Tag Archives: Fortescue Metals Group

Fortescue to test battery-electric, fuel cell tech in prototype 240 t haul truck

Environmental, Mining equipment, Mining services, Power supply for mines, Steel and iron ore, Sustainable mining, , , , , ,

Fortescue Metals Group has confirmed it is in the process of developing an in-house, non-diesel 240 t haul truck prototype that will test both battery-electric and fuel-cell electric drivetrain technology in the Pilbara of Western Australia.

Speaking at its Investor and Media Day on Wednesday, Fortescue Chief Operating Officer, Greg Lilleyman, said the two-phase project would “offer a step-change opportunity to reduce our emissions”.

He explained: “With around a quarter of Fortescue’s Scope 1 and 2 emissions attributable to our mobile haul fleet, this is a significant opportunity to drive our pathway to net-zero operational emissions.”

The drivetrain of the 240 t prototype truck will be powered by the company’s integrated renewable energy network, he added.

Phase one of the project will see a battery-electric powertrain on-board the prototype truck tested and trialled, from an operational perspective, in the Pilbara. Phase two of the project will consider hydrogen fuel cell powertrains, Lilleyman added. The drivetrains will have the capacity to regenerate power on downhill haulage.

While no specific timeline was provided for the project, the company did say the program schedule was targeted to align with the replacement cycle of the company’s existing haul trucks.

Weir adds aftermarket and service contract to Iron Bridge remit

Comminution of minerals, Equipment maintenance, Mineral processing, Mineral project development, Mining equipment, Mining maintenance, Mining services, Steel and iron ore, , , , , , , , , , , , , , , , ,

The Weir Group says it has won a £95 million ($127 million) order to provide aftermarket components and service to the Iron Bridge magnetite project in Western Australia.

The aftermarket contract follows Weir’s success in winning a record £100 million order for original equipment for the Iron Bridge project in 2019, including its Enduron® High Pressure Grinding Rolls (HPGRs, pictured) that, it says, will enable dry processing of ore and use at least 30% less energy than traditional alternatives.

The Iron Bridge magnetite project is a $2.6 billion joint venture between Fortescue Metals Group’s subsidiary FMG Magnetite Pty Ltd and Formosa Steel IB Pty Ltd located in the Pilbara region, around 145 km south of Port Hedland.

Both the aftermarket order and revenues will be recognised over the seven-year period of the agreement, which starts in 2022, in line with the 22 Mt/y project’s initial production.

Ricardo Garib, President of Weir Minerals, said: “This is another landmark order for Weir. Having helped design an energy and water efficient magnetite processing plant, we are delighted to provide operational support for Iron Bridge from 2022. It is an excellent example of the value that Weir’s innovative engineering and close customer support can create for all our stakeholders and reflects the key role we have to play in making mining operations more sustainable and efficient.”

Weir’s Enduron HPGRs are increasingly replacing conventional mills in comminution circuits, Weir says. In addition to their energy and water savings, they also reduce grinding media consumption, while their wearable components last longer, reducing maintenance costs. Additionally, HPGRs contribute significantly to carbon dioxide emission savings.

Stuart Hayton, Managing Director of Weir Minerals Netherlands, where the Enduron HPGRs are designed and manufactured, said: “This is an important project for Weir and for the broader mining industry. We know comminution is one of the most energy intensive parts of the mineral process and, with our Enduron HPGRs, we have a unique ability to offer significant cost, energy and water savings to customers around the world. As the mining industry evolves, we are commited to continuing to innovate, reducing miners’ costs and environmental impact.”

This latest contract award means Weir now has more than £200 million of orders from the Iron Bridge project including its Enduron HPGRs, GEHO® and Warman® pumps, Cavex® hydrocyclones and Isogate® valves.

To support the project and future growth, Weir says it will build a new service centre in Port Hedland, Western Australia, thereby providing employment and training opportunities in the area, with a particular emphasis on supporting greater Aboriginal representation in the broader mining workforce.

ABB to deliver drives and motors to Fortescue’s Iron Bridge Magnetite project

Comminution of minerals, Mineral processing, Mineral project development, Mining equipment, Mining services, Power supply for mines, Steel and iron ore, , , , , , , , , , ,

ABB has won a $26 million order from Fortescue Metals Group to deliver water-cooled variable speed drives and high voltage induction motors to FMG’s majority-owned Iron Bridge Magnetite project in Western Australia.

The project, operated under an unincorporated joint venture between Fortescue subsidiary, FMG Magnetite Pty Ltd, and Formosa Steel IB, covers the development of a new magnetite mine, including processing and transport facilities. The $2.6 billion development is expected to produce 22 Mt/y (wet) of high grade, magnetite concentrate, with first ore in 2022.

As part of the project, the Iron Bridge Joint Venture required a cost-effective energy efficient variable speed drive solution, according to ABB. These drives, to be installed in eight switch rooms, operate with a separate transformer that is located outside the room. This reduces the heat generated inside, resulting in less energy required to maintain the 25°C room temperature.

ABB’s water-cooled drives also directly support a higher voltage 33 kV network, it said. “This eliminates the need for a lower voltage intermediate switchboard and additional components, which ultimately reduces the total cost of the project,” the company explained.

Iron Bridge also selected ABB high voltage induction motors to power high pressure grinding rolls, grinding mills and baghouse fans used to separate the ore from the dust at Iron Bridge. Engineered to withstand harsh conditions, the motors offer high power efficiency, but in a frame size smaller than competitive alternatives, it said.

Mike Briggs, Business Manager for ABB Motion, Australia, said: “We have worked closely with the Iron Bridge team to ensure that we delivered an energy efficient, reliable and innovative solution. We are especially pleased to have won both the drive and the motor business, and look forward to continuing our strong relationship with Fortescue beyond the delivery of this project and supporting them throughout the mine’s lifecycle.”

BOC and Linde recruited for hydrogen coach project at FMG’s Christmas Creek

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Leading gas and engineering company, BOC, a subsidiary of Linde plc, has announced a project to provide hydrogen production and refuelling infrastructure for the first fleet of hydrogen coaches at Fortescue Metals Group’s Christmas Creek iron ore operation in the Pilbara region of Western Australia.

The A$32 million ($23 million) renewable hydrogen supply project will enable Fortescue’s 10 coaches to be fuelled with renewable hydrogen and will transport workers from its base camp to the mine site.

Christmas Creek will be the first mine in Australia to deploy hydrogen for transport and transition from diesel engines, according to BOC.

BOC will supply two 700 kW ITM electrolysers to produce renewable hydrogen through electrolysis. The electrolysers will have capacity to produce enough renewable hydrogen to power 10 hydrogen fuel cell coaches that carry around 3,000 workers to and from the mine site every day. A state-of-the-art Linde hydrogen refuelling station will also be supplied by BOC at a site in the Pilbara.

The 10 full-sized hydrogen coaches, custom built by HYZON Motors, will replace the existing fleet of diesel coaches at Christmas Creek.

The project is expected to be completed by early 2022.

Linde is at the forefront in the transition to clean hydrogen and has installed over 190 hydrogen fuelling stations and 80 hydrogen electrolysis plants worldwide, according to BOC.

John Evans, Managing Director, BOC South Pacific, said the project will demonstrate BOC’s expertise in customised hydrogen solutions to suit the most challenging environments.

“BOC is proud to be the chosen partner in this exciting project that will demonstrate how renewable hydrogen can be used as a fuel for heavy vehicles in remote environments.

“Mining is a 24/7 operation which, together with the remoteness of the site, means that reliability is essential. BOC provided a solution that recognised the criticality of the application and we collaborated with Fortescue to design an application to protect the electrolyser and refueller from the environment in the Pilbara region.”

He concluded: “We look forward to working with Fortescue and our other partners to expand the use of hydrogen in heavy transport and remote applications – which are key priorities outlined in the Western Australian Renewable Hydrogen Strategy.”

Fortescue completes autonomous haul truck fleet conversion in Western Australia

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Fortescue Metals Group says it has completed its Chichester Hub autonomous haulage project, with 183 trucks now operating in AHS mode across its Solomon and Chichester Hubs, in Western Australia.

The project represents one of the largest fleet conversions to autonomous haulage systems (AHS) in the industry. It was aided by the involvement of Thiess.

The multi-class fleet includes Cat 793F, 789D and Komatsu 930E haul trucks and has safely travelled more than 52 million km and moved 1,500 Mt of material since 2013, according to FMG. An additional 900 assets, such as excavators, wheel loaders and light vehicles, are integrated with the autonomous fleet using Cat MineStar Command for hauling technology, which is operated from the Fortescue Hive, the company’s integrated operations centre in Perth, Western Australia.

Chief Executive Officer, Elizabeth Gaines said, “Mining is one of the most innovative industries in the world, and Fortescue continues to build on our leading autonomy capability to deliver productivity and efficiency benefits.

“Most importantly, the introduction of AHS technology has improved safety outcomes across our operations and we’re very pleased that the team achieved this important milestone in the truck conversion program to the highest safety standards.

“Our approach to autonomy has been to be open and transparent with our plans and to work closely with our team members to offer opportunities for re-training and re-deployment. Around 3,000 Fortescue team members have been trained to work with autonomous haulage, including over 200 people trained as Mine Controllers and AHS system professionals.”

Group President, Resource Industries, Caterpillar Inc, Denise Johnson, said: “Fortescue is a leader in the implementation of autonomous solutions. This important milestone further reinforces the transformation Fortescue has made with autonomy to improve safety, site productivity and machine utilisation. We congratulate Fortescue on this significant achievement.”

Fortescue Chief Operating Officer, Greg Lilleyman, said: “Fortescue’s autonomous haulage fleet has delivered a 30% increase in productivity. Looking ahead, the flexibility of our efficient, multi-class autonomous fleet offers considerable potential for further productivity and efficiency gains.

“Our operations are more connected than ever before and, by using data from our autonomous haulage fleet, we can paint an accurate picture of our operations and focus on the optimal opportunities for improvement, such as haul road design and maintenance scheduling.

“Our autonomous haulage system is a foundational tool which allows us to streamline processes and improve outcomes, ultimately delivering increased value for our shareholders.”

Aqura to supply LTE equipment to Iron Bridge magnetite project

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Veris Ltd subsidiary, Aqura Technologies, has secured a contract to supply advanced LTE equipment for the Iron Bridge Magnetite project, a joint venture between Fortescue Metals Group subsidiary FMG Magnetite Pty Ltd and Formosa Steel IB Pty Ltd, in the Pilbara of Western Australia.

The A$2 million ($1.4 million) contract reflects Aqura’s strong focus to understand the evolving technology needs of the project and demonstrate its industry-leading capability to identify and design robust technology solutions that will support clients’ future operational strategies, the company said.

Aqura Technologies CEO, Travis Young, said: “This contract award is a great validation of the strategy the Aqura team are pursuing to leverage their expertise to enable other organisations to achieve positive business outcomes with leading-edge technology. We are very pleased to be supporting the great work of FMG and look forward to assisting them with their longer-term technology transformation program.

“Aqura continues to lead in high-performance industrial connectivity with advanced engagements for new rollouts, and other developments such as the imminent completion of our first 5G-enabled LTE network to bring the benefits of private LTE to a broader spectrum of businesses.”

The $2.6 billion Iron Bridge Magnetite project is expected to see a new magnetite mine developed to support production of 22 Mt/y of high-grade concentrate, according to Fortescue. First concentrate is expected to be produced by mid-2022.

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

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

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

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

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

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

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

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

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

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

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

Primero banks new work with Fortescue, Rio Tinto and Hazer Group

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Primero Group says it has recently booked new business totalling some A$55 million ($39 million) with Fortescue Metals Group, Rio Tinto and the Hazer Group as it continues to build out its 2021 financial year contracted order book.

First, it has been awarded the engineering, procurement and construction contract for the Non-Process Infrastructure (NPI) at Fortescue’s Eliwana mine and rail project, in the Pilbara.

Works commenced in late July based on a limited notice to proceed, with the full contract now awarded to Primero following a successful Early Contractor Involvement (ECI) process. The contract includes the complete engineering design, procurement and construction of heavy vehicle workshops and washdown and refuelling infrastructure required for the new Eliwana mine, with works expected to be completed in the 2021 financial year.

Once completed, the $1.275 billion Eliwana project, which includes the building of a 30 Mt/y iron ore processing facility, will maintain Fortescue’s overall production rate of a minimum 170 Mt/y over 20 years.

With Rio Tinto, Primero has been awarded two multi-year Master Service Agreements for NPI and Structural, Mechanical, Piping services across the miner’s Pilbara operational and project locations. The two contracts have an initial term of three years, with an option for a two-year extension. They cover sustaining capital and maintenance projects required over that period across all Rio Tinto Iron Ore Pilbara sites, it said.

The services cover design, procurement and construction activities for engagement under negotiated commercial terms in a “panel style agreement”, according to Primero.

Primero has also been awarded an EPC contract for Hazer Group’s hydrogen/graphene commercial demonstration plant in Western Australia at the Woodman Point Water Treatment Facility.

Hazer is undertaking the commercialisation of the Hazer Process, a low-emission hydrogen and graphite production process. This process enables the effective conversion of natural gas and similar methane feedstocks, into hydrogen and high-quality graphite, using iron ore as a process catalyst, according to the company.

“The full project award has followed a successful ECI process that has extended over the past 12 months,” Primero said. “This process was targeted at developing the technology engineering to the point where a commercial contract could be executed to deliver the project. The project is the first of its kind in the new global renewables energy market and is patented groundbreaking technology in the hydrogen space.”

Alongside this, Primero said it had been awarded the detailed design contract for a 130 km water delivery pipeline and associated pumping stations for the Covalent Lithium Mt Holland project feasibility study in Western Australia.

Primero said its committed order book for the 2021 financial year now stands at around A$285 million.

Pindan lands design and construct contract at Iron Bridge

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Integrated property and construction group, Pindan, says it has been awarded another contract for works linked to the Iron Bridge Magnetite project in the Pilbara of Western Australia.

Iron Bridge, an unincorporated joint venture between Fortescue Metals Group subsidiary FMG Iron Bridge and Formosa Steel IB Pty Ltd, have awarded Pindan a A$3.6 million ($2.6 million) contract to design and construct the $2.6 billion project’s landside airport, it said.

Pindan Executive Director, Tony Gerber, said this new scope of work would kick off in October and was due to be finished by the end of the year.

“We have a long and successful history of working in this part of Western Australia and are already on the ground at Iron Bridge, having been awarded a A$3.4 million contract in June this year to design, supply and install a number of office buildings, as well as deliver associated infrastructure, at Fortescue’s Herb Elliot Port facility in Port Hedland,” Gerber said.

“This contract sees us manage civil works, design, and roadworks, and supply all resources, support facilities, labour and materials for this part of the project. It also includes the construction of a communications tower for the airport terminal building, as well as fitting out the airport.”

Iron Bridge is a new magnetite ore processing facility located 145 km south of Port Hedland. The project is on track to create around 3,000 jobs during construction and 900 full-time operational positions, and will deliver a premium product of high grade 67% Fe magnetite concentrate product with the first ore on ship scheduled for mid-2022.

Central Systems secures $41 million Fortescue Solomon contract

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Resource Development Group’s Central Systems subsidiary has been awarded a contract to design and construct the central facilities at the Fortescue Metals Group’s Solomon mine site in the Pilbara of Western Australia.

The contract with FMG Solomon Pty Ltd has a value of approximately A$57.5 million ($41.3 million) and is due for completion in June 2021.

Fortescue’s Solomon Hub is in the Hamersley Ranges and comprises the Firetail and Kings Valley mines, which together have a production capacity of 75 Mt/y. At the hub, higher iron grade, low cost Firetail ore is blended with low phosphorous Chichester ore to create the company’s Fortescue Blend.

RDG also advises that its 80%‐owned subsidiary, Crushing Service Solutions (CSS), recently demobilised from the Minjar gold plant near Southern Cross, Western Australia, as a result of early contract termination with Tianye SXO Gold Mining.

In the company’s recent annual financial report, it said it was in the process of reviewing the operations of CSS as it seeks to determine its future direction to ensure profitability.