for the preparation and concentration of copper ore in Majdanpek consists of the following phases of work:

• Crushing of excavated ore, • Milling and grading, • Flotation, • Drainage and hydraulic transport • Filtering the concentrate, • Placing of tailings and recovery of technical water in the process.

Realized production

Production capacity constraints of the flotation plant Majdanpek are linked to the capacity of the installed equipment in flotation plant Majdanpek which is rated at 12.0 Mt per year.



Section 3Page 28

Table 3.2.5 Summary of Majdanpek Ore Processing in the Period 2005-2009

No. Name Un. 2005 2006 2007 2008 2009

1. Ore-wet t 1100000 1330000 1730000 1796000 24900002. Dry-ore t 1078000 1303400 1695400 1760080 24402003. Cu in wet ore % 0,367 0,365 0,319 0,333 0,2714. Cu in dry ore % 0,374 0,372 0,326 0,340 0,2775. Cu in ore t 4037 4855 5519 5981 67486. Au in ore kg 566,50 542,64 451,53 466,96 540,337. Ag in ore kg 2726,90 2806,30 2818,17 2729,92 2878,44

8. Humid concentrate t 32213 33491 36249 34531 44989


10. Cu in conc. t 3301 3904 4535 4999 552711. Au in conc. kg 198,8415 197,1042 169,0077 180,5734 197,004312. Ag in conc. kg 1244,830 1386,593 1218,578 1191,337 1152,81513. Cu gain % 81,77 80,42 82,17 83,58 81,90

Figure 3.2.14 The volume of produced humid and dry concentrate in the period 2005 -2009 (blue-wet concentrate, red-dry concentrate)



Section 3Page 29

Concentrate transportation

Wet concentrate from the flotation plant Majdanpek was transported to metallurgical plant RTB Bor, the Smelter at Bor, 75 km away, by rail wagons carrying 30 tons. The amount of concentrates, which was driven, depended on the daily production and needs of smelting and was 3-4 wagons per day, in average.

3.3 Rtb Bor Strategic Plan For Copper Concentrate Production

3.3.1 Strategic Plan Development

Strategic development of RTB Bor in the field of mining and copper production will be based on the mass exploitation of copper ore by surface mining method in Bor and Majdanpek mines, as follows:

In Veliki Krivelj

On-site Kraku Bugaresku (deposits Cerovo 1 and Cerovo 2)

Cerovo primary; and

In pits of the copper mine Majdanpek (Southern and Northern Revir).

A significant factor in the strategic development of RTB Bor will be ore production by pit mining from the existing ore bodies and future exploitation of the deposit ‘Borska reka’. Processing ore from the open pit Veliki Krivelj in combination with mining in the bearing Kraku Bugaresku (Cerovo 1 and Cerovo 2) and bearing Cerovo-primary, could reach an annual capacity of the ore flotation of 15.5 × 106 t in Veliki Krivelj.

In the Bor pit, small ore bodies (Brezanik "and" T "in preparation) rich in gold and copper (more than 5.5% Cu and more than 2 g / t Au) are currently being exploited.

Study on ore reserves of the deposit ‘Borska Reka’ is made and certified and their amount is 319,969.179 tons of ore at 0.3% Cu contours with an average content of 0.53% Cu. In the future, this bearing will be a significant resource for obtaining the copper in RTB Bor Company. With the previous preparatory work, it is possible to start operation in 2011 in the upper part of the deposit ‘Borska Reka’ (above the horizon XVII), in the amount of about 7 million tons of ore. Majdanpek Copper Mine has two active open pits in Northern and Southern deposits Revir. Very small production capacities are achieved considering the potentiality of mineral raw materials base because of the equipment deficiency, drainage problems and defective transport system for the ore and barren soil. The profitability of this mine can be determined after making a detailed strategy for the development of the mine. On the basis of previous considerations, processing capacity of the mine can be a 4 ÷ 8 × 106 t of ore per year.



Section 3Page 30

Tables 3.3.1 to 3.3.5 give an overview of the projected production estimates for individual production in sites and overall in RTB Bor for the period 2010 to 2033.

3.3.2 Future Strategic Production Plan In Rtb Bor Company

Future Production Estimates

As shown in Table 3.3.4, production is planned to continue at the Veliki Krivelj Mine until 2033. Production capacity will be 8,5x106 t/year until 2012, and from 2013 to the end of life of the mine life in 2033 the production rate and processing capacity is projected to increase to 12,5x106 t of ore annually. Processing would be conducted by the same technological scheme as before. In order to achieve and increase production capacity in the future, an investment in the mine, mining site and flotation of the amount of $72 million U.S is needed.

When ore exploitation is renewed as planned, processing of ore from Cerovo will be carried out in the Veliki Krivelj flotation facilities. Ore excavated from the pit's surface on Cerovo would be crushed and milled in processing objects in Cerovo itself, so the ore (i.e. the pulp processed at Cerovo) will be transported to Veliki Krivelj flotation by a hydrotansport system, where further processing would be conducted on the new flotation concentration equipment. Production capacity in the period 2011-2014 year would be 2.5 x106 t of ore per year, and in the period 2015-2033 year would be 5.0 x 106 tons of ore per year. In order to achieve and subsequently increase production capacity, investment in the mine, mining site and flotation Veliki Krivelj in amount of $64.4 million U.S. is needed,

Processing of ore from the Bor pit will be conducted in Bor flotation, with processing capacity that is shown in Table 3.3.4. As shown in Table 3.3.4 processing capacities will grow from 0.264 x106 tons of ore per year in 2010, to 0.9 x106 t of ore per year during the period from 2013th to 2018th year. In order to achieve production and increase the production capacity an investment in Bor pit and Bor flotation in amount of $20 million U.S. is needed.

Slag processing will proceed as before in the flotation Bor. Slag processing capacity will not change and will be at the level of 0.9 tons per year x106 in the 2010-2014 period. In order to achieve production capacity in the period from 2010-2014, an investment in depot 1 and Bor flotation in the amount of $1,939 million U.S. is needed.

Processing of ore from the mine in Majdanpek will take place in existing treatment plants whose capacity will be increased from 3.2 x 106 tons of ore per annum in the period 2010-2012 years to 5.0 x 106 tons of ore per annum in the 2013-2018 period and 5.5 x 106 tons of ore per annum in the 2019-2033 period. In order to achieve production capacity and increase it in the future, investment in surface mining and flotation Majdanpek, in amount of $67.5 million U.S. is needed.



Section 3 Page 31

Table 3.3.1 The Planned Schedule of Production in RBB Bor (Mining)

Year of Production >> 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 TOTAL

Annual capacity of wet ore with copper content of 0.30%

×106 ( t/year)

8.5 8.5 8.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 162 (246)

Copper mine Veliki Krivelj

Annual capacity of copper in concentrate

(t/year) 2100

0

2100

0

2100

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

2600

0

4010

00

(609

000)


×106 (t/year)

2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 22.5 Copper mine

Cerovo bearing‘Kraku

Bugaresku’ Annual capacity of copper in

concentrate (t/year)

6000

6000

6000

6000

6000

6000

6000

6000

6000

5400

0


×106 ( t/year )

2.5 2.5 2.5 2.5 2.5 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 82.5 Copper mine

Cerovo bearing ‘Cerovo primary’ Annual capacity of copper in

concentrate (t/year)

7000

7000

7000

7000

7000

1400

0

1400

0

1400

0

1400

0

1400

0

1400

0

1400

0

1400

0

1400

0

1400

0

1400

0

1400

0

1400

0

1400

0

2310

00

Total production of wet ore ×10

6 (t/year)

8,5 11.0 11.0 13.0 15.5 15.5 15.5 15.5 15.5 15.5 15.5 15.5 15.5 15.5 15.5 15.5 5.0 (15.5)

5.0 (15.5)

5.0 (15.5)

5.0 (15.5)

5.0 (15.5)

5.0 (15.5)

5.0 (15.5)

5.0 (15.5)

267 (351)

Total production of copper in concentrate (t/year) 21

000

2700

0

2700

0

3200

0

3200

0

3900

0

3900

0

3900

0

3900

0

3900

0

4000

0

4000

0

4000

0

4000

0

4000

0

4000

0

1400

0

(400

00)

1400

0

(400

00)

1400

0

(400

00)

1400

0

(400

00)

1400

0

(400

00)

1400

0

(400

00)

1400

0

(400

00)

1400

0

(400

00)

6860

00

(894

000)



Section 3 Page 32

Table 3.3.2 The Planned Schedule of Production in RTB Bor (The Pit)

Year of Production >> 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 TOTAL

7.5 (6.9)% ×10

6 ( t/year) 0.

081

0.08

5

0.1666

Mining body T (rich ore)


(t/year) 6060

5850

1191

0

Annual capacity of wet ore with copper content

of 1.9 (0.93)% ×10

6 ( t/year)

0.18

3

0.17

0

0.22

0

0.573 Mining body T (poor ore) and

Brezonik 1.16% Cu Annual capacity of

copper in concentrate (t/year) 17

65

1580

2050

5395

Annual capacity of wet ore with copper content

of 0.53% ×10

6 ( t/year)

0.4 0.9 0.9 0.9 0.9 0.9 0.9 0.9 6.7

Mining body Borska reka


(t/year) 1700

3850

3850

3850

3850

3580

3850

3850

2865

0


6 (t/year) 0.264 0.655 1.120 0.9 0.9 0.9 0.9 0.9 0.9 7.439

Total production of copper in concentrate (t/year) 78

25

9130

5900

3850

3850

3850

3850

3850

3850

4595

5



Section 3 Page 33

Table 3.3.3 The planned schedule of production in RBM, total production in RBB-Bor and total production in RTB-Bor

Year of Production 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 TOTAL

Annual capacity of wet slag with copper content 0.75%

×106 ( t/year)

0.9 0.9 0.9 0.9 0.9 4.5

Slag Annual capacity of copper

in concentrate (t/year) 28

67

2867

2867

2867

2867

1433

4


×106 ( t/year)

3.2 3.2 3.2 5.0 5.0 5.0 5.0 5.0 5.0 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 89.1

RBM Annual capacity of copper

in concentrate (t/year) 90

00

9000

9000

1550

0

1550

0

1550

0

1550

0

1550

0

1550

0

2050

0

2050

0

2050

0

2050

0

2050

0

2050

0

2050

0

2050

0

2050

0

3045

00


×106 ( t/year) 9.

664

12.5

55

13.0

20

14.8

00

17.3

00

16.4

00

16.4

00

16.4

00

16.4

00

15.5

00

15.5

00

15.5

00

15.5

00

15.5

00

15.5

00

15.5

00

5.0

(15.

5)

5.0

(15.

5)

5.0

(15.

5)

5.0

(15.

5)

5.0

(15.

5)

5.0

(15.

5)

5.0

(15.

5)

5.0

(15.

5)

277

(361

)

RBB

Annual capacity of copper in concentrate (t/year) 31

692

3899

7

3576

7

3871

7

3871

7

4285

0

4285

0

4285

0

4285

0

4000

0

4000

0

4000

0

4000

0

4000

0

4000

0

4000

0

1400

0 (4

0000

)

1400

0 (4

0000

)

1400

0 (4

0000

)

1400

0 (4

0000

)

1400

0 (4

0000

)

1400

0 (4

0000

)

1400

0 (4

0000

)

1400

0 (4

0000

)

7399

55

(947

955)


6 (t/year) 12

,864

15.7

55

16.2

20

19.8

00

22.3

00

21.4

00

21.4

00

21.4

00

21.4

00

21.0

00

21.0

00

21.0

00

21.0

00

21.0

00

21.0

00

21.0

00

5.0

(21.

0)

5.0

(21.

0)

5.0

(21.

0)

5.0

(21.

0)

5.0

(21.

0)

5.0

(21.

0)

5.0

(21.

0)

5.0

(21.

0)

370.

6 (4

54.1

6

Total production of copper in concentrate

(t/year) 4069

2

4799

7

4476

7

5421

7

5421

7

5835

0

5835

0

5835

0

5835

0

6050

0

6050

0

6050

0

6050

0

6050

0

6050

0

6050

0

3450

0 (6

0500

)

3450

0 (6

0500

)

3450

0 (6

0500

)

1400

0 (4

0000

)

1400

0 (4

0000

)

1400

0 (4

0000

)

1400

0 (4

0000

)

1400

0 (4

0000

)

1058

789

(126

6789

)



Section 3 Page 34

Table 3.3.4 The Planned Schedule of the Concentrate Production in Mines Separately and/in Total for RTB-Bor

Part 1 – Projected Concentrate in Mines Separately

Veliki Krivelj Majdanpek Kraku Bugaresku Cerovo

Year Wet concentrate

Dry concentrate

Cu in conc.

Cu in conc.

Wet concentrate

Dry concentrate

Cu in conc.

Cu in conc.

Wet concentrate

Dry concentrate

Cu in conc.

Cu in conc.

t t % t t t % t t t % t 2010 116.667 105.000 20.00% 21.000 68.027 61.224 14.70% 9.000 2011 116.667 105.000 20.00% 21.000 55.556 50.000 18.00% 9.000 33.333 30.000 20.00% 6.0002012 116.667 105.000 20.00% 21.000 50.000 45.000 20.00% 9.000 33.333 30.000 20.00% 6.0002013 144.444 130.000 20.00% 26.000 95.679 86.111 18.00% 15.500 33.333 30.000 20.00% 6.0002014 144.444 130.000 20.00% 26.000 86.111 77.500 20.00% 15.500 33.333 30.000 20.00% 6.0002015 144.444 130.000 20.00% 26.000 90.643 81.579 19.00% 15.500 72.222 65.000 20.00% 130002016 144.444 130.000 20.00% 26.000 78.283 70.455 22.00% 15.500 72.222 65.000 20.00% 130002017 144.444 130.000 20.00% 26.000 78.283 70.455 22.00% 15.500 72.222 65.000 20.00% 130002018 144.444 130.000 20.00% 26.000 86.111 77.500 20.00% 15.500 72.222 65.000 20.00% 130002019 144.444 130.000 20.00% 26.000 103.535 93.182 22.00% 20.500 72.222 65.000 20.00% 130002020 144.444 130.000 20.00% 26.000 103.535 93.182 22.00% 20.500 77.778 70.000 20.00% 14.0002021 144.444 130.000 20.00% 26.000 103.535 93.182 22.00% 20.500 77.778 70.000 20.00% 14.0002022 144.444 130.000 20.00% 26.000 103.535 93.182 22.00% 20.500 77.778 70.000 20.00% 14.0002023 144.444 130.000 20.00% 26.000 103.535 93.182 22.00% 20.500 77.778 70.000 20.00% 14.0002024 144.444 130.000 20.00% 26.000 103.535 93.182 22.00% 20.500 77.778 70.000 20.00% 14.0002025 144.444 130.000 20.00% 26.000 105.943 95.349 21.50% 20.500 77.778 70.000 20.00% 14.0002026 144.444 130.000 20.00% 26.000 108.466 97.619 21.00% 20.500 77.778 70.000 20.00% 14.0002027 144.444 130.000 20.00% 26.000 111.111 100.000 20.50% 20.500 77.778 70.000 20.00% 14.0002028 144.444 130.000 20.00% 26.000 77.778 70.000 20.00% 14.0002029 144.444 130.000 20.00% 26.000 77.778 70.000 20.00% 14.0002030 144.444 130.000 20.00% 26.000 77.778 70.000 20.00% 14.0002031 144.444 130.000 20.00% 26.000 77.778 70.000 20.00% 14.0002032 144.444 130.000 20.00% 26.000 77.778 70.000 20.00% 14.0002033 144.444 130.000 20.00% 26.000 77.778 70.000 20.00% 14.000

TOTAL 3.238.889 2.915.000 20.00% 609.000 1.635.425 1.471.882 20.69% 304.500 1.583.333 1.425.000 20.00% 285.000



Section 3 Page 35

Table 3.3.5 The Planned Schedule of the Concentrate Production in Mines Separately and/in Total for RTB-Bor

Part 2 – Projected Pit. Slag, and Total Concentrate Production

Pit Slag RTB Total

Year Wet concentrate

Dry concentrate

Cu in conc.

Cu in conc.

Wet concentrate

Dry concentrate

Cu in conc.

Cu in conc.

Wet concentrate

Dry concentrate

Cu in conc. Cu in conc.

t t % t t t % t t t % t 2010 79.040 71.136 11.00% 7.825 24.503 22.052 13.00% 2.867 288.237 259.413 15.69% 40.6922011 92.222 83.000 11.00% 9.130 24.503 22.052 13.00% 2.867 322.280 290.052 16.55% 47.9972012 36.420 32.778 18.00% 5.900 24.503 22.052 13.00% 2.867 260.922 234.830 19.06% 44.7672013 21.389 19.250 20.00% 3.850 24.503 22.052 13.00% 2.867 319.348 287.413 18.86% 54.2172014 21.389 19.250 20.00% 3.850 24.503 22.052 13.00% 2.867 309.780 278.802 19.45% 54.2172015 21.389 19.250 20.00% 3.850 328.699 295.829 19.72% 58.3502016 21.389 19.250 20.00% 3.850 316.338 284.705 20.49% 58.3502017 21.389 19.250 20.00% 3.850 316.338 284.705 20.49% 58.3502018 21.389 19.250 20.00% 3.850 324.167 291.750 20.00% 58.3502019 320.202 288.182 20.65% 59.5002020 325.758 293.182 20.64% 60.5002021 325.758 293.182 20.64% 60.5002022 325.758 293.182 20.64% 60.5002023 325.758 293.182 20.64% 60.5002024 325.758 293.182 20.64% 60.5002025 328.165 295.349 20.48% 60.5002026 330.688 297.619 20.33% 60.5002027 333.333 300.000 20.17% 60.5002028 222.222 200.000 20.00% 40.0002029 222.222 200.000 20.00% 40.0002030 222.222 200.000 20.00% 40.0002031 222.222 200.000 20.00% 40.0002032 222.222 200.000 20.00% 40.0002033 222.222 200.000 20.00% 40.000

Total 336.016 302.414 15.20% 45.955 122.513 110.261 13.00% 14.334 7.060.620 6.354.558 19.81% 1.258.789



Section 3 Page 36

Figure 3.3.1 - The planned schedule of the concentrate production in mines separately and total in RTB-Bor (Y axes-production)



Section 3 Page 37

It is planned that the total processing capacity of RTB Bor of 12.864 x 106 tons of ore per year in 2010 year will increase to 21.4 x106 tons of ore per year by 2015. Between 2016 and the end of production in 2033 the level of production will be maintained at a level of 21.0 x 106 tons of ore per year.

For such a planned production of the company RTB Bor, investments at the level of total of 234 million U.S. $ will be required.

3.3.3 Transportation Plan for RTB Bor’s Future Production The following identifies the concentrate transport requirements associated with the following facilities:

Veliki Krivelj flotation;

Bor Floatation;

Majdanpek floatation; and

Bor Smelter Complex

Figure 3.3 1 identifies the concentrate transport movements for the flotation facilities discussed below.

Figure 3.3.2 addresses the transport of copper product from the modernized RTB Bor smelter facility.

Concentrate transport from future production in Veliki Krivelj flotation

Since the production from ore from open pit Veliki Krivelj (position 1, on Figure 3.4.1) and open pits from Cerovo (position 9) will be conducted in Veliki Krivelj flotation (position 2) in copper minerals concentration section, concentrates from both ores will be obtained. Concentrates will, as before, be transported to metallurgical plants in Bor, smelter in Bor (position 13.), by trucks carrying 22 tons which will go the same route as before, i.e. industry road (position 10.) 12 km in length bypassing the Bor town. Trucks are to be used for transportation of the concentrate with an open crate. For the transport of the concentrate obtained by processing ore from open pit mine and the Veliki Krivelj Cerovo, 19-22 trucks will be needed in the period from 2010-2014, and for period from 2015-2033 will be needed 23-28 trucks per one day, depending on concentrate production and needs in Bor smelter.

Concentrate transport from future production in Bor flotation

Considering that ore from the Bor pit and slag will continue to be processed during the following period in Bor flotation (position 5 on Figure 3.4.1), copper concentrate will be



Section 3 Page 38

obtained in Bor flotation from these two raw materials. The plan is to eliminate driving of copper concentrate from copper filtration in Bor flotation to Beding i.e. entrance to Bor smelter (position 13.) in the following period and to transport concentrates by belt conveyers which were in use before (ie. 70's, 80's and 90's of last century), instead. Length of the transport system from copper filtration in Bor flotation to Beding, i.e. entrance to Bor smelter, is 150 m. Putting the transport system in the operational function in order to avoid the involvement of a truck transport of concentrate may lead to significant cost savings.

Concentrate transport from future production in Majdanpek flotation

The transportation way of concentrates, which will be obtained from Majdanpek flotation, is not supposed to be changed, i.e. concentrate transport will as always be conducted using railroad wagons in capacity of 30 t. Wagons will directly enter into the complex RTB Bor where the system of unloading from wagons will be involved so that concentrate will be directly loaded to Beding, i.e. entrance to the Bor smelter (position 13, on Figure 3.3.2).

Bor Smelter Production

The present Bor Smelter is presently operating at a low concentrate throughput of 40,000-50,000 t/y compared to the original design base capacity of 125,000 t/y.



Section 3 Page 39

Figure 3.3.2 Identifying the Concentrate Transport Movements for the Floatation Facilities

Documents

Table of Contents - RTB Bor · Table of Contents 3.0 CURRENT COPPER ... RTB BOR ... Table 3.2.1 Overview of processing ore from the open pit\Veliki Krivelj in the period 2005-2009