Tag Archives: coal

Rio Tinto and Uni of Nottingham partner on biomass-backed low-carbon steelmaking project

Environmental, Mineral processing, Mining industry recognition, Mining services, Power supply for mines, Steel and iron ore, Sustainable mining, , , , , , , ,

Rio Tinto says it is progressing an innovative new technology to deliver low-carbon steel, using sustainable biomass in place of coking coal in the steelmaking process, in a potentially cost-effective option to cut industry carbon emissions.

Over the past decade, Rio Tinto has developed a laboratory-proven process that combines the use of raw, sustainable biomass with microwave technology to convert iron ore to metallic iron during the steelmaking process. The patent-pending process, one of a number of avenues the company is pursuing to try to lower emissions in the steel value chain, is now being further tested in a small-scale pilot plant.

If this and larger-scale tests are successful, there is the potential over time for this technology to be scaled commercially to process Rio Tinto’s iron ore fines, Rio said.

Rio Tinto Iron Ore Chief Executive, Simon Trott, said: “We are encouraged by early testing results of this new process, which could provide a cost-efficient way to produce low-carbon steel from our Pilbara iron ore. More than 70% of Rio Tinto’s Scope 3 emissions are generated as customers process our iron ore into steel, which is critical for urbanisation and infrastructure development as the world’s economies decarbonise. So, while it’s still early days and there is a lot more research and other work to do, we are keen to explore further development of this technology.”

Rio Tinto’s process uses plant matter known as lignocellulosic biomass, instead of coal, primarily as a chemical reductant. The biomass is blended with iron ore and heated by a combination of gas released by the biomass and high efficiency microwaves that can be powered by renewable energy.

Rio Tinto researchers are working with the multi-disciplinary team in the University of Nottingham’s Microwave Process Engineering Group to further develop the process.

The university’s Head of Department, Chemical and Environmental Engineering, Professor Chris Dodds, said: “It is really exciting to have the opportunity to be part of a great team working on a technology that, if developed to commercial scale, has the potential to have a global impact through decarbonising key parts of the steel production process.”

The use of raw biomass in Rio Tinto’s process could also avoid the inefficiencies and associated costs of other biomass-based technologies that first convert the biomass into charcoal or biogas, the company said.

Lignocellulosic biomass includes agriculture by-products (ie wheat straw, corn stover, barley straw, sugar cane bagasse) and purpose-grown crops, which would be sustainable sources for the process. Importantly, the process cannot use foods such as sugar or corn, and Rio Tinto says it would not use biomass sources that support logging of old-growth forests.

Trott added: “We know there are complex issues related to biomass sourcing and use and there is a lot more work to do for this to be a genuinely sustainable solution for steelmaking. We will continue working with others to understand more about these concerns and the availability of sustainable biomass.”

If developed further, the technology would be accompanied by a robust and independently accredited certification process for sustainable sources of biomass, Rio said.

PT Kaltim Prima Coal feels the effects of AECI IntelliShot electronic blasting initiation system

Explosives and blasting, Mine operation news, Mineral project development, Mining equipment, Mining services, , , , , , , , , , , , ,

Having previously relied on conventional non-electric initiation systems, Indonesia-based PT Kaltim Prima Coal (KPC) has turned to AECI Mining Explosives’ IntelliShot® electronic blasting initiation system to improve the safety and efficiency of its operations.

Located close to Sangatta and Bengalon, East Kalimantan, Indonesia, KPC operates one of the largest open-pit mines in the world with coal resources of 9,275 Mt. The mine employs load and haul operations within its numerous pits, which are managed by two mining divisions: Mining Operation Division (MOD) and Contract Mining Division (CMD).

KPC commenced with coal production in 1992 and today moves approximately 500 million bank cubic metres of overburden per year, which allows the production of 60 Mt of coal. About 80% of the overburden requires drilling and blasting to enable efficient excavation, AECI says.

The mine has traditionally used conventional non-electric initiation within its CMD area, where AECI Mining Explosives Indonesia (AECI Indonesia) is contracted as the blasting services provider. This method required a lead-in-line to be run from the blast location to the firing position. In 2017, this method of initiation consumed approximately 650 m of lead-in-line per blast location, according to AECI.

High daily production targets set by KPC require multiple locations from where blasts could be initiated safely.

“Whilst this is possible within the strict safety parameters set by the mine, it sometimes requires some clever footwork, especially related to moving expensive capital equipment out of harm’s way,” AECI says. “This cumbersome method isn’t always the most efficient and often result in a loss of production time.”

AECI Indonesia, as the incumbent blasting services provider for KPC CMD since 2009, suggested IntelliShot, the company’s advanced electronic blasting initiation system.

IntelliShot has the capability to initiate one or more initiating systems wirelessly, known as remote firing. This application has the ability to generate much needed efficiencies by only using a short length of harness wire as opposed to the cost of a full lead-in-line when non-electric blast initiation is applied in the same application, the company says.

“Any new application of technology at the mine requires careful planning and demonstration of the ability to safely maintain improvement of these parameters,” it says. “The AECI Indonesia team embarked on a carefully controlled trial to test the applicability of the system and to ensure that KPC gets the full benefits.”

In addition to saving on costly lead-in lines, remote firing through the IntelliShot system offers additional safety benefits such as an advanced security system, the possibility to easily initiate the blast at larger and safer distances, allowance for the blaster to fire from locations that give greater visual security of the blast area during firing, and eliminating potential slap, snap and shoot that is possible with shock tube.

The introduction of remote firing at KPC was performed as a project and carried out in stages in the CMD area of KPC. Focused key performance indicator (KPI) targets agreed by the project team were carefully monitored on a daily basis to ensure the best possible outcome.

The project was conducted in the three CMD contractor pit areas at Sangatta and Bengalon under the management of KPC drill and blast department. AECI Indonesia successfully delivered multiple events of remote firing blasting in all areas. The team also complied with all safety and efficiency KPIs, AECI says.

The average usage of harness wire per remote firing event was around 100 m, compared with 650 m per blast of lead-in-line used in conventional blast initiation and has reduced the cost of blast initiation in KPC CMD by over 50%, AECI claims.

Yuli Prihartono, KPC Drill & Blast Manager, says: “Throughout the trial project of remote firing at CMD pits, AECI Mining Explosives has demonstrated its capability to deliver safe and efficient project to world class operations. Remote firing has successfully delivered quantifiable cost benefits for KPC. We expect AECI Mining Explosives to expand this initiative by introducing remote firing to all blast locations at CMD KPC.”

NSW regulator recognises Thiess and MACH Energy’s Mount Pleasant mine rehab work

Environmental, Mine operation news, Mining industry recognition, Mining services, Sustainable mining, , , , , , , , ,

Thiess’ Mount Pleasant Operations (MPO) team has been recognised by the New South Wales Resources Regulator for its industry-leading rehabilitation practices, it says.

Recently publishing an information release about the operation’s rehabilitation controls, the regulator recognised how the team enables long-term landform design stability and manages surface water drainage networks through strong quality assurance measures, according to Thiess.

Thiess, in collaboration with MACH Energy Australia (MACH Energy), has introduced quality assurance controls including the sign-off of inspection and test plans across each construction phase – design, bulk shaping, topsoil placement, ripping and seeding and drain construction, to support progressive rehabilitation and reduce ongoing liabilities.

Thiess Environment & Civil Manager, James Anderson, said these controls provide an unmatched foundation for sustainability, maximising rehabilitation outcomes and managing compliance with confidence.

“The implementation of these controls is an example of how we channel our global experience and insight to create advantages for our projects,” Anderson said. “Our proven systems and processes help deliver immediate efficiencies, reduce rework time and lower life of mine costs for our clients.”

Some 2.5 km from Muswellbrook in the Upper Hunter Valley of New South Wales, the Mount Pleasant Operation’s complex landform design aims to meet end land use objectives while minimising impacts and delivering a more visually appealing landscape for the local community, Thiess explains.

Since 2017, Thiess has provided construction services to MACH Energy including bulk profiling and shaping of mine spoil, construction of drainage networks, erosion and sediment control structures, final surface preparation, installation of habitat features, topsoil ripping, seeding and planting.

This includes delivering the operation’s first rehabilitation two months before first coal was mined.

Thiess Environment Superintendent, Peter York, says the team’s robust processes and strict quality controls are critical to ensuring rehabilitation is delivered on time and to design specifications.

“Our rehabilitation is not just about quantity,” York said. “The final outcomes have to be quality as well, capable of meeting an agreed end land use. To help facilitate this, we work with MACH Energy to identify improvement opportunities to proactively manage environmental risks and adapt to changing regulatory conditions and evolving community expectations.

“Our systematic approach is helping us achieve industry firsts for rehabilitation while restoring self-sustaining native woodland ecosystems.”

Thiess will continue to deliver a full suite of mining services at the Mount Pleasant Operation, including rehabilitation, under a new 4.5-year contract extension commencing in April 2022.

Bravus to employ SMW Group Ultrahaul truck trays on Carmichael Cat 796 AC fleet

Coal technology, Equipment maintenance, Mining consumables, Mining equipment, Mining services, , , , , , , , , , , , ,

Bravus Mining & Resources has awarded contracts worth more than A$3 million ($2.2 million) to Rockhampton-based SMW Group for a series of new Ultrahaul mine truck trays and a bore field maintenance program.

Bravus Mining & Resources CEO, David Boshoff, said Bravus was keen to capitalise on SMW Group’s 20 years of experience servicing central Queensland’s coal fields.

“There’s an extensive mining services knowledge base in our region, and it has always been our intention to use this and work with businesses based in central Queensland wherever possible,” Boshoff said.

“The Ultrahaul tray is a class-leading product for mine haul trucks that SMW Group has developed specifically for the central Queensland coal industry. The trays are tailored for our fleet of Cat 796 AC haul trucks and will help to maximise production and improve operational efficiency.

“We have been impressed by SMW Group’s willingness to work with us to get the product right for our operations and look forward to seeing the results of this relationship over time.”

SMW Group Chief Operating Officer, Frank Humphreys, said that the contract was a great result for the company and central Queensland manufacturing.

“Securing a contract to supply Ultrahaul trays to the Carmichael Project is a great outcome for SMW Group and is a vote of confidence for central Queensland’s mining services industry,” Humphreys said.

“We are excited to be involved with a high-profile operation like the Carmichael Project.”

Boshoff said the contract would have direct benefits for Mackay and Rockhampton, bolstering the local economies against the impacts of COVID restrictions.

“Having this level of manufacturing capacity in our region is a huge boost, because we can continue to grow our fleet and ramp up operations with minimal impact from COVID induced restrictions and border closures,” he said.

“We are proud to have made good on our promises to Queensland, and especially regional Queensland. We have created more than 2,600 jobs and signed more than $2.2 billion in contracts.

“More than 88% of our contracts are being delivered in Queensland. This work has been spread across all corners of the state to give as many regions as possible the opportunity to benefit from our project, while also enabling us to tap into the highly-skilled construction and resources industry workforce that Queensland possesses.

“We are ramping up our mining fleet and construction on the Coal Handling and Processing Plant is well underway. We are excited to be so close to delivering on our promise to ship first coal this year.”

BHP Mitsui Coal and Barada Barna Aboriginal Corp sign South Walker Creek agreement

Environmental, Mining industry recognition, Steel and iron ore, Sustainable mining, , , , , , , ,

The Barada Barna Aboriginal Corporation (BBAC), on behalf of the Barada Barna people, have entered into a Native Title Project Agreement with BHP Mitsui Coal Pty Ltd (BMC) for the South Walker Creek Mine in central Queensland, Australia.

It is the first agreement of its kind between Barada Barna Aboriginal Corporation and BMC, and is structured to deliver immediate and intergenerational benefits to the Barada Barna people, according to BHP.

The agreement will, BHP says, provide mutual benefits and certainty for BMC and Barada Barna.

Financial benefits will be directed towards priority community projects that enable Barada Barna people to live and work on-country, strengthening their important connection. The agreement also delivers ongoing financial security for socio-economic purposes and non-financial contributions in the form of contracting, business, employment, education and training opportunities for Barada Barna people.

The agreement will also support for the ongoing development and operation of South Walker Creek Mine – including a framework for the parties to work together on cultural heritage management and protecting areas of cultural and environmental significance.

Barada Barna Aboriginal Corp Chairperson, Luarna Walsh, said the agreement will ensure lasting and sustainable benefits for the Barada Barna people.

“The agreement will not only provide long-term benefits for the Barada Barna community, it will also achieve projects that BBAC have had in the pipeline for a considerable amount of time.

“Importantly, it sets Barada Barna on a path of self-determination. It will ensure BBAC is sustainable into the future and help our next generation of descendants achieve their goals through schooling and university, and employment and training. This agreement also provides BBAC with the ability to diversify our income streams, by creating Traditional Owner business’ that can tender for a variety of contracts on country.

“I’m very proud to have been involved in this negotiation alongside fellow Barada Barna Directors, and, after tough and sometimes testing negotiations, to say we have reached a successful outcome.”

BMC Asset President, Elsabe Muller, said the agreement sets out the long-term partnership with the Barada Barna people.

“We’re looking forward to continue working with the Barada Barna people and contributing to their communities benefitting from sustainable economic, social and cultural initiatives,” Muller said.

“The agreement outlines a path forward for a long-term relationship based on trust, respect and mutual benefit. It will also see BMC and Barada Barna work together in relation to the management of cultural heritage at South Walker Creek and deepen our workforces’ knowledge and understanding of Barada Barna history and connection to country through cultural awareness training.”

The Barada Barna people are the native title holders (determined in September 2016) over approximately 3,000 sq.km of land in central Queensland, where BMC’s South Walker Creek open-pit mine is located.

Hillery Group to deliver A$15 million of rail infrastructure for Carmichael

Bulk handling, Coal technology, Mining services, , , , , ,

Bowen Rail Company has contracted the Hillery Group to construct a new rail yard at the Carmichael coal mine and rail project in Queensland, Australia.

The A$15 million ($11 million) rail yard will be an important part of the business’ long term operating plan but is not required for the company to commence rail operations later this year, Bowen Rail said.

Bowen Rail Company CEO, Trista Brohier, said partnering with Hillery was another example of how Bowen Rail was delivering on its promises of jobs and work packages for the Whitsunday region.

“We’re pleased that we can now share with the Bowen community how our commitments on jobs and contracts for the Whitsundays are coming to life,” Brohier said. “Partnering with Hillery is a perfect example of this and we couldn’t have picked a better local company to do the job considering their strong technical expertise and knowledge of the region.”

Hillery Group is a family-owned business in Bowen, Queensland, stablished over 30 years ago with, currently, more than 100 employees. Hillery Group specialises in civil construction and plant hire and is an operator of four local quarries, supplying these materials across regional Queensland.

CEO of Hillery Group, Luke Hillery, said the project was a big win for his business and the community.

“We’re really proud to have been given the opportunity to deliver this critical piece of infrastructure for Bowen Rail,” Hillery said. “We see the value that this business will bring to our region for the long term, and it’s great to be one of the first cabs off the rank to win a big contract of this nature. It’s not often we see contracts to build rail yards in Bowen, so we were excited at the opportunity to partner with the Bowen Rail team.”

Brohier said clearing and earthworks are now well progressed in the rail yard’s delivery, with other exciting announcements for Bowen Rail expected shortly.

“We launched the Bowen Rail company in August last year, and we have been enthusiastically working behind the scenes since then to establish our business for operations,” she said.

“We’ve been busy setting up our systems, team and infrastructure, and we’re looking forward to sharing our ongoing progress with our fellow community members as we work towards running trains with our first customer’s coal product from the Carmichael mine later this year. Watch this space!”

Thiess extends relationship with MACH Energy Australia at Mount Pleasant

Coal technology, Environmental, Mine operation news, Mining services, , , , , , , , , ,

Thiess has been awarded a contract extension by MACH Energy Australia to continue providing mining services at the Mount Pleasant Operation in the Hunter Valley, New South Wales, Australia.

The contract extension, which will commence in April 2022, will generate revenue of approximately A$920 million ($678 million) to Thiess over four-and-a-half years.

Having commenced operations when Mount Pleasant was a greenfield coal mine in 2017, Thiess is to continue providing full-scope mining services including drill and blast, overburden removal, coal mining services and rehabilitation.

Thiess Chief Executive Officer and Executive Chairman, Michael Wright, said: “Since 2017, Thiess has provided expert planning and optimum mine sequencing to deliver exceptional outcomes for our client. This contract extension builds on our strong five-year relationship with MACH Energy at Mount Pleasant. We’re pleased to continue to drive long-term social, environmental and economic value for the Upper Hunter region.”

Thiess Executive General Manager Australia & Pacific, Shaun Newberry, said: “We’re proud to continue our work at Mount Pleasant where we have a proven track record of delivering industry-leading environmental practices. We also look forward to continuing our strong relationship with the Muswellbrook community to ensure we deliver mutually beneficial outcomes.”

Thiess says it has a strong presence in the Hunter Valley where it provides mining services at three mines.

Mining fleet changes hands at Boggabri coal operation

Coal technology, Equipment maintenance, Mining equipment, Mining services, , , , , , ,

Most of the major mining equipment used at the Boggabri coal mine in New South Wales, Australia, is to be sold to Boggabri Coal Operations (BCO), part of the Idemitsu Group, following the exercise of an option between BCO and Golding Contractors, a subsidiary of NRW Holdings.

The transaction for the fleet, which includes 38 major mobile mining assets, has a target completion date of the end of July 2021.

Golding will continue to perform maintenance services on site across these, and another 50 (approximately) pieces of major mining equipment, engaging a workforce of over 150 personnel on site, NRW said.

The equipment will be sold for circa-A$81 million ($61 million) of which circa-A$64 million will pay down asset financing debt, NRW said.

NRW’s CEO and Managing Director, Jules Pemberton, said: “The option for BCO to acquire all or part of the associated mining fleet was identified at the time of the acquisition of BGC Contracting. This transaction will reduce debt and increase return on capital employed.

“We look forward to continuing to support BCO to ensure we are best placed to continue to provide our services beyond the current contract completion date of December 2022.”

New Cat D11 dozer arrives at Stanwell’s Meandu coal mine

Coal technology, Mine operation news, Mining equipment, Mining services, , , , , , ,

Stanwell’s Meandu coal mine in Queensland, Australia, has taken delivery of a new Cat D11 dozer from local distributor Hastings Deering.

Ensuring safe and efficient operation, the dozer provides operators with full command, as well as delivering higher productivity at lower cost, Stanwell said.

The mine, owned by Stanwell, has a 7 Mt/y thermal coal capability and is in Queensland’s South Burnett Region.

Engineered to be rebuilt multiple times, the new D11 has a redesigned main frame delivering lower total cost of ownership over the life of the machine, Cat says. Time-saving service updates reduce daily maintenance and boost machine uptime.

The unit comes with new load-sensing hydraulics, high-horsepower reverse and the latest technology to provide higher material movement at a lower cost per tonne.

The first new generation D11 dozer in the world started work at BHP Mitsubishi Alliance’s (BMA) Blackwater coal mine in Queensland, in 2019. National Group secured the first of these dozers earlier from Cat dealer Hastings Deering as part of an order that would see six of these machines hauled by its National Heavy Haulage subsidiary.

Wescoal after RoM upgrade with Acrux, IMS Engineering XRT ore sorting solution

Coal technology, Environmental, Mine operation news, Mineral processing, Mining services, Water management, , , , , , , , , , ,

Acrux Sorting Technology has announced that its advanced sensor-based sorting technology is to be deployed at a Wescoal Holdings Ltd-owned coal mining operation in South Africa.

Acrux subsidiary, Acrux Sorting Coal (ASC), has signed a coal beneficiation agreement with two wholly owned subsidiaries of Wescoal, whereby ASC will deploy advanced sensor-based sorting technology to upgrade lower-grade coal from the mines.

Under the agreement, ASC will provide a fully funded turnkey crushing, screening and sensor-based sorting solution centred around advance dual-energy X-ray Transmission (XRT) unit to process run of mine (RoM) coal.

The plant is to be designed, constructed, commissioned, operated and maintained by IMS Engineering Limited, Acrux’s partner on such ore sorting projects. IMS Engineering is a subsidiary of Germany-based HAZEMAG & EPR GmbH.

ASC’s sorting solution offers significant economic benefits as coal resources can now be upgraded to be included as a saleable product, which will reposition the mines along the cost curve, it said.

Paul Bracher, Managing Director of IMS, said: “The XRT technology has proven its ability to upgrade RoM coal through rejecting material that has sulphur or ash content that exceeds programmed parameters.”

The solution will also have a positive environmental impact as no water is used during beneficiation, and the carbon footprint is reduced through the optimisation of transportation and materials handling.

Wescoal’s Executive Director, Thivha Tshithavhane, said: “This sorting technology solution will enable us to impact on ESG, while creating shareholder value from optimising our coal resources at no capital investment.”

Sean Browne, ASC’s Chairman and Group Founder, added: “Partnering with Wescoal underlines our commitment to driving sustainable innovations that reduce the environmental impact of mining.”