Utah International Island Copper Complex

Historic Project: Groundbreaking Work From Earlier in Fluor’s History

Client: Utah International, Inc.

Location: Vancouver Island, BC, Canada

Business Segment: Urban Solutions

Industry: Mining & Metals

Map showing the location of Utah International Island Copper Complex

Executive Summary

The Island Copper mine is located on the northern end of Vancouver Island about seven miles south of Port hardy, in a remote logging and fishing community with a population of 2,000 people. Fluor built the existing Island Copper complex in 1971. The concentrator has a capacity to process 33,000 tons of ore per day.

Island Copper's six autogenous grinding mills, each 32 feet in diameter and 14 feet in length, formed the largest totally autogenous grinding circuit in the copper industry at the time. The grinding mills convert the ore into approximately 230,000 tons annually of copper concentrate and 1,800 tons of molybdenum concentrate.

The client also awarded us the follow-on work for the conceptual engineering and detail design for the extension to the 45,000 tpd copper concentrator building to house a new ball mill.

Client's Challenge

The copper mine on Vancouver Island was Canada's second-largest and had estimated reserves of 280 million tons of ore averaging 0.52% copper and 0.025% molybdenum. Reserves were sufficient for about 25 years at the anticipated rate of production. Utah International had long-term contracts to Japanese firms for export.

The Island Copper mill and related mining facilities provided about 400 permanent jobs for the residents of the Port Hardy area.

In concert with the Provincial Government and the University of British Columbia, the client had established an elaborate environmental control program to protect the ecology of Rupert Inlet and the surrounding waters. The program included an emergency catch basin capable of storing mine tailings up to six months. Utah International also developed plans for the eventual reclamation of the mine site and waste rock dump areas.

Fluor's Solution

The copper concentrator was designed and built by Fluor at a cost of $50 million. The concentrator had a capacity to process 33,000 tons of ore per day. The grinding mills converted the ore into approximately 230,000 tons annually of copper concentrate and 1,800 tons of molybdenum concentrate.

Island Copper's six autogenous grinding mills, each 32 feet in diameter and 14 feet in length, were the largest totally autogenous grinding circuit in the copper industry at the time.

An autogenous mill separated the mineral from the ore without rods, balls or other grinding media characteristics of conventional mills.

Conclusion

Utah International commenced operation of its Island Copper concentrator near Port Hardy, B.C, in fall 1971, with the mill operating at design capacity at year-end.

The client also awarded us the follow-on work for the conceptual engineering and detail design for the extension to the 45,000 tpd copper concentrator building to house a new ball mill.