Tag Archives: Iron ore

Binding Solutions Limited builds up R&D capabilities for green steel tech

Environmental, Steel and iron ore, , , ,

Binding Solutions Limited (BSL), the developer of green steel technology, has announced the completion of significant upgrades to its R&D capabilities at its technology centre in Middlesbrough, UK.

BSL is now able to accelerate the commercialisation of its Cold Agglomerated Pellet (CAP) technology by offering clients – including iron ore miners – an enhanced range of research, technical support and product testing services significantly reducing development timelines.

Following the commissioning of the first phase of BSL’s pilot plant in November 2023, the company has now completed the commissioning of the second phase of the plant. The phase two expansion increases the pilot plant’s capabilities through the integration of an ore drying system, milling plant and pellet curing system. These additions significantly expand BSL’s processing capabilities, enabling the pelletisation of a wider variety of ores, BSL says.

In addition, new state of the art hot testing equipment has been installed and commissioned at the technology centre, enabling BSL to simulate conditions in direct reduction plants and blast furnaces to ensure its CAPs meet customer requirements covering key ISO standards. Due to significant demand, BSL is already conducting a feasibility study to further increase hot testing capacity, it says.

Julian Lee, CEO of Binding Solutions, said: “Our continued investment in our world leading Middlesbrough Technology Centre reflects our growing confidence in BSL’s cold agglomeration technology and the contribution it can make to enabling green steel production. The upgraded facilities will enable our team to work more closely with customers and accelerate the commercialisation of our technology.

“This further enhances the competitive advantage we are building through our investment, the deep expertise of our team and the growing technical know how we are building.”

BSL calls itself a fast-growing technology company, having developed a patented and proprietary process for significantly reducing carbon emissions in iron making, enabling green steel production at scale. Its cold agglomeration technology reduces process complexity, lowers capital requirements and significantly cuts emissions of CO2, NOx and SOx by replacing traditional technologies (induration) in iron and steel making.

It says it has commercially proven its technology at a major steel plant in the UK where it has operated since 2013. It enables reductions of up to:

  • 80% in energy usage;
  • 70% in carbon dioxide emissions; and
  • 86% in capital expenditure.

BSL estimates that its technology has a very large addressable market of more than 1,000 Mt.

In August 2023, BSL successfully completed a $17.5 million fundraise from Mineral Resources Limited to support the development of a demonstration plant. BSL’s Pilot Plant completed Phase 2 and is fully operational, producing up to 2 t/hr of CAPs for large scale furnace trials.

BHP to trial prototype battery-electric HiLux light vehicle at Port Hedland ops

Environmental, Mine operation news, Mining equipment, Mining services, Power supply for mines, Sustainable mining, , , , , , , ,

Toyota Australia and BHP have announced a trial of the first-ever battery-electric HiLux double cab ute prototype, with the vehicle set to be deployed at the Port Hedland operations in Western Australia where it will be used in a range of applications traditionally performed by diesel-powered light vehicles.

Starting in late November, the trial will run for about 12 months, with BHP to provide feedback to Toyota after the conclusion of the trial.

Toyota Australia President and CEO, Matthew Callachor, said the trial marked an exciting opportunity for both companies and was a significant milestone in the HiLux’s history.

“Toyota has long advocated a multi-pathway approach towards decarbonisation, and when we do something, we want to make sure we do it right,” Callachor said. “Joining with BHP to help further develop this HiLux BEV prototype is an important step in creating low-emission technologies in the light commercial vehicle space, particularly for use in harsh and demanding mining environments.

“This trial is also a demonstration of the commitment shown by both parties to the Memorandum of Understanding (MoU) signed last year, which leverages the strengths of both companies to develop new, safe and exciting technologies to address decarbonisation,” he said.

BHP President Australia, Geraldine Slattery, said BHP was thrilled to trial the first-ever battery-electric HiLux in an environment where safety and reliability are essential.

“Our ambition to electrify our light vehicle fleet and lower greenhouse gas emissions across our operations depends on enabling technology that can only be achieved through collaborations like this, with leading suppliers like Toyota,” Slattery said.

“With around 5,000 light vehicles at our sites across Australia, we look forward to putting the battery-electric HiLux through its paces and seeing the potential it can bring, not only to reduce diesel use in mining but eventually for all HiLux drivers too.”

BHP Group Procurement Officer, Rashpal Bhatti, said the partnership with Toyota was a terrific example of working with major suppliers to achieve better outcomes.

“The path to decarbonising our operations is one we cannot walk alone,” Bhatti said. “To accelerate the development of new technologies, we are collaborating with original equipment manufacturers and stakeholders in the industry,” Bhatti said.

“Our work with Toyota highlights our shared commitment to developing solutions that ultimately make the world a safer and more sustainable place to live and work,” he said.

BHP’s Port Hedland operation is the largest iron ore loading port in Australia, and one of the largest in the world.

The BHP trial follows the signing of a MoU by the two companies in August 2023, with the stated aim of working together to further decarbonisation measures within BHP’s Australian operations. The MoU aims to see BHP and Toyota Australia collaborate on the areas of safety, engineering and product development, with a particular focus on light vehicle design and the potential and challenges of future technologies.

RCR Mining Technologies’ SPF set to redefine the future of apron feeder tech

Comminution of minerals, Mining equipment, , , , , , , , , ,

RCR Mining Technologies has announced the launch of the Sealed Pan Feeder (SPF), a world-first, industry-leading product redefining the future of apron feeder technology, it says.

Combining the robust elements of an apron feeder with the sealing properties of a belt feeder, RCR has created a two-in-one machine that, it says, offers benefits beyond any traditional apron feeder.

Both the RCR Sealed Pan Feeder and the RCR Apron Feeder boast low-maintenance designs, outperforming alternatives in the market. The Sealed Pan Feeder shares over 90% of its components with the RCR Apron Feeder, ensuring durability while introducing key improvements:

  • Enhanced performance: The SPF reduces the need for maintenance outages, offering approximately 50% fewer outages and 39% less tool time over a 15-year period compared with standard, non-RCR apron feeders, the company claims;
  • Maximised production: The reduction in maintenance frequency and outage duration translates directly to more ore throughput without increasing the size or speed of the feeder; and
  • Cost efficiency: By eliminating the need for dribble conveyors, the SPF delivers more efficient operating costs, addressing carry-back and leakage with its fully sealed and scrapable material-carrying surface.

RCR’s Head of Engineering, Elia Khoury, said the company was thrilled to launch this world-first, next-generation apron feeder that is set to “revolutionise materials handling”.

The SPF has already proven its worth in the field, with Fortescue Metals Group Project Director, Matthew Erceg-Hurn, remarking: “Having the Sealed Pan Feeders means we have a lot more uptime, which means we can keep running tonnes through the plant and produce more revenue as opposed to stopping and maintain the plant more regularly.”

The Sealed Pan Feeder was recently showcased at MINExpo 2024, in Las Vegas, where it garnered significant attention from industry leaders, according to the company, with Alister MacPherson, Head of Strategy, Growth & Innovation at RCR, characterising the interest as “phenomenal”.

Neville Kelly, Business Development Manager at RCR, concluded: “With its superior design and proven benefits, the Sealed Pan Feeder represents the future of apron feeder technology, helping companies maximise production, reduce costs and streamline operations.”

NRW to help support ‘sustainable production’ at BHP’s majority-owned Jimblebar iron ore mine

Mine operation news, Mining services, Steel and iron ore, , , ,

NRW Holdings Limited’s NRW Civil & Mining business has been awarded a development contract for BHP at the Jimblebar mine in the east Pilbara (some 39 km east of Newman).

The scope of the contract includes various civil, building, mechanical and electrical works to support sustainable production at Jimblebar.

The project will include bulk earthworks and covers the construction of a number of permanent facilities.

The contract also includes the construction of a new floodway and an light vehicle access road complete with heavy and light vehicle standpipes and washdown facility. Additionally, the contract requires a HDPE pipeline re-alignment and installation of a 33 kV overhead powerline.

The contract is valued at approximately A$109 million ($73 million) and will commence in November 2024. The project is scheduled for completion in the June quarter of 2026 and will employ a team of up to 120 personnel and 55 items of plant and equipment.

The Jimblebar iron ore mine is a part of an 85:15 joint venture between BHP and Mitsui and ITOCHU. It is one of five mines and four processing hubs that make up Western Australia Iron Ore – an integrated system of joint ventures connecting 1,000 km of rail infrastructure and port facilities.

Jimblebar is home to BHP’s first fully autonomous truck operation.

Decmil wins A$61 million Marble Bar Road upgrade works from HanRoy

Mining maintenance, Mining services, Steel and iron ore, , , , ,

Macmahon Holdings Limited subsidiary, Decmil, has been awarded the A$61 million ($42 million) Marble Bar Road Upgrade project in Western Australia.

Decmil received a notice of award from HanRoy Iron Ore Projects Pty Ltd (HanRoy) for approximately 23 km of road construction upgrade works to Main Roads Western Australia standards on Marble Bar Road. Works are expected to commence in October 2024.

HanRoy is part of Hancock Prospecting, which is currently developing the McPhee iron ore project in the northeast Pilbara region of Western Australia, some 100 km north of Roy Hill Mine and 30 km north of Nullagine, with an expected production rate of approximately 9.5-9.7 Mt/y (wet). Primary crushed ore will be hauled via road train from McPhee to Roy Hill for processing, transport to the port and shipping. The Marble Bar Road is part of this route.

MacMahon CEO and Managing Director, Michael Finnegan, said: “I am pleased to see Decmil continue their great start of securing new, strategically aligned work. We look forward to delivering the Marble Bar Road upgrade project and continuing to build our relationship with HanRoy.”

LKAB selects Hardox 600 for wear steel at iron ore operations

Equipment maintenance, Mine operation news, Mining consumables, Steel and iron ore, , , ,

Looking at a typical mining site, wear steel is used as liners in hoppers, feeders and chutes, as well as for hammers in crushers or in screens for sorting.

Hardox® 600 is, SSAB says, a wear steel that performs well across a surprisingly wide range of abrasive materials, operating requirements and types of equipment, including for iron ore miner LKAB.

Hardox 600 has a nominal hardness of 600 HBW. Despite its hardness, it has a toughness that is rare for such a hard wear steel, according to the company. This gives it outstanding wear resistance, while enabling it to resist impact damage from rocks and other heavy loads. It is also through-hardened, with a minimum core hardness of 90% of the guaranteed minimum surface hardness.

As a major iron ore company, LKAB can’t afford any loss in productivity. Unscheduled downtime can severely impact throughput and, in turn, financial performance. It ships around 30 Mt of iron ore each year from its harbour in Narvik, above the Arctic Circle in Norway.

When LKAB started to experience too many unplanned shutdowns – and unwanted associated costs – it looked for a more durable wear steel for its skips and chutes. That’s why it chose Hardox 600, one of the hardest grades of Hardox steel. Before its decision, LKAB collaborated with SSAB on a performance optimisation project, which ultimately gave it the green light to go ahead with Hardox 600.

Due to the many factors influencing wear life in mining operations, SSAB says it always recommend a thorough assessment by wear specialists. For LKAB, a 600 HBW steel was the best choice. In most wear situations, there is a sweet spot where the wear rate drops significantly if the steel’s hardness is high enough relative to the severity of the abrasive material.

Rio Tinto ships four billionth tonne of iron ore to China

Mine operation news, Steel and iron ore, , , , ,

Rio Tinto has today celebrated the shipment of 4 billion tonnes of iron ore from the Pilbara in Western Australia to China.

The shipment was loaded at Dampier Port on July 19, bound for China Baowu Steel Group, the world’s top steel producer by output. This milestone comes 51 years after the first shipment of almost 22,000 t of Pilbara iron ore was sent from Dampier Port to China’s Shanghai No.1 Steel Mill, which has since become part of China Baowu.

Over more than half a century, China has grown to become Rio Tinto’s largest customer with about 250 Mt/y of iron ore shipped.

Four billion tonnes is enough iron ore to produce the steel needed for about 45,000 Sydney Harbour Bridges, or more than 23,000 Beijing National Stadiums (Bird’s Nest), Rio Tinto says.

Rio Tinto partnered with China for the country’s first ever investment in a foreign mining project, and its largest ever foreign investment at the time, by forming the Channar joint venture in 1987. That jv in Western Australia laid the foundation for many projects to follow, and for decades of mutual growth and prosperity between Rio Tinto, China and Australia, the company says.

Western Range, Rio Tinto’s newest mine, is the latest joint venture partnership with China Baowu. Production from the mine is expected to commence in 2025, with an annual capacity of 25 Mt of iron ore.

Rio Tinto Iron Ore Chief Executive, Simon Trott, said: “China has been a critical partner for Rio Tinto and for Australia’s mining industry for more than five decades. China’s strong demand for high-quality minerals such as iron ore has generated substantial opportunities for investment and trade between the two countries.

“Every time I visit China and see the skyscrapers, the high-speed rail, and all the infrastructure that has helped improve the lives of 1.4 billion people, it makes me proud to think that most of what I see contains steel that was made with Rio Tinto iron ore.

“We look forward to continuing our relationship with China well into the future as we continue to deepen our strategic partnership.”

Rio Tinto to invest A$8 million in Pilbara conservation programs

Environmental, Mining services, Sustainable mining, , , , , , , ,

Rio Tinto says it will invest A$8 million ($5.3 million) over five years in a partnership with Western Australia’s Department of Biodiversity, Conservation and Attractions (DBCA) on a new project to enhance conservation land management and support Traditional Owner ranger programs in Karijini and Millstream Chichester National Parks.

The Pilbara Conservation Project will protect areas of high conservation value and integrate Traditional Owners’ knowledge of the land into conservation land management. This includes weed management, feral animal control and bushfire management at Karijini, Millstream Chichester and other high conservation value Pilbara sites, through implementation of the Pilbara Conservation Strategy.

The project will also support ranger training and fee for service work for Aboriginal Ranger Groups.

Rio Tinto, DBCA and Traditional Owners have been partnering to protect the Karijini and Millstream Chichester National Parks since 2015.

The new project adds to a range of partnerships Rio Tinto has with Traditional Owners to support Aboriginal Ranger Programs in the Pilbara, including the Pilbara Ranger Network and partnerships with Aboriginal Corporations to deliver various ranger programs.

Rio Tinto Vice President, Health, Safety, Environment & Communities, Cecile Thaxter, said: “This project will enable DBCA and Traditional Owners to continue caring for Country and importantly put Traditional Owner knowledge at the heart of conservation management for this environmentally, culturally and economically significant region.

“Maintaining Pilbara biodiversity is critical not only for our business today but also for future generations within the region, and we recognise our responsibility to understand and effectively mitigate our impacts on nature through collaborative partnerships.

“Partnerships like the Pilbara Conservation Project are crucial to delivering nature-positive outcomes, with collaboration, resource sharing, innovation, local engagement and collective effort needed to address the complex challenges with environmental conservation and restoration.”

Western Australian Environment Minister, Reece Whitby MLA, said: “Conservation is a shared responsibility, and this new partnership demonstrates how Government, industry and Traditional Owners can work together to manage biodiversity values through practical on-ground actions.

“The Pilbara is a special place – its habitat is home to some species of animals and plants you can’t find anywhere else in the world.

“Karijini National Park is the Pilbara’s key tourist attraction, with over 300,000 visitors annually. This project will do wonders for its conservation into the future.”

FLSmidth wins multi-year contract to service HPGRs at Chile mines

Comminution of minerals, Equipment maintenance, Mineral processing, Mining equipment, Mining services, , , , ,

A leading Chile-based iron ore miner has awarded FLSmidth with a multiple year contract to service its five high pressure grinding rolls (HPGRs) across three of its mines in Chile, with the key focus for the customer to enhance productivity and extend the lifetime of its HPGRs.

HPGRs are subject to significant wear and tear. Consequently, keeping them in operation is key to securing a mine’s productivity and throughput as well as reducing customers’ operational costs. To facilitate to this, having a strong service setup around HPGRs is paramount.

The new service order on these five HPGRs, which originally have been installed by another equipment provider, proves that FLSmidth’s HPGR service offerings are among the most attractive in the market, the company says. All assembly works as well as repairs on shafts are included in the contract.

The service contract will be managed and executed by FLSmidth’s Chilean service centre, which is in close proximity to the three mines, thereby reducing logistic costs to customer and providing best in class services, it added. FLSmidth’s service centre is fully equipped to manufacture large HPGR parts and allows all work to be performed in a clean environment and using best in class tools.

Prior to winning this new service contract, FLSmidth has previously delivered HPGR roll tyres to the customer, which have proven to last more than three times as long as the originally installed roll tyres as well as increased operational availability and significantly reduced recirculation, the company says.

Joshua Meyer, Service Business Line President at FLSmidth, says: “For long our HPGR solution has been regarded among the best in the industry. The fact that we can win a large service contract on a non-FLSmidth HPGR platform proves that we have the service concept to back up the technology, securing enhanced productivity and extended lifetime.”

Kumba’s Sishen and Kolomela iron ore mines achieve IRMA 75 accreditation

Mine operation news, Steel and iron ore, Sustainable mining, , , , , , , , , ,

Kumba Iron Ore, majority owned by Anglo American, has announced that its Sishen and Kolomela mines in South Africa have been assessed against the Initiative for Responsible Mining Assurance’s (IRMA) comprehensive mining standard, achieving the IRMA 75 level of performance.

This reflects Anglo American’s integrated approach to sustainability and its commitment to transparency in striving for the highest levels of responsible iron ore production, the company said.

Mpumi Zikalala, Chief Executive of Kumba Iron Ore, said: “We are proud of our teams’ efforts and the outstanding progress made across both of our operations to promote responsible mining practices. As part of our commitment to leading in ESG practices, we are dedicated to delivering premium quality iron ore products that help to reduce carbon emissions in the steelmaking process, while helping our customers meet the growing demand for responsibly sourced materials in an efficient and independently verified way. Through the IRMA assurance process, we have been able to evaluate our sustainability performance at Sishen and Kolomela mines, identify areas for improvement and ensure that we strive to adhere to the highest standards of responsible mining.”

Themba Mkhwanazi, Anglo American’s Regional Director – Africa and Australia, said: “We are pleased that Kumba is the first iron ore producer in Africa to complete the IRMA audit, providing stakeholders with a way of accounting for sustainability practices that is transparent, verifiable and comparable. Launched last year, our digital traceability platform Valutrax™ is available to customers purchasing Anglo American mined products, helping them to trace metals and minerals through a tailored selection of key provenance and sustainability indicators, including third-party assurance such as IRMA. The IRMA results demonstrate further progress on our Sustainable Mining Plan commitment of having all our operations undergo third-party audits against responsible mine certification standards by 2025. IRMA improves our ability to build an understanding of areas where we can continue to improve our ESG performance.”

Aimee Boulanger, Executive Director of IRMA, said: “Through detailed IRMA audit reports, mining companies, communities and companies that purchase mined materials can gain the information they need to decide what’s going well — and what may require more attention — at specific mines. The Sishen and Kolomela reports demonstrate that these mines can point to transparent, independent evaluations of their environmental and social performance.”

The IRMA scoring system recognises four levels of performance: IRMA Transparency, in which a mine is third-party-assessed and publicly shares its scores; IRMA 50, 75 or 100, signifying that a mine meets a core set of critical requirements together with at least 50%, 75% or 100% of the requirements in each of the four sections of the Standard for Responsible Mining being met respectively.

IRMA’s Standard for Responsible Mining has been developed over a decade through a public consultation process with more than 100 different individuals and organisations, including mining companies, customers and the ultimate downstream users of mined products, NGOs, labour unions and communities and is considered to be one of the most rigorous certification processes, IRMA says.

Sishen and Kolomela join other Anglo American operations such as Minas Rio, Barro Alto, Mototolo and Unki in gaining IRMA 75 accreditation.