Tag Archives: Crushing

BEUMER Group and FAM ‘the right project partner for all challenges’, Hotz says

Bulk handling, Equipment maintenance, Mineral processing, Mining equipment, Mining mergers and acquisitions, Mining safety, Mining services, Water management, , , , , , , , , , , , , , ,

In June, BEUMER Group completed the acquisition of the FAM Group of Magdeburg, Germany, in the process, increasing its conveyor system and loading technology offering and becoming a significant player in the in-pit crushing and conveying (IPCC) space.

Close to six months after closing, IM put some questions to Stefan Hotz, Director Sales FAM Group, to find out how the integration of the two companies is going and how the transaction should strengthen the enlarged company’s market position in the minerals and mining sectors.

IM: Where – regionally – do you see the most opportunities in the mining sector for the integrated company to gain market share? South America has been a particularly strong market for FAM in the past; do you see this as a big opportunity for the integrated group?

SH: FAM – member of BEUMER Group – is one of the world’s leading full-range suppliers of bulk handling and processing systems. The customers come from more than 80 countries and the solutions are successfully in use everywhere. With BEUMER’s acquisition of the FAM Group, we were able to expand our portfolio to include bulk material handling, crushing technology as well as conveyor technology. Customers receive solutions from a single source with which they can work efficiently. In addition to engineering and project execution competences, FAM also brings the complete value chain, including after-sales service, to the BEUMER Group. This makes us a sought-after partner worldwide.

Of course, South America is a strong market, especially countries with iron ore and copper resources such as Brazil, Chile and Peru. For example, in Peru, the mining companies are transporting iron ore to the stockyards, which are often located at distances of several kilometres from the port. Callao Port, for example, is home to the most modern and largest ship loading terminal in the country. A reliable and safe connection for material transport is required, which at the same time ideally prevents the emission of particles into the atmosphere. Conveyors are the preferred solution here that can be individually adapted to the respective environmental and technical requirements and to the topography, as well as protect the environment from dust emissions.

IM: Are you expecting to increase your manufacturing capacity or acquire new premises to fulfil this demand, or do you have enough capacity to serve these growing markets in the near-to-medium term?

SH: The FAM Group has subsidiaries in Brazil, Chile, China, Canada and India. In addition, there are the numerous subsidiaries and agencies of the BEUMER Group. This means that we are very well positioned worldwide and can optimally serve these growing markets in the short to medium term. In our project business it’s a must to be, on the one hand, close to our customers but, on the other hand, using our global resource network and know-how to balance workloads. But, of course, we expand the network of our subsidiaries if we notice that we cannot serve certain regions with the desired reliability.

IM: Is the company already pursuing mining projects that involve the solutions/expertise of FAM and BEUMER Group? Can you elaborate on what type of projects these are and what solutions they involve (ie overland conveyors, bucketwheel excavators, spreaders, etc)?

SH: Yes, we are already in the process to support our mining clients from one hand, integrating FAM and BEUMER solutions. For example, we are working on one large project for gold extraction, where BEUMER is providing the long-distance overland conveyor and FAM supports the client with spreader technology to dump overburden. We have combined this with an attractive digitalisation and service package to ensure optimisation of the client’s total cost of ownership.

IM: With this transaction the company has effectively become a major player in the IPCC space. Do you see this as a major growth area for BEUMER Group going forward?

SH: In general, with this new setup, we expand our product portfolio and we are significantly strengthening our market position worldwide, especially in the field of large-scale mining equipment. But the most important thing is that we can provide our customers with even more comprehensive support over the whole value chain from pit to port, including digitalisation and service for our projects. Due to our many years of experience, we also support our clients in complex upgrade, lifetime extension and refurbishment jobs for existing machines. This means we avoid interfaces and customers now have only one contact.

IM: Do you see your ability to offer not only the solutions but also the engineering and design expertise underpinning these solutions as differentiating your offering from your competitors in the IPCC market? What other differentiators will serve you well in winning business in this market?

SH: I don’t want to say much about our market competitors, but I am sure that together with FAM we stand out positively from the market, specifically for continuous soft rock and overburden IPCC applications. Furthermore, we have long-term partners with whom we are serving the needs of our clients in terms of mine planning and pre-engineering. This ensures that we are defining  a solution for the client with a focus on CAPEX and OPEX optimisation. Specifically for IPCC applications, we are convinced of adding value during the first months of operation by providing integrated training and service packages to ensure successful implementation of continuous mining systems after commissioning. In doing so, the specialism is characterised in particular by distinctive engineering at a high level.

IM: What other areas of your business do you see growing with the need for mining companies to move away from their reliance on diesel-powered mobile mining equipment for material transport? Are you seeing more interest in your overland conveyor portfolio, for instance?

SH: Our belt conveyor systems are used successfully all over the world. They solve complex transport problems for any bulk material and are suitable in many cases as an economic alternative to truck transport. While the basic task – to transport bulk materials from the mine to the final discharge point – appears very comparable, no two systems are alike. The range of potential materials to be conveyed, alone, requires individual consideration of the components to be used in terms of wear resistance or the maximum permissible gradients of a conveyor. In addition, above all, the mass flow to be transported and the height to be overcome determine the dimensioning of the drive unit of an overland conveyor. Plants at high altitudes pose a further challenge. At altitudes above 4,000 m, as is often the case in the Andes for example, it must be taken into account that the air pressure and, thus, the density of the air decreases with increasing altitude. This reduces both the cooling effect and the insulating capacity of the air. We are the right project partner for all these challenges.

Sandvik completes acquisition of Schenck Process Group

Comminution of minerals, Mineral processing, Mining equipment, Mining mergers and acquisitions, , , , ,

Sandvik says it has completed the previously announced acquisition of the mining related business of Schenck Process Group (SP Mining).

SP Mining is one of the market leaders in screening, feeding, screening media and train loading solutions in the industry, according to Sandvik. It also has a strong aftermarket business, which includes application support, screen refurbishment, product engineering design and manufacturing and digital support services.

It will be reported in Stationary Crushing and Screening, a division in Sandvik Rock Processing Solutions (SRP).

The two companies already had a global partnership agreement in place dating from 2016 that brought together Sandvik’s high productivity cone crushers and Schenck Process’ high capacity multislope screens.

In 2022, SP Mining expects revenues of about €200 million ($199 million) of which approximately 70% is aftermarket, and an EBITA margin accretive to Sandvik Rock Processing Solutions’ margin, Sandvik said.

Sandvik announced the planned acquisition of SP Mining back in May.

Iron Bridge Magnetite project progresses with first ore feed milestone

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Fortescue Metals Group has reached a new milestone on its majority-owned Iron Bridge Magnetite project in the Pilbara of Western Australia, with first ore fed into the processing plant.

With first production anticipated in the March 2023 quarter, Iron Bridge will see the world’s fourth largest iron ore miner deliver an enhanced product range and create 900 new jobs, it said.

Significantly, it could become one of Fortescue’s first fossil fuel free sites, enabled by the recently announced $6.2 billion decarbonisation investment to reach “real zero” Scope 1 and 2 emissions by 2030.

At a milestone event held at Iron Bridge today, Fortescue’s Executive Chairman, Andrew Forrest, was joined by Chief Operating Officer Iron Ore, Dino Otranto, Fortescue Board members, Elizabeth Gaines and Penny Bingham-Hall, representatives from joint venture partner Formosa, Western Australian Deputy Premier and Minister for State Development, Roger Cook, along with company executives, valued partners and suppliers.

Traditional Custodians also attended the milestone event to welcome over 100 guests to Nyamal country.

Iron Bridge, 145 km south of Port Hedland, will deliver 22 Mt/y of high grade 67% Fe magnetite concentrate. This product enables Fortescue to enter the high iron ore grade market segment, providing an enhanced product range while also increasing annual production and shipping capacity, it said.

Since the investment decision in April 2019, more than 12.8 million workhours have culminated in the design and construction of the mine, pipelines, village and infrastructure at Iron Bridge. There are currently 3,470 people working across the Ore Processing Facility and pipelines scope of work.

Forrest said: “At Fortescue, we take pride in the fact that we consistently deliver what we say we will, and Iron Bridge is no different. Building on our track record of safely and successfully developing and operating iron ore projects in the Pilbara, Iron Bridge will lead the way for magnetite operations in Western Australia.

“This project demonstrates Fortescue’s commitment to our strategic pillars of investing in the long-term sustainability of our iron ore business, investing in growth, maintaining balance sheet strength, as well as delivering strong returns to our shareholders.

“As we transition to a global green energy, technology and resources company, Iron Bridge is an obvious choice to be considered as one of our first decarbonised, fossil fuel free sites, as we deliver on our target to achieve real zero Scope 1 and 2 emissions by 2030.”

Otranto said: “The Iron Bridge high grade magnetite product is a significant differentiator for Fortescue, and led by the highly experienced project team, I am incredibly pleased with the significant progress made to achieve first ore feed into the processing plant.

“This is a project that has been delivered during a challenging environment, and despite a global pandemic, rising inflationary pressures and a tight labour market, the Fortescue Values have risen to the forefront and demonstrated our ability to continue delivering this ground-breaking project.”

The nature of the Iron Bridge orebodies and Fortescue’s use of a dry crushing and grinding circuit together contribute to the project’s operational efficiency across energy, water use and cost.

Low cost power will be delivered to Iron Bridge through Fortescue’s investment in the Pilbara Energy Connect project, which includes energy transmission line infrastructure, solar gas hybrid generation and associated battery storage solution.

The Iron Bridge Magnetite project is an unincorporated joint venture between FMG Magnetite Pty Ltd (69%), and Formosa Steel IB Pty Ltd (31%). The joint venture partners are each responsible for their equity share of the total capital expenditure.

Bellevue Gold on its way to achieving ‘holy grail’ with EDL pact

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Bellevue Gold Limited says it has taken a pivotal step towards its aspirational goal of becoming Australia’s first ASX-listed gold miner with net-zero emissions by signing an Early Works Agreement with Energy Developments Pty Ltd and locking in long-lead items for its power station, ready for the processing plant commissioning in mid-2023.

The purchasing of the long lead items will see the company continue its carbon mitigation strategy, based off proven technologies with a Tier 1 power supplier, it said.

This agreement is a key step in Bellevue’s strategy to be powered by a forecast average of 80% renewable energy each year using a wind, solar and battery hybrid power solution.

EDL built, owns and operates a similar turnkey power solution at the Agnew gold mine, around 35 km south of the Bellevue gold project.

Bellevue and EDL are currently negotiating a Power Purchase Agreement for the project, which is subject to approval by the boards of both EDL and Bellevue.

Bellevue says its power solution is central to the company’s goal of generating the lowest carbon emissions per ounce of gold produced by any major Australian gold mine, with forecast emissions of between 0.15-0.20 t of CO2e/oz.

“As well as being the lowest emitter on a per ounce basis, the project is forecast to have the lowest total Scope 1 emissions of any major mine in Australia,” it said. “This will give the project the cleanest power supply in Australia based on a greenhouse gas per kilowatt hour basis of power generation.”

By reducing greenhouse gas emissions, with a renewable energy power station and undertaking other sustainable initiatives, Bellevue aims to produce carbon-neutral gold, giving the company a major competitive advantage in global investment markets, it says. This also provides potential for the company to seek a premium for the sale of ‘green gold’, it added.

The power station will prioritise the use of renewable energy and will also include a gas engine configuration, which, it says, will ensure there is sufficient power for the mine, even in the rare absence of solar and wind resources.

EDL will supply trucked LNG to the project to maintain optionality for any future technological innovations in thermal generation alternative fuels. Trucked LNG provides a much cleaner fuel than diesel, which was an important consideration to reduce emissions as far as possible, it said.

At a steady-state production rate of 1 Mt/y, renewable energy is expected to meet up to 80% of the project’s annual electricity needs, taking advantage of the region’s strong solar and wind resources.

Bellevue says it has been modelling the wind speeds and direction with a SODAR unit, which has allowed for the integration of wind turbines to increase the renewable energy penetration rate.

Maximising renewable energy uptake has been a key design consideration for the processing facility. The facility will have the ability to use more power – such as crushing and heating – when increased renewable energy is available, reducing thermal requirements, according to the company.

The planned infrastructure includes an oversized crushing circuit to facilitate a processing rate of more than 1.5 Mt/y (against current throughput rate of 1 Mt/y), allowing the operational flexibility in this area for an optimised match up of the renewable energy demand to the renewable energy resource.

The designed infrastructure will allow Bellevue to have a cost-effective renewable energy supply and optimise the power demand curve to better align with key daytime (solar) and night time (wind) energy peaks and troughs. Through the generation of power from renewable energy sources, it will create the optionality for the crushing circuit to maximise crushing in peak renewable energy generation periods. This will have the potential to offset more than 1 MW in demand on thermal power generation and lead to a direct cost saving and emissions reduction.

Bellevue Managing Director, Steve Parsons, said: “EDL is a leader in hybrid off-grid power stations. Their skills and experience will help ensure we maximise the use of renewable energy at the Bellevue gold project.

“Bellevue is forecasted to be a 200,000 oz a year gold miner with low all-in sustaining costs of A$1,000-A$1,100/oz ($644-$708/oz) powered by circa-80% renewable energy, with a pathway to net-zero emissions as a world-leading company in the race to decarbonise the mining sector.

“Our pre-production carbon mitigation strategy has been strategic and is world leading. It achieves the ‘holy grail’ of lower emissions and a direct cost reduction in power generation.

“The combination of these metrics is expected to will position Bellevue as one of the most sustainable and financially successful Australian gold miners, maximising returns for all stakeholders. It will also underpin the company’s strong appeal to global investors, who demand performance on both financial and ESG measures.”

On the same day as the EDL announcement, the company signed a Native Title Agreement with Tjiwarl (Aboriginal Corporation) RNTBC, being the native title rights and interests holders and traditional owners of the land which hosts the Bellevue gold project.

Rio Tinto and Baowu to invest $2 billion in Western Range iron ore development

Bulk handling, Comminution of minerals, Mineral project development, Mining equipment, Mining services, Steel and iron ore, , , , , , , , , , , , ,

Rio Tinto and China Baowu Steel Group Co. Ltd have agreed to enter into a joint venture with respect to the Western Range iron ore project in the Pilbara, Western Australia, investing $2 billion to develop the mine.

Western Range’s annual production capacity of 25 Mt of iron ore will help sustain production of the Pilbara Blend from Rio Tinto’s existing Paraburdoo mining hub. The project includes construction of a primary crusher and an 18 km conveyor system linking it to the existing Paraburdoo processing plant.

Construction is expected to begin in early 2023 with first production anticipated in 2025. The construction phase will support approximately 1,600 jobs with the mine requiring about 800 ongoing operational roles, which are expected to be filled by existing workers transitioning from other sites in the Paraburdoo mining hub.

Rio Tinto’s share of the capital costs are already included in the group’s capital expenditure guidance of around $9-10 billion for each of 2023 and 2024. Both parties will pay their portion of capital costs for the development of the mine, and mine operating costs, plus a nominal ongoing resource contribution fee calculated by reference to Western Range production volumes. There is no upfront consideration being paid by either party.

Rio Tinto and Baowu, which own 54% and 46%, respectively, of the joint venture, have also agreed to enter into an iron ore sales agreement at market prices covering a total of up to 126.5 Mt of iron ore over approximately 13 years. This volume represents Baowu’s 46% interest in the anticipated 275 Mt of production from Western Range through the joint venture.

Rio Tinto has a long history of successfully partnering and investing with customers to develop new mines in the Pilbara. Rio Tinto and Baowu’s partnership in the Pilbara dates back to the 2002 Bao-HI joint venture to develop the Eastern Range deposits in the Hamersley Ranges (Eastern Range) and Western Range, subject to a production cap of 200 Mt. It is now expected the production cap will be sourced entirely from Eastern Range, and this transaction will continue Rio Tinto’s relationship with Baowu through development of Western Range.

Rio Tinto Iron Ore Chief Executive, Simon Trott, said: “This is a very significant milestone for both Rio Tinto and Baowu, our largest customer globally. We have enjoyed a strong working relationship with Baowu for more than four decades, shipping more than 200 Mt of iron ore under our original joint venture, and we are looking forward to extending our partnership at Western Range.

“The development of Western Range represents the commencement of the next significant phase of investment in our iron ore business, helping underpin future production of the Pilbara Blend, the market benchmark.

“At the same time, Rio Tinto and Baowu continue to work together on low-carbon steelmaking research, exploring new methods to reduce carbon emissions and improve environmental performance across the steel value chain.”

Baowu Resources Chairman, Shi Bing, said: “The signing of the joint venture agreement for the Western Range project is a significant event in the history of cooperation between Baowu and Rio Tinto. We fully appreciate the persistent efforts of both teams in accomplishing the important achievement. The Bao-HI joint venture has been successfully operating for more than 20 years, leading us to a win-win result, and reaping friendship and trust.

“We hope that the two parties will deepen the mutually beneficial and win-win partnership, continue to carry forward the spirit of sincere cooperation and further expand cooperation in more fields and aspects on the basis of working together to operate the project well.”

Rio Tinto has worked closely with the Traditional Owners on whose country Western Range is situated, the Yinhawangka People, to co-design a Social and Cultural Heritage Management Plan for the project, designed to protect signiticant cultural and heritage values in the area.

The plan, which was agreed with Yinhawangka Aboriginal Corporation and announced earlier this year, outlines protocols for joint decision-making on environmental matters and mine planning.

Rio Tinto’s Paraburdoo hub is comprised of three operating mines, Paraburdoo, Channar and Eastern Range. Western Range contains two deposits, 36W–50W and 55W–66W, which are located within the Hamersley Basin of Western Australia. The deposits’ mineralisation is primarily hosted by the Brockman Iron Formation with additional detrital mineralisation present. The 36W–50W and 55W-66W deposits contain a measured resource of 22 Mt at 59.1% Fe, indicated resource of 102 Mt at 61.5% Fe and an inferred resource of 108 Mt at 61.4% Fe. The 36W–50W deposit contains a proven reserve of 109 Mt at 62.1% Fe and a probable reserve of 56 Mt at 61.7% Fe.

FLSmidth to highlight full flowsheet expertise with ShalkiyaZinc project delivery

Automation, Base metals, Comminution of minerals, Mineral processing, Mining equipment, Mining services, , , , , , , , , , , , , , , , , , , , , ,

FLSmidth has signed a contract, valued at around DKK950 million ($130 million), to supply a range of mineral processing equipment to ShalkiyaZinc, the operator of a zinc-lead mine in the Kyzylorda Region of Kazakhstan.

The equipment will transform the plant into a world-class facility that efficiently separates minerals with a minimised environmental impact, the OEM says.

Under the agreement, FLSmidth will supply two underground crushing stations with a materials handling system to the process plant; a full package of comminution and separation equipment, including SAG and ball mills, mill circuit pumps and cyclones; the zinc-lead concentrate flotation and regrinding circuit, including nextSTEP, VXP vertical mills, concentrate thickeners and Pneumapress filters; and reagents preparation and dosing area. Full plant automation is also included, as well as installation and commissioning supervision services.

The new concentrator will be supported from FLSmidth’s new in-country service Supercentre in Karaganda, Kazakhstan.

The equipment delivery is to be completed during 2024, with commissioning to start before the end of that year.

Mikko Keto, Group CEO at FLSmidth, said: “We are excited to receive this first order from ShalkiyaZinc, which highlights our full flowsheet expertise. The wide range of equipment included in the order will help ShalkiyaZinc save on both capital expenditure and operating expenditure; our new nextSTEP flotation technology will improve the quality of the concentrates, the SAG mill will provide more flexibility, while the automation and digital solutions will further enable water and energy savings alongside safer operations.

“We look forward to making this a success on so many levels.”

Assel Rakhimova, Chief Project Director of Tau-Ken Samruk, which owns ShalkiyaZinc, said: “After testing and basic design work executed by FLSmidth, we are pleased to enter this new phase of collaboration with the procurement of critical technologies to improve the productivity and sustainability of our plant. We believe in successful execution and look forward to receiving the ordered equipment according to the schedule for installation and to continue working with FLSmidth on commissioning services and spare parts.”

CMIC’s CanMicro technology wins top prize in Crush It! Challenge

Comminution of minerals, Environmental, Mineral processing, Mining events, Mining industry recognition, Mining services, Power supply for mines, Sustainable mining, , , , , , , , , , , , , ,

The Canada Mining Innovation Council’s cleantech solution, CanMicro, has been named as the grand prize winner of the Crush It! Challenge, being awarded a C$5 million ($3.9 million) grant to further develop the solution.

CanMicro combines microwave-assisted comminution and multi-sensor ore sorting technology to selectively break particles and sort waste from desired minerals, reducing crushing and grinding requirements. CMIC says the CanMicro technology can provide over 35% energy savings across several commodities.

The Crush It! Challenge was announced in October 2018 by Natural Resources Canada (NRC) with the aim to realise an innovative breakthrough in the mining industry’s most energy-intensive and inefficient processes: crushing and grinding.

The primary objectives of the challenge are to fight climate change by creating innovative technologies that reduce energy consumption and pollution, increase competitiveness by developing world-leading clean technologies, and transform the mining cycle to establish a new “future in mining”.

Semi-finalists (up to 12) received C$10,000 to help them pitch their ideas to the Challenge Jury, with up to six finalists being granted up to C$860,000 to build and test their clean technologies. The winner and innovator demonstrating the most superior energy breakthrough to crush and grind rocks was awarded a C$5 million prize to fully develop and roll out their solution.

The grand prize winner of the Crush it! Challenge was selected through a competitive and rigorous process designed and delivered by NRC.

Crush It! is one of six initial clean technology challenges led by NRC under the Impact Canada Initiative – a government-wide approach to introduce innovative approaches to help solve Canada’s biggest economic, environmental and social challenges. NRCan invested C$75 million in its cleantech challenges: Crush It! Challenge, Charging the Future Challenge, Indigenous Off-diesel Initiative, Power Forward Challenge, Women in Cleantech Challenge and The Sky’s the Limit Challenge.

CanMicro is the only technology to combine microwave-assisted comminution and sorting, according to CMIC. The treatment selectively heats value minerals, resulting in micro-fractures along grain boundaries that help reduce ore competency and increase mineral liberation after grinding. It also generates a thermal signature that can be used to sort ore particles so that only those containing value minerals are subjected to fine grinding.

Aside from the potential energy savings, which the team – made up of CMIC (Project Administrator), Dr Erin Bobicki (Technical Lead), Sepro Mineral Systems (Project Participants), Glencore Canada (Project Participants), COREM (Project Participants) and Queens University (Subject Matter Experts) – believe could be up to 70%, this has significant environmental implications for tailings.

Gold Fields Agnew to decarbonise crushing operations with new Sandvik solution

Comminution of minerals, Environmental, Mine operation news, Mineral processing, Mineral project development, Mining equipment, Mining maintenance, Mining services, Mining software, Power supply for mines, Precious metals, Sustainable mining, , , , , , , , , ,

Gold Fields’ Agnew mine in Western Australia is continuing to innovate, with its latest technology development involving the installation of a new modular Sandvik Rock Processing Solutions crushing system that can align with its day-time solar generation capabilities on site.

The operation has recently completed one of the biggest hybrid renewable projects in the mining sector – one that includes solar, wind, battery storage and a backup gas turbine (the Agnew Hybrid Renewable Power Station). This project has put the mine on track to source some 60% of its overall energy needs from renewables.

At the same time as this, Agnew is also testing out battery-electric equipment to further decarbonise its operations, which consist of two underground mines (Waroonga and New Holland) amalgamated into the Agnew One Mine Complex.

The innovative integrated thinking has gone further than this, with a planned plant throughput increase looking to leverage as much renewable energy as possible.

In this latest project, the mine has invested A$35 million ($25 million) in the construction of a new modular crusher. The latest milestone has seen all the concrete in the construction of the project poured, with the southern run-of-mine (ROM) access ramp completed and the final stage of backfilling of the ROM wall having commenced.

The construction team are 60% of the way through erecting the crusher structure and all key crusher components – crushers, screens, feeders, magnets and metal detectors – are on site.

IM put some questions to the Agnew Technical Team to find out more about this project.

IM: Are you able to share what type of crusher the new installation is? Could you also mention what crusher model it is replacing?

ATT: We opted for a Sandvik solution (modular plant solution and automation-ready). There were several reasons for going with Sandvik and deciding on a modular-style plant. This choice has now proven beneficial two years down the track with the challenges we have seen obtaining steel and fabrication services around the globe during COVID. We began early design work with Sandvik back in June 2020, however, we also worked through various other design and equipment options with other key crushing and screening suppliers on the market.

Gold Fields were involved in the design of the circuit as the configuration needed to accommodate for potential production increases in the future, whilst also efficiently crushing the current throughput rates.

The Gold Fields project team managed the electrical design through a third-party electrical engineering company. The automation and control philosophy has been undertaken in-house by the Gold Fields Process Control team. This has been a good opportunity to demonstrate the skills and knowledge we are now building in that space. The project has been executed by the Agnew project team with an external engineering firm.

We are installing a CJ412 primary jaw crusher, two 840i cone crushers (secondary and tertiary), a double-deck product screen and several bits of auxiliary equipment such as magnets, weightometers and a rock breaker above the jaw crusher. The process design criteria was 1.7 Mt per annum with a P80 of 6 mm. The circuit replaces a JW42 jaw crusher, three 1350Z cone crushers (one secondary and two tertiaries) and two product screens.

IM: On top of the reduction in conveyor belts (the old crusher comprised of 16 conveyor belts; the new crusher circuit has six), what other benefits is the team expecting to receive with installation of the new crusher?

ATT: The new circuit will be simpler and more efficient to operate with less equipment, as well as being more modern. There are less transfer points and wear areas, which will reduce the maintenance costs associated with running the current crushing circuit.

In addition, the design and automation of the new circuit will mean the crusher is operated remotely from the main control room, removing the need for a second process operator to be situated in a standalone control room. The three Sandvik crushers have a larger capacity and slightly higher power draw, but they will produce a finer product size more efficiently based on being the latest technology on the market. This will have a positive impact upstream in the processing plant once the ore reaches the grinding circuit.

The design has included the ability to monitor the power draw of each section of the circuit, which will be fed from the Agnew Hybrid Renewable Power Station. Having the ability to crush at a higher throughput rate will also mean being able to operate the crusher more during daylight hours by taking advantage of the solar-generated power. Last year, 56% of the power Agnew draw came from renewables.

IM: When does the team plan to have the new crusher in place and commissioned?

ATT: Commissioning is scheduled for mid-August.

Metso Outotec and Malvern Panalytical to collaborate on bulk ore sorting projects

Bulk handling, Environmental, IoT, Mineral processing, Mining services, Sustainable mining, , , , , , , , , , , , ,

Metso Outotec and Malvern Panalytical have signed a collaboration agreement to, the OEM says, provide sensor-based bulk ore sorting solutions to the mining industry.

The combination of the companies’ expertise in crushing and bulk material handling solutions, and ore analysers enables the parties to offer an industry-leading portfolio of solutions for bulk ore sorting, Metso Outotec said.

“With this offering, mining customers can substantially improve the head grade by pre-concentrating the ore at the crushing stage and, thereby, reduce their energy consumption and related environmental footprint in the comminution stage,” Metso Outotec said.

The agreemeent will see Metso Outotec’s crushing and bulk material handing solutions integrated with Malvern Panalytical’s cross-belt analysers. The latest generation of cross-belt analysers, CNA³, has been designed for tough environments such as underground mines, and features the Sodern neutron solution, which is powered by Pulsed Fast Thermal Neutron Activation (PFTNA) technology. The technology has been used by Anglo American, among others.

Rashmi Kasat, Vice President, Digital technologies at Metso Outotec, said: “Sustainability is a top priority for our entire industry. Collaboration with partners like Malvern Panalytical will allow us to meet the industry’s increasing sustainability and resource efficiency needs in an enhanced way in the early comminution stage. Sensor-based bulk ore sorting and data-driven analysis upgrades low grade or waste stockpiles making them economical and far less energy-intensive to treat.”

Jarmo Lohilahti, Sales Manager at Malvern Panalytical, said: “Malvern Panalytical’s cross-belt analysers provide high-frequency online data for cost-efficient bulk material analysis of major commodities. This collaboration enables customers to benefit from the in-depth know-how from both companies.”

Renato Verdejo, Business Development Lead for Bulk Ore Sorting at Metso Outotec, concluded: “Bulk ore sorting allows waste rock elimination early in the process and, when combined with Metso Outotec’s complementary crushing and bulk material handing solutions portfolio, it provides more sustainable flowsheets for our customers. Enhanced bulk ore sorting will contribute to Metso Outotec’s Planet Positive portfolio.”

On the particle sorting side of the business, Metso Outotec and TOMRA have a non-exclusive cooperation in place to supply particle ore sorting solutions for the mining and metallurgical industries.

Core Lithium enlists CSI for crushing services at Finniss

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Core Lithium says it has executed a crushing services contract with CSI Mining Services (CSI), a subsidiary of Mineral Resources Ltd, for the Finniss lithium project in the Northern Territory of Australia.

Run of mine ore will be stockpiled prior to feeding into the CSI crusher circuit, after which crushed ore will be stockpiled before being processed by the dense media separation (DMS) plant to make spodumene concentrate for export.

The crusher civil works are nearing completion with CSI expected to start mobilising to the project during June 2022, the company said.

Core Managing Director, Stephen Biggins, said: “The award of the crushing contract is another significant step in the development of the Finniss lithium project. Core staff have done a great job getting the site ready for CSI to start work next month.”

In mid-2021, Core released a definitive feasibility study for the Finniss project, marking a major milestone in its goal to become Australia’s next major lithium producer by the end of 2022.

The study highlighted an average production of 173,000 t/y of high-quality lithium concentrate at a C1 operating cost of $364/t and a start-up capital cost of A$89 million ($63 million) thanks to the incorporation of a 1 Mt/y DMS processing plant in the project’s design.