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iron-ore concentrator design

iron-ore concentrator design
CVG Ferrominera Orinoco C.A.
Puerto Ordaz, Venezuela

international team provides fast-track design and engineering services for iron-ore concentrator

C.V.G. Ferrominera Orinoco C.A. (FMO) a Venezuelan government-owned mining company, proposed to build a 12-million-ton-per-year iron-ore concentrator to process a combination of higher-grade natural ore and low-grade taconite ore. Barr was hired to replace another engineering firm a year into the design phase. We had already provided services for the project’s pilot plant, including a feasibility study, preliminary design, capital and operating cost estimates for two alternatives, technical requirements for design/build specifications, and technical evaluations of bids.

Working with an engineering, procurement, and construction management firm from Spain, Barr organized and led a team from five engineering firms to design the iron-ore concentrator. The team of mechanical, electrical, process, civil, structural, and geotechnical engineers and designers developed over 1,400 documents/drawings in approximately 62,000 man hours during an aggressive 18-month schedule. Our team's project work included:

  • Reviewing existing and developing new flowsheets

  • Reviewing and updating equipment specifications and selection

  • Reviewing technical analysis on process development work

  • Developing plant general arrangement drawings

  • Developing detailed design of pumping and piping systems for all process and auxiliary circuits in the plant

  • Developing detailed design of all platework including sumps, tanks, launders, etc.

  • Developing process and instrumentation diagrams (P&ID) for all process control systems

  • Developing functional description for all operating systems to be used for programming control system

  • Designing electrical and instrumentation systems within the plant

  • Reviewing concentrator civil work design by others

  • Designing tailings basin including multiple year deposition, management plan, dam design, pumping, tailings pipeline, pipeline and road alignment, reclaim water pumping and piping systems

The project is under construction with completion and start-up anticipated for 2019.