Our Projects

Tujuh Bukit Ore Preparation



Merdeka Copper Gold
Minerals Processing
East Java Province, Indonesia

PT Bumi Sukesindo (BSI) a subsidiary of Merdeka Copper Gold, is responsible for gold and copper production at the flagship Tujuh Bukit Project. The plant is located in Indonesia, in the province of East Java on the side of a complicated mountainous terrain requiring an elevation change of over 65m in a linear distance of only 240m.

Primero was engaged to complete the detailed design and procurement for the Ore Preparation Plant for stages 1 & 2 of the Tujuh Bukit Heap Leach Gold Plant.

Detailed Design

The ore preparation process plant consists of a two-stage open-circuit crushing plant and an agglomeration circuit. Stockpiled agglomerated ore is reclaimed and loaded into haul trucks for delivery to the heap leach pad.

The plant is located on the side of a steep embankment with a total fall of 65m over a linear distance of only 240m. This challenging terrain created a unique set of difficulties requiring an innovative design approach. Primero’s solution consisted of 10 cascading process pad areas following the natural ground contours.

The resulting pads limited the amount of earthworks and provided an optimised process layout. The project scope included civil, structural, mechanical, electrical and control systems design in addition to vendor procurement and management.

Design Management

Primero utilised a 3D Building Information Modelling (BIM) design process to streamline the flow of information from Primero to local installation contractor. A hybrid system of smart 3D models in conjunction with traditional 2D drawings was transferred to the local contractor to compress the design schedule, reduce the number of design hours and decrease the chance of errors between design and construction.

Innovation through engineering process improvement and industry-leading safety in design resulted in a successful multi-disciplinary design delivery.

Throughput Expansion

After the successful delivery of stage 1, Primero was sole-sourced to execute the design of stage 2, increasing the capacity of the original plant from 4Mtpa to 8.2Mtpa by means of a second parallel plant and upgrades to the existing plant agglomeration circuit. This involved navigating significant technical challenges as they related to the existing plant layout and challenging topography of the region.

Primero was responsible for the process, mechanical, structural, piping and electrical aspects of the detailed design activities as well as management of equipment procurement, site support during construction and commissioning assistance.