Tag Archives: conveyor

Weir’s ore characterisation work shifts gears to value generation loop

Base metals, Comminution of minerals, Environmental, Mineral processing, Mining equipment, Mining services, Steel and iron ore, Sustainable mining, , , , , , , , , , , , , , , , , ,

Chris Carpenter, VP of Technology for Weir ESCO®, is on a crusade to educate the mining industry on the importance of orebody knowledge.

As an executive with more than 35 years of experience and 40 patents to his name, he has heard numerous stories about “sub-optimal operational decisions” being made at mine sites due to a lack of information.

Through an ore characterisation project under development within several teams at Weir, Carpenter shared the company is focused on developing cost-effective solutions to provide this information in real time.

He is, however, aware that the mining sector, as a whole, needs convincing.

“I can tell you that many of our customers do not yet acknowledge the full value of what we are looking to provide the sector,” he told IM.

This is changing, with industry studies on the correlation between poor orebody knowledge and negative financial impacts and risks in the mine development process coming to light – IMDEX, the Mineral Deposit Research Unit and the Bradshaw Research Institute for Minerals and Mining at the University of British Columbia and Ideon Technologies are, for instance, currently engaged on such a study.

In announcing the study, IMDEX Chief Geoscientist, Dave Lawie, hit on a similar theme to Carpenter: “For the mining industry to adopt this technology, it must have clear evidence of the financial impacts and risks of poor or no orebody knowledge and a way of assessing the most efficient methods of collecting, analysing and optimising it.”

What “this technology” is remains open to debate, with many pre-concentration and ore sorting technologies continuing to sprout up among fertile innovation soil in the mining sector.

ESCO and Carpenter believe this technology – at least in a base metals and iron ore application context – has roots in Sustainable Development Technology Canada (SDTC), an arm’s-length foundation created by the Government of Canada to fund new clean technologies. Motion Metrics International Corp received SDTC funding back in 2020 for a project using the core innovations of hyperspectral imagery (HSI) sensors, 3D particle size distribution (PSD) analysis and machine-learning algorithms to control energy-intensive mining equipment, an SDTC backgrounder from 2020 explained.

Chris Carpenter, VP of Technology for Weir ESCO

Motion Metrics, in a separate announcement, said the 3.5-year project would lead to the design, development and deployment of a commercial mine-to-mill energy efficiency solution.

“Upon successful completion, mines worldwide will be able to order and deploy this solution, without changing their daily operations, to meet their sustainability targets while reducing their comminution costs,” it said.

University of British Columbia’s Norman B. Keevil Mining Engineering Department and several other organisations partnered with Motion Metrics for this project.

A lot has changed in the four years since this announcement, with Weir Group having acquired Motion Metrics International Corp and been incorporated into ESCO.

IM initially reported on developments of what Carpenter referred to as an “ore characterisation” project in 2022. At that time, this consisted of a BeltMetrics™ trial installation using a MOTION METRICS™ advanced imaging sensor for PSD analysis and a commercial, HSI sensor positioned above a conveyor that was directly after the crusher in a mine’s flowsheet.

When IM caught up with Carpenter in late July, he could report on not only progress with the BeltMetrics installation, but also a fixed-term trial of “ore characterisation” in a TruckMetrics™ installation.

“We have now run two different applications for the technology,” he said. “The belt monitoring trial continues to operate and has demonstrated the ability to predict SAG mill throughput based on the input ore characteristics. We also ran a very successful trial of bulk sorting using similar technology looking at the content of haul trucks. The trial monitored and analysed around 1,000 trucks and several were identified as low grade. Extensive lab testing continues as we evaluate mine ore samples to understand the capabilities of our approach. Based on our lab and field evaluations we are convinced the technology will allow us to quickly and accurately monitor grade, alteration, deportment and deleterious minerals.”

The BeltMetrics trial installation uses a MOTION METRICS advanced imaging sensor for PSD analysis and a commercial, HSI sensor positioned above a conveyor that is directly after the crusher in the mine’s flowsheet

“I would say our proof of concept work has really allowed us to now pick up the pace of investment and search for more development partners to further this technology.”

The TruckMetrics ore monitoring trial – carried out on 100-232 t-payload trucks – may pique interest here, but Carpenter says the initial product development path lies in the processing plant and on the conveyor.

“We are looking to, first, put more minimum viable products (MVPs) out in the market for belt-based solutions,” he said. “While our initial entry into this space was to look at bulk sorting – and we recognise this is still the ‘big target’ – [the] voice of [the] customer research has identified a huge need to provide plant-based systems for applications in managing stockpiles and feed grades.”

These MVPs are likely to be deployed on “development partner” sites with existing separation mechanisms downstream of the crusher – ie apron feeders – where diversions can be made based on the HSI and PSD data.

This same voice of the customer research highlighted the need for an in-pit system that could boost productivity, throughput and recovery ahead of the plant, yet the financial amount estimated for a commercial system based on the HSI and PSD sensor combination did not find favour.

“This has led to our own research into what we feel is a new-to-the-world application or modification of standard HSI,” Carpenter said. “We believe this will give us a competitive edge in the market.”

Illumination restrictions and uses have often been touted as the potential drawbacks of using spectral imaging in the ore sorting space, which IM understands is one of the areas of focus for Weir’s own R&D and lab-based testing.

But there are also other factors to consider ahead of a commercial Weir proposition – whether that is in the pit or plant – landing on the market.

“We don’t just want to be sensor salespeople,” Carpenter says. “The complexity and variety of applications will require a shift to specific solutions for our customers and the need to back that up with the aftermarket service our customers expect becoming their productivity partner.

“What we are proposing is more than just technology; it needs to be a solution that validates the value on a regular basis in a continuous loop.”

That same loop comes back to Carpenter’s and Lawie’s assessment of the industry need to acknowledge the value of such data ahead of adopting the technology.

“Fortunately, our ‘Mining technology for a sustainable future’ focus at Weir is allowing us to invest the money the industry needs to provide both the value generation and value acknowledgement to make such solutions viable and effective,” Carpenter concluded. “This type of work – and orebody knowledge more widely – is critical for the future of mining.”

Bedeschi stacker, conveyor being commissioned at Shougang Hierro iron ore ops

Bulk handling, Mine operation news, Mineral project development, Mining equipment, Mining services, Steel and iron ore, , , , , ,

Close to eight months after announcing the contract award, Italy-based Bedeschi S.p.a. has delivered a stacker and conveyor to Peru-based iron ore miner, Shougang Hierro Peru SAS.

The STK33/1000 stacker and conveyor have been designed to operate at a 1,800 t/h rate, and are being used as part of an expansion project. They have been installed in the San Nicolas beneficiation area where the mineral is processed and stocked before being dispatched.

Both pieces of equipment are in the commissioning phase ready to be handed over to the mine operators, Bedeschi said.

Back in December, the company announced the order from Shougang Hierro, saying it would be responsible for engineering, manufacturing and delivery of one conveyor (width 1,000 mm and total length of 710 m) and one stacker STK33/1000 designed for a nominal stacking rate of 1,500 t/h of iron ore.

It was also supporting Shougang Hierro in the optimisation of existing equipment, implementing DEM analysis and optimised design on interfaces with the new supplied equipment.

Shougang Hierro’s open-pit mine uses Chinese TYHI WK12 rope shovels loading Komatsu HD1500-7 and Caterpillar 785C trucks to transport ore to primary crushers, from where ore is conveyed to San Nicolas via a belt approximately 15.3 km long and with a capacity of 2,000 t/h.

The secondary crushing plant at San Nicolas sees the iron ore reduced in size by approximately 95% then fed to a magnetic separation plant for mill grinding and concentration via cyclones, magnetic separation and flotation, separated into two types of products, high-grade iron concentrate for sintering and the other used to feed the pelletising plant, after going through a filtration process. In the filter plant, thickening, homogenisation and filtering of the pulp received from the magnetic plant are carried out, leaving the ore ready to be made into pellets.

Yamana Gold retains electrification path for Wasamac in new study

Automation, Comminution of minerals, Environmental, Mine ventilation, Mineral processing, Mineral project development, Mining equipment, Power supply for mines, Precious metals, Sustainable mining, Water management, , , , , , , , , , , , , ,

Yamana Gold has reiterated a plan to minimise the amount of carbon emissions generated with the development and operation of the Wasamac gold project in Quebec, Canada, in its first study since acquiring the asset from Monarch Gold.

Monarch, prior to being taken over by Yamana Gold, had laid out plans for an underground mine at Wasamac producing 6,000 t/d, on average, with an expected mine life of 11 years. It expected to use a Rail-Veyor® electrically powered, remote-controlled underground haulage system in addition to an almost entirely electric fleet of production and development equipment.

The December 2018 feasibility study by BBA indicated the Wasamac deposit hosted a measured and indicated mineral resource of 29.86 Mt at an average grade of 2.7 g/t Au, for a total of 2.6 Moz of gold, and proven and probable mineral reserves of 21.46 Mt at an average grade of 2.56 g/t Au, for a total of 1.8 Moz of gold. The study forecast average annual production of 142,000 oz of gold for 11 years at a cash cost of $550/oz.

With drilling, due diligence and further studies, Yamana Gold, in studies forming the new feasibility level studies, has come up with baseline technical and financial aspects of the Wasamac project that, it says, underpin the decision to advance the project to production.

This has resulted in a few changes to the Wasamac plan.

For starters, the company plans to use the extract the now 1.91 Moz of reserves quicker than Monarch’s strategy, with a rapid production ramp-up in the first year followed by sustained gold production of approximately 200,000 oz/y for at least the next four years.

Including the ramp-up phase, average annual production for the first five years of operation is expected to be 184,000 oz, the company said, with life of mine production of 169,000 oz/y. Mill throughput has been increased to 7,000 t/d, on average, but the plant and associated infrastructure were being sized for 7,500 t/d. Production could start up in the December quarter of 2026, the initial capital expense was expected to be $416 million and all-in sustaining costs over the life of mine had been calculated at $828/oz.

The use of a conveyor is still within this plan, but a company spokesperson told IM that Yamana was now considering a conventional belt conveyor rather than the Rail-Veyor system.

Yamana explained: “The optimised materials handling system uses ore passes and haul trucks to transport ore from the production levels to a central underground primary crusher. The haul trucks will be automated to allow haulage to continue between shifts. From the underground crusher, ore will be transported to the crushed-ore stockpile on the surface using a 3-km-long conventional conveyor system in two segments.”

Yamana added: “Using a conveyor rather than diesel trucks to transport ore to surface reduces CO2 emissions by 2,233 t/y, equivalent to taking 500 cars off the road. Over the life of mine, the company expects to reduce CO2 emissions by more than 20,000 t.”

The aim to use electric vehicles wherever possible remains in place.

“The Wasamac underground mine is designed to create a safe working environment and reduce consumption of non-renewable energy through the use of electric and high-efficiency equipment,” the company said. “Yamana has selected electric and battery-electric mobile equipment provided that the equipment is available at the required specifications.

“Battery-electric underground haul trucks are not yet available at the required capacity with autonomous operation, so diesel trucks have been selected in combination with the underground conveyor. However, Yamana continues to collaborate with equipment suppliers with the expectation that the desired battery-electric equipment will be available before Wasamac is in operation.”

In tandem with this, the company plans to use a ventilation on demand solution and high-efficiency fans to reduce its power requirements. This will likely rely on an underground LTE network.

“Heating of the underground mine and surface facilities is designed with the assumption of propane burners, but an opportunity exists to extend the natural gas line to the project site,” it added. “Yamana has initiated discussions with the natural gas supplier and will study this opportunity further as the project advances.”

The site for the processing plant and offices is confined to a small footprint strategically located in a naturally concealed area, and the processing plant has been designed with a low profile to minimise the visual impact as well as minimise noise and dust, according to Yamana.

The primary crusher, previously planned to be located on surface, has been moved underground, with the crushed material transported to surface from the underground mining area using conventional conveyors and stored on surface in a covered stockpile to control dust.

Several design improvements to the previous Wasamac plans have also been made to reduce consumption of fresh water to minimise the effect on watersheds, according to Yamana. Underground mine water will be used in the processing plant, minimising the draw of fresh water and reducing the required size of the mill basin pond.

The Wasamac tailings storage strategy is designed to minimise environmental footprint and mitigate risk, it added.

“Around 39% of tailings will be deposited underground as paste fill and 61% of tailings will be pumped as a slurry to the filter plant located approximately 6 km northwest of the processing plant and then hauled to the nearby dry-stack tailings storage facility,” Yamana said.

Strategic phasing of the tailings storage facility design allows for the same footprint as previously planned, even with the increase in mineral reserves, the company clarified. Also, the progressive reclamation plan for this facility minimises the possibility of dust generation and expedites the return of the landscape to its natural state.

Doppelmayr ropeway tackles mine backfill task at Buriticá gold operation

Bulk handling, Mine operation news, Mining equipment, Mining services, Precious metals, , , , ,

A Doppelmayr ropeway is now up and running at the Buriticá underground gold mine in northwest Colombia, navigating mountainous terrain to transport backfill material from the bottom of the valley to the mouth of the mine.

In October 2017, Austria-based Doppelmayr was awarded the contract to build a 1.4 km long ropeway with material buckets for a transport capacity of 175 t/h. The system was conceived as a continuous bi-cable ropeway, with a fixed tensioned track rope for the material buckets with their carriage to travel on. The buckets are driven by the continuously moving haul rope loop to which they are attached via detachable grips.

The area where the mine, owned by Zijin Mining, is located is mountainous and therefore logistically challenging. The reusable residues of the gold extraction process are used as underground backfill, which is why they must be taken from the bottom of the valley to the mouth of the mine at 1,700 m above sea level, thereby covering a difference in altitude of approximately 646 m. What would be an arduous and long journey for trucks, with plenty of exhaust emissions, becomes a swift and efficient job if a material ropeway is used, Doppelmayr says.

To allow for the haul rope to be run at a constant speed, the buckets are detached from the loop in the stations and slowed down before they are loaded via a chute. Once a bucket has been filled, it is accelerated to running speed again and re-attached to the haul rope before leaving the station.

In the unloading station, the bucket is once more taken off the haul rope. At the designated unloading point a special mechanism unlocks the latch on the bucket, the bucket is tipped, and the material is safely transferred onto another chute. The bucket then returns to its original position. It is locked again and re-attached to the haul rope before travelling back into the valley empty.

In the past, continuous bi-cable ropeways have often been used for material transport applications, the company explained.

“For the Buriticá project, Doppelmayr’s engineers have revised the design and mechanics of continuous bi-cable ropeways from scratch and optimised it for the transport of material in buckets,” it said. “The system complements Doppelmayr’s portfolio of material transport solutions.”

Put into service in February 2021, the solution has a transport capacity of 175 t/h of gold residues, a running speed of 6 m/s, and comes with 20 carriers and one tower.

Mechel’s Southern Kuzbass Coal Company launches new longwall

Coal technology, Mine operation news, Mineral project development, Mining equipment, Steel and iron ore, , , , , , , ,

Mechel, one of Russia’s leading mining and steel companies, has launched a new longwall at the Southern Kuzbass Coal Company-owned V.I. Lenina underground mine in Russia.

Investment in the new longwall totalled around RUB470 million ($6.4 million), the company said.

The new longwall #0-16-10’s reserves are estimated at 435,000 t, with the average seam height coming in at 1.8 m. The longwall is nearly 200 m long with an extraction panel of 720 m.

The longwall is equipped with a 134-section powered support system, a cutter-loader, as well as a crusher, longwall conveyor and belt conveyor, Mechel said. All the longwall’s equipment is compliant with modern industrial and labour safety requirements, it added.

“V.I. Lenina Underground Mine’s reserves consist of coking coal with excellent quality characteristics, which is high in demand with coke producers,” Mechel Mining Management’s Chief Executive Officer, Igor Khafizov, said. “Southern Kuzbass Coal Company will be working this new longwall for eight months. The concentrate we will produce from its coal will be marketed both domestically and internationally.”

Newmont overcomes COVID-19 challenges to complete Musselwhite gold mine work

Bulk handling, Mine operation news, Mining equipment, Mining services, Precious metals, , , ,

Newmont says it has successful completed two key projects at its Musselwhite mine at Lake Opapimiskan, Ontario, Canada, with the full commissioning of the mine’s conveyor system and the material handling project.

Newmont’s President and CEO, Tom Palmer, said: “I am extremely proud of the work that has been completed by the team at Musselwhite to safely deliver these two critical projects, whilst managing through the unprecedented challenges caused by COVID-19. Musselwhite is an important part of our North America region, and with the commissioning of these two projects is positioned to contribute to Newmont’s portfolio for many years to come.”

The conveyor system and the material handling systems work in association to efficiently move material from deeper mine levels to the surface, according to Newmont. Haul distances are reduced as the ore crushed at depth will be hoisted from the underground crushers to the conveyor system and brought to the surface for processing.

Work on the $90 million materials handling project to improve the movement of ore to the mill started back in 2016.

E and I Zambia helps power up process plant for copper miner

Base metals, Mine operation news, Mineral processing, Mining services, Power supply for mines, , , , , , , , , , ,

Electrical control and instrumentation specialist, E and I Zambia, says it has successfully completed a large project on a new process plant for one of Zambia’s leading copper miners.

The contract included the installation of six electrical substations, 20 transformers, five 1,250 kVA diesel generators for back-up power and a 950 m overland conveyor. Almost 250 km of cable was pulled and nearly 15 km of cable racking was constructed, according to the company.

Also completed were six earth mat rings, 12 mast lights and a range of general plant earthing and lighting installations around the plant, as well as the fitting and termination of instruments. E and I Zambia conducted the work between January 2019 and April 2020, in close collaboration with both a leading design house and the end-client, the company said.

According to Projects Manager, Dave Opperman, the company has a sound track record in the country, having been active on the copperbelt and beyond since 2002.

“The experience of our team on site, the quality of our artisans and the training of workers ensured that the quality of this job was world class,” Opperman says. “While prioritising safety and quality, we were still able to adapt to the inevitable fine-tuning of project parameters and schedules, and to deliver on the client’s timelines.”

The safety standards were reflected in the achievement of 395 Lost-Time Injury Free days. This was achieved despite a busy site – peak manpower grew to over 270 employees and subcontractors – in a project that consumed almost 590,000 manhours. Almost all the staffing on the project was local, the company said.

“Being so well established in Zambia, we have a solid database of skilled artisans that we can draw upon for large projects like this one,” Opperman says. “The country has a good foundation of these trades, and we can select the most suitable profile of skills to match the project.”

He noted that the company is also able to optimise its local procurement through its network of reliable suppliers, while maintaining a strong cross-border supply chain for large and specialised equipment and components from South Africa.

In line with quality standards, each phase of the project involved the sign-off of both in-house and external quality control officers. This ensured all work was carried out in accordance with engineering designs and industry standard specifications before being certified ready for use.

E and I Zambia is also able to draw on the extensive technical capacity of South Africa-based EnI Electrical, an operating entity within Zest WEG.

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

Bulk handling, Mineral project development, Mining services, Steel and iron ore, , , , , , , , , , , , ,

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.”

ABB, TAKRAF complete commissioning of Chuquicamata conveyor system

Base metals, Bulk handling, Mine operation news, Mining equipment, Mining services, Power supply for mines, , , , , , , , , , , ,

ABB, working with TAKRAF, has completed commissioning and testing of the world’s highest-powered gearless conveyor drive system at the Codelco-owned Chuquicamata copper mine in Chile.

ABB has provided engineering design, gearless conveyor drives (GCD), electrical equipment for power supply, energy distribution and automation of a new underground and overland conveyor system at one of the world’s largest copper mines.

Chuquicamata is currently transitioning from open-pit to underground mining, with the conveyor system, commissioned in just four months, part of a new underground project that is expected to extend operations for the next 40 years.

Project management and engineering for the full electrical, control and instrumentation scope was led by ABB in Germany, with long spells on site in northern Chile to work side-by-side with TAKRAF to equip the site’s new underground operation with a large conveying system that overcomes an altitude difference of 1,200 m and covers a distance of almost 13 km, ABB said.

The three principle 11,000 t/h conveyors feature GCDs equipped with large ABB AC synchronous motors with a rated power of 5 MW each, resulting in a motor shaft torque of about 900 kNm. With every line in constant use, high availability and low maintenance are essential. Designed with a minimum of transfer stations, just one was required underground, saving significant project cost, ABB said.

Based on continuous conveying technology, the infrastructure is completely truck-less, eliminating the need for 120 large haul trucks. This results in saving around 130 million litres/y of gasoline consumption, bringing the carbon emissions from 340,000 t/y down to 100,000 t/y. It is also the first transportation system in the world to employ premium steel cable belt technology, ST10000, for use on uphill tunnel conveyors, according to ABB.

ABB high power motors in position

“This mega project achieves a number of firsts, from the system’s installed drive power to the application of the ST10000 conveyor belt,” Marc Hollinger, TAKRAF Project Manager, said. “With this project, we firmly establish TAKRAF as one of the world’s only providers capable of delivering a mega project of this nature incorporating advanced technologies that push the boundaries of what has been done before. This is a complex project of the highest magnitude demanding global cooperation between internal and external parties.”

Ulf Richter, Global Product Manager for Belt Conveyor Systems at ABB, said: “This is a new milestone in underground applications for continuous mining. It is the highest drive power ever installed on a conveyor and uses a wide range of features for data acquisition, equipment assessment and process optimisation.

“In piloting this gearless drive application with TAKRAF, we have overcome tremendous technical and logistical challenges due to underground situations, elevation change and capacity requirements.”

ABB liquid-cooled MV voltage-source frequency converters, together with large synchronous motors, deliver a decrease in active and reactive power consumption at the operation. This is highly energy efficient, and without additional network filters, it says.

ABB’s Mining Conveyor Control Program ensures smooth belt operation and safe synchronisation between high power motors and high power hydraulic brakes, necessary for secure operation of steep uphill conveyors. The drive systems also work without mechanic backstops, ABB said.

A novel embedding concept, developed jointly by TAKRAF and ABB, enables straightforward installation and alignment of the GCD motors, saving installation time and longer deployment of maintenance teams. This was considered a major benefit compared with existing GCDs in cantilevered construction, ABB said. The concept also meant motors were 100% factory assembled and tested. They can also be mechanically disconnected from the drive pulley quickly so operations can continue if drive failure occurs. The total installed drive power for the entire system, including multiple feeder conveyors, totals 58 MW, of which there are 11 x 5 MW gearless synchronous motors.

ABB has also installed ABB Ability™ Ventilation Optimizer at Chuquicamata reducing carbon emissions and providing clean air to workers in line with the strict health, safety and environment requirements.

Vale looks for increased operational flexibility with S11D iron ore expansion plan

Bulk handling, Mine operation news, Mineral project development, Mining project news, Steel and iron ore, , , , ,

Vale is to increase the capacity of its S11D iron ore operation, in Canaã dos Carajás, Brazil, after its Board of Directors approved the implementation of the Serra Sul 120 project.

The $1.5 billion Serra Sul 120 project will see the S11D mine-plant capacity increase by 20 Mt/y to 120 Mt/y. Start-up is expected in the first half of 2024, Vale says.

The project includes the opening of new mining areas, the duplication of the long-distance conveyor, the implementation of new processing lines at the plant and the expansion of storage areas, among other measures.

“The Serra Sul 120 project will create an important buffer of productive capacity, ensuring greater operational flexibility to face eventual production or licensing restrictions in the Northern System,” Vale said.

The $385 million investment to duplicate the existing long-distance conveyor, in addition to providing flexibility, also aggregates important elements for the reduction of operational risks, adding reliability to the system, according to the company. The existing long distance conveyor is part of a major in-pit crushing and conveying system at the mine. It could see Vale’s Northern System capacity rise by 20 Mt/y to 260 Mt/y.

“The expansion of the mine-plant capacity and the development of additional logistics capacity are important steps for the iron ore volume growth, the maximisation of margin and the flight-to-quality optimisation,” the company said.

With the anticipated investment for Serra Sul 120 and the delay in the execution of projects in 2020 due to the COVID-19 pandemic, Vale says it will, in due course, revise and update its investment guidance for 2021, currently at $5 billion, and in the period between 2022-2024, with an average of $4.5 billion.