Process Infrastructure

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That means combining ingenuity and insight to produce extraordinary results for our clients, worldwide.

As a growing company with big ideas, we welcome change. We embrace it. It gives us the opportunity to provide more for our clients, our people and the communities we serve.

So now, PSI Pipeline Division and PSI Control Systems are Ausenco PSI, and as part of the Process Infrastructure business line we can now drive our success to new heights. From mines to pipelines, ports, bulk terminals, and control systems, our people and partnerships deliver ingenious solutions to optimise our clients’ resources.

We specialise in the engineering and design of long-distance pipelines, tailings management systems and control systems design and integration. We thrive on breaking new ground and have been involved in many breakthrough ventures.

In Chile, we were responsible for the first gravity and longest copper ore system ever built. We designed the first iron ore concentrate pipeline and first slurry pipeline in China; the world’s longest copper ore concentrate slurry pipeline in Argentina; the world’s first nickel laterite slurry pipeline in Madagascar; and the longest slurry pipeline in India.

In Brazil, we designed the world’s first bauxite slurry pipeline and at Los Pelambres, Chile, our copper tailings pipeline is the largest and one of the world’s longest. In Peru, we’ve designed a sulfide tailings system that will build what will be the world’s highest sand dam. We also designed the first long-distance pipeline in Peru – a pipeline that travelled from a height of 4,200m right down to sea level. With a capacity to carry both copper and zinc, this was the first multi-product pipeline designed in a mountainous region.

Our Da Hong Shan iron concentrate pipeline in China

is not only one of the country’s largest, it also has the highest operating pressure of any pipeline in China. It is one of the few pipelines in the world to pump steeply uphill over most of its length and has the largest total lift of any pipeline, anywhere.

In Brazil, we are now well on the way to completing the longest pipeline we’ve ever designed, no mean feat when you consider its 522km length. Not surprisingly, when complete, it will be the longest and largest tonnage iron concentrate pipeline in the world.

Apart from designing better pipelines, we’ve also designed and developed better software solutions to operate and control them. Our Pipeline Simulator™ is an advanced customisable software package offering pipeline operation simulation, accident simulation and operator training. It provides clients with critical training and tools to ensure safe and efficient operation of complex pipeline systems.

Pipeline Advisor™ is our customisable operations tool that was developed to meet the challenges of operating and monitoring multi-phase fluid transport. It offers invaluable help on the pipeline, including visualisation, batch tracking, leak detection and remote pipeline diagnostics. The bottom line with Advisor, is that clients can maximise their operational efficiency and dramatically reduce downtime.

At Ausenco PSI we never stop innovating. We’ve already designed the first solar powered, motor operated slurry pipeline valve station, for what has become the first pipeline system to be monitored via the Internet.

All around the world, we set our sights on new horizons. And we look to one another to adapt, adjust to and overcome new challenges.

At Ausenco we believe anything is possible.

In the resources and energy sectors, we dig deeper to set high global standards for leading edge engineering and project management services.

Ausenco provides services across the full project lifecycle. We constantly search for new and better ways to add value to our clients’ projects by following a disciplined and inventive approach.

We Evaluate We’re inspired by uncharted territory. Our prefeasibility studies, feasibility studies and conceptual design services will keep you moving in the right direction.

We set out to identify project opportunities, risks, options and solutions early. We try to cover as many aspects as possible through laboratory testing, complex hydraulic modelling, route selection and preparation of bankable capital and operating cost estimates.

We Innovate We take on the most unconventional problems to deliver groundbreaking solutions through our basic and detailed engineering and design services.

We place a high emphasis on innovation at every stage and have become acknowledged experts at designing and integrating SCADA/DCS and telecommunications systems.

We CreateWe strive to leave a positive and lasting impression on the world around us through our detailed, cost efficient, high quality procurement, construction management, commissioning and start-up services.

We OptimiseAt Ausenco PSI, helping our clients optimise their resources is a top priority. We’ve geared all of our operational support services such as onsite engineering, to identify and optimise client opportunities wherever possible.

It’s one reason why we deliver success on project after project, yet no two solutions we offer are the same. We continually strive to look at clients’ problems from new angles and deliver imaginative solutions.

0302 | Ausenco PSI Process Infrastructure

Optim

ise

Evaluate

Create

Project

Innovate

We have designed our mix of services to match our clients’ needs and the realities of project lifecycles.

As a result of the integration of Ausenco, Ascentis, PSI, Sandwell and Vector, we have created areas of specialist expertise in Energy, Environment & Sustainability, Minerals & Metals, Process Infrastructure, and Program Management.

One unified organisation working together across every step of the project lifecycle.

Our client solutions offering

Our core values are the cornerstone of everything we do. They enable us to discover through ingenuity and lead by example.

An inspired way of working with clients Our values guide the way we work

Safety in all we doWe let nothing compromise our safety performance. All around the world, we believe our valued people deserve to return home safely each and every night.

The client is our focusWe develop trusting relationships with our business partners and clients. Helping them build better businesses and deliver outstanding results means we can do the same.

Our people are our strengthWe prize the abilities, diversity and creativity of our people. The way that we care for our people, as well as develop and encourage their talents, is a key part of our culture – and we do all we can to grow their skills.

Respect the community and environmentWherever we operate in the world, we respect the diverse communities and environments. We understand that our actions leave a lasting impression, and we want to make sure it’s a good one for future generations.

We seek ingenious solutionsWe encourage our people to be lifetime learners. This nurtures the ingenuity, flexibility and creativity that we need to find solutions and manage change.

We are open, honest and collaborativeWe respect the diversity and differences of all our people and various stakeholders, and we support this with straightforward and open communications at all times.

Evaluate

Innovate

Create

Optimise

Evaluate

Minerals& Metals

Process Infrastructure

Program Management

Processing facilities for:

– Precious metals

– Coal

– Iron ore

– Base metals

– Industrial minerals

– Mineral sands

– Uranium

– Phosphates

– Fertilisers

– Potash

Ports and marine

Long distance slurry and liquid pipelines

Paste and tailings disposal systems

Materials handling

Rail

Commercial and industrial buildings

Pulp and paper

Supply chain simulation and optimisation

Control systems

Waste water treatment

Infrastructure

Energy

Conventional gas

Non-conventional gas

Gas conversion

Renewable energy

Biofuels

Oil and gas pipelines

Power generation and transmission

Coal gasification

Off gas treatment

Carbon storage

Oil sands

Oil shale

Environment& Sustainability

Civil and geotechnical engineering

Waste treatment, processing and storage

Mine waste management

Environmentaland sustainability services

Permitting and licensing

Water resource management

Landfill design and gas recovery

Laboratory andfield services

Program and project management

Procurement

Logistics

Construction management

Stakeholder relations management

Statutory approvals management

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Our specialist services

Process Infrastructure

Pipelines Ausenco PSI is the recognised world leader in the design and delivery of state-of-the-art long-distance slurry pipeline systems. In fact, for over 30 years, Ausenco PSI personnel have played key roles in the engineering of most long-distance slurry transportation systems installed worldwide. More impressive still, several of our most senior personnel were part of the pioneering group that first developed slurry pipeline technology.

Over the years we have designed pipelines to transport virtually every form of mineral imaginable, from the various concentrates such as copper, zinc, lead and iron to crushed ore, bauxite, nickel laterite, phosphate, potash, limestone, oil sands, and coal.

Slurry pipeline technology, or ‘hydrotransportation,’ is more environmentally responsible and generally more economical than other forms of transport. It is a safe transportation alternative that reduces pollution, fuel costs, manpower requirements and the need to maintain high-use transportation corridors. Hydrotransportation is a safe, green and cost-effective transportation method that minimises impacts on local communities and the environment.

Designing pipelines to transport petroleum products, safely and efficiently, has become another area of our expertise. We have completed a variety of assignments covering local and long-distance transportation of crude and refined oil, gas, oil sands, ethanol and alternative fuels.

The full range of pipeline applications we offer includes:

• Long-distance slurry pipelines (mineral concentrates, mineral ores, coal, industrial minerals)

• Tailings management• Oil, gas and products pipelines• Ethanol and alternative fuels pipelines• Hydraulic ore hoisting• Control systems design and integration

Tailings management We specialise in the design of tailings management systems that couple innovative design approaches with the latest materials for the effective recovery and relocation of tailings. We apply our expert understanding of complex hydraulics and tailings disposal to develop economical and environmentally feasible solutions that result in longer design lives, reduced failure risk and increased efficiency.

Our full range of tailings management applications includes:

• Conventional tailings management – Cyclone sand separation and distribution – Single point discharge – Perimeter spigotting – Open channel flow (launder system) – Drop box systems

• Deep sea tailings placement (DSTP)

• Water delivery and reclaim systems

• Paste and thickened tailings – Surface deposition – Underground hydraulic/paste backfill systems – Dry stacking – Bauxite residue (red muds)

• Ash management – High concentrated slurry disposal (HCSD) – Fly ash, bottom ash – Central ramp discharges – Side hill discharges

Control systems We have experts who can monitor and control the operation of a pipeline without going anywhere near it. Our control systems group has extensive experience designing supervisory control and data acquisition (SCADA) systems to give our clients the control and intelligence needed to effectively monitor and operate virtually every aspect of their process management systems.

We also specialise in the design and provision of critical telecommunications backbones utilising the latest technology. In addition to being the data backbone for SCADA, they are also used for voice communications, including mobile solutions, which are critical for safe pipeline operations; data transmission for administration and operations teams; video surveillance for security and operations; and secure connection of the pipeline private network to the larger public network and the Internet. We have designed and provided systems based on fiber optics, radio (various frequencies) and satellite – and hybrids of all three.

Our complete range of control systems solutions includes:

• Electrical engineering • I&C engineering • Industrial IT • Control panels • System integration • Data management and analysis • Field services

We also design and provide complete remote SCADA and power enclosures to operate the pipeline instrumentation, equipment, cathodic protection and communications. And, we have provided a host of backup power solutions, including solar and thermo-electric generators.

No matter what the need, Ausenco PSI can provide a complete package for design, engineering, programming, commissioning and operations to efficiently get our clients’ process management system into service and keep it operating.

Software solutions Our world renowned engineers have developed two advanced and exclusive software solutions that help our clients to achieve safety objectives and optimise their operations, and ultimately their resources.

Pipeline Advisor™ is a proven software solution designed to maximise the effectiveness and profitability of even the most complex slurry or tailings pipeline system. Pipeline Advisor offers important features like visualisation, batch tracking, leak detection and remote pipeline diagnostics.

By providing continuous monitoring, Pipeline Advisor can help clients to reduce operator error and downtime, and achieve safe, energy and cost-efficient pipeline operations.

Pipeline Simulator™ is a sophisticated software solution for pipeline system design, operation sequence determination, operator training, operations planning and pipeline safety assessment. Pipeline Simulator offers complete virtual training in critical areas, including pipeline operation and accident simulation.

These easy-to-use software solutions are fully customisable and can be adapted to each client’s unique needs and system specifications.

At Ausenco PSI we offer specialist areas of expertise to a wide range of disciplines and sectors.

It’s not every day that you’re asked to design the largest iron concentrate pipeline system in China, complete with freezing temperatures and desolate terrain.

-34̊ CAusenco PSI duly launched a full feasibility study to check the project’s logistical and economic viability. We were subsequently selected by the client to provide a full range of services, including basic and detailed engineering, construction supervision, start-up and commissioning.

In early January 2010, amidst freezing conditions and with daytime temperatures plummeting as low as -34˚C, we successfully ran the first batch of slurry through the 145km, 14 inch diameter iron concentrate pipeline.

When fully commissioned in 2010, the pipeline will transport 5.5 million tonnes of iron concentrate per year. A 130km, 36 inch water pipeline will transport 2,500m3/h of Yellow River water per year. The high-pressure water pipeline, the longest water pipeline in China and serviced by only one pump station, was designed to transport water across an arid region in support of both ore beneficiation and the livelihood of nearby communities. The pipeline transport system will also include a 2.9/2.5km, 22/14 inch thickened tailings and paste surface disposal system to handle 7.0 million tonnes of tailings per year.

The pipeline systems are controlled and monitored with our supervisory control and data acquisition (SCADA) system, which is distributed among all of the pipeline stations.

The fiber optic SCADA system, so vital to pipeline operation, includes human machine interfaces (HMI), data historian server, programmable logic controller (PLC) based control hardware and Pipeline Advisor.

The project has reduced the environmental impact to the city of Bao Tou from Bao Tou Steel Bai Yun West Mine tailings, and has created favorable conditions for Bao Tou Steel to further bring tailings under control. Since the pipelines are buried underground, they provide an ecologically favorable alternative to conventional forms of transport.

At Bao Tou, our experience in the pipeline business came together to achieve outstanding client results with a project that will serve as an exceptional role model for energy savings and reduction of emissions.

ProjectBao Tou Iron Concentrate and Water Pipelines and Thickened Tailings and Paste Surface DisposalLocationChinaClientBao Tou Steel GroupServiceEPCM TimeframePlanned completion 2010

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Imagine our reaction when a client in Brazil challenged us to disprove one of the longest standing beliefs in the mining industry: bauxite could not be transported via pipeline.

Performing world first pipeline engineering feats has almost become second nature to us at Ausenco PSI. Yet even we expressed initial doubts when client Vale approached us with their vision of building the world’s first long-distance bauxite pipeline.

A variety of minerals have been successfully transported for many years via pipeline, over distances ranging from a few kilometres to more than 400km. However, until Mineracao Bauxita Paragominas (MBP) came along, bauxite had not been one. But our design of the world’s first long-distance bauxite slurry pipeline in the State of Para, Brazil – and its successful commissioning in 2007 – put the hard-to-transport myth to rest once and for all. The planned expansion of the Alunorte alumina plant – and its need for additional bauxite sources – was the catalyst for the project.

A vision to link the remote Miltonia bauxite mine to the alumina plant, led to pipeline transport being considered – and prompted us to think differently about how that could occur.

Bauxite ore is normally delivered to the alumina plant in dry form, but on the MBP project we proposed a slurry pipeline. That meant incorporating dewatering facilities as part of this first-of-its-kind pipeline transportation system. It also meant that we needed to invest significant time and work to assure its technical and economic feasibility.

In the end, the pipeline system was successfully designed to transport 9.0 Mtpy with a pump station expandable to 13.5 Mtpy by adding a second station.

The 244km, 24 inch diameter pipeline system is monitored by a sophisticated state-of-the-art leak detection system. This project proved beyond doubt that not only was a bauxite ore hydrotransport system feasible – it was reliable and economically viable.

ProjectMBP Bauxite Ore Slurry Pipeline SystemLocationBrazilClientValeServiceEngineering and construction supervision Timeframe2007

Anything is possible

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In 1996, we were selected to perform the basic and detailed engineering for the 300km slurry pipeline connecting the mine – at an elevation of 4,200m – to the port.

Our role did not stop there. We were appointed to handle all the procurement support, construction quality assurance and field engineering support, start-up and commissioning. To top off our involvement, we were asked to provide the complete SCADA system and telecommunications system detailed design – so crucial to the pipeline’s successful operation.

It is worth recapping our key accomplishments on this project. We’ve designed an extremely complex 300km, multi-product pipeline that accommodates an elevation drop of 4,200m. It is one of the longest and highest pipelines – crossing two mountain ranges with a high point of 4,700m – in the world.

It is further distinguished from most concentrate pipelines in that it transports both copper (four grades) and zinc concentrates. It also achieves higher pumping pressures than any other slurry pipeline in operation

and, thanks to Ausenco PSI’s Pipeline Advisor, features a leak detection system. The pipeline is controlled and operated by a SCADA system that utilizes a fiber optic telecommunications system we installed parallel to the pipeline.

Since the pipeline became operational in 2001, the client has continued to retain us to provide operating assistance and participate in a number of additional related projects. In recognition of both our practical and client service skills, we’ve been engaged on over 35 individual projects at Antamina over the last dozen years.

ProjectAntamina Multi-Product Concentrate Pipeline SystemLocationPeruClientCompania Minera AntaminaServiceEPCM Timeframe2001

Ausenco PSI became involved with the Antamina project in 1996, when our initial studies successfully proved the economic and environmental viability of transporting copper and zinc via pipeline.

Process Infrastructure

Making ends meet at high altitude

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3,500m above sea level, high in the Andes, in fiercely steep and mountainous terrain, our client presented us with an imposing challenge.

Faced with insufficient room at the central mine location to expand its concentrator and tailings storage facility (TSF), our client asked us to design an ore pipeline that would transport ore to a far-off valley, where new concentrator facilities could be built and a more seismically stable location for the TSF could be found.

Our response was to design the first and longest copper ore slurry transport system ever conceived. The incredibly steep terrain encountered on the project – with a slope exceeding the typical 15% limit – represented an enormous engineering challenge.

Our solution featured a unique gravity flow system that required the inclusion of extensive and complex hydraulics to ensure continuous successful operation. The pipeline’s design complexity was directly related to the significant height drops and resulting energy |that needed to be overcome.

The pipeline was designed to last for the estimated maximum operating life of the mine, a period of approximately 30 years. We successfully commissioned the initial 57km, 20 inch diameter pipeline system in 1992. Several years later, the client asked us to complete a full range of engineering services for a 57km, 24 inch replacement pipeline. The replacement pipeline, which permitted a throughput increase from 37,000 to 54,000 tonnes per day, was put into operation in 2004.

And then, in 2008, Ausenco PSI began work to design a new 52km, 28 inch pipeline with five high-pressure choke stations and a water recovery pumping system that includes five pump stations and their power supply. The project, which is expected to be complete in 2011, is testament to Ausenco PSI’s long-standing reputation for long-term, successful client relationships. Not to mention, our reputation for achieving extraordinary successes for our clients – and successes of history-making proportions at that.

ProjectLos Bronces Copper Ore Pipeline SystemLocationChileClientAnglo AmericanServiceEPCM TimeframeInitial Pipeline 1992Expansion Pipeline 2004Second Expansion Pipeline estimated completion 2011

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History-making engineering project

Project Location Commodity Length, Diameter, Throughput

1 Minas-Rio Brazil Iron Concentrate 522km, 24/26in, 24.5mtpy

2 Escondida Chile Copper Concentrate 167km, 6-9in, 2.0mtpy

3 La Perla Hercules Mexico Iron Concentrate

4 Samarco 2nd Pipeline Brazil Iron Concentrate 400km, 14/16in, 8.0mtpy

5 Essar India Iron Concentrate 268km, 14/16in, 7.0mtpy 253km, 20in, 12.0mtpy

(2nd pipeline)

6 BRPL India Iron Concentrate 217km, 13.25in, 4.0mtpy

7 Esperanza Chile Copper Concentrate 144km, 5-7in, 0.9mtpy (Concentrate) 144km, 36-38in, 2268m3/h (Water)

8 Antamina Peru Copper/Zinc Concentrate 302km, 8-10in, 1.5mtpy

9 Collahuasi and Expansion Project Chile Copper Concentrate 203km, 7in, 1.0mtpy 108km, 8in, 1.5mtpy (Expansion)

10 Alumbrera Argentina Copper Concentrate 312km, 6in, 0.9mtpy

11 Da Hong Shan China Iron Concentrate 177km, 9in, 2.3mtpy

12 Jian Shan China Iron Concentrate 105km, 9in, 2.0mtpy

13 Weng Fu China Phosphate Concentrate 45km, 9in, 2.0mtpy

14 Bao Tou China Iron Concentrate 145km, 14in, 5.5mtpy (Concentrate) 130km, 36in, 2500m3/h (Water) 2.9/2.5km, 22/14in, 7.0mtpy (Thickened Tailings & Paste Surface Disposal)

15 Oleoducto Transandino Argentina Crude Oil SCADA

16 Baku Tbiisi Ceyhan Turkey Crude Oil

17 Falcondo Dominican Republic Crude Oil SCADA

18 Los Bronces and Expansion Project Chile Copper Ore 57km, 20in, 1.0mtpy (Ore) 57km, 24in, 20.0mtpy (Expansion) 52km, 24in, 2200m3/h (Water)

19 Mineracao Bauxita Paragominas Brazil Bauxite Ore 244km, 24in, 9.0-13.5mtpy

20 Goro New Caledonia Nickel Laterite Ore & Tailings

21 Ambatovy Madagascar Nickel Laterite Ore 225km, 24in, 7.0mtpy

22 GATX USA Products SCADA

23 Arco Oriente Ecuador Products SCADA

24 Alaska Fiberstar USA Fiber Optic System

25 Kidd Creek Mine D Canada Paste Backfill System (Zinc)

26 Greens Creek USA Paste Backfill System

(Silver/Zinc/Gold/Lead)

27 Myra Falls Canada Thickened/Paste Tailings (Zinc)

28 Kennecott Utah USA Copper Tailings

29 Tintaya Peru Copper Tailings

30 Cerro Verde and Expansion Project

Peru Copper Tailings 4km, 48in, 39.4mtpy 2km, 48in, 43.8mtpy (Expansion)

31 Gold Ridge Solomon Islands Gold Tailings

32 Batu Hijau Indonesia Deep Sea Tailings

Placement (Copper) 10km, 44in, 55.0mtpy

33 Manitou-Goldex Canada Gold Tailings 24km, 12in, 2.5mtpy

34 Atacocha Peru Copper Tailings SCADA

35 Cerro Corona Peru Copper Tailings 2km, 18/28in, 6.4mtpy

36 Doe Run Cobriza Peru Thickened/Paste Tailings (Copper)

37 Perseverance Canada Zinc Tailings

38 Morenci USA Copper Tailings

& Control System SCADA

39 Bagdad USA Process Control System SCADA

40 Voisey’s Bay Canada Nickel Tailings 10km, 9in, 2.4mtpy

41 Los Pelambres and Expansion Project

Chile Copper Tailings 50 km, 36in, 53.0mtpy (Tailings) 50 km, 28in, 28.0mtpy (Expansion) 60 km, 32in, 3420m3/h (Water)

42 Cayeli Bakir Isletmeleri Turkey Deep Sea Tailings

Placement (Copper/Zinc) SCADA

43 Minahasa Indonesia Deep Sea Tailings Placement (Gold)

44 Transgas Portugal Gas Transmission

45 ADNOC United Arab Emirates Gas Transmission

Our key Process Infrastructure experience

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Key

Copper ConcentrateCopper/Zinc Concentrate Iron Concentrate Phosphate Concentrate

Oil

Bauxite OreCopper Ore Nickel Laterite Ore

Products

SCADAControl System Fibre Optic System

Copper TailingsGold Tailings Nickel Tailings Thickened Tailings Thickened/Paste Tailings Zinc Tailings

Deep Sea Tailings Placement

Gas

Process Infrastructure

4442

16

45

56

32

43

31

20

24

252733

37

28

22

3

17

30

35

3629

2

18

7

15

1

4

19

26

14

11

12

13

21

3839

40

10

9

41

23

834

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All over the world, we are wherever our clients need us to be.

From the sea ice off the coast of Russia to the jungles of Southeast Asia, and even as far as the peaks of the Andes, we find ourselves working under some of the most challenging conditions on earth. We apply our ingenuity to tackle problems and engineer innovative solutions.

We discover through ingenuity, we lead by example.

We are Ausenco.

+1 925 939 4420 info@ausencopsi.com www.ausenco.com