507 FROM STRATEGY TO RESULTS: IMPLEMENTING INTEGRATED MINE-TO-PROCESS OPTIMIZATION AT TOROMOCHO A. Muñoz1*, M. Condori1, P. Carrillo1, W. Valery2, R. Valle2, E. Tabosa2, K. Duffy2, R. Hayashida2, C. Plasencia2 and B. Gonzales2 1Minera Chinalco Perú S.A, Perú (Chinalco), Junin, Perú, (*Presenting author: amunoz@chinalco.com.pe) 2Hatch Pty Ltd (Hatch), Brisbane, Australia. ABSTRACT Minera Chinalco Peru S.A. has implemented an integrated Mine-to-Process optimization program at the Toromocho operation to increase throughput when treating harder than anticipated feed ore. The plant design was based on ore hardness values considerably softer than the current feed. Therefore, the specific energy consumption is higher than design and throughput was constrained below design capacity. The comprehensive Mine-to-Process optimization program, conducted in collaboration with Hatch, developed integrated strategies to maximize production and profitability of the overall operation considering the variable feed ore properties. This requires a structured approach and was implemented in phases, commencing with drill and blast optimization to improve ROM fragmentation, which has a significant impact on comminution circuit performance and capacity. Since 2017, structured blasting initiatives have reduced ROM P80 and increased fines content, providing the foundation for comminution optimization. Subsequent optimization of comminution and flotation identified improvements to leverage these upstream benefits through the value chain. Integrated analysis and modelling identified opportunities to increase throughput by up to 14% across both grinding circuits, but this higher throughput would be detrimental to flotation recovery. However, quick wins identified for the flotation circuit could improve overall copper recovery by approximately 1.5% with additional recovery benefits possible from several major CAPEX initiatives. The implemented quick wins have already delivered measurable gains in throughput, recovery, and operational stability, while the longer term planned upgrades are expected to enable the operation to reach or exceed design capacity. Several aspects of this project have been presented previously (Fangrong et al., 2025, 2023, 2022). However, this paper documents the entire project, presenting the structured methodology, results for each phase and the implementation progress. This illustrates how a comprehensive and structured optimization strategy recognizing and accounting for changing ore characteristics can be effectively translated into sustained operational results. KEYWORDS Mine-to-Process, strategy, optimization, comminution, flotation, throughput, copper, recovery, process, simulations, sustainability. 1. INTRODUCTION Minera Chinalco Perú S.A. (Chinalco) operates the Toromocho open pit copper mine in the Andean region of Junín, Peru at ~4,500 m above sea level. Toromocho is one of the largest copper reserves in Peru and globally, with estimated reserves of 1.52 billion tonnes at an average head grade of approximately 0.48% Cu. The comminution circuit includes a primary gyratory crusher feeding a coarse ore stockpile, which supplies two SABC grinding circuits with different installed capacities (Phase I and Phase II). Phase I comprises a 40’×26’ SAG mill (28 MW), two pebble crushers and two 28’×44’ ball mills (22 MW each). Phase II, commenced operations in 2020 and comprises a 36’×17’ SAG mill (13.5 MW), one pebble crusher and one 28’×44’ ball mill (22 MW). The target product size for both grinding lines is 80% passing (P80) 195 µm. The grinding product feeds the bulk flotation circuit. Bulk flotation consists of two rougher lines (Phase I and II), which are fed separately by each grinding line, respectively. The rougher concentrate is combined before feeding the bulk cleaner circuit. If
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