Industrial Training Report

INDUSTRIAL TRAINING REPORT
RAMU NICO MANAGERMENT (MCC) LIMITED
Submitted by
JYRUS BAYUVE
(19302053) BEMN/4
Submitted in partial fulfillment to the

Requirements for the award of
DEGREE OF ENGINEERING IN MINING ENGINEERING
Submitted to
PAPUA NEW GUINEA UNIVERSITY OF TECHNOLOGY

DEPARTMENT OF MINING ENGINEERING
Date submitted: January 1st, 2023
INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 1

I. CERTIFICATION .1: MANAGEMENT

II. CERTIFICATION .2: SECTION HEADS
III. STUDENT DECLARATION

ACKNOWLEDGMENT
Firstly, I would like to thank my industrial coordinator and lecturer Mr. Gideon G. Yowa for liaising with
Ramu Nico Mine and securing my Industrial training. Secondly, I would like to thank and appreciate the
Ramu Nico (MCC) limited under the management of General Mine Manger Mr. Joseph Umare and His
Deputy Mr. Mathew Francis and The Human Resource team (Mr. Jeffers Teargun), for making it possible
with necessary arrangement and also the accommodation and hospitality throughout the 6 weeks of my
Industrial training. Finally I would like to acknowledge and thank the Engineers, Aipias, Samson, Eloi and
Rex for the guidance throughout my training. Also I would like to express my innermost gratitude to the
superintendant, supervisors, Team leaders, and employers of the respective departments; Hydro mine,
Wash Plant, Mine division, Beneficiation, mine Technical Services and Health Safety & Environment for
the experience and Knowledge shared during my observation, which is the very idea captured in this
report. It has been my pleasure training with you and I appreciate the opportunity.

I. EXCECUTIVE SUMMARY
The mining operation at Kurumbukari located in Using-Bundi District of Madang province. The Mining
operation is a joint venture of several Chinese companies and is managed by a Chinese Owned company
The Ramu Nico MCC management Limited. The main commodity of interest mined is Nickel and Cobalt,
however throughout the process, chromate is also extracted. The operation is a medium scaled and it
applies Conventional and water Sluicing method to mine the ore the associate ore body.
The operations is very shallow, which Ore Is mined in benches and hydro sluicing and is transported to
washing plant, where the ore is screened and converted to slurry state. From washing plant the slurry
are transported to Beneficiations where chromate is extracted and further screening and slurry
treatment occurs before being transported to Basamuk for Nickel and Cobalt separation.

II. ABOUT THE COMPANY
Ramu Nickel Joint Venture (RNJV) was founded in 2004. Ramu NiCo Management (MCC) Ltd (RNML) was
appointed by the RNJV as the manager for the construction and operation of the Project. The Joint
venture companies includes: MCC China (67%), Jinchuan Nonferrous Metal Co. (7%), Jien Nickel
Industries Co.(13%) and Jiuquan Iron & Steel Co (JISCO),(13%). Jinchuan and Jien are the largest and
second largest nickel producers in China. Jiuquan is the third largest stainless steel producer in China.
Fig.ii. Project Owners and joint ventures
III. LOCATION OF THE PROJECT (MINE SITE)

The project is located 18 kilometres to the west of the nearest Local Government station Bundi of The
Usino-Buindi District, Madang province and 80 km south west of the Madang capital. The license mine
area is located on the lower slopes of the Bismarck Range on the edge of the Ramu valley and covers
elevations from 110m to 800m above mean sea level.
Fig.iii. Location of the KBK mine operation

Contents
I. CERTIFICATION .1: MANAGEMENT .......................................................................2
II. CERTIFICATION .2: SECTION HEADS ..................................................................3
III. STUDENT DECLARATION ......................................................................................3
ACKNOWLEDGMENT ......................................................................................................4
I. EXCECUTIVE SUMMARY ........................................................................................5
II. ABOUT THE COMPANY ..........................................................................................6
III. LOCATION OF THE PROJECT (MINE SITE) ...........................................................6
CHAPTER 1. GEOLOGY & MINERALIZATION ................................................................9
1.1. Geology and Mineralization of New Guinea Thrust Belt zone ..........................9
1.2 Regional Geology & Mineralization of the Kurumbukari Deposit ...................10
1.3 Resource and Reserve of Ramu Nico – Kurumbukari mine deposit ..............11
CHAPTER 2. MINING METHOD .....................................................................................12
2.1 Conventional Open Pit Mining method .............................................................12
2.2 Hydro Sluicing ...................................................................................................12
CHAPTER 2. MINE TECHNICAL SERVICES (MTS) ......................................................13
2.1 Road Designs Specifications ............................................................................13
CHAPTER 3. MINING OPERATIONS (MINE OPS) .....................................................14
3.1 Mine Development ..............................................................................................14
3.12 Overburden Stripping ......................................................................................14
3.13 Mine Development Fleets ..................................................................................15
3.2 Conventional Mine Operation .............................................................................15
3.21 Currently Active Mining operation (Pits) ..........................................................16
3.3 Conventional Mining fleets ................................................................................16
3.4 Ore Bin operation................................................................................................17
3.5 Dispatch and GPS Operations .........................................................................18
3.6 Emergency Response Operation (ERT) ............................................................18
3.8 Summary ............................................................................................................18
CHAPTER 4. HYDRO SLUICING MINING ......................................................................19
4.1 Hydro sluicing operation ..................................................................................19
4.2 Active Hydro Mine Pits (Current) .....................................................................20
4.3 Equipments and fleets ......................................................................................20
4.4 Summary ...........................................................................................................21
CHAPTER 5. WASH PLANT ...........................................................................................21

5.1 Washing Plant Operation ..................................................................................21
5.2 Wash plant equipment .......................................................................................22
5.3 washing Plant crew.............................................................................................22
5.3 Summary ...........................................................................................................23
CHAPTER 6. BENEFICIATION PLANT ........................................................................23
6.1 Chromites Separation Process ........................................................................24
6.11 Equipments Utilized in Chromate separation Process....................................25
6.2 Slurry Treatment and Thickening .......................................................................25
6.3 Summary ............................................................................................................26
CHAPTER 7. HEALTH SAFETY AND ENVIRONMENT (HSE) .......................................26
7.1 Health Safety ...............................................................................................26
7.2 Environment ...............................................................................................26
CHAPTER 8. SUMMARY .......................................................................................27
CHAPTER 9. APPENDIX .........................................................................................28
Appendix Content ..........................................................................................................28
1. Appendix. A: Compiled Recommendations ...................................................28
2. Appendix. B: Training Schedule .......................................................................28
3. Appendix. C: Hydro mine week based Report ................................................28
4. Appendix. D: Mine Division week based Report .............................................28
5. Appendix. E: Washing Plant week based Report ...........................................28
6. Appendix. F: Beneficiation Plant week based Report ....................................28
7. Appendix. G: Pit Road Safety Assessment Report-Mine technical Service .28
8. Appendix. H: Safety Training Recommendation..............................................28

CHAPTER 1. GEOLOGY & MINERALIZATION
1. KURUMBUKARI ON PNG GEOLOGY
1.1. Geology and Mineralization of New Guinea Thrust Belt zone

Kurumbukari is located on the Ramu Markham Fault in the New Guinea Thrust Belt zone, which is the a
major thrust belt that is enclosed by the Papuan Fold Belt to the south, Finisterre terrenes to the north,
and the Aure Fold Belt to the east (Sheppard and Cranfield, 2012).
The belt is characterized by late Miocene, sub-horizontal to shallowly north-dipping, stacked thrust
sheets of regionally metamorphosed and strongly cleaved Triassic to Eocene fine-grained sedimentary
rocks and minor volcanic rocks (Sheppard and Cranfield, 2012).
Igneous intrusive activity within the New Guinea Thrust Belt comprises subaqueous and sub-aerial
volcanism, and associated intrusions, that vary from batholiths to stocks and dykes.The occurrence of
Ramu Nickel-Cobalt mineralization, gold-copper related intrusion, alluvial gold, and sub-volcanic massive
sulfide mineralization is hosted within the New Guinea Thrust Belt. A large area of ultramafic rock
composed of upper-mantle constituents, exposing along the front of Bismarck Range and south of Ramu
River, in which laterite deposit of Nickel and cobalt (Ni-Co),that has been altered by the continuous
tropical weathering.(Queen et al., 2001).
Fig.1.1 PNG Geological Features (Williamson and Hancock, 2005).

1.2 Regional Geology & Mineralization of the Kurumbukari Deposit
The northern margin of the New Guinea thrust zone hosts the two dormant host rocks which is Dunites
and Gabbros which has been altered by Miocene Marum Basic Belt through deep tropic weathering
which exposing laterite deposit of Nickel and cobalt (Ni-Co) and chromium (Cr). Minor exposure of rock
such as pyroxenite, harzburgite, norite and peridotite were also through this geological occurrence and
activity (RNML, 2021).Based on the exploration (EL193) highlights, average of average of 10-30 meters
thickness containing irregular amount of Nickel (Ni), Cobalt (Co) and Chromium (Cr).The laterite profile
of the deposit developed over an underlying dunites and peridotites of the Marum Basic Belt.
(Jakanduo, 2021).
Fig.1.21 Kurumbukari deposit’s Regional Geology
Fig.1.22 Laterite Profile of KBK deposit

1.3 Resource and Reserve of Ramu Nico – Kurumbukari mine deposit
Based on 2019 resource and reserve update the Ramu Nico project is mining Nickel at 0.5% cut off grade
with the minimum mineable ore deposit thickness of 0.5m thick.

CHAPTER 2. MINING METHOD
The Kurumbukari (KBK) Nickel-Cobalt Mine applies two mining methods to mine the ore. Since the mine
is shallow and soft rock the operation at Kurumbukari mine (KBK) assign two method of mining to mine
its ore body. Initially, KBK applies Conventional open pit mining method, until Hydro sluicing was
introduced in 2014.
2.1 Conventional Open Pit Mining method

The conventional mining method practiced at Kurumbukari mine is slightly different to other hard rock
mining around Papua New Guinea. The mine is said to be soft rock, shallow mine, which ore is mined in
an open pit structure with bench height of 5 meter high and a berm of 3 m wide. This is due to stability
of the surface. The mining direction applies top down mining method. According to the Mine Probation
Report, 2021, the design height of working benches ranges from 3m – 5m, with bench face angle of 65°.
There are two types of working benches; combination benches (2-3 benches) and single bench.
Combination benches are used for continuous mining when the surface slope is greater than 15° or
when the ore body thickness is greater than 15m.
Table 2.1A Mine surface Parameters
Fig. 2.1B Conventional loading of Ore
2.2 Hydro Sluicing

The hydro mining technique is applicable only to soft rock and soil deposits. It is less cost with high
productivity; however it is very high intense activity. The probability of mining recovery of ore is very
high with less cost associated in mining and transporting of the ore. The hydro mine operation at KBK is
a successful operation, operating for almost 8 years. The usage of water to blend the ore during the
mining phase and transportation via slurry has save the cost of washing plant and also hauling cost. This
helps recover the investment cost within a short period of time. The usage of manual water cannons is
very effective however is very risky when operation is at rocky area and also rainy seasons, thus to ease
the operation and mitigate this issues, it is much better to reintroduce remote water cannons, despite
cost.

CHAPTER 2. MINE TECHNICAL SERVICES (MTS)
Mine technical services are responsible for design and monthly production plans. Since the mine assign
simple operations, the Technical services construct short to medium term planning’s only. The plans are
inclusive of monthly production plans, safety standardizations, tonnage calculations, road designs, pit
designs, waste dump designs and sediment ponds designs.
2.1 Road Designs Specifications

Design and construction of haul roads is of vital concern especially in open pit mining operations. The
Roads are design in specific standard procedure to met the requirement of the hauling operations and
avoid accidents, tyre grazing, high friction, and substantial slippery in the rainy weather.
Kurumbukari mine roads are design and constructed basing on the considerations such as road life,
types of vehicle and traffic management. According to the KBK road design MTS SOP, types of roads
that are design constructed in KBK mine are;
I. Main haul roads – dual lane

II. Branch haul roads – dual lane
III. Connecting haul roads – single lane
Table 2.1 HAUL ROAD STANDARD DESIGN PARAMETERS (MTS SOP, 2022)

CHAPTER 3. MINING OPERATIONS (MINE OPS)
The mining operation is overseen by mine division/department which monitors operations under sub-
divisions such as;
I. Conventional mining operation

II. Dispatch Unit & GPS Operation
III. Emergency Response Team/Unit (ERT)
IV. Mine Development operation
The general working specifics of the mine division is to develop a mine by establishing logging and
vegetation clearance, overburden stripping, pit and access road construction, and mining using the
excavators and haul trucks. Also oversees truck and excavator scheduling and monitoring operations.
3.1 Mine Development

Prior to the excavation of the ore, the mine development team clears the area by cutting down trees
and clearing up the land by excavating the top soil (Humic soil). Also the development team establish
necessary infrastructure like, access roads, haul roads and transit site office for the mining operation to
commence.
Table 2.1 Mine Development operations
Development operation Unit

Main Haul Road System m
Feeder and Access Mining Roads m
Mining Benches m3
Land clearing (logging & vegetation clearing) m2
Top soil and overburden Stripping m3
Rehabilitation m2
3.12 Overburden Stripping

Overburden stripping is done/carried out in two ways;
I. When over burden is less than 2m, bulldozers are utilized for stripping.
II. When the overburden thickness is greater than 2m, excavators and trucks are utilized
for overburden stripping
Table 3.12 Stripping face parameters (KBK probation report, 2021 )

3.13 Mine Development Fleets
The mine development operation utilizes machines/equipments such as chainsaws, Dozers and
excavators to execute the development phase of the mine.
Table 3.13 Mining Development fleets (KBK probation report, 2021)
3.2 Conventional Mine Operation

The mineral soil which is mined contains famous elements such as Aluminum, Magnesium, Nickel,
Cobalt, and compound chromites which are a compound of Iron Magnesium and Chromium. However,
the mineral of interest is Nickel and Cobalt. Since the mineral Nickel and cobalt are found in soil, the
mine is said to be soft rock mining, thus no drilling and blasting operations are not performed at KBK
mine operation. The unique KBK mining operation involves excavation, loading, hauling and dumping.
According to the Mine Probation Report, 2021, the design height of working benches ranges from height
3m – 5m, with bench face angle of 65°. There are two types of working benches; combination benches
(2-3 benches) and single bench. Combination benches are used for continuous mining when the surface
slope is greater than 15° or when the ore body thickness is greater than 15m.
Fig.3.2A Conventional mine chart Table 3.2B Mine surface Parameters

3.21 Currently Active Mining operation (Pits)
 Currently active pits are pit 11 and 21
 Pits currently undergoing stripping phase based on the geotechnical design constraints 11, 13,
14, 15, 16, 17, 18 and 20
 Pit 12, 16 and 19 are mined using Hydraulic mine. (Note: Pit 16 was initially mined using hydro-
sluicing but is now planned and scheduled for conventional mining method.)
Fig.3.21. Actively operating pits map pointing out boundaries of current operations
3.3 Conventional Mining fleets

The fleets responsible for the mining operations have been increasing recently to meet the optimum
annual target of the production by optimizing the operations. The fleets of equipments can be
categorized into primary and secondary fleets. The primary fleets are equipment responsible for mining
operations while the secondary fleets are the assistance fleets facilitating the service and maintenance
to ease the production and operation of the mine.

Table 3.3A Primary fleets (KBK Probation Report, 2021)
Table 3.3B Secondary/Ancillary fleets (KBK Probation Report, 2021)
3.4 Ore Bin operation

The ore bin crew monitor the operation at ore bin, making sure there no over that it runs smooth, for
instance if there’s a problem at the wash plant the ore bin crew shut down the particular ore bin till the
problem is fixed. Also they monitor the material accumulation at ore bin. If the ore been is full the crew
instruct the trucks to dumped the ore at the stock pile, and if it is empty or if the pit production stops,
then the ore from the stock piles are then fed to the ore bin to maintain the overall production. There
are four (4) ore bin altogether, which operates simultaneously.
Table 3.4 Ore Bin Equipment

3.5 Dispatch and GPS Operations
The dispatch or GPS unit monitor the overall operation of both Hydro and conventional mining. For
instance, the allocation of Volvo haul trucks to the excavators per pit, the allocation of water sluicing
gun to achieve blended ore slurry, and also monitoring the trucks speed and cycle time via GPS. The
dispatch unit also monitors the beneficiation process. The team consists of office crews who monitor the
operations via computers and GPS, and ground crews which actually travel from pit to pit to monitor the
operation of the conventional mining.
Fig.3.5 Dispatch/GPS Monitoring office
3.6 Emergency Response Operation (ERT)

The emergency response team (ERT) is established/setup to respond to emergency calls such as
accidents or fire hazards and also to monitor speed of the light vehicles within the mine areas. Also the
ERT assist in the Assert Protection Department (APD) in safe guarding the company’s properties. The
actual APD operations are carried out by the Mobile Squared of RCPNG which oversees whole mine
security and protection.
3.8 Summary
The mining operations are carried out in specific order, with mine development operations as the initial
operation before mining operations are carried out. Operations such as ERT and Ore bin operations are
auxiliary or support operations carried out for effective production. Some operations such as
maintenance of Pit roads, mobile equipment maintenance, workshop operations and catering services
which are not mentioned in this report are also support operations established to facilitate and ensure
the mining operation is effective.

CHAPTER 4. HYDRO SLUICING MINING
Hydro sluicing is a surface variation mine technique, which water is shot at high pressure to the deposit
face to cut and crush the mineral contained soft rocks and soils and converts them into slurry/mud from
which ore recovered from (USGS, 2005).
4.1 Hydro sluicing operation

The hydro sluicing operation at KBK is carried out in a way
that the ore is blended during the operation. During the mine
development phase, overburden stripping of overburden and
red limonite are done and dumped in the gullies which are
then reclaiming to be used for rehabilitation of a mined out
pit.
Based on the mineralization geology of the deposit, it is

shown that the Humic and red limonite has a low Nickel (Ni)
and high aluminum (Al) content, while the grade of nickel
increase down the depth through yellow limonite and Rocky
Saprolite 1 and 2. Based on that understanding, the setup of
water cannons /guns was made in order to mine the ores
bodies, which the blended ore slurry are produced. Fig.4.01 Deposit Phase
The slurry are transported through drainage system and is captured in the slurry pound 0.5 -1 km away
from the mining site. The production at slurry pond is structured in a way which, slurries are captured
within an hour and is pumped every 5 minutes into another hour to the beneficiation plant, and then it
captured the slurries for the next hour.
Fig.4. Pit 12 hydro mine

4.2 Active Hydro Mine Pits (Current)
Currently hydro mine method is used to mine ore bodies at pit 12 and 19. Previously pit 16 was mined
using hydro sluicing technique; however after engineering considerations, the pit was redesign to be
mined using conventional method.
Fig.4.2 Current active Hydro mine Pit (Areas)
4.3 Equipments and fleets

Hydro mine at pit 12 and 19 utilizes equipments such as water cannons, excavator and mechanize
pumps in mining the ore body with the pressurized water head.
Table 4.3 Hydro Mine Fleets
No Equipment(s) Equipment(s) size
1 Excavators 5
2 Water Cannons/Guns 14
3 Mechanize Pumps 6

4.4 Summary
mining phase and transportation via slurry form and pump system has save the cost of washing plant
and also hauling cost. This helps recover the investment cost within a short period of time. The usage of
manual water cannons is very effective, however is very risky when operating at rocky area and also
rainy seasons, thus to ease the operation and mitigate this issues, it is much better to reintroduce
remote water cannons, despite cost.
CHAPTER 5. WASH PLANT

The Washing Plant which is also known as the Ore De-agglomeration plant plays an important role in the
separation and screening of the material from the conventional mining and also 3rd phase separation
from the hydro sluicing mining. The principal importance of the Ore washing operation is essentially to
screen out the boulders, chips, aggregates and dirt from the mined material (mineral soil) and convert
the mineral soil (solid) into slurry, to ease the beneficiation operation and slurry transportation to
Basamuk.
5.1 Washing Plant Operation

The material/ore from the conventional mining is fed through the 4 ore bins which separate large
boulders. The medium size rocks with soils are then passes through the 4 heavy duty apron feeders,
which assist the materials into the 4 trammel (washer drum). From the trammel washer drum, the 2nd
phase separation of medium rocks is separated from the chips. The slurry and chips are then fed
through the 8 log washers. The log washer separates chips from sands, and then it passes the sands and
slurry to the slurry storage tank 3, while the chips are discharge through conveyor 2. From tank 3, slurry
is pumped back to vibrating screen 1, also the slurry from the hydro mine is fed to the vibrating screen
2. From the vibrating screen the 3rd phase separation took place, which the dirt and granular sands are
screened out from the slurry. The slurry is then piped to the slurry storage tank 1 and 2 which then
pumped to beneficiations. The granular sand is then discharge via conveyor 4.
Fig.5. Wash Plant Operations

5.2 Wash plant equipment
In achieving optimum screening and washing, the wash plant operation utilizes equipments such as
trammels, log washers and vibrating screen for optimum screening and washing.
Table5.2 Equipment that are utilized to achieve wash plant operations
No Equipment(s) Equipment size(s)

1 Ore bin 4
2 Apron Feeder 4
3 Trammel 4
4 Log Washer (submerge Spiral Concentrator) 8
5 Vibrating screen 2
6 Conveyor System 3
5.3 washing Plant crew
Table 5.3 Washing Plant Crew and job specifications
No Crew Obligations Assign

1 The wash plant management team is made up of Supervisors, superintendant,
Management and team leader with their assistance. The Management Team oversees the
operation and maintenance of the plant.
2 This team consists of local workers who monitor the drum washers, the log
Monitoring washers, feeders, conveyors, pumps reports any faults back to team leader who
team then reports to supervisor/ superintendant, for maintenance
3 The maintenance team is in charge of maintaining the wash plant. They carry
Maintenance basic repair of the equipments every day, depending on the operating status of
Team the equipment. They carry basic arc welding, oiling the bearing, conveyor
maintenance, and etc.
4 The entire wash plant operation, including feeder speed, trammels and log
Control room washer rotational velocity, vibration of screen, and the conveyor system is
team monitored in the control room. For instance when, identifying an issue with any
one of the system, then the control room shut downs the specific
equipments/systems for maintenance and repairs. All the operations are
connected to the control room.

5.3 Summary
The de-agglomeration/Wash plant process basically involves the separation of larger boulders, rocks and
also chips and dirt. The whole Idea of this operation is basically do material screening and converting
mineral containing soil into slurry. The waste rocks as an over feed of the ore bin, trammel, log washer
and vibrating screen is reused in the construction of pit berm, pit road and also camp building
foundations. The process is continuous 24 hours. The wash plant only shut down when there is a
maintenance issues along the main pipeline system to Basamuk or if the basamuk processing plant is
undergoing maintenance, others the process is continues whole year round in respect to the production
target.
CHAPTER 6. BENEFICIATION PLANT

Slurry from the de-agglomeration plant (wash Plant) is pumped to the beneficiation for further
separation, chromate extraction and thickness treatment before being pumped to Basamuk for Nickel
and Cobalt extraction. In this Phase of operation there are two sub-phase operation which are Chromate
separation and Slurry Thickness Treatment.
Slurry from
washing plat
Fig.6.The Beneficiation Plant Operation and Process (Green colored Boundary)

6.1 Chromites Separation Process
The Chromate Separation and Operation Process inclusively utilizes equipments such as Hydro cyclone,
Spiral Concentrator, shaking table, Ball mill Crasher, Magnetic Separator, Submerged Spiral Classifier and
series of pumps to separate chromate from the mineral content slurry. Also by this operation the
granular materials are further grinded to fully slurry ingredient. The chromate are then stockpiled and
transported to Lae via trucks, for exportation.
Fig. 2.1 Chromate Separation Process Phase

6.11 Equipments Utilized in Chromate separation Process
Table 6.2 Chromate Separation Equipment
No Equipment(s) Equipment(s) Operational Standby

Size
1 Hydro Cyclone Classifier 3 3 0
2 Spiral (Vertical) classifier 26 26 0
3 Shaker Table 104 52 52
4 Magnetic Separator 3 2 1
5 Submerge Spiral Classifier 2 1 1
6 Ball Mill (Crusher/Grinder) 1 1 0
6.2 Slurry Treatment and Thickening

This phase the beneficiation operation involves final screening of slurry, flocculent preparation, slurry
thickening, slurry storage and pumping system to Basamuk (BSK) for processing. The flow chart below
gives clear insight of the process of slurry preparation.
Fig. 6.2 Slurry treating and thickening flow chart

6.3 Summary
Beneficiations operation is an inclusive of two phase operations;
1. The chromites separation phase. Since chromites are abrasive material, it has a risk concern on
the pipeline system thus it needs to be separated and only the Ni-Co slurry is transported to
basamuk. The Chromites separations process is quite similar to that of the alluvial operations,
but slightly different as separation is based on density, weight and magnetic properties of the
chromites. The separation is achieved through utilization of equipment such as hydro cyclone
classifier, spiral concentrator, shaker table, ball mill and magnetic crusher.
2. The second phase is basically final screening of slurry and thickens before the slurry is being
pumped to basamuk for further chemical separation of Nickel and Cobalt. The thickening of
slurry utilizes the flocculent to basically grip the slurry together so that it ease the flow ability
process throughout the pipeline to avoid any cluster and deposition of the material that will
leads to the pipe blockage. In addition, Heavy duty vibrating screen and series of heavy duty
pumps are used for the final screening and pumping mechanism for the slurry transportation.
CHAPTER 7. HEALTH SAFETY AND ENVIRONMENT (HSE)

Health Safety and Environment (HSE), is an obligatory established division that overlooks the safety and
environmental compliance of the Ramu Nico operation. The HSE department in KBK is made up of two
Sub-sections, the Safety and the environment.
7.1 Health Safety

The health safety is responsible for the safety employers in the work place. The safety sections monitors
the operations daily to identify hazards and risks the operation is posing to the workers and do reports
and recommendations on the mitigation and rectifications of this hazards and risks. Safety officers also
monitor and ensure safety is paramount and is adopted by every worker in term of PPE’s , seatbelts,
traffic rules and etc., are of optimum compliance and also necessary compliance such as Job Safety
Analysis (JSA), Good to Go (G2G) and Golden Rules and met throughout operations.
7.2 Environment
The environment section monitors the safety of environment and the surrounding environment in
compliance to the regulation set by CEPA. The Environment Department at KBK asses’ environmental
risk imposes by the mine to the surrounding environment like sedimentation deposit down slope. The
sector also do rehabilitations plan for the mine reclamation and closure plan.

CHAPTER 8. SUMMARY
The operation at Kurumbukari in the Usino-Bundi District of Madang province is a shallow mining
operation that applies Hydro sluicing and Conventional open pit operation. The economic Mineral of
interest mined is Nickel, Cobalt and Chromate as by product. The operations are basically mining and
physical separation process. The ore is mine then it is screened in the process of washing and solid
convention to slurry. The slurry is further screen and chromate is separated from the slurry then the
slurry is treated with flocculent to thicken it in order to avoid abrasion and cluster in the pipeline
throughout the transportation pipeline to Basamuk refinery. The Operation is run by Ramu Nico MCC
management, which is a Chinese national owned company.
Fig.8. Summarized Mine Flow Chart of all mining and processing operations at KBK

CHAPTER 9. APPENDIX
Enclosed in the appendix section is the weekly based report of the various sections which the
observation and training was carried out during the 6 weeks time frame of the industrial training. The
sections which the full training and reporting was done and enclosed in this chapter of this report
include;
1. Hydro Mine Operation

2. Mining Operations – Mine Division
3. Washing Plant operation
4. Beneficiation Plant Operations
Additionally, Pit access road safety assessment report which was carried out as part of job training is
also attached in this section/chapter.
Appendix Content
1. Appendix. A: Compiled Recommendations

2. Appendix. B: Training Schedule
3. Appendix. C: Hydro mine week based Report
4. Appendix. D: Mine Division week based Report
5. Appendix. E: Washing Plant week based Report
6. Appendix. F: Beneficiation Plant week based Report
7. Appendix. G: Pit Road Safety Assessment Report-Mine technical Service
8. Appendix. H: Safety Training Recommendation

KBK 2022
Proposed Recommendations
Proposed By: Jyrus Bayuve (Trainee Engineer)
Mine Technical Services
Date of Observation: 14/11/2022 – 24/12/2022
Date Submitted: 28/12/2022

Contents
1. EXECUTIVE SUMMARY ........................................................................................................................ 3
2. Hydro Mine......................................................................................................................................... 4
3. Mine Division (Conventional Mine Operation) ................................................................................... 6
4. Washing Plant..................................................................................................................................... 7
5. Beneficiation Plant ............................................................................................................................. 9
6. Summary ............................................................................................................................................. 12
Proposed Recommendations Page 2

1. EXECUTIVE SUMMARY
The ultimate aim of the mining operations is to improve the production, optimize recovery and minimize
operational and maintenance cost and to provide safe and risk free working environment. The aim can
only be achieved with effective short- medium term planning. The planning delivers basic scheduling
and designs that will improve the production and operation, while minimizing the cost related
simultaneously in an inversely proportional manner. The Maintenance and operation cost increases
when there’s a lack in improvements of the operation and this obviously leads to the profit loss of the
company.
The proposed recommendations are based on a weekly observations carried out on;
I. Hydro Mine (Pit 12 / 19)

II. Mine division ( Conventional mine Operations)
III. Washing plant
IV. Beneficiation Plant

2. Hydro Mine
Based on the one week observation of Hydro mine operation at pit 12, KBK, the following
recommendation were proposed, at least to improve the production and operation and also will reduce
continuous maintenance and operational cost.
I. Geo Mat slurry drainage system
Setback Observed:
Distance is directly proportional to deposition of mineral slurry and inversely proportional to the mineral
recovery rate at slurry pond. The Longer the distance of travel, the high grades are deposited along the
drainage system due to their weight and density properties. That is inclusive of chromates as well.
Solution Proposed:
Installing of Geo mat, specifically Geo-Drain Quattro fabricated mat to the drainage surface. The mat will
act as a slurry guide and will avoid the slurry from being deposit along the drainage system. Considering
the Geo-Drain properties, the polymerized and thick surface will be prone to the chromate frictional
surface and can be reused when shifting mining to new pit after mining the existing pit.
Benefits:
This will improve the recovery rate of nickel, cobalt and also chromate and also increased the
production target annually.
Geo Mat Type proposed:
Thick polymerized
surface
Fig. 2.0 Geo-Drain Quattro

Fig.2.1 Over view of Geo-Mat Drainage Profile
Fig.2.2 Geo-Mat Installation Profile

In addition to the Geo-mat slurry Drainage, other areas of the Hydro mine that needs improvements
includes;
II. Re-introduce remote water cannon. This will optimize production by estimated 80% and will
reduce labor cost and also reduce accidental risk during rainy season.
III. Replace steel pipes with hose. This will ease connection and transportation and also reduce the
down time or the connection time.
IV. Compose weekly plan and schedule for the operation of respective pit. Composing of weekly
plan and proper schedule of production pit will help increase the production as down time and
overall operation will be based according to the plan, thus helps the supervisor to provide a
weekly report of the production based on the plan. This will reduce production down time
caused by unplanned relocation of pumps and water guns.
3. Mine Division (Conventional Mine Operation)
Find below are the suggestions which have been proposed during the observation on the conventional
mining operation.
I. Choosing the shorter route for ore hauling.

The shorter the route will save fuel cost and also increase the production hauling, thus increased
the production target. Also this will reduce the trucks down time for maintenance.
II. Schedule 3 trucks for each excavator at each active pit that is closer to the ore bin.
This is to speeds up the loading and hauling of the ore in reference to the time (if any allocated).
The operation will of: one truck load, the other haul and the other doing return trip and the
cycle continuous. Since the distance to the ore bin is shorter, the operation will be effective.
III. Schedule more than 3 trucks for each excavator that is further away from ore bin such as pit 21.
This is basically based on the conventional mining procedure, stating: assign more trucks to the
operation in relation to the distance, for effective operation.
IV. Upgrade and Install Full GPS monitoring system for each excavators and appoint full monitoring
team that can monitor each truck so the truck abides by the scheduling routes .This will reduce
the unnecessary stopping and misuse of the trucks during the working hours.
V. Night operations should be well monitored in terms of loading and Hauling counts, and also
improved the miscount system of the truck.

4. Washing Plant
Setback Observed :
The wash operation is slightly not effective due to the unplanned down time and maintenance of the
equipments such as wash trammel and feeder. Since there is no scheduled maintenance time for the
operation, the production is slightly affected when two or more equipments are under maintenance.
Proposed Solution:
Below is the proposed planned scheduled for the equipment, which illustrates the downtime and
maintenance period of the specific equipment at one time daily. The recommended schedule below is
based on a week based observation of wash plant‘s daily maintenance activities.
I. Daily schedule for inspection and Maintenance on Trammels, Apron feeders and log Washers
Table 4.1 Proposed daily schedule for inspection and Maintenance on

Trammels, Apron feeders and log Washers
Key: I & M = Inspect & Maintenance

Remarks
The inspection and maintenance should be carried out in reference with the standard operating
procedure of the individual equipment which is to be undergoing inspection and maintenance. The
proposed schedule will keep records of daily inspection and maintenance and also will optimize the
operation and production by allowing 3 series of equipments running at very one time while the other 1
series undergoes inspection and maintenance at that one time every hour.

II. Daily schedule for Inspection and Maintenance on vibrating screen and conveyors
Table 4.2 Proposed daily schedule for Inspection and Maintenance

on vibrating screen and conveyors
Key: I & M = Inspect & Maintenance

Remarks:
For the vibrating screen and conveyor system, not necessarily needs maintenance every hour, however
inspections on the equipment’s components such as screen sieve/size, motor, spring, conveyor belt and
conveyor motor is vital at every 3 hours daily. This will help indentify down time and also reduce
maintenance time to keep production on going. Maintenance of the vibrating screen and conveyors
components will reduce the down time and also optimize their working capacity effectively.
Recommendation Summary
The wash plant has been in operation for over a decade since the beginning of production and it is one
of the key operations that aids to the recovery process of the mineral mined. The equipments used in
the ore phase are very vital for inspection and maintenance as it is what makes up the wash plant.
However, during the one week observation of the wash plant operations, the equipments are not on
schedule for inspection and maintenance. Therefore, the schedule proposed above, is believed to be
effective and will have the operation in order in terms of maintenance, and will reduce the down time
and will significantly reduce the maintenance cost.

5. Beneficiation Plant
I. Shaker table catchment pocket
Setback identified 1.
There are two catchment pockets for the material passing the shaker table. This has lead to the loss of
the Ni-Co which most of these materials are caught in the chromate catchment pockets. This leads to
the dilution of chromate thus result in both chromate and Ni-Co loss.
II. Shaker Table setup
Setback identified 2.
The main reason for the problem 1 is shown in the problem 2 pictured the shaking table being setup at
0o inclination angle.

Setback summary
According to the Standard Operating Procedure of Shaker table, the working specification and setup
specification mentions that all shaking table should be positioned/setup at a working inclination angle
rage of 5o – 10o in reference to the horizontal plane. The angle range of 5o – 10o is adjustable only within
that limit range for optimum recovery of material or ore feeds. Therefore it is believed that the problem
Identified at 1 is basically due to the problem identified at 2.
Proposed solution
The proposed deign for the addition catchment pocket for the material containing Ni-Co and chromate
which will be at the lower center of the shaker table discharge edge.
 Possible shaker table modification (design) by adding catchment pocket (2) for capturing the
Chromate, Ni-Co slurry
Fig.5.2A Proposed modification design on the shaker table catchment pocket

 Possible shaker table setup at adjustable incline angle range of 5o - 10o basing on the Operating
standard.
Fig.5.2B Proposed design setup of the shaker table based on the shaker table
working specifics (SOP)
Recommendation Remarks
Based on the standard operating procedure of the shaker table, if the above proposed
recommendations are taken into considerations, the separation of feed through shaker table will be
very effective so thus will the waste be minimized and the production will be optimize.

6. Summary
The recommendations were based on a weekly observations carried out during the 6 weeks training
period. The recommendations that are proposed are basically to;
 Improve the operation

 Improve the recovery of Mineral (ore)
 Reduce the maintenance cost of both equipment and plant
 Shorten the down time of equipments
 Optimize various process such as wash plant and beneficiation
 Meet the mine target in shorter period
The recommendations that are proposed are of basic improvements which the operation overlook and
are not attend to or are seen as minor, however it has invisibly cost the operations over a period of time
and thus needs improvements if the mine is in favor to optimize and improves its production and
operations.

RNML
2022
[HYDRO MINE REPORT-KBK ]

The report analysis and recommendation captured in this document where through
one week observation at the hydro mine site, specifically Pit 12. This report
contains contents of hydro mine operation in Kurumbukari mine site.
.
Report Produced By;

Jyrus Bayuve – Trainee Engineer (Mining)
Duration of Observation: 20th November to 25th November, 2022

th
Date of Submission: 28 November, 2022
Hydro Sluicing Mine @ KBK, 2022
I. Acknowledgements
I would like to take this time to acknowledge the hydro Mine superintendent Mr. Gao and his assistant
Mr.Liu for having me in their section for a week. I would also like to thank and appreciate the local hydro
miner’s leader Mr. Paias Ayenas and assistant, Mr. Mathew for guidance and training that were thought
through hands on experience. Not forgetting all the Day crew of Pit 12 , thank you and I wish you all
safe and optimum production in mining pit 12.
II. Declaration
This report was based on the daily observation and experience during the one-week observation at pit
12 and there are no assumptions or any other information, except where stated otherwise by reference
or acknowledgment, the work presented is entirely based on my own observation.
Approved By;
…………………………………………… ……………………………………………
Mr.Gao Zhiling Mr. Paias Yanes
Hydro Mine Superintendent Hydro Mine Crew Leader (day shit)
2|Pa ge
[By Jyrus Bayuve-Trainee Mine Engineer, 2022]
Content Page
1. Background ........................................................................................................ 4
1.1 Hydro sluicing at KBK ........................................................................ 4
1.2 Task .................................................................................................. 5
2. Operations.......................................................................................................... 5
2.1 Working crew/personals.......................................................................... 6
2.2 Fleets & Equipment............................................................................ 6
3. Production .......................................................................................................... 7
4. Summary ............................................................................................................ 8
5. Recommendation ............................................................................................... 8
6. Appendix ............................................................................................................ 9
3|Pa ge
1. Background
Hydro sluicing is a surface variation mine technique, which

water is shot at high pressure to the deposit face to cut and
crush the mineral contained soft rocks and soils and
converts them into slurry/mud from which ore recovered
from (USGS, 2005). The method of water sluicing has been
used in centuries, where early gold rushers used water to
flash out gravel and sand in order to obtain alluvial Gold in
the late 80’s.
1.1 Hydro sluicing at KBK

The hydro sluicing mining technique was introduced at pit 2 as trial operation in 2014. According to the
RNML KBK Mine OHS Year Book (2017), the mining operation at pit 12 commenced in late 2015 and by
mid 2016 a remote control cannon (gun) was introduced, which improves the production and safety.
The operation fully utilize the remote water gun/ cannon in year 2017 as well which increases the
production and reduces the cost and risks associated in the sluicing operation.
The hydro sluicing operation at KBK is carried out in a way

that the ore is blended during the operation. During the
mine development phase, overburden stripping of humic
and red limonite are done and dumped in the gullies which
are then reclaiming to be used for rehabilitation of a mined
out pit. Based on the mineralization geology of the deposit,
it is shown that the Humic and red limonite has a low Nickel
(Ni) and high aluminum (Al) content, while the grade of
nickel increase down the depth through yellow limonite and
Rocky Saprolite 1 and 2. Based on that understanding, the
setup of water cannons /guns was made in order to mine
the ores bodies, which the blended ore slurry are produced.
Fig.1.1 Deposit phase
The slurry are transported through drainage system and is captured in the slurry pound 0.5 -1 km away
from the mining site. The production at slurry pond is structured in a way which, slurries are captured
within an hour and is pumped every 5 minutes into another hour to the beneficiation plant, and then it
captured the slurries for the next hour. The process continues for 8 straight hours then the next shift
carries on into another 8 hours and the cycle continues until the whole pit is mined out.
4|Pa ge
1.2 Task
Observe the hydro sluicing operation and production (location- Pit 12) for a period of 6 and a half days
and compile a week observation based on daily observation report regarding the Hydro sluicing
Operation at KBK.
2. Operations
There are two areas that are currently operates using hydro sluicing method and they are pit 12 and pit
19, also this sites are called Hydro mine site. The hydro mining at pit 12 operates with a crew of 14
personals, 2 excavators, 10 water gun and 3 mechanize assisting pump. The operations were scheduled
for 12 hours per shifts (day and night). The hydro mine consist of both water sluicing and excavation
stone washing. Where there’s exposed rock beds, the excavators were used to excavated and then
water is applied to the excavated soil/rocks for washing and conversion of soils/soft rocks in to slurry,
this type of mining operation is called stone mine by the Hydro sluicing miners at KBK.
Water Guns/cannons
Stone mine- Rock washing
Water hose
Slurry flow
Fig.2. Pit 12 hydro mine
5|Pa ge
2.1 Working crew/personals

The crew consists of 14 working personals for each shift. The
crew is overseeing by team leader, who do prestart checks,
monitors and relay information from the supervisor and
superintendent to the crew and report back or updates the
supervisor and superintendent of the operation and production
stability. The maintenance crew does necessary service to the
excavator and pumps during the prestart checks, before the
operation commences during initial hour of shifts. The pipe
connectors connect water pipe prior to the relocation of pumps
or water guns to ease the operation. Fig. 2.1 Connecting pipe from the pump
Table 2.1 Working crew summary for pit 12 and 19
Pit /site Number of Shift Crew summary

Crews
12 12hrs/shift (day/night) The crews of 14 miners consist of ;
16  team leader and his assistant
 2 maintenance personals,
 4 water gun operators
19 8 hrs /shift for 1 shift (day)
 3 excavator operators
14 crews
 3 water pipe connectors
2.2 Fleets & Equipment

The fleets of equipments that facilitates the operations for both pit 12 and pit 19 consist of 14 water
cannons, 5 excavators, and assistant mechanized pumps that helps increase the water pressure for
optimum water mining of ore body. The table below displays brief summary of fleets, however this were
the fleets available during the observation week, and might increase or decrease do to the operation
and downtime.
Pit Number of Fleets Fleet summary

/site (Equipments)
3 Excavators 8hrs/shift for 2 shift Both Operational
(PC 300) (day/night)
10 water Guns 8hrs/shift for 2 shift 4 Operational, 6 maintenance &
12 (day/night) Standby
3 Mechanize 8hrs/shift for 2 shift All operational
Hydro pumps (day/night)
3 light vehicles 8hrs/shift (day) All operational
(LV)
6|Pa ge
19 2 Excavators 8hrs/shift for 2 shift Both Operational

(PC 300) (day/night)
4 water Guns 8hrs/shift for 2 shift 3 Operational, 6 maintenance &
(day/night) Standby
3 Mechanize 8hrs/shift for 2 shift All operational
Hydro pumps (day/night)
8hrs/shift (day) All operational
Fig.2.2.0 Water pump Fig.2.2.1 PC 300 Excavator
3. Production
The production of the Hydro Mine undergoes a continuous process within 24 hours, 7 days a week, until
the targeted pit is mined out completely. The slurry in the slurry pond is stored within an hour and is
pumped to the beneficiation plant as a bulk within same hour thus, gives an estimated hourly
production rate. According to the Hydro mine superintendent, Mr.Gao Zhiling, the monthly production
rate is of about 35% compared to the 65% conventional mine monthly production. There is no proper
plan that governs the operation so far in terms of water Gun location, pump down time, excavators
down time, pit section mining plan, however the mine is run on iterations of the productivity, hence the
equipments are relocated around in achieving optimum production per day.
7|Pa ge
4. Summary
mining phase and transportation via slurry has save the cost of washing plant and also hauling cost. This
helps recover the investment cost within a short period of time. The usage of manual water cannons is
very effective however is very risky when operation is at rocky area and also rainy seasons, thus to ease
the operation and mitigate this issues, it is much better to reintroduce remote water cannons, despite
cost.
5. Recommendation
Based on the one week observation of Hydro mine operation at pit 12, KBK, the following
recommendation were proposed, at least to improve the production and operation.
I. Re-introduce remote water cannon. This will optimize production by estimated 80% and will
reduce labor cost and also reduce accidental risk during rainy season.
II. Replace steel pipes with hose. This will ease connection and transportation and also reduce the
down time or the connection time.
III. Compose weekly plan and schedule for the operation of respective pit. Composing of weekly
plan and proper schedule of production pit will help increase the production as down time and
overall operation will be based according to the plan, thus helps the supervisor to provide a
weekly report of the production based on the plan. This will reduce production down time
caused by unplanned relocation of pumps and water guns.
8|Pa ge
6. Appendix
This section of the report contains actual daily activities and hands on experiences attained throughout
the one-week of observation at pit 12.
Day/date Task/ training Summary

attained
Before commencing of the operation prestart
checks are carried out on all equipments and
6:30 A.M/P.M Prestart Check analyze their productivity and availability.
Also basic service like fueling, oiling, pump

rechecks and water hose connection
assessments.
Introduced to the hydro mine crew, and overall

introduction and orientation of the hydro mine
Monday Orientation, operation by superintendent Mr.Gao.
observation and
21/11/22 SOP review Do overall observation on the operation, pump
location, water gun station, pit view, and overall
pit 12 maps. Also done Standard operation
procedure of equipment to familiarize with their
operation capability.
Tuesday Operates water gun under supervision of skilled

Observe and operator, Mr. Clement Yawai, and mine an ore
22/11/22 Operates water Gun body west of pit12.
Wednesday Refueling pump generator, excavator and helping

Service and out basic equipment servicing. Also do
23/11/22 refueling maintenance on a pump with the maintenance
crew.
Assisting the pipe connecting crew to

Thursday Disconnecting and connecting of pipes prior to
the relocation of water gun.
24/11/22 Pipe connecting
Also pipes from the mined out area were
disconnected and was transported by excavator
to the site office for storing. Where there’s a need
of extending pipes then the pipes are used.
Friday Monitoring stone mine along with assistant Crew
9|Pa ge
leader, Mathew. Basically, stone mine is usually

25/11/22 Monitoring stone monitored, as both excavator and water gun is
mine used to mine the ore body. This is to instruct or
be a spotter of the operator to avoid accident to
the water Gun operator.
Finalizing of week’s report and compiled a

Saturday complete report for submission to the Hydro Mine
Finalize week report Superintendent
26/11/22
Fig.6.1 Water Gun Operation
Fig.6.2 Reconnecting pipe to the pump
10 | P a g e
Fig.6.3 Operation at West of Pit 12
Fig. 6.4 Overall map of the mining pits
11 | P a g e
KBK 2022
Conventional Mine Report – KBK Mine Operation
The report, analysis and recommendation captured in this document were

through one week observation at the Mining Division. The contents of this
report are specifically based on a week observation.
Date of observation: 28/11/2022 ----------03/12/2022
Report Produced By: Jyrus Bayuve – Trainee Engineer (Mining)

Mine Division (Mine Ops), 2020
A. Background of Conventional Mining

Conventional mining is a mining method in which ore body is mined then is loaded and hauled to the
crusher or stockpile for further crushing and processing.
Drill &
Blast
Dumping Loading
Hauling
Fig. A. General Conventional Mining Process
B. Conventional Mine Operation at KBK
of the surface. The mining direction applies top down mining method. The Mining does not involve
conventional drill and blast, however mineral of interest is excavated in an shallow open pit structure.
Excavation
Dumping Loading
Hauling
Fig. B. Conventional Mining Process at KBK
Jyrus Bayuve-Trainee Mine Engineer | Background of Conventional Mining 2

Contents
A. Background of Conventional Mining ................................................................................................ 2
B. Conventional Mine Operation at KBK ............................................................................................... 2
1. Introduction ...................................................................................................................................... 4
2. Mining Division.................................................................................................................................. 5
2.1 Mine Development Unit ........................................................................................................... 5
2.10.1 Stripping ................................................................................................................................ 6
2.10.2 Mine Development Fleets ..................................................................................................... 6
2.11 Conventional Mining ................................................................................................................. 7
2.12 Active Operational Pits -2022 ................................................................................................... 8
2.12.1 Mine Operation Fleet ............................................................................................................ 9
2.12 Ore Bin Unit............................................................................................................................... 9
2.13 Dispatch or GPS Unit ............................................................................................................... 10
2.14 Emergency Response Team .................................................................................................... 10
3. Summary ......................................................................................................................................... 11
4. Recommendations .......................................................................................................................... 11
Jyrus Bayuve-Trainee Mine Engineer | Conventional Mine Operation at KBK 3

1. Introduction
The conventional mine division oversees operations under sub-divisions such as;
I. Conventional mining operation

II. Dispatch Unit & GPS Operation
III. Ore bin Unit
IV. Emergency Response Team/Unit (ERT)
V. Mine Development Unit
The general working specifics of the mine division is to develop a mine by establishing logging and
vegetation clearance, overburden stripping, pit and access road construction, and mining using the
excavators and haul trucks. Also oversees truck and excavator scheduling and monitoring operations.
The mining operation is based on the designs constrains compiled by the Mine Technical Services and
Geotech/Geology departments. The ore is mined based on the pit sample assays by the geologists,
which follows the short term mining (daily) plans to optimize the blending of ore during the operation so
the blending is recovered at the optimized level. Ore that is mined is hauled to the ore bins where it fed
the ore to the wash plant and undergoes washing and separation of rock basing on their sizes.
Mine
Development
APD and ERT

Mining Dispatch &
Operation GPS
Ore Bin
operation
Fig.4.1 Mining Operations
Jyrus Bayuve-Trainee Mine Engineer | Introduction 4

2. Mining Division
The mining division or section consist of subsection, which basically assist in the entire mining operation,
for both Hydro mine and conventional mine. The subsections that made up mine division are; Mine
Development Team, Dispatch or GPS Unit, Ore Bin Unit Emergency Response Team.
2.1 Mine Development Unit

Before excavation of the ore, the mine development team clears the area by cutting down trees and
clearing up the land by excavating the top soil (Humic soil). Also the development team establish
necessary infrastructure like, access roads, haul roads and transit site office for the mining operation to
commence.
Table 2.1 Mine Development operations ( KBK Probation Report, 2021)
Development operation Unit

Main Haul Road System m
Feeder and Access Mining Roads m
Mining Benches m3
Land clearing (logging & vegetation clearing) m2
Top soil and overburden Stripping m3
Rehabilitation m2
Cleared land through; Newly cleared area

- Logging Pit Road (Logging)
- Vegetation clearance
constructed
- Overburden stripping
Fig.2.1 Mine Development operation by mine development unit
Jyrus Bayuve-Trainee Mine Engineer | Mining Division 5

2.10.1 Stripping
According to the 2021 KBK Probation summary report, overburden stripping is done/carried out
in two ways;
I. When over burden is less than 2m, bulldozers are utilized for stripping.
II. When the overburden thickness is greater than 2m, excavators and trucks are utilized
for overburden stripping
Table 2.10.1 Stripping face parameters (KBK probation report, 2021)
2.10.2 Mine Development Fleets
The mine developers utilize machines equipments such as chainsaws, Dozers and excavators to execute
the development phase of the mine. The lists of fleets are listed in the table below.
Table 2.11 Mining Development fleets (KBK probation report, 2021)

2.11 Conventional Mining

of the surface. The mining direction applies top down mining method. According to the Mine Probation
Report, 2021, the design height of working benches ranges from 3m – 5m, with bench face angle of 65°.
There are two types of working benches; combination benches (2-3 benches) and single bench.
Combination benches are used for continuous mining when the surface slope is greater than 15° or
when the ore body thickness is greater than 15m.
The mineral of interest is contained in the soil.

The mineral soil contains famous elements such
as Aluminum, Magnesium, Nickel, Cobalt, and
compound chromites which is a compound of
Iron Magnesium and Chromium. However, the
5m
mineral of interest is Nickel and Cobalt. Since the
mineral Nickel and cobalt are found in soil, the
mine is said to be soft rock mining, thus no
drilling and blasting operations are not performed
at KBK mine operation. The unique KBK mining
operation involves excavation, loading, hauling
and dumping.
Table 2.13 Mine surface Parameters

(KBK, 2021)
Fig.2.2a Conventional mine chart Fig.2.2b Conventional loading of Ore

2.12 Active Operational Pits -2022
 Currently active pits are pit 11 and 21

 Pits currently undergoing stripping phase based on the geotechnical design constraints 11,
13, 14, 15, 16, 17, 18 and 20
 Pit 12, 16 and 19 are mined using Hydraulic mine. (Note: Pit 16 was initially mined using
hydro-sluicing but is now planned and scheduled for conventional mining method.)
Fig. 2.12 Currently operating pits
Fig.2.12. Actively operating pits map pointing out boundaries of current operations

2.12.1 Mine Operation Fleet

The fleets responsible for the mining operations have been increasing recently to meet the optimum
annual target of the production by optimizing the operations. The fleets of equipments can be
categorized into primary and secondary fleets. The primary fleets are equipment responsible for mining
operations while the secondary fleets are the assistance fleets facilitating the service and maintenance
to ease the production and operation of the mine.
Table 2.13a Primary fleets (KBK Probation Report, 2021)
Table 2.13a Secondary/Ancillary fleets (KBK Probation Report, 2021)
2.12 Ore Bin Unit

The ore bin crew monitor the operation at ore bin, making sure there no over that it runs smooth, for
instance if there’s a problem at the wash plant the ore bin crew shut down the particular ore bin till the
problem is fixed. Also they monitor the material accumulation at ore bin. If the ore been is full the crew
instruct the trucks to dumped the ore at the stock pile, and if it is empty or if the pit production stops,
then the ore from the stock piles are then fed to the ore bin to maintain the overall production. There
are four (4) ore bin altogether, which operates simultaneously.

2.13 Dispatch or GPS Unit

The dispatch or GPS unit monitor the overall operation of both Hydro and conventional mining. For
instance, the allocation of Volvo haul trucks to the excavators per pit, the allocation of water sluicing
gun to achieve blended ore slurry, and also monitoring the trucks speed and cycle time via GPS. The
dispatch unit also monitors the beneficiation process. The team consists of office crews who monitor the
operations via computers and GPS, and ground crews which actually travel from pit to pit to monitor the
operation of the conventional mining.
Fig.2.4 Dispatch/GPS Monitoring office
2.14 Emergency Response Team
The emergency response team (ERT) is established/setup to respond to emergency calls such as
accidents or fire hazards and also to monitor speed of the light vehicles within the mine areas. Also the
ERT assist in the Assert Protection Department (APD) in safe guarding the company’s properties. The
actual APD operations are carried out by the Mobile Squared of RCPNG which oversees whole mine
security and protection.

3. Summary
The week observation with mine division involves:
 Going through standard operation procedures (SOP’s) of loaders, graders, excavators, fire
trucks, Volvo haul trucks chainsaws, water trucks and ERT operations.
 Active operational pit visitations and site seeing
 Observing excavation, Loading ,Hauling and Dumping operations of the conventional mining
phase
 GPS monitoring of the excavators, front loaders and haul trucks
 Monitoring Ore bin operations
 Mine development Standard operating procedure briefings
 Dispatch operations of the entire conventional mine phase
4. Recommendations
Since the mining division covers lot of sub-departments, one week is not enough to observe and done
recombination based on these observations for all the sub-departments, however much concentration
of the observations were diverted to the conventional mining phase. Find below were the basic
proposed suggestions which has been overseen throughout the conventional mining operation.
 Choosing the shorter route for ore hauling.

 Schedule 3 trucks for each excavators at each active pits that is closer to the ore bin
 Schedule more than 3 trucks for each excavator that is further away from ore bin such as pit 21.
 Upgrade and Install Full GPS monitoring system for each excavators and appoint full monitoring
team that can monitor each truck so the truck abides by the scheduling routes .This will reduce
the unnecessary stopping and misuse of the trucks during the working hours.
 Night operations should be well monitored in terms of loading and Hauling counts, and also
improved the miscount system of the truck.
The operation can be seen as effectively working due to the fact that production targets are met
monthly; however the above recommendations can improve the production and reduce the production
and equipment maintenance cost.
Jyrus Bayuve-Trainee Mine Engineer | Summary 11

KBK 2022
Washing Plant Report – KBK Mine Operation

through one week observation at the Washing Plant . The contents of this report
are specifically based on a week observation.

De-agglomeration (Wash Plant), 2022
Contents
1. Introduction .......................................................................................................................... 3
2. Operations ............................................................................................................................ 4
 Major operating systems/equipments ................................................................................. 4
2.1 Heavy duty Apron Feeder ................................................................................................. 4
2.2.1 Drum washer Technical Summary .................................................................................... 5
2.3 Log washers ...................................................................................................................... 5
2.4 Vibrating screens .............................................................................................................. 6
2.5 Conveyors ......................................................................................................................... 6
2.6 Heavy duty pumps & slurry Pipeline ................................................................................ 6
2.7 Slurry storage Tank ........................................................................................................... 7
2.8 Back water Dam................................................................................................................ 7
2.9 Office & wash Equipment control room ........................................................................... 7
2.10 Stock piles ......................................................................................................................... 8
3. Wash plant crew ................................................................................................................... 8
4. Summary............................................................................................................................... 9
5. Recommendation ................................................................................................................. 9
5.2 Recommendation summary .................................................................................................. 10
6. Appendix............................................................................................................................. 11
Jyrus Bayuve –Trainee Mine Engineer | 2

1. Introduction
The wash plant which is also known as the Ore De-agglomeration plant plays an important
role in the 3 phase separation of the material from the conventional mining and also 3rd
phase separation from the hydro sluicing mining. The material/ore from the conventional
mining is fed through the 4 ore bins which separate large boulders. The medium size rocks
with soils are then passes through the 4 heavy duty apron feeder, which assists the materials
into the 4 trammel washer drum. From the trammel washer drum, the 2nd phase separation
of medium rocks is separated from the chips. The slurry and chips are then fed through the 8
log washers. The log washer separates chips from sands, and then it passes the sands and
slurry to the slurry storage tank 3, while the chips are discharge through conveyor 2. From
tank 3, slurry is pumped back to vibrating screen 1, also the slurry from the hydro mine is fed
to the vibrating screen 2. From the vibrating screen the 3rd phase separation took place,
which the dirt and granular sands are screened out from the slurry. The slurry is then piped
to the slurry storage tank 1 and 2 which then pumped to beneficiations. The granular sand is
then discharge via conveyor 4.
Fig.1. De-agglomeration (Wash Plant) Operations (Blue Border)
Jyrus Bayuve –Trainee Mine Engineer | Introduction 3

2. Operations
Wash plant operates 12 hour shifts during day and night. The morning shift starts at 6:30 am
and ends at 6:30pm, from which the night shift starts at 6:30pm and ends at 6:30 am, and
the shift cycle continuous. The down time of the machines or system is depending on the
maintenance, which one system is stopped and maintained while the other three operates.
The total shutdown is depending on the maintenance at Basamuk Plant or beneficiation,
then there’s a complete shutdown of the wash plant.
 Major operating systems/equipments

1.0 Ore Bin
The ore bin facilitates the feeding of materials to the apron feeder. The material ore from the
pit and also from the stock pile are dumped direct into the ore bins which the ore bin act as a
hopper that assist the ore to the apron feeder. There are total of four (4) ore bins at the
de-agglomeration plant. The ore bins are monitored by mine division. If there is more
materials at the ore bin, then the ore bin is closed and the trucks that allocated to the ore
bin is redirect to the nearby stockpile. The ore bin operation is assisted by the three
excavators which do the first screening of larger materials or boulders. The retaining
boulders and rocks are used in the construction such as; safety berm, pit road, sediment
Catchment pond and etc...
Fig. 1.1 Ore Bin area (circled-red)
2.1 Heavy duty Apron Feeder

Apron feeder is used for feeding material continuously to the drum washer. The apron feeder
adopts the behavior of the adjustable frequency device to adjust feeding rate of the apron at
the adjustable speed range of 0.025-0.05 m/s. There are 4 apron feeder connects to 4 ore
bins and drum washer respectively.
Table1.1 Apron feeder Specification

Plate width 1800 mm
Sprocket base 9500 mm
Capacity 350 t/h

Material Bulk D 1.4 – 3.54 t/m3
Power rating 45KW
Jyrus Bayuve –Trainee Mine Engineer | Operations 4

2.2 Drum Washer (Trammel)
There are 4 drum washers connected to the apron feeder and also log washer and conveyor.
The drum washer established a rotational motion as materials fed from the feeders are
washed using water as the drum rotates in revolutions. The larger materials of size greater
the 75 mm are discharged onto a conveyor #1, while the slurry and material size less than 74
mm are passed to the log washer during the process of washing. The simple diagram below
describes the wash drum specifics.
Anti-clock wise
rotational
motions
Fig1.3. Long sect. view of a Drum washer Fig.1.31. Front view of the Drum washer
2.2.1 Drum washer Technical Summary

Drum washers operates in a rotational manner at an adjustable velocity while the
materials fed from the feeder are washed and also screening of lager rocks greater than
75mm are removed and discharge onto a conveyor 1. The overall operation of a drum
washer is similar to the alluvial Gold Trammel.
Feeding water pressure is about >0.3Mpa
Feeding water volume is about 749 m3
2.3 Log washers

The log washer contains a spiral plate that moves in a rotating motion separating chips from
the slurry. For every wash drum, there are two log washers connected to boost the
separation process. Materials of size less than 74 mm which are under screened from the
drum washer are further separated and screened down to 2mm. The over screened
material greater than 2mm are then fed to the conveyor #2, while the under screened
material of size less than 2mm are pumped to tank 3.
Table 4.1 Log Washer Technical Specifics
Max. Feed size 75mm

Capacity 50-110 TPH
Operating speed 32 rpm

Power rating 110 KW
Fig.4 Log Washer
Jyrus Bayuve –Trainee Mine Engineer | Drum Washer (Trammel) 5

2.4 Vibrating screens

The vibrating screen is a double deck screen which does the further separation of material
dirt from both the conventional ore and hydro ore. The vibrating screen consists of vibrating
motor that, that induced the mechanical vibration to separate the dirt from the slurry.
Materials from tank 3 are then pumped back to the vibrating screen 1, for further separation
of dirt and materials. The materials that are over screened from the vibrating screen are then
fed to the conveyor 4. The slurry from the water mine are pumped direct into vibrating
Screen two for screening of dirt. The dirt are sucked onto conveyor 4 while the slurry from
both vibrating screen 1 and 2 is pumped into tank 1 and 2 for and then pumped to
beneficiation.
Fig.2.3 Vibrating Screen 1 and 2
2.5 Conveyors
There are four (4) conveyor system from which conveyor (3) is no longer working. The other
conveyors (conveyor 1, 2 & 4) facilitate the transportation of the oversize materials from the
drum washer, log washer, and the vibrating screen to their respective stockpile. The table
below displays the conveyors technical specifications.
Table 2.4 Conveyors technical specifications

Conveyors Specifics 1 2 4
Start point Wash drum Log washer Vibrating screen
End point Stockpile .1 Stockpile. 3 Stockpile .2
Width 1200mm 800mm 800mm
Speed 1.25m/s 1.25m/s 1.25m/s
Transfer volume 130 t/h 114t/h 100t/h
Material type Stone size >75mm Chips size >2mm Sand size
2.6 Heavy duty pumps & slurry Pipeline

There are total of 6 slurry pumps, specifically centrifugal slurry pumps that assist in the
movement of slurry from tank to vibrating screens and also the transportation of slurry from
wash plant storage tank to beneficiation. The pipeline that transports slurry from
de-agglomeration plant to the beneficiation consist of two 610x11 mm with length of 2.5km
Jyrus Bayuve –Trainee Mine Engineer | Vibrating screens 6

2.7 Slurry storage Tank

There are three (3) slurry storage tanks. Tank 1 and 2 are storage tanks that capture slurry
straight from the two vibrating screens and pumped them to the beneficiation for chromate
extraction. The tank 3 serves as the temporary storage that captures slurry from the drum
washer and log washer, then it is pumped back to the vibrating screen #1 for further screenings.
The movement of slurries out and into the tanks is assisted by the mechanical pumped pumps.
Fig 2.6 Slurry Storage tank 1, 2 and 3
2.8 Back water Dam

Water used for the wash plant is taken from the thickener pond at beneficiation and also rain
water sources captured in the backwater dam, pictured below.
Fig. 2.7 Back Water dam used for ore washing
2.9 Office & wash Equipment control room

The office area contains office of the superintendants, temporary workers locker, and the control
room which monitors all the electrical and mechanical equipments electronically. Also the
production volume, water velocity, drum frequency, pump pressure, conveyor speed and etc, are
directly controlled via control room.
Fig.2.8 Control operation room
Jyrus Bayuve –Trainee Mine Engineer | Slurry storage Tank 7

2.10 Stock piles

The temporary stockpiles are used for storing discharged boulders and chips then, these
materials are then used in sediment catchment ponds, road construction, safety berm
construction, road maintenance, and other construction works.
Fig. 2.9 Discharge Stockpiles and temporary stockpiles for material waste
from
3. Wash
wash plantplant crew
The wash plant crew is made up of;
i. Management
The wash plant management team is made up of Supervisors, superintendant, and team
leader with their assistance. The Management Team oversees the operation and
maintenance of the plant.
ii. Monitoring team
This team consists of local workers who monitor the drum washers, the log washers,
feeders, conveyors, pumps reports any faults back to team leader who then reports to
supervisor/ superintendant, for maintenance
iii. Maintenance Team
The maintenance team is in charge of maintaining the wash plant. They carry basic repair of
the equipments every day, depending on the operating status of the equipment. They carry
basic arc welding, oiling the bearing, conveyor maintenance, and etc.
iv. Control room team
The entire wash plant operation, including feeder speed, trammels and log washer rotational
velocity, vibration of screen, and the conveyor system is monitored in the control room. For
instance when, identifying an issue with any one of the system, then the control room shut
downs the specific equipments/systems for maintenance and repairs. All the operations are
connected to the control room.
Jyrus Bayuve –Trainee Mine Engineer | Stock piles 8

4. Summary
The de-agglomeration process basically involves the separation of larger boulders, rocks and also
chips and dirt. The whole Idea of this operation is basically do material screening and converting
mineral containing soil into slurry. The waste rocks as an over feed of the ore bin, trammel, log
washer and vibrating screen is reused in the construction of pit berm, pit road and also camp
building foundations. The process is continuous 24 hours. The wash plant only shut down when
there is a maintenance issues along the main pipeline system to Basamuk or if the basamuk
processing plant is undergoing maintenance, others the process is continues whole year round in
respect to the production target.
5. Recommendation
The operation is slightly not effective due to the unplanned down time and maintenance of the
equipments such as wash trammel and feeder. Since there is no scheduled maintenance time for
the operation, the production is slightly affected when two or more equipments are under
maintenance. Therefore, below is the rough planned scheduled for the equipment, which
illustrates the downtime and maintenance period of the specific equipment at one time daily.
The recommended schedule below is based on a week based observation of wash plant‘s daily
maintenance activities.
Table 5.0 Proposed daily schedule for inspection and Maintenance on

Trammels, Apron feeders and log Washers
Remarks
The inspection and maintenance of the wash plant equipments proposed here is on a week
based observation. The inspection and maintenance should be carried out in reference with the
standard operating procedure of the individual equipment which is to be undergoing inspection
and maintenance. The proposed schedule will keep records of daily inspection and maintenance
and also will optimize the operation and production by allowing 3 series of equipments running
at very one time while the other 1 series undergoes inspection and maintenance at that one time
every hour.
Jyrus Bayuve –Trainee Mine Engineer | Summary 9

Table 5.1 Proposed daily schedule for Inspection and Maintenance on

vibrating screen and conveyors
Remarks:
For the vibrating screen and conveyor system, not necessarily needs maintenance every hour,
however inspections on the equipment’s components such as screen sieve/size, motor, spring,
conveyor belt and conveyor motor is vital at every 3 hours daily. This will help indentify down
time and also reduce maintenance time to keep production on going. Maintenance of the
vibrating screen and conveyors components will reduce the down time and also optimize their
working capacity effectively.
5.2 Recommendation summary
The wash plant has in operation for over a decade since the beginning of production and it is one
of the key operations that aids to the recovery process of the mineral mined. The equipments
used in the ore phase are very vital for inspection and maintenance as it is what makes up the
wash plant. However, during the one week observation of the wash plant operations, the
equipments are not on schedule for inspection and maintenance.
Therefore, the schedule proposed above is believed to be effective and will have the operation in
order in terms of maintenance, and will reduce the down time and will significantly reduce the
maintenance cost.

6. Appendix
Fig.6.1 maintenance crew doing maintenance on a wash trammel
Fig.6.2 Conveyor 2 transporting chips from log washer to discharge stockpile

Fig.6.3 Remains of dirt from water mine slurry on the vibrating screen 2
waste discharge sump
Fig.6.4 Volvo Front loader loading discharge chips from log washer to a
temporary stockpile

KBK 2022
Beneficiation Report – KBK Mine Operation

through one week observation at the beneficiation Plant. The contents of this
report are specifically based on a week observation.

Beneficiation, 2022
Contents
1. Introduction .......................................................................................................................................... 3
2. Operations ............................................................................................................................................ 4
2.1 Phase1. Chromate Separation .......................................................................................................... 5
I. Slurry storage tank ............................................................................................................................ 6
II. Hydro Cyclone seizer ......................................................................................................................... 6
III. Spiral concentrator ....................................................................................................................... 7
IV. Shaking table ................................................................................................................................. 7
V. Sump ................................................................................................................................................. 8
VI. Magnetic separator ....................................................................................................................... 8
VII. Submerged Spiral Classifier........................................................................................................... 8
VIII. Ball Mill crasher............................................................................................................................. 9
2.2 Phase2. Slurry Thickness Treatment .............................................................................................. 10
1. Flocculent Mixing ........................................................................................................................ 11
2. Vibrating Screen .......................................................................................................................... 11
3. Thickening ................................................................................................................................... 12
4. Storage ........................................................................................................................................ 12
3. Summary ................................................................................................................................................. 13
4. Recommendation .................................................................................................................................... 13
4.1 Problem Identification ............................................................................................................ 13
4.2 Possible Proposed Solution (Design)....................................................................................... 15
4.3 Recommendation Remarks ..................................................................................................... 16
5. Appendix ............................................................................................................................................. 17
Jyrus Bayuve-Trainee Mine Engineer, 2022 | 2

Beneficiation, 2022
1. Introduction
Slurry from the de-agglomeration plant (wash Plant) is pumped to the beneficiation for further
separation, chromate extraction and thickness treatment before being pumped to Basamuk for Nickel
and Cobalt extraction. In this Phase of operation there are two sub-phase operation which are Chromate
separation and Slurry Thickness Treatment.
Fig.6.The Beneficiation Plant Operation and Process (Green colored Boundary)
Jyrus Bayuve-Trainee Mine Engineer, 2022 | Introduction 3

Beneficiation, 2022
2. Operations
The phase1 Operation inclusively use the help of Hydro cyclone, Spiral Concentrator, shaking table, Ball
mill Crasher, Magnetic Separator, Submerged Spiral Classifier and series of pumps to separate chromate
from the mineral content slurry. Also by this operation the granular materials are further grinded to fully
slurry ingredient. The chromate are then stockpiled and transported to Lae via trucks, for exportation.
For the second phase of the operation, the slurry from the first phase after extraction of Chromate
Undergoes Further screening then flocculent is added to increase the slurry’s thickness then it is stored
in the temporary storage tank and then transported down to basamuk via pipeline, for extraction of
Nickel and Cobalt. The picture below shows the general location of the beneficiation plant.
Fig.2.1 Chromites Separation and Extraction facility
Fig.2.2 Slurry Thickening Dam and facility
Jyrus Bayuve-Trainee Mine Engineer, 2022 | Operations 4

Beneficiation, 2022
2.1 Phase1. Chromate Separation

The flow chart below gives a brief outline of the Chromate separation process.
Fig. 2.1 Chromate Separation Phase
Jyrus Bayuve-Trainee Mine Engineer, 2022 | Phase1. Chromate Separation 5

Beneficiation, 2022
I. Slurry storage tank

Slurry from the de-agglomeration plant is stored in the two slurry storage tank. From the two slurry
storage tank is then pumped to the Hydro cyclone for chromate separation. The Figure below displays a
slurry storage tank 1 & 2.
II. Hydro Cyclone seizer

The cyclone seizer does the first separation process of the chromate, from the slurry that is fed through
slurry storage tank. The cyclone seizer operation is similar to the cyclone, as the seizer creates a whirling
motion. During the process, the lighter particles which is mainly pure slurry is sacked into pipe that
transport it to the vibrating screen, located at the slurry thickener pond. The heavier particles from the
seizer are then fed to the distributors which distributes the material to the spiral concentrator. There
are 2 cyclone seizer, 8 distributors and 26 spiral concentrators. The flow chart below shows the circuit of
first separation process.
Fig.2.2 Flow layout of the chromate extraction.

Beneficiation, 2022
III. Spiral concentrator

The spiral concentrator does the second separation process of the under feed (U/F), that passing
through cyclone seizer. The spiral concentrator further separates the material into lighter and heavier
material group. The lighter which contains sands lesser then 1mm is collected in the light sump which is
connected to the inner channel of the spiral concentrator. The heavier material is almost full chromate
proportion, with slight proportion of other sandy materials is directly channeled on to the shaking table
for final chromate separation from the slurry.
Distributor
Spiral concentrator connected

to distributor
Fig.2.3 Spiral concentrator
IV. Shaking table
The shaking table further separates the heavier material

fed from the spiral concentrator. The vibrating screen
operates in the forward/backward motion with water
source, shaking the material feed and does physical
separation of materials based on their weight. The first
catchment from the shaking table is very light material,
thus collected in to the light sump and is mixed with the
ones collected from spiral concentrator. The second
catchment which is almost pure chromate is much heavier
thus it is collected in the heavier sump then piped to the
magnetic concentrator for further chromate extraction.
There are 26 shaking table operation, and is setup in a
way in which, two shaking table are connect to one spiral
concentrator. Fig.2.4 Series of shaking tables

Beneficiation, 2022
V. Sump
The lighter sump is the collector bin of the lighter material passing both spiral concentrator and shaking
table. The material from the lighter sump is then pumped to the ball mill crasher for further grinding of
material. A heavier material from the heavier sump is pumped to the magnetic separator.
VI. Magnetic separator
The magnetic separator separates materials basing on the magnetic properties. Since Chromate contains
chromium and Iron, which both having high magnetic properties, thus the metal chromate is separated
from the gangue sands. The materials passing magnetic separator is then fed to the Submerged Spiral
Classifier. The waste material from the magnetic separator is piped to the temporary waste dam, and
then it is further discharge in the chromate waste stockpile. There are 3 separator, from which 1 is on
standby.
Fig.2.5. The Magnetic

separator
VII. Submerged Spiral Classifier
The classifier is the final phase of chromate separation at beneficiation. The Classifier then does extra
classification of chromate then feds the extracted chromate to the conveyor of less than 70m which
discharge on the temporary stockpiles. Then the chromate is transported to the chromate designed
stockpile, from which it is then transported via trucks to Lae for export shipment. There are 3 classifiers
from which two are operational and the other is standby.

Beneficiation, 2022
VIII. Ball Mill crasher
The materials from the light sump is then fed to the Ball mill crasher for further grinding and crashing of
materials in to pure slurry, then it is fed to the connected hydro cyclone . The hydro cyclone then
separated the pure slurry in the first catchment and is pumped to the vibrating screen on the thickener
plant. The heavier materials from the hydro cyclone are again fed to the ball mill for grinding. The cycle
is repeated while material from lighter sump is continuously fed to the ball mill.
Hydro cyclone classifier
Ball Mill
Ball Bearings inside ball crusher,

which does continuous grinding and
crushing of material/sandstones into
slurry
Fig.2.7. The Ball mill Operations

Beneficiation, 2022
2.2 Phase2. Slurry Thickness Treatment
The Phase 2 of the beneficiation process involves final screening of slurry, flocculent preparation,
thickening process, slurry storage and pumping system to Basamuk (BSK) for processing. The flow chart
below gives clear insight of the process of slurry preparation.
Flocculent
Slurry from
mixer
Phase1.
Flocculent
mixture
Vibrating screen 1 Heater
Thickener 2
Thickener 1
Pump station
Pump station
Slurry to BSK
Treated slurry storage
Tank
Fig. 2.2 Slurry treating and thickening flow chart
Jyrus Bayuve-Trainee Mine Engineer, 2022 | Phase2. Slurry Thickness Treatment 10

Beneficiation, 2022
1. Flocculent Mixing
The process of flocculent mixing involves;
I. Mixing flocculent (solid powder) with water

II. Heating the mixture
III. Transportation to the mixing sump
Fig.1a). Flocculent Mix Chart., 1b).Flocculent stock house.
2. Vibrating Screen
The heavy duty vibrating screen does the final screening of dirt materials prior to the thickening phase.
The slurry that is pumped from the chromate separation phase (Phase 1), undergoes full screening
through the vibrating screen, which also prepares the slurry to be mixed with flocculent for thickening
phase.
Slurry (phase 1.) intake
Heavy Duty Vibrating screen
Thickening pond
Fig.2. Vibrating screen situated on the thickening pond

Beneficiation, 2022
3. Thickening
The flocculent mixture is pumped into the two mixing sumps in the thickening pond for slurry
thickening. The mixing sumps contain a turbine structured mechanism that rotates around mixing slurry
and flocculent thickening it. The thickened slurry is then pumped to the storage tank.
Fig.3 Thickening Sump mixing the flocculent mixture and slurry. ( Insert: thickened Slurry).
4. Storage
The treated slurry which contains slurry and flocculent, are pumped from the mixing sump to the two
20m height storage tanks. The other two 20m height tanks store water which is used to submerge the
thickened slurry to ease the transportation of slurry from KBK to BSK.
Fig.4. Slurry & water storage tank

Beneficiation, 2022
3. Summary
Beneficiations operation is an inclusive of two phase operations;
1. The chromites separation phase. Since chromites are abrasive material, it has a risk concern on
the pipeline system thus it needs to be separated and only the Ni-Co slurry is transported to
basamuk. The Chromites separations process is quite similar to that of the alluvial operations,
but slightly different as separation is based on density, weight and magnetic properties of the
chromites. The separation is achieved through utilization of equipment such as hydro cyclone
classifier, spiral concentrator, shaker table, ball mill and magnetic crusher.
2. The second phase is basically final screening of slurry and thickens before the slurry is being
pumped to basamuk for further chemical separation of Nickel and Cobalt. The thickening of
slurry utilizes the flocculent to basically grip the slurry together so that it ease the flow ability
process throughout the pipeline to avoid any cluster and deposition of the material that will
leads to the pipe blockage. In addition, Heavy duty vibrating screen and series of heavy duty
pumps are used for the final screening and pumping mechanism for the slurry transportation.
4. Recommendation
For the recommendations the observations were concentrated on the shaking table, which is believed
to be the reasons for the chromate and Nickel-Cobalt loss. The loss is due to the design and setup of the
shaker table as shown below.
4.1 Problem Identification
 Possible Problem 1.
Chromate Catchment Ni-Co slurry catchment

Pocket pocket
Jyrus Bayuve-Trainee Mine Engineer, 2022 | 3. Summary 13

Beneficiation, 2022
 Possible Problem 2.
Shaker table being setup at 00 Ni-Co slurry loss to the Chromate

inclination angle catchment pocket
 Problem Identification Remarks
I. Problem1. There are two catchment pockets for the material passing the shaker table.
This has lead to the loss of the Ni-Co which most of these materials are caught in the
chromate catchment pockets. This leads to the dilution of chromate thus result in both
chromate and Ni-Co loss.
II. Problem 2. The main reason for the problem 1 is shown in the problem 2 pictured the
shaking table being setup at 0o inclination angle.
 Problem Summary
According to the Standard Operating Procedure of Shaker table, the working specification and setup
specification mentions that all shaking table should be positioned/setup at a working inclination angle
rage of 5o – 10o in reference to the horizontal plane. The angle range of 5o – 10o is adjustable only within
that limit range for optimum recovery of material or ore feeds. Therefore it is believed that the problem
Identified at picture 1 is basically due to the problem identified at picture 2.
Jyrus Bayuve-Trainee Mine Engineer, 2022 | 4. Recommendation 14

Beneficiation, 2022
4.2 Possible Proposed Solution (Design)
The proposed deign for the addition catchment pocket for the material containing Ni-Co and chromate
which will be at the lower center of the shaker table discharge edge.
 Possible shaker table modification (design) by adding catchment pocket (2) for capturing the
Chromate, Ni-Co slurry
Slurry catchment
pocket (1)
Chromate Catchment pocket (3)
Chromate-Ni-Co content
Catchment pocket (2)
Fig.4.2A Proposed modification design on the shaker table catchment pocket

Beneficiation, 2022
 Possible shaker table setup at adjustable incline angle range of 5o - 10o basing on the Operating
standard.
Fig.4.2B Proposed design setup of the shaker table based on the shaker table
working specifics (SOP)
4.3 Recommendation Remarks
Based on the standard operating procedure of the shaker table, if the above proposed
recommendations are taken into considerations, the separation of feed through shaker table will be
very effective so thus will the waste be minimized and the production will be optimize.

Beneficiation, 2022
5. Appendix
Fig.5.1.The beneficiations and office area
Fig.5.2 The flocculent Mixing facility
Jyrus Bayuve-Trainee Mine Engineer, 2022 | Appendix 17

PIT ACCESS ROAD SAFETY ASSESSMENT
Section (Pit) Assessed: Pit 21 & Pit 19
Assessed by: Jyrus Bayuve
(Trainee Engineer)
Mine Technical Services
Date of Assessment: December 26, 2022

1. Hazard Identified: Narrow Turn (Blind spot)
Location: Pit 21 access road

Rectification Proposed
1. Extend slope face by cutback

Possible risk Induce;
(LHS)
 Blind turned 2. Install mirror (RHS)
 Truck collision possibility
2. Hazard Identified: No Safety marker
Location 1: Pit 17-21 road Location 2 : Pit 21- 19 Back Road
Possible Risk Induce:
 High Off road possibility

 Risky to night the operation
Rectification 1. Rectification2 :
 Install Safety bar  Install Safety bar
(LHS & RHS) ( RHS)
Pit 21 & 19 Access Road Safety Assessment

2. Hazard Identified: No Run off culvert
Location: Pit 21- 19 Back Road
Possible Risk Induce to the road Rectification:
 Mud accumulation  Installation of culvert

 Road worn out (600 mm Dia. Culvert)
 Costing maintenance
General Remarks
The safety assessment reported is of vital need adherence, and needs to be

attained to in order to avoid unnecessary accidents and maintenance cost.
Pit 21 & 19 Access Road Safety Assessment

Industrial Training Report - KBK-RNML (MCC) - Jyrus Bayuve

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RAMU NICO MANAGERMENT (MCC) LIMITED

Submitted in partial fulfillment to the

PAPUA NEW GUINEA UNIVERSITY OF TECHNOLOGY

Date submitted: January 1st, 2023

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 1

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 2

III. STUDENT DECLARATION

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 3

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 4

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 5

Fig.ii. Project Owners and joint ventures

III. LOCATION OF THE PROJECT (MINE SITE)

Fig.iii. Location of the KBK mine operation

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 6

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 7

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 8

1. KURUMBUKARI ON PNG GEOLOGY

1.1. Geology and Mineralization of New Guinea Thrust Belt zone

Fig.1.1 PNG Geological Features (Williamson and Hancock, 2005).

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 9

Fig.1.21 Kurumbukari deposit’s Regional Geology

Fig.1.22 Laterite Profile of KBK deposit

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 10

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 11

2.1 Conventional Open Pit Mining method

Table 2.1A Mine surface Parameters

Fig. 2.1B Conventional loading of Ore

2.2 Hydro Sluicing

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 12

2.1 Road Designs Specifications

I. Main haul roads – dual lane

INDUSTRIAL TRAINING REPORT Compiled by Jyrus Bayuve –BEMN/4 Page 13

I. Conventional mining operation

3.1 Mine Development

Development operation Unit

3.12 Overburden Stripping

Table 3.12 Stripping face parameters (KBK probation report, 2021 )

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Table 3.13 Mining Development fleets (KBK probation report, 2021)

3.2 Conventional Mine Operation

Fig.3.2A Conventional mine chart Table 3.2B Mine surface Parameters

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3.3 Conventional Mining fleets

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Table 3.3B Secondary/Ancillary fleets (KBK Probation Report, 2021)

3.4 Ore Bin operation

Table 3.4 Ore Bin Equipment

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Fig.3.5 Dispatch/GPS Monitoring office

3.6 Emergency Response Operation (ERT)

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4.1 Hydro sluicing operation

Based on the mineralization geology of the deposit, it is

Fig.4. Pit 12 hydro mine

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Fig.4.2 Current active Hydro mine Pit (Areas)

4.3 Equipments and fleets

Table 4.3 Hydro Mine Fleets

No Equipment(s) Equipment(s) size

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CHAPTER 5. WASH PLANT