KAZ Minerals

HIGH GROWTH – LARGE SCALE – LOW COST – FOCUSED ON COPPER

Bozshakol construction site

Bozshakol – delivering transformational growth

Bozshakol is the largest single mine development in the CIS region by both scope and volume of production. The mine will deliver transformational growth equivalent to more than doubling KAZ Minerals' current production levels. The Bozshakol mine & concentrator will have a production life of over 40 years, including the processing of stockpiled ore for 4 years, and once fully operational will employ around 1,500 workers. The ore body also contains highly valuable by-products of gold and molybdenum.

Commissioning of the sulphide concentrator commenced in December 2015, with first copper concentrate produced in February 2016 and the first shipment to China in March 2016. The capital cost for the project is $2.15 billion, funded from a $2.7 billion financing facility provided by the China Development Bank.

The board approved the development of the project on 25 August 2011. See the photo report below to see how the site has evolved since 2010.

The project commenced production of copper concentrate at the main sulphide concentrator in February 2016, with the first shipment made in March. Commissioning works at the clay plant commenced on 29 September 2016.

  • Ore stockpile area
  • Primary crusher
  • Flotation area
  • Flotation area
  • Mining at Bozshakol
  • Ore loading at Bozshakol
  • Railway link to Bozshakol
  • Tailings thickener
  • Conveyor
  • Tailings Pump House

The board approved the development of the project on 25 August 2011. See the photo report below to see how the site has evolved since 2010.

As of June 2015 we have completed all key sulphide concrete and steel works, non-process buildings, permanent camp, main access road and railroad, 220 kV power line and substation tie-in; mining equipment including haul trucks, shovels and excavators delivered and assembled and shells, heads and stators for all three mills are assembled. In the coming months we will be working on the installation of the primary crusher, the rougher and cleaner flotation cells and bulk material for underground piping and electrical works, installation and testing of ball and SAG mills and the construction of the clay plant. We started pre-production mining in June 2015 and the project is on track to commence commissioning in Q1 2016.

  • Road to Bozshakol
  • Tailings thickener
  • View of the tailings thickener, concentrator and part of the conveyor
  • The concentrator and part of the conveyor
  • View of the concentrator from rear
  • View of the concentrator
  • Permanent camp
  • Construction of the clay plant
  • View from primary crusher
  • Primary crusher, conveyor and clay plant
  • Part of the conveyor
  • Clay plant under construction
  • Primary crusher, control room
  • Concentrator and concentrator maintenance workshop
  • Clay plant, steel structures and foundations of the mills
  • Clay plant under construction
  • Mining truck at the mine maintenance workshop
  • Conveyor leading to the concentrator
  • One of the two ball mills in the concentrator
  • Inside the concentrator
  • Overland conveyor and primary crusher
  • Mine maintenance workshop, introduction to mining equipment
  • Clay plant construction
  • Mine maintenance workshop, introduction to mining equipment
  • Concentrator building
  • Ball mills in the concentrator
  • Water filtration tanks inside concentrator
  • Inside the concentrator
  • Part of the conveyor leading to the concentrator
  • SAG mill in the concentrator
  • Bozshakol project general plan
  • View from above
  • Ball mill – shell installation complete
  • Ball mill – mechanical installation
  • Clay plant
  • Mills heads cleaning
  • Conveyor
  • Mills
  • One of the rooms at the permanent camp
  • Tailings pump house – pump installation

The board approved the development of the project on 25 August 2011. See the photo report below to see how the site has evolved since 2010.

In the first half of 2014 we completed the construction of the main concentrator building and the 220kV power line. During the autumn months we completed the construction of the permanent camp and the assembly of haul trucks and shovels for pre-production mining in Q1 2015. We also commenced installation of the mills and internal steel platforms in the grinding and flotation areas and started the construction of the overland ore conveyor. The project is due for commissioning in Q4 2015.

  • Concentrator building
  • Installation of sole plates for SAG mills
  • Mine haul trucks
  • Mine maintenance workshop / warehouse office
  • Ramp to SAG mills
  • Construction works inside the concentrator
  • Overview of the permanent camp
  • Permanent camp
  • Railway to the main processing building

The board approved the development of the project on 25 August 2011. See the photo report below to see how the site has evolved since 2010.

In 2013 we finished most of the foundation works and most of the main buildings were enclosed. We also completed the steel structure of the accommodation building at the permanent camp, laid the foundation and erected the steel frames of the plant maintenance workshops and completed the main access road to permit transportation of the heavy equipment to the site. We delivered the first shipment of heavy equipment from Antwerp to Bozshakol with parts of ball mills and SAG mils to the site in the end of July 2013. We are almost 50% complete, and you can see the shape of the final project now.

  • Primary crusher
  • Tailings pump house cladding and ring beams
  • Ball and Sag mills parts and GMD’s
  • E-houses and emergency generators
  • Concentrator mine maintenance workshop
  • Main concentrator building
  • Load out station, structural steel works
  • 220 kV transformers installation
  • Inside the concentrator building
  • Construction works at Bozshakol
  • Enclosed concentrator building
  • Enclosed workshop building
  • Enclosing concentrator workshop
  • Concentrator and tailings thickener ring beams construction
  • Primary crusher under construction
  • Tailings thickener ring beam and a workshop
  • Tailings thickener ring beams construction
  • Top view of the construction site
  • Top view of the construction site
  • View of the construction site
  • Foundation works at the site
  • Grinding plant of the future concentrator – where ball mills 1 & 2 will be placed
  • Tailings thickener, rings beam concrete works, and tailings pump house structural steel erection
  • Ore stockpile tunnel, concrete works
  • Pebble crusher construction
  • Mine maintenance workshop, concrete and structural steel works
  • Concentrator maintenance workshop cladding
  • Preparations for concrete works at the future lime load out and slaking facility
  • Main access road, asphalt works
  • Railway sleepers installation
  • Permanent camp construction works
  • Primary crusher construction
  • View of the future concentrator and its maintenance workshop
  • Inside the concentrator during daytime
  • Inside the concentrator in the evening
  • View of the future concentrator
  • View of the concentrator maintenance workshop
  • Working at heights
  • Works on the primary crusher, preparing intermediate slab
  • Building annex of the flotation plant at the future concentrator
  • Building annex of the flotation plant at the future concentrator
  • Building annex of the flotation plant at the future concentrator
  • Building annex of the flotation plant at the future concentrator
  • Building annex of the flotation plant at the future concentrator
  • Building annex of the flotation plant at the future concentrator
  • Building annex of the flotation plant at the future concentrator
  • Building annex of the flotation plant at the future concentrator
  • Building annex of the flotation plant at the future concentrator
  • Building annex of the flotation plant at the future concentrator
  • Loading equipment on the vessel
  • Loading equipment on the vessel
  • Loading equipment on the vessel
  • Loading equipment on the vessel
  • Loading equipment on the vessel
  • Primary crusher
  • Primary crusher
  • Loading equipment on the vessel
  • Nameplate on the equipment
  • Securing the mills in the cargo hold
  • Securing the mills on the board of the vessel
  • Securing the mills in the cargo hold
  • Equipment loaded and secured on the vessel's cargo hold
  • The mills loaded and secured on the board of the vessel
  • The vessel at the port in Antwerp
  • The vessel leaving the port
  • View from Primary Crusher to Main Process Plant
  • Concentrate foundations and main process building

The board approved the development of the project on 25 August 2011. See the photo report below to see how the site has evolved since 2010.

In 2012 we completed the water supply piping, and having received construction equipment, commenced the earthworks on site. We established an office building, built a temporary camp for the construction workforce, laid the foundation and commenced the erection of structural steel frames and walls for the main buildings, erected a roof beam on the grinding building and started the construction of the tailing thickeners walls.

The board approved the development of the project on 25 August 2011. See the photo report below to see how the site has evolved since 2010.

Bozshakol is located very close to existing major roads and a railway, which allowed us to complete ground work and build initial site infrastructure in a short timeframe.

The board approved the development of the project on 25 August 2011. See the photo report below to see how the site has evolved since 2010.

The site is located in North Kazakhstan, and is accessible by road and rail from the capital Astana. We started working from a greenfield site. This is the beginning of our journey.

Project Video

KEY FACTS

Commenced commissioning of:
– Concentrator – Dec 2015
– Clay plant – Sept 2016

Processing capacity:
– Concentrator: 25 MT of ore pa
– Clay plant: 5 MT of ore pa

Mineral resource: 1,220 MT at an average copper grade of 0.36%

By-products:
– 5,255 koz contained gold
– 57 kt contained molybdenum

Net cash cost – 70-90 USc/lb*

*Estimated net cash cost for copper cathode equivalent sales in the first 10 years after the concentrator has been commissioned (in 2016 terms), calculated using a long-term gold price of $1,200 per ounce and $12,000 per tonne of molybdenum.