Metcalf Expansion Project – Morenci, Arizona

Reliable Controls was proud to recently be a part of the Metcalf Expansion Project in Morenci, Arizona. Partnering with owner Freeport-McMoRan, Reliable Controls was pleased to be able to assist with the engineering of the project in 2012, the construction in 2013 and be there when first concentrate was achieved in May of 2014.

The Metcalf Expansion Project consisted of the development and expansion of the copper plant in addition to the expansion of the crushing and molybdenum plant. The $1.4 billion dollar expansion increased annual production by approximately 225 million pounds of copper, milling rates increased from 50,000 metric tons of ore per day to 115,000 and the mining rates grew from 700,000 to 900,000 short tons per day.

A unique aspect of this project was the fact that it was a “fast-track” project. Meaning, that construction of the plant began when the engineering aspect of the project was only 20% complete. With this being the case, Reliable Controls acted as the owner representatives for FMI and ensured that all deliverables were completed with our main responsibility being to check and review the work that was being done, review and enforce the projected schedule and assist in optimizing costs at the project.

Another interesting aspect of this project that should be mentioned is the Hydraulic Roll Crusher. A Hydrolic Roll Crusher (known as a HRC) was implemented on the project and although prototypes and smaller test versions had been created before, this project was the first in the world to incorporate an actual large production, build version and commission it into use.

Finally, RCC was pleased to be able to assist on the commissioning aspect of this project once the engineering and construction phase was completed.

Reliable Controls had a great experience working with FMI on the Metcalf Expansion Project and looks forward to many more chances to partner together to achieve each other’s goals.