Tag Archives: BMA

Jord International addresses pressing issues for BMA Caval Ridge

Coal technology, Equipment maintenance, Mine operation news, Mineral processing, Mining equipment, Mining maintenance, Mining safety, Mining services, Steel and iron ore, Water management, , , , , , , , , , , ,

Jord International has recently taken up a challenge from BHP to come up with a safer solution to filter press maintenance at the Caval Ridge metallurgical coal mine, in Queensland, Australia, as part of the New South Wales-based company’s expanding remit to unlock new technologies for the wider mining industry.

The plant and systems designer, developer and service provider was awarded the project, part of BHP’s Supplier Innovation Program challenge, earlier this year. It has seen Jord design and construct the first concept prototype in tandem with the maintenance team at the mine.

The prototype comprised a belt cartridge installer within a self-contained steel frame that holds a new belt and removes the old, damaged belt. The first commercial belt installer is expected to be in use by July, according to BMA.

Craig Samuel, Jord’s Mechanical Engineer for Aftermarket and Reliability, said the filters the company worked with at BMA Caval Ridge are 3 m wide x 5 m long, with the product path through the filter around 14 m long. While the solution was designed for Caval Ridge specifically, he said it could have applications on any site or with any commodity using filter presses.

“The idea came from the understanding of how the filter belts are installed, and a cartridge-style installer just made sense considering Caval Ridge has a readily available crane to move the cartridge around,” Samuel told IM. “The mechanics of the installer required some out-of-the-box ideas to develop a continuously variable speed ratio between the new belt roll and the old belt roll.”

Samuel said he expected the belt change time to be cut in half with this new solution.

Jord has already applied for another BHP Supplier Innovation Program challenge that could leverage a dust management and cleaning innovation, but the company has also been investing in research and development to commercialise new minerals beneficiation technologies for more efficient and effective liberation of ore, according to Kevin Barber, Jord’s General Manager of Resources.

“Our goal is to unlock new technologies that provide step-change improvements to current processes in the industry,” he said of these new technologies. “It’s about using less energy, using less water and removing some of the environmental challenges with particular focus on tailings. We’re finding alternative ways of dealing with problematic ores and resources.”

Civmec captures another contract at BMA’s Hay Point coal terminal

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Civmec Ltd has been awarded a contract to manufacture wharf girders and associated structures for the development of port infrastructure at the Hay Point loading port, owned by BHP Mitsubishi Alliance (BMA), in central Queensland, Australia.

The BMA agreement will see Civmec make over 13,500 t of these girders and associated structures, with procurement and shop detailing activities commencing immediately and fabrication starting in the June quarter.

Loadout onto Heavy Lift Vessels is scheduled to start in early 2022, with the last vessel planned for load out in the June quarter of 2022. The project will employ over 350 people during fabrication and assembly at the company’s Henderson facility, in Western Australia.

BMA has already engaged Civmec to fabricate, modularise and commission the 1,800 t SL2A ship loader using pre-contract capital ahead of a large infrastructure replacement project at Hay Point.

Civmec’s Chief Executive Officer, Patrick Tallon, said: “The award for the Hay Point port infrastructure work is the second significant package of works that we have been trusted to deliver for this port upgrade. We look forward to delivering a high-quality product to McConnell Dowell to allow them to have a seamless installation at the site location and welcome the opportunity to work alongside all stakeholders on this project.”

These works are part of the Shiploader 2 and Berth 2 Replacement (SABR) project at Hay Point, which McConnell Dowell is heading up. The SABR project scope encompasses replacement of one of the three berths and shiploaders at the terminal.

Wolff Mining breaks monthly drilling record at BMA Saraji Mine

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Wolff Mining, part of the National Group, has been breaking records at BHP Mitsubishi Alliance’s (BMA) Saraji mine, having recently achieving a drilling milestone at the Queensland coal operation.

Wolff Mining is known for its heavy earthmoving capabilities, being a key supplier of heavy earthmoving equipment to the mining sector on a dry hire or wet hire basis, with drilling equipment and services also offered.

For the past 16 months, the company has been assisting BMA Saraji in a “sprint drilling capacity”, providing drilling equipment and full contract mining services.

It currently supplies BMA Saraji with a Cat MD6420B drill with GPS, and provides operational labour such as supervisors, drillers and fitters.

The MD6420B is one of Cat’s heavy-duty drills designed for open-pit mining, delivering reliable performance and operational safety. It is one of the favoured models by drillers around the world and encompasses leading features from the ultra-class to the mid-size rotary drill line, according to Wolff.

Some of the advanced features available include improved fuel efficiency, electro-hydraulic controls that provide increased operator safety and precision, computer-controlled drilling, enhanced diagnostics and autonomous ready functions, it said.

November drilling at BMA Saraji has been undertaken in 270 mm holes ranging in depth from 30-65+ m in tertiary material, according to Wolff.

The company recently achieved a milestone of 43,794 drilled metres (dm) for the month of November, beating the previous record of 41,500 dm at BMA Saraji.

“The performance of our Cat MD6420B drill has been exceptional,” notes Mark Ackroyd, National Group Managing Director. “It is very rare that a drilling company exceeds 40,000 dm a month, so breaking the site record of 41,500 dm at BMA Saraji, and setting a new record of 43,794 dm for the month of November, is a great achievement.”

He added: “To achieve a milestone such as this takes a highly skilled and motivated team and a high-quality piece of mining machinery such as the Cat MD6420B drill. I would like to congratulate the team here at Wolff Mining for their outstanding efforts and praise the performance of the Cat drill.”

Civmec to build and supply modules for BMA Hay Point shiploader, Iron Bridge project

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Civmec says it has secured new contracts with a combined value of around A$175 million ($126 million) including new projects with BHP Mitsubishi Alliance (BMA) and the Iron Bridge magnetite project.

BMA has engaged Civmec to fabricate, modularise and commission the 1,800 t SL2A ship loader using pre-contract capital ahead of a large infrastructure replacement project at Hay Point Coal Terminal (pictured, still subject to final board approval by BHP and Mitsubishi).

The contract awarded to Civmec includes the supply and assembly of the complete ship loader, up to the no-load commissioning stage. The large material handling equipment will be fabricated at the company’s Henderson manufacturing facility in Western Australia and will be assembled undercover in the company’s newly built assembly hall from where it will be delivered Free Along Side to the Australian Marine Complex Wharf for loading onto a heavy lift ship.

Work will commence immediately, with completion anticipated in the second half of 2022, Civmec says. The award of this scope of work will provide an estimated peak of 150 jobs in Perth.

The Iron Bridge JV contract includes the supply of 4,700 t of conveyor, trusses and trestles for the Iron Bridge Magnetite project, a joint venture between Fortescue Metals Group subsidiary FMG Iron Bridge and Formosa Steel IB.

Work will commence this month, with most of this completed in Civmec’s 2021 financial year. The scope will be predominately delivered from the company’s Henderson facility.

Back in July, Civmec was awarded a standalone civil contract to build the structural concrete components for the dry plant at Iron Bridge.

In addition to the above contracts, Civmec has recently secured new and increased scope packages across its Minerals & Metal and Oil and Gas Sectors, including the replenishment of orders for the fabrication of tray bodies for dump trucks from the Newcastle manufacturing facility.

Civmec’s Chief Executive Officer, Patrick Tallon, said: “We are extremely pleased to be given this opportunity to further support BHP in the delivery of a ship loader. This contract follows on from other smart modules and machines delivered by Civmec for BHP projects as part of our partnership delivering high quality, complex machines.”

He added: “We are delighted to extend our relationship with Fortescue with further work awarded on the Iron Bridge project. Having recently commenced the on-site activities for the recently awarded civil concrete package for the same project and, as we draw closer to completion on the Eliwana project for Fortescue, it is pleasing to get the opportunity to further underpin the relationship.”

BMA to invest in autonomous haul trucks at Daunia coal mine

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BHP Mitsubishi Alliance (BMA) has announced a A$100 million ($69 million) investment and new jobs as part of the introduction of 34 autonomous trucks at its Daunia mine in central Queensland, Australia.

The first retrofit trucks will begin working from February next year, with the rollout expected to be completed by the end of 2021, it said.

The 4.5 Mt/y Daunia coal mine opened in 2013 and has a truck fleet that includes Cat 793Fs.

BMA Asset President, James Palmer, said this was a multi-generational investment in the industry and  state at a time when it is needed.

“We acknowledge the important role our business and industry can play in supporting Queensland communities and the local economy during this time,” he said.

“This announcement is a vote of confidence in Central Queensland. At least 10 regional and indigenous businesses will be employed to support the rollout, with contracts worth A$35 million. This will result in 150 additional project roles for BMA people and contractors. This is on top of 56 new permanent roles on site.”

He reiterated that there would be no job losses as a result of the decision and anyone who currently works with the company – as an employee or labour hire worker – would be given the opportunity to continue to do so.

Hastings Deering’s Central Queensland operations will see an additional 30 jobs required to assist with truck and ancillary fleet conversion.

Hastings Deering CEO, Dean Mehmet, said: “This contract is a huge boost to our local business and the region. We will need 30 additional people to support the work that is required to convert the trucks and ancillary mining fleet into autonomous vehicles at Daunia. It’s exciting work to build on that allows us to grow and develop local talent to deliver technology solutions into the resources sector.”

Other examples of local businesses that will directly benefit from this decision include NB Industries, who will complete the light vehicle fleet conversion, and Radlink who will install wireless communication hardware across the mine.

NB Industries is also involved in completing the fit out of ancillary equipment for the AHS rollout at BMA’s Goonyella Riverside mine, in Central Queensland.

Palmer highlighted the employee engagement and training that is central to this decision.

“We have engaged with our workforce at Daunia over the previous 18 months on the possible rollout of autonomous haulage. Our people have told us that they are eager for new job opportunities and skills. That is why we are confident this is the right decision for Daunia.

“It will further increase safety and performance and help the mine remain competitive over the long term.

“We understand this decision represents some change. But it also offers a unique opportunity for people to gain new, highly valued skills that will create additional opportunities for growth into the future.”

To help prepare for Daunia’s autonomous future, it is estimated over 30,000 hours of training will be delivered, ranging from general awareness to extensive training for those operating equipment, interacting with the autonomous haul trucks, or taking on new roles.

In addition to pledging to bring autonomous trucks to Daunia and Goonyella Riverside, BHP is looking to start the roll out of autonomous trucks at its Eastern Ridge mine site in the Pilbara of Western Australia shortly.

LDO Group looks to accelerate away from Australia BEV competitors

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LDO Group of New South Wales is looking to capitalise on the push toward reducing diesel emissions in underground mining operations in Australia by supplying Rokion battery-powered crew and utility vehicles that not only decarbonise mining environments, but also potentially boost mine productivity.

LDO has held the exclusive distributor mantle for Canada-made Rokion battery-powered vehicles in Australasia since 2018. In that two-year period, the company has seen interest in electrification gradually increase.

In South Australia, BHP has trialled light electric utility vehicles at Olympic Dam with Voltra’s LandCruiser conversions. In Victoria, Safescape’s Bortana EV has built up four months’ worth of usage data from Kirkland Lake Gold’s Fosterville mine; the vehicle has also had a brief outing in Western Australia’s renowned Kambalda nickel district. Other mine-ready utility vehicles have also made an appearance in Australia such as the Tembo 4×4 Electric Cruiser and Electric HLX.

These come on top of the battery-electric ST14 LHD Epiroc has delivered to the Glencore-owned CSA mine at Cobar in New South Wales, plus the interest logged from the recent tour of Sandvik-owned Artisan Vehicle Systems’ Z50 battery-electric haul truck.

The last 12 months has been a busy period for LDO, with initial interest from the Australian market being converted into trials (more on that later) or much more advanced discussions, according to LDO Managing Director, Peter Ross.

“There has always been an interest since we started looking into this in 2015, but, in the last year especially, we have seen it spread right throughout the coal industry,” he told IM.

It is the Australian coal sector the company is currently focused on, a market that, until now, has been further down the pecking order for battery-electric vehicle producers. Most have homed in on the country’s hard-rock mines.

Underground coal mines are also a new environment for Rokion’s trucks, which are currently proving their worth at Vale’s Sudbury nickel operations in Canada.

Alan Ross, Sales Manager at LDO Group, says the Rokion battery-powered vehicles are prepared for the challenge of operating in an underground coal mining environment.

“Most of the tailoring is from an Australian regulatory perspective,” Alan Ross said. “The machine has already been specifically designed for underground environments, so will be able to cope with these conditions.”

While acknowledging the “serious competition” from other electric vehicle suppliers, Peter Ross said the Rokion products are second to none in their class: “Rokion trucks are engineered from the ground up for mine use, and built by an OEM with significant mining pedigree – these vehicles are not conversions.”

He added: “It’s all well and good having battery-powered machines, but they have to be able to deal with the realities of operating in an underground mine, protecting personnel while navigating roads and ramps that can deteriorate from one hour to the next.”

The benefits of improved drive ergonomics and environmental conditions are often overlooked while focusing on vehicle performance, according to Peter Ross.

“Our trucks produce no emissions, generate less heat and less noise than all other mining vehicles,” he said. While difficult to measure, it is expected that an improved working environment would allow mine personnel to perform to their potential, boosting overall mine performance.

Drive ergonomics and employee performance are not the only selling points.

Rokion trucks are equipped with lithium iron phosphate batteries – the safest battery technology currently available, according to Rokion. Battery modules are (re)charged on ramp descent thanks to the vehicle’s regenerative braking capacity, which contributes to longer operating times without charge. Other benefits include reduced brake and drive wear, extending the duration between maintenance intervals, Rokion says.

The vehicles can also navigate mine sites with 20% grade at a full gross vehicle weight and full speed while travelling more than 70 km per charge – typically more than enough to get the battery through a full shift.

On top of this, Rokion has manufactured its battery-powered vehicles for simple and easy maintenance.

The modular change-out options – which extend to both the battery and drive system – are “ideal for remote mining locations where the priority is to have dedicated service personnel with expertise in production mining equipment rather than in electric vehicle technologies”, Rokion says. This will come in handy in the coal mining hub of the Bowen Basin, in Queensland, where maintenance staff with battery-electric expertise are in demand and in short supply.

Broadmeadow baseline

It is this region where LDO has made some serious headway of late with the Rokion vehicles.

The BHP Mitsubishi Alliance (BMA) is in the process of preparing a Rokion R400 to go underground at the Broadmeadow mine, near Moranbah in the Bowen Basin. This follows an above-ground trial of the smaller Rokion R200 at the same mine.

BMA is a 50:50 joint venture between BHP and Mitsubishi Development Co that operates seven metallurgical coal mines in the Bowen Basin, plus the Hay Point Coal Terminal near Mackay.

Paul Wyatt, Electrical Engineering Manager, Governance & Technical Stewardship Superintendent at BMA Broadmeadow, said the company initially visited Rokion in Canada back in 2017. At this time, the Rokion range included the R100 that came in a two-passenger utility or four-person crew configuration and the R200, built on a slightly larger four-passenger vehicle platform with double the battery capacity (44 kWh).

On the lookout for a battery-electric personnel carrier vehicle to test at its Australian mine sites, BHP agreed to trial an R200 at Broadmeadow. This was part of a group-wide project to reduce health impacts from diesel particulate matter exposure at BHP underground operations.

In 2018, the R200 then took part in an above-ground trial at the underground Broadmeadow mine.

Wyatt explained to IM: “We mapped the underground RLs (Reduced Levels) and we did a series of trials around the surface of the mine to get a grip on the dynamics of the machine, its performance in this replicated environment, the charging time, and how it coped with the extreme heat of Australia compared with Canada where it had previously worked.”

This trial proved successful on all fronts.

“That surface trial laid the platform for us to move into the underground environment,” Wyatt said. “We then knew the vehicle was capable of working underground, and we also knew it could be charged on the surface ahead of a shift and would not need charging again.”

The latter factor was important for the Broadmeadow team as the establishment of underground charging infrastructure would have added complexity to the project.

A zonal system coordinated through RFID tags on the R200 and underground mine infrastructure meant the non-explosion-protected vehicle could roam around 80% of the underground mine without entering hazardous areas close to the working face. Modifications to the gas monitoring capabilities of the machine also meant it ticked the regulatory box required for underground coal mine use.

More testing ensued, with the results, again, proving positive.

“The operators liked the quietness of the machine, the reduced heat generation and the fact you could have a conversation with other people while operating the vehicle,” Wyatt said.

The Broadmeadow team were still keen to see how the newest Rokion machines would perform at the underground mine considering the product advancements the Rokion Engineering team had made since the 2018 R200 was delivered for testing, hence the latest R400 trial.

The R400 platform allows for a diverse range of vehicle configurations from three or six passenger utility up to nine or 12 passenger crew variants, Rokion says. It also comes with 100 kWh of battery capacity and a much smoother ride, according to Wyatt.

Wyatt said the R400 was only weeks away from going underground at the mine after arriving at Broadmeadow earlier this year.

While using the same underground blueprint the R200 had in place – coordinated through the RFID tags equipped on the machine and mine – the R400 will be used as a “development support” vehicle in this latest trial, taking people close to the working face, but staying within the ‘non-hazardous’ zones of the mine as the R400 is not yet explosion-protected, something Rokion and LDO are working toward changing.

The two companies are expecting to release the explosion-protected version of the R400 sometime in 2021.

This is not the only battery-electric machine set to be tested at Broadmeadow in the medium term, with a battery-electric LHD trial also being eyed up, according to Darren Wood, BMA Broadmeadow’s Project Manager of Mods & Small Projects.

In the meantime, the R400 trial will allow Broadmeadow to gain a better understanding of how it could eventually use battery-electric utility vehicles for crews of up to 12: the number it currently transports in diesel-powered personnel carriers at the mine.

Rokion says it is well positioned to meet this demand as development of a 12-passenger R400 is now complete while development of an explosion-protected model is well underway.

The BEV race

LDO hopes the progression of the R400 trial at Broadmeadow will generate further interest in battery-powered technologies in Australia.

BMA’s reviews to date will help this cause, with Wyatt saying the advancements in engineering from the R200 it had on trial to the new R400 waiting to go underground at Broadmeadow were impressive.

LDO will be hoping to make the most of this opportunity, ensuring it retains its lead over battery-electric competitors only now starting to look at Australia’s underground coal market as a lucrative proposition.

McConnell Dowell to bring marine construction expertise to BMA project at Hay Point

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McConnell Dowell says it has signed an Early Contractor Involvement (ECI) contract with the BHP Mitsubishi Alliance (BMA) for its Shiploader 2 and Berth 2 Replacement (SABR) project at the Hay Point Coal Terminal, in Queensland, Australia.

The SABR project scope encompasses replacement of one of the three berths and shiploaders at the terminal. The wharf and shiploader being replaced have reached end of life, according to McConnell Dowell, and the SABR project will see replacement of both facilities. At the same time, it will improve operability (with a berth extension) and storm immunity (by raising of the berth).

In collaboration with BMA and its design engineer Aurecon, McConnell Dowell will work in an “integrated project delivery environment” to optimise the facility design and construction methodology, so the project can be completed in 2023, the company said.

The scope of the contract includes the “provisions of constructability input”, advice, and preparatory work for construction, including assisting with facility design; construction execution planning; and estimating and planning assistance, McConnell Dowell said.

Back in 2015, BMA opened the new third berth at its Hay Point coal terminal, which lifted the export capacity from 44 Mt/y to 55 Mt/y.

“McConnell Dowell is thrilled to be partnering with BMA once again and bringing our leading marine construction expertise to drive innovation and project certainty.”

BMA Blackwater coal mine starts up new gen Cat D11 dozer

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The first Caterpillar new generation D11 dozer in the world has started work at BHP Mitsubishi Alliance’s (BMA) Blackwater coal mine in Queensland, Australia, according to mining, resources, transport and logistics group National Group.

National Group secured the first of these dozers earlier this month from Cat dealer Hastings Deering as part of an order that would see six of these machines hauled by its National Heavy Haulage subsidiary, the company said.

While the specifics of this new dozer are not yet known, Cat did plan to launch an update to its D11 earlier this year. This would have seen the machine receive new load-sensing hydraulics and new drivetrain components among other additions.

BMA’s Blackwater coal mine, in Queensland’s Bowen Basin, produced close to 2.1 Mt of coal in the most recent September quarter, according to BHP.

In a Hastings Deering release in mid-December, National Group’s Managing Director, Mark Ackroyd, said: “The D11 is the industry’s best large dozer so it was a logical choice for us to bring in six new dozers to add to our expansive fleet.”

Along with load sensing hydraulics reducing fuel burn, the new D11 will extend out component life from fuel burn to overhaul, according to the company. Caterpillar has developed this machine to ensure faster cycle times to produce more dirt at a lower cost per tonne, National Group added.

Ackroyd said the contribution the dozers will add to production and efficiency will boost overall performance on site. “We expect to lower maintenance and repair costs by up to 5% thanks to a new case and frame design, improved bearings, redesigned pin joints, and a 30% larger oil pan.”

Jason Garea, Mining Account Manager at Hastings Deering, said: “There is a single frame now used between both the D11 standard dozer and the carry dozer applications. It’s a beefed-up frame that now does both.”

National Group has lined up all six dozers to be fitted with the new Reclamation blade, or XU Blade, which takes the dozer from a 34 cu.meter blade, to a 42.2 cu.m, according to Garea. “The best thing here is that it still handles like a U-Blade and can go into the same applications. They are far, far more productive which reduces the cost per tonne.”

The second D11 dozer is expected to be commissioned onsite at Blackwater in January.

BMA to automate haulage operations at Goonyella Riverside coal mine

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BHP Mitsubishi Alliance (BMA) says it will implement autonomous haulage at its Goonyella Riverside coal mine, in central Queensland, next year.

BMA Asset President, James Palmer, said haul trucks would be retrofitted with autonomous vehicle technology, allowing the completion of an extensive study and engagement with the workforce, community and all levels of government.

“Autonomous haulage will help us improve safety and productivity performance, and it is our people who will be at the centre of making this change a success,” he said.

“While the first autonomous vehicles will not operate at the site until 2020, and full roll-out will take around two years, we want to give people in our workforce and the community as much notice as possible of this change,” Palmer said.

The introduction of autonomous haulage at Goonyella Riverside will involve the staged conversion to an autonomous fleet of up to 86 Komatsu trucks over the next two years. It will build on the mine’s strong production record by increasing truck hours and delivering more consistent cycle times, according to BMA. Haulage automation is also expected to improve safety by reducing risk exposure and decreasing significant events.

There will be no forced employee redundancies at Goonyella Riverside as a result of this decision with respect to autonomous haulage, according to BMA. With recent recruitment of new permanent positions in BHP Operations Services and creation of new roles through autonomous haulage, overall permanent job numbers across BMA operations will increase, the company said.

Palmer said BMA’s long term commitment to the region is underpinned by a responsibility to provide training opportunities for local workers to ensure they have access to the skills and capabilities to succeed in the future of mining.

To help prepare for Goonyella Riverside’s autonomous future, it is estimated over 40,000 hours of training will be delivered, ranging from general awareness to extensive training for those operating equipment, interacting with the autonomous haul trucks, or taking on new roles.

As BMA’s first site to implement autonomous haulage, Palmer said BMA had been talking to its workforce and the local community about the potential for increased automation of mining operations for several months leading up to today’s announcement.

“We understand that automation represents a significant change. It also offers a unique opportunity for people to gain new, highly valued skills,” he said.

No further decisions have been made to implement autonomous haulage at any other site in BMA’s Queensland Coal division, with the company saying any future decisions to implement autonomous haulage will be made on a site-by-site basis.

The first autonomous trucks are expected to be operational in the first half of 2020.

Golding and BMA strengthen ties with Blackwater civil works contract

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Golding Contractors has been awarded a contract by BHP Mitsubishi Alliance (BMA) for civil works at the Blackwater coal mine in Queensland, Australia.

The NRW Holdings’ wholly-owned subsidiary’s scope of works to be undertaken included establishing alternate access for heavy vehicles outside of the mining footprint; providing civil infrastructure to enable the relocation of a communication mast; relocating critical mine infrastructure (HDPE pipeline, high voltage power lines, fibre optic cable); constructing the drainage structure, to remove water flows from the proposed mining area into an existing creek system; and providing flood protection (levees) for the new and existing mining pits.

As part of this project, around 1.2 Mm³ of earthworks, 4 km of HDPE pipelines, 22 km of fibreoptic cabling and 21 km of overhead cabling is expected to be installed.

The works have an approximate value of A$35 million ($23.7 million) and contract completion is anticipated to be in January 2021.

NRW’s CEO and Managing Director, Jules Pemberton, said it was pleasing to be awarded this contract following work secured in July for the same client at Goonyella, with a value of circa-A$34 million.

Those works, also being undertaken by Golding, include around 950,000 m³ of earthworks and 10 km of new pipework, with completion scheduled in August 2020.