BACKGROUND

The Bhp Copper Mine is the largest underground copper mine in the world. It produced 282 million pounds of copper in 1995. Due to economic conditions in the copper mining industry, BHP made a strategic decision to close down its San Manuel facility. The company wanted to protect the mine operation equipment from corrosion, in case the mine would need to be reopened or sold.

Equipment included: a block-caving underground copper mine, a 62,000 ton per day concentrator, a heap leach, and in-situ leach, an SX-EW plant, a 1,300,000 ton smelter, a 3,000 ton per day acid plant, a 345,000 ton per year electrolytic refinery and a 180,000 ton per year rod plant.

PROBLEM

The customer needed help to shut down the mine and protect the equipment. BHP was especially worried about corrosion that would inevitably occur on idle equipment left unprotected. They needed a vendor that could provide a “One-Stop” solution for the protection of their various systems. Their requirements included the large mining equipment the plant used on a daily basis. The protection was also needed for the cooling tower and boiler systems, pumps and compressors, locomotive engines, electrical/electronic systems, gearboxes, manual transmissions, differentials & transfer cases, bearings and bushings.

The shutdown and layup program had to provide:

a. Protection for up to two years
b. Ability to restart with minimal effort
c. Environmentally sound products
d. Technical support and service during the life of the project

Cortec® Corporation and their Arizona distributor designed a Total Corrosion Control program for the BHP mine. Cortec’s solution addressed all of BHP’s needs. The system of products would protect for up to two years, require no removal before start-up and incorporate Cortec’s biodegradable, non-toxic and non-hazardous products.

The following is a description of each of the products in the system and how they were used.

APPLICATION

1. Cortec® VpCI-307: This corrosion inhibiting powder was blown, sprinkled and fogged into boilers, compressors, exhaust systems, etc. Typical dosage: 0.3 oz (8.4 grams) per one cubic foot (300 g/cubic meters)
2. Cortec®Emitters VpCI-101, VpCI-105 and VpCI-111: Cortec® emitters were applied to non-ventilated and enclosed spaces such as control boxes, tool boxes or cabinets. Typical dosage: One 101 emitter per one cubic foot of space, One 105 emitter per five cubic feet of space, and One 111 emitter per eleven cubic feet of space.
3. Cortec®VpCI-329 Oil Additive: VpCI-329 corrosion-inhibiting oil additive was added into the engine oil and automatic transmissions at 10% by volume. Typical dosage: 10% by volume
4. Cortec®VpCI-369: VpCI-369 was used as an oil additive/temporary coating. It was applied to gearboxes, manual transmissions, differentials and transfer cases. It was also used to protect hydraulic and air cylinder shafts and other “bright steel” in a covered condition.
5. Cortec®VpCI-369 CorrLube Grease: This VpCI grease was used as a chassis grease for all types of bearings and bushings.
6. Cortec®VpCI-705 Fuel Additive: VpCI-705 additive was added to gasoline, diesel, gasohol mixtures and alcohol fuels as a corrosion inhibitor fuel stabilizer and water emulsifier. Typical dosage: 0.75 fl. oz. per 5 U.S. gallons (112 ml/100 litres)

CONCLUSION

Cortec® Total Corrosion Control solution will protect the mining equipment from corrosion for a minimum of two years. The projected Return on Investment is 122.5%. Using Cortec® Corporation’s layup expertise, BHP will gain approximately $25 million with a small investment.

LOCATION
San Manuel, Arizona

PRODUCT
VpCI-307
VpCI-101
VpCI-105
VpCI-111
VpCI-326
VpCI-329
VpCI-369
VpCI-705

CUSTOMER
BHP Copper Mine

DATE
1999

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