Tag Archives: Dino Otranto

Zero emission haul truck developments on the IMARC 2023 agenda

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IMARC 2023 is off to a bang, with two of the first keynote interviews – featuring speakers from Fortescue and BHP – kicking off what is expected to be a constant flurry of mining technology news.

During a Mining Keynote Interview, titled, ‘The Reshaping of the Fortescue Business: A Showcase of the Past, Present and Future of the Mining and Resources’ Industry,’ Dino Otranto (pictured on the right), CEO of Fortescue, talked up the mining company’s ‘Real Zero’ terrestrial emissions (Scope 1 and 2) 2030 aim.

Speaking to Jennifer Hewett (pictured on the left), National Affairs Columnist, The Australian Financial Review, Otranto highlighted the recent arrival of the first 240-t-class Liebherr Mining T 264 trucks at its Eliwana iron ore mining site in the Pilbara of Western Australia, which is expected to be converted to Fortescue’s in-house battery solution developed by WAE in the near term.

Looking further out, Otranto said the company’s first zero emission fleet at Eliwana was expected to be “on parity” with the diesel haulage equivalent from a cost and productivity perspective. “In the future, they could be even more productive,” he added.

Fortescue is currently working on a number of “zero emission” solutions across its mining operations – battery-electric and green hydrogen, among them – and Otranto said the company was confident that the electric powertrain is “the future”, with the system that generates the power to supply this being “agnostic”.

“In the future, we will not be beholden by the OEM and a single product,” he said, explaining that the captive energy source tied to where the resources and reserves were located would play a crucial role in the chosen system.

Soon after Otranto left the stage, Hewett was joined by James Agar, Group Procurement Officer at BHP, for another keynote interview, titled ‘The Importance of Supplier and Community Partnerships to Create Value’.

Agar was quick to pick up from where Otranto left off, referencing the company’s own zero-emission haulage plans, which included the expected rollout of a zero emissions truck at its operations next year. The company has previously signalled that a Cat Early Learner battery truck could come arrive for trials at its operations in 2024.

Alongside this, Agar referenced ongoing work with Bridgestone and Michelin related to battery-electric haul truck developments.

“We have realised that if we reduce the rolling resistance of tyres by 1-2%, it can have a big impact on battery life,” he said. “Equally, these trucks are going to be able to travel at faster speeds, so tyre life will be affected. This is another area we are studying.”

Dyno Nobel, Fortescue sign tech alliance focused on drill and blast decarbonisation

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Incitec Pivot Limited’s Dyno Nobel is to extend its supply relationship with Fortescue, with the two parties agreeing to a long-term extension that will see Dyno Nobel continue providing explosives technology and collaborating on key decarbonisation projects to assist Fortescue in reaching its ‘Real Zero’ goal.

A key focus of the new agreement is an innovative technology alliance. As part of this, Dyno Nobel will invest A$5 million ($3.2 million) in new technologies to support Fortescue’s decarbonisation efforts within its drill and blast process. The new agreement will apply across Fortescue’s Pilbara operations: Cloudbreak, Christmas Creek, Solomon and Eliwana. The Iron Bridge project, which Fortescue has a majority stake in, is supplied by Dyno Nobel under a separate contract the two companies announced last year.

Dyno Nobel Asia Pacific President, Greg Hayne, said: “We’re incredibly proud of our relationship with Fortescue who are at the forefront of efforts to decarbonise the mining industry. The agreement will see us ramp up our decarbonisation efforts which will include conversion of our MPU (mobile processing unit) fleet to renewable energy sources and investigating the use of lower carbon footprint, bio-fuel based explosives.

“This is about providing our customers with technology solutions that lower our carbon footprint and, in turn, theirs.”

Fortescue Metals CEO, Dino Otranto, said: “We’re looking forward to continuing our successful partnership with Dyno Nobel, which will deliver blasting services as well as provide new technologies to help us achieve our industry leading target of Real Zero emissions across our Australian iron ore operations.”

The agreement will provide Fortescue with the opportunity to benefit from Dyno Nobel’s commercialisation of a reduced GHG emissions DIFFERENTIAL ENERGY® solution, an explosives method that tailors the energy delivered to different rock layers within a blast hole and across a blast. The efficiencies generated through the use of DIFFERENTIAL ENERGY reduce both overall mining costs and emission volumes for customers, according to Dyno Nobel, with the reduced emissions solution able to reduce Scope 1 emissions by up to 25% in normal blasting circumstances.

Hayne said that since Dyno Nobel’s DIFFERENTIAL ENERGY technology was introduced to the Australian market in 2018 it has provided customers with production and environmental benefits.

“Fortescue has already seen the technology deliver value at their Iron Bridge operations, one of the first sites in Australia to fully benefit from DIFFERENTIAL ENERGY and the results have been very positive. We are now pleased to be increasing these advantages via a reduced emissions offering. It is just another example of our technology innovation happening on the ground.”

He said Dyno Nobel’s technology development aligned with Fortescue’s vision.

“We are looking forward to continuing our successful partnership with Fortescue which has evolved into finding innovative and sustainable solutions for the future by working together,” he said.

Hybrid Systems Australia delivers Western Australia’s ‘largest network-integrated BESS’ to Fortescue

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Hybrid Systems Australia, Pacific Energy’s integrated renewables subsidiary, says it has delivered Western Australia’s largest network-integrated battery energy storage system (BESS) as a part of Fortescue Metals Group’s Pilbara Energy Connect project, which aims to power the miner’s Pilbara iron ore operations with renewable energy.

Hybrid Systems Australia designed, installed and commissioned 42 MW of interconnected battery storage for two Fortescue mine sites, making it one of the world’s largest network-connected BESS to be developed for a mining application, the company says.

The batteries, which are now fully operational, have been developed alongside solar and new low emissions gas-fired generation that will be owned and operated by Fortescue as part of the company’s Pilbara Energy Connect (PEC) program.

HSA said: “The battery systems use industry-leading grid stabilising control systems, including millisecond-response capabilities and Kokam battery technology, to provide greater protection against load spikes and dips and ensure overall network stability.”

The batteries’ primary role is for grid stability and support, providing spinning reserve backup to any gas generation outages or sudden changes in the solar output. They will store energy from Fortescue’s planned 150 MW of nearby solar power, enabling mining activities to be powered by more renewable energy and cutting the annual carbon emissions of the mines.

Mike Hall, Executive Director of Hybrid Systems Australia, said the project represented one of the largest and most technologically advanced BESS projects the company had undertaken, and that systems of this size were critical to Fortescue’s move towards eliminating the use of fossil fuels in their operations by 2030.

“Our industry-leading design, network integration experience and strong partnerships meant we could readily deliver a large-scale solution that will allow Fortescue to continue its rapid upscale of renewable capacity and deliver on its real zero target,” he said.

“Our BESS are built specifically for remote Australia’s harsh conditions and can be sized from 1 MW to 200 MW, which makes them ideal for large-scale mining applications where the objective is greater reliance on clean energy.”

Fortescue Chief Operating Officer Iron Ore, Dino Otranto, said: “At Fortescue, we are committed to eliminating the use of fossil fuels across our operations by 2030. We were pleased to partner with Hybrid Systems Australia on the BESS, which are a significant component of our investment in the PEC program.

“PEC will not only supply low-cost power to our Iron Bridge operations, but importantly will support Fortescue’s world-leading decarbonisation agenda, allowing the incorporation of additional large scale renewable energy into our network in the future.”

The project included specialised involvement from its subsidiaries, Pacific Energy Pty Ltd, which is delivering the PEC’s low-emissions gas-fuelled power station, MVLV Power Solutions, which designed, manufactured and installed the switchgear and BESS enclosures, and Digital Intelligence, which delivered the BESS control systems.

Hybrid Systems Australia partnered with Hitachi Energy and Kokam to bring together expertise and key battery components from the two specialist equipment suppliers to deliver a solution for Fortescue. It also worked closely with Supply Nation accredited vendors, including electrical contractor, Boodjara Pty Ltd, and local electrical wholesalers, Myelec and D&W Electrical.

Rio Tinto, BHP, Fortescue devise pilot program to tackle sexual harassment, bullying and racism

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Rio Tinto, BHP and Fortescue are launching a pilot program aimed at helping to eliminate disrespectful behaviour in the resources industry including sexual harassment, bullying and racism.

The launch comes after the three companies formed a partnership in October last year as part of their combined response to reports of unacceptable sexual harassment in the mining industry.

The three companies have worked together with leading experts to design and develop the industry-first program aimed at educating new entrants to the sector, they said.

The evidence-based program will educate participants about the impact of sexual harassment, bullying and racism, including how to recognise and report these behaviours.

The Building Safe and Respectful Workplaces pilot program project, managed by the Australian Minerals and Energy Skills Alliance (AUSMESA), will be delivered on November 15 and 16 by experienced facilitators from Griffith University. The pilot program will be completed by 30 volunteers who are currently undertaking apprenticeships or traineeships with the three companies.

The results of the pilot will be fully evaluated and feedback from the participants will be used to finalise the learning program.

It is intended the program will be delivered from early in 2023 with a particular focus on new entrants to the mining industry.

As part of an ongoing commitment to educate about respectful behaviour, the companies will engage across industry and education providers on how to broaden the reach of the program.

It is anticipated the training course will be made available to other industries in the future through a range of education pathways.

Rio Tinto Iron Ore Chief Executive, Simon Trott, said: “The launch of this pilot is a key milestone in our broader commitment to create a workplace culture that is safe, respectful and inclusive. Building awareness through education on how we can create safer work environments through the prevention and elimination of sexual harassment, bullying and racism is vital to ensuring those joining our industry feel safe.

“We’re proud to be collaborating with experts in this field, in partnership with industry leaders, and we look forward to the findings from the pilot and the opportunity to share with broader industry for the benefit of all Australians.”

BHP WA Iron Ore Asset President, Brandon Craig, said: “Programs such as this help educate the next generation of workers to ensure our workplaces are safe, respectful and inclusive. While we know there is more to do, this pilot is part of our redoubled efforts to eliminate sexual harassment, and is in addition to a range of other measures including improved security at accommodation villages, additional public disclosures, specialised resources and company-wide training.

“We’re proud to be working with leading industry partners to deliver this important program as we work together to eliminate disrespectful behaviours from our industry.”

Fortescue Chief Operating Officer Iron Ore, Dino Otranto, said: “At Fortescue, safety is our first priority and we have zero tolerance for inappropriate behaviour. We remain firmly committed to ensuring that Fortescue has safe and inclusive workplaces, and that the mining industry as a whole is a safe and welcoming place for everyone who works within it.

“We’re pleased to be working with our industry peers towards the common goal of ensuring that sexual harassment, bullying and other inappropriate behaviours do not occur in the mining industry.”

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.

Komatsu’s MC51 hard-rock cutting tech up and running at Vale’s Garson mine

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Vale and Komatsu’s mechanical rock excavation (MRE) collaboration has moved into another gear, with the Komatsu MC51 machine featuring DynaCut mechanical cutting technology now operating underground at Vale’s Garson nickel mine in Sudbury, Canada, Vale’s Dino Otranto confirmed at MINExpo 2021, in Las Vegas, today.

Speaking at the ‘Creating value together: Special one-time presentation with Vale’ event on Monday, Otranto, Chief Operating Officer of North Atlantic Operations and Asian Refineries for Vale, said the machine was in operation, 2.5 km underground at Garson after recently being assembled.

The machine is scheduled to carry out a 1,400 m initial test run at the mine, according to Komatsu, with the exercise seen as a way to bring the technology to market quicker for Vale and other customers, Rudie Boshoff, Director of Hard Rock Cutting systems at Komatsu, said during the presentation.

Andy Charsley, a Principal Mining Engineer at Vale, says this trial is the largest hard-rock cutting trial Vale has ever committed to.

Through more than 10 years of research and development, Komatsu says it has determined how to break rock continuously and precisely through a fully electric system that outputs zero emissions. By automating and controlling processes so the machine can be operated remotely via line of site, Komatsu customers have the opportunity to move their operators further from the cutting face and from harm’s way leveraging DynaCut technology and the MC51 machine. DynaCut technology, which has previously been tested at Newcrest Mining’s Cadia underground mine in Australia, is billed as offering cutting accuracy of within 50 mm to plan.

Otranto says the partnership with Komatsu is the first step to “really prove and understand the technology, while meeting our high standards for safety”.

Last year, Charsley and colleague Luke Mahoney spoke to IM about this partnership, which is part of the mechanical cutting demonstration within the CMIC (Canada Mining Innovation Council) Continuous Underground Mining project.

Vale said back then that the trial planned to demonstrate the ability to cut rock in excess of 250 MPa; cut at a commercial rate of more than 3.5 m/shift; quantify the cost per metre of operation and start to look at the potential comparison with conventional drill and blast development; assess the health, safety and environmental suitability of the MRE process; and gain insight into the potential of an optimised MRE process.

Charsley says the integration of the MC51 with bolters, trucks, scoops and other equipment at the operating mine will be included within the company’s assessment of the technology.

Since announcing this collaboration, the South Australian Government has awarded a A$2 million grant to Hillgrove Resources to trial the new underground mining technology being progressed by Komatsu.

Komatsu and Vale’s DynaCut Garson collaboration to be highlighted at MINExpo

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Komatsu and Vale are set to reveal more about their underground hard-rock mechanised cutting technology collaboration at the upcoming MINExpo 2021 event next month.

The companies, through the Canada Mining Innovation Council, have been engaged on a project to advance the future of underground hard rock excavation through optimising use of Komatsu’s DynaCut mechanical cutting technology.

The technology was previously tested at the Cadia underground mine in New South Wales, Australia, operated by Newcrest Mining, which IM revealed last year as part of an exclusive interview with Vale’s Luke Mahony, Head of Geology, Mine Engineering, Geotechnical and Technology & Innovation for the Global Base Metals Business; and Andy Charsley, Project Lead and Principal Mining Engineer, Technology & Innovation.

Vale and Komatsu will start trialling DynaCut’s capabilities on Komatsu’s new MC51 machine at Vale’s Garson Mine in Sudbury, Ontario, Canada, shortly, working together to increase the pace at which the innovative technology will be available to the larger market.

The machine is set up at Garson and expected to start cutting in the next month, IM understands.

“True innovation requires effective collaboration between the end user and suppliers to ensure the technology meets the needs of the industry,” Dino Otranto, Chief Operating Officer of North Atlantic Operations and Asian Refineries for Vale, said. “This partnership is that first step to really prove and understand the technology, while meeting our high standards for safety.”

Through more than 10 years of research and development, Komatsu says it has determined how to break rock continuously and precisely through a fully-electric system that outputs zero emissions. By automating and controlling processes so the machine can be operated remotely via line of site, Komatsu customers can move their operators further from the cutting face and from harm’s way leveraging DynaCut technology and the MC51 machine, it said.

Rudie Boshoff, Director of Hard Rock Cutting Systems at Komatsu, said: “We’re excited to be trialling this new machine and technology because it offers the potential to really change the way our customers mine. Not only does the DynaCut technology provide a very controllable way of cutting rock – within 50 mm accuracy to plan – the machine itself, the MC51, is designed to advance more sustainable mining methods by reducing the amount of equipment required to get to the orebody.”

Komatsu and Vale will be co-presenting about their partnership to drive innovation on September 13, 2021, on stage at the Komatsu booth in Las Vegas.

Just this week, Hillgrove Resources said it was set to trial the DynaCut technology on an MC51 machine to develop a portal and underground decline at the Kanmantoo mine in South Australia following a A$2 million grant from the South Australia Government.