Tag Archives: Iron ore

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

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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.

Cummins and China’s NHL commission diesel-hybrid haul truck at Baiyun iron mine

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Cummins Inc says it has commissioned its diesel-hybrid solution in partnership with one of China’s leading rigid mining truck manufacturers, North Hauler Joint Stock Co., Ltd. (NHL), demonstrating progress in decarbonisation for industrial customers.

The hybrid NHL NTH260, a 220-t payload mining truck, rolled off the production line in January and is headed to Baiyun iron mine of Baogang Group, China, to begin field testing in March. As a power solutions provider, Cummins’ optimised hybrid system allows the truck engine to be downsized from the previous 2,500 horsepower QSK60 to the current 2,000 HP two-stage QSK50.

“We’re excited to share this significant milestone in our journey to advance bridge technologies and provide our mining customers with innovative, practical decarbonisation solutions,” Jenny Bush, Cummins Power Systems President, who joined key leaders from Cummins Power Systems China for the commissioning ceremony in the NHL industrial park in Bautou, China, said.

The truck is expected to provide a leading total cost of ownership based on initial cost advantages, fuel efficiency and extended service life of the engine, Cummins says. Improved fuel efficiency directly correlates to emissions and greenhouse gas reductions. Advanced hybrids have the potential to improve fuel efficiency up to 30% dependent on the mine profile and advanced battery technology and controls integration, according to the company.

Haiquan Guo, General Manager, NHL, said: “Our partnership with Cummins spans 40 years and advancing the hybridisation of our equipment is another demonstration of what we can accomplish together for the benefit of miners globally.”

NHL produces trucks with payload range from 35 t to 360 t, with Cummins as the standard engine configuration.

Molly Puga, Cummins Power Systems Executive Director of Strategy, Digital and Product Planning, added: “We are intent on enabling multiple pathways to carbon neutrality for industrial markets, including both first-fit and retrofit solutions. It’s partnerships with our customers like NHL and Baiyun iron mine that will accelerate product availability in the market and make both near- and long-term carbon reduction goals attainable.”

In 2023, Cummins announced approval of unblended renewable diesel use in all industrial high-horsepower engines.

Red Hawk Mining plots Blacksmith iron ore project haulage path with MGM Bulk

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Red Hawk Mining says it has entered into a strategic partnership with MGM Bulk Pty Ltd (MGM Bulk) for the haulage of iron ore from the company’s 100%-owned Blacksmith iron ore project, in Western Australia, to the Utah Point bulk handling facility in Port Hedland.

The haulage agreement enables Red Hawk and MGM Bulk to work collaboratively through the prefeasibility study (PFS) and definitive feasibility study (DFS) phases to develop and optimise the transport and logistics strategy, focusing on maximising productivity and reducing unit operating costs, the company says.

Following completion of the studies, MGM Bulk has the exclusive right to enter into a haulage services agreement on terms equivalent to those contained in the DFS. MGM Bulk will be responsible for providing a fleet of 150 t ultra-quad trucks and drivers plus associated loading and other equipment and infrastructure.

In a February presentation deck, Red Hawk Mining claimed over 200,000 m of drilling has defined the largest direct shipping ore (DSO) resource of any ASX-listed junior iron ore company (excluding magnetite) at Blacksmith with 174 Mt at 60% Fe. It said there was potential for thee project to be a long-term supplier of at least 3 Mt/y of 60.5% Fe DSO for over 20 years.

Red Hawk’s Managing Director, Steven Michael, said: “We are excited to work with the team at MGM Bulk to establish a haulage strategy optimised for the Blacksmith project. MGM Bulk’s operations in the Pilbara, centred around delivering iron ore into the Utah Point, are second to none. Their fleet size, quality, operational performance and safety record are critical factors in ensuring the success of the Blacksmith project.

“Our PFS team is working closely with MGM Bulk’s commercial and operations team to deliver operating and capital cost estimates with a high degree of certainty, which can easily be translated into an operational haulage contract.”

MGM Bulk’s CEO, Michael Giacci, added: “We are immensely proud to be forging a long-term partnership with Red Hawk Mining on the mine-to-port haulage solutions for their Blacksmith iron ore project.”

Grange Resources plots underground move at Savage River with electric mining equipment

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A completed definitive feasibility study looking at the potential for underground mining below the North Pit and its integration with Grange Resources’ current open-pit mine at Savage River, in Tasmania, Australia, has showcased not only “robust financial outcomes”, but the potential for reducing carbon emissions by 80% at the mine, with the application of electric mining equipment and material handling systems underground.

This DFS development is in line with company’s environment, social and governance (ESG) initiatives to develop Green Pellet Production from the mine.

The study, according to Grange, presents a technically achievable and financially favourable underground mine at Savage River, with integration with the current open-pit mining operation to deliver “excellent” projected financial returns and sustains a mine life of 15 years. In line with this, the Savage River ore reserve is increasing by 12.5 Mt to 109 Mt with integration of the underground operation.

The new life-of-mine-plan will deliver a substantial reduction of 30% in operating costs with underground mining costs at an average of A$13/t ($8.4/t). It also delivers an internal rate of return of 34% based on an average product price of approximately A$177/t. The ore delivery of 64 Mt of ore produces 28 Mt of concentrate with an iron grade of over 66% over 15 years, Grange said.

A sub-level caving (SLC) transition mine to recover ore left in the walls of the North Pit provides early access to ore and contingency production during the establishment and ramp-up of the block cave mine. Over 2 km of exploration decline has been completed, which reduces the risk for many technical and cost elements of the project, with a further commitment for additional decline development and geotechnical investigation drives in 2024, the company said.

The prefeasibility study for this project considered several haulage options with associated underground configurations and underground and surface infrastructure. The underground crushing and inclined conveying option was chosen as the go forward case for DFS for the following reasons:

  • Significant reduction in emissions and ability to meet the long-term requirements of the updated Safeguard legislation;
  • Lower operating costs by the removal of production trucks and significant reduction in diesel;
  • Better future proofing with higher ore production levels possible allowing the option of higher concentrate production;
  • Improvement to the underground operating environment with improved air quality;
  • Increased options for future automation.

In addition, the single gyratory crusher that was presented in the prefeasibilty study has been replaced with two eccentric roll crushers, which provides redundancy in the material handling system. Crushed ore is transferred to the inclined conveyor system via apron feeder and conveyors.

Another PFS change saw the extraction level layout changed from ‘El Teniente’ diagonal to an offset herringbone to enable the use of tethered electric loaders and to mitigate effects of potential inrush events.

A board decision for Grange to move forward with execution planning and permitting will occur over 2024 with final construction decision in the second half of 2024, the company said.

The Government of Canada awards Rio Tinto’s IOC funding for decarbonisation project

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The Government of Canada has awarded C$18.1 million ($13.4 million) from its Low Carbon Economy Fund to Rio Tinto’s Iron Ore Company of Canada (IOC) to support the decarbonisation of iron ore processing at its operations in Labrador West, the mining company says.

The funding will enable IOC to reduce the amount of heavy fuel oil consumed in the production of iron ore pellets and concentrate, according to Rio Tinto. The company will install an electric boiler to displace emissions from the usage of the heavy fuel oil boilers, as well as instrumentation and fuel-efficient burners to further reduce heavy fuel oil consumption from induration machines.

Over the lifetime of this project, IOC will see a cumulative reduction of about 2.2 Mt of greenhouse gas emissions.

Installation of the new equipment will begin in the June quarter of 2024 and is expected to be completed in the first half of 2025. The project will create more than 100 jobs during the construction and implementation stages in Labrador West.

IOC President and Chief Executive Officer, Mike McCann, said: “Rio Tinto IOC has a plan to decarbonise and continue producing some of the lowest carbon-intensity high-grade iron ore products in the world, right here in Canada. This project alone will eliminate approximately 9% of IOC’s greenhouse gas emissions. We look forward to collaborating with the Government of Canada and other partners towards our goal of achieving net zero emissions by 2050.”

Labrador Member of Parliament, Yvonne Jones, said: “By working with organisations across Canada, such as IOC, we can help the community save money on monthly operating costs and grow the economy, all while fighting climate change. Through the Low Carbon Economy Fund, the Government of Canada is partnering with climate leaders nationwide to cut emissions. I applaud the leadership shown by IOC for helping to keep our air clean and build resilient communities in Newfoundland and Labrador.”

The Government of Canada’s contribution represents approximately 25% of the total cost of the project, with IOC funding the remainder of the investment, Rio Tinto clarified.

BHP, BlueScope and Rio Tinto to investigate Australia low-carbon steelmaking options

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Australia’s two largest iron ore producers, Rio Tinto and BHP, and its biggest steelmaker, BlueScope, have partnered in their efforts to accelerate the decarbonisation of steelmaking by agreeing to jointly investigate the development of the country’s first iron making electric smelting furnace (ESF) pilot plant.

Under a new framework agreement, the companies will consolidate the work each party has completed to date, leveraging both BHP’s and Rio Tinto’s deep knowledge of Pilbara iron ores with BlueScope’s operating experience in ESF technology.

The collaboration provides a platform to develop and potentially invest in a pilot facility and aims to demonstrate that production of molten iron from Pilbara ores is feasible using renewable power when combined with direct reduced iron (DRI) process technology, they said. If successful, it could help open a potential pathway to near-zero greenhouse gas emission-intensity operations for steelmakers that rely on Australian iron ore to meet global steel demand.

The parties will assess several locations in Australia for the proposed pilot facility, and will consider factors like supporting infrastructure, available workforce, access to target industry and supply chain partners, and suitability for operational trials. The prefeasibility study work program is expected to conclude at year-end. If approved, the pilot facility could be commissioned as early as 2027.

Rio Tinto Iron Ore Chief Executive, Simon Trott (right), said: “The carbon intensity of iron and steelmaking requires profound change to meet the needs of our planet and our climate objectives. We must find better ways to enable these materials to be made more sustainably through leveraging technology.

“We firmly believe the best way to tackle a challenge of this scale is through collaboration with industry and importantly this new agreement will leverage the more than two years of work we have already completed with BlueScope on this technology. We are excited to add this partnership to the suite of projects we have underway with our customers and suppliers to find better ways to accelerate their efforts to meet their decarbonisation targets.”

Incoming BHP Western Australia Iron Ore (WAIO) Asset President, Tim Day (left), said: “We are thrilled to partner with Rio Tinto and BlueScope to progress what we see as a potential breakthrough in reducing carbon emissions from steel production. Collaborations like this are so important for the success of these technologies and build on our work on blast furnace abatement projects, and our ongoing research and development projects with leading steelmakers, research institutes and technology providers around the world.

“Combining our expertise, we hope to help fast track near-zero emission-intensity pathways for steelmakers using Pilbara ores. Technology pathways compatible with renewable energy and scalable to the order of hundreds of millions of tonnes of steel production would be a major step forward in setting up Pilbara ores, and the world, for a low greenhouse gas emission future.”

BlueScope Chief Executive Australia, Tania Archibald (centre), said: “We have a clear vision for BlueScope in Australia as a vibrant, modern and sustainable manufacturer with a clear role to play in enabling Australia’s energy transition. Building a pathway to low emission-intensity iron and steelmaking in Australia is a key priority for our business. We’re excited to be partnering with Rio Tinto and BHP to explore the decarbonisation of the ironmaking process, and leverage the natural advantages of Australia – namely our iron ore resources and the abundant potential for renewable energy.

“We believe DRI is the most prospective technology to decarbonise our Australian business, and the development of ESF technology is key to unlocking Australia’s unique advantages in this decarbonisation journey – and, more importantly, has the potential for wider adaptation across the global steel industry. We believe that this collaboration where we can contribute BlueScope’s unique experience in operating an ESF will be key to cracking the code for Pilbara ores in low emission-intensity ironmaking.”

SpectraFlow wins second Crossbelt Analyzer order from Vale

Bulk handling, Mineral processing, Steel and iron ore, Sustainable mining, , , ,

SpectraFlow Analytics says it has received a second order from Vale for a Crossbelt Analyzer as part of the mining company’s quality monitoring processes at its iron ore dispatch terminal of Ponta da Madeira (TMPM), in Maranhão, Brazil.

While it is the second order from Vale, it is the third order for a minerals Crossbelt Analyzer in South America.

The company said: “After the very successful installation of a SpectraFlow Crossbelt Analyzer for the same application in the Terminal Ilha Guaíba in Rio de Janeiro, this is now second installation of a SpectraFlow Analyzer within Vale to enhance the ship loading with real-time data.”

SpectraFlow analysers are already installed in the cement, iron ore, gold, platinum, copper, potash, bauxite and recycling industries. They leverage Near Infrared Sensors, providing measurements of dry raw material composition at key points in mining, processing and refining value chains.

Tapojärvi kicks off open-pit mining contract at Kaunis Iron

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Tapojärvi Sverige Ab recently began a new contract mining gig at the Kaunis Iron mine in Pajala, Sweden, at the same time as the temperatures in that region plummeted to around -40°C.

The service contract with Kaunis Iron covers machine work in ore production as well as production support work, which includes all open-pit production activities other than rock transportation, drilling and charging.

Miika Miettinen, Production Manager at Tapojärvi, said the contract began as agreed on January 1, with the company compiling a service package in only six weeks.

The start of a new service contract requires new personnel and equipment to carry out production in line with the contract. Additionally, production control systems, infrastructure, offices and production facilities, as well as maintenance services, are needed. A mining contractor must also consider safety at every step of production.

Approximately 60 new employees were recruited, and additional personnel were borrowed from other Tapojärvi sites, to bring this contract in within the six-week timeframe.

Miettinen highlights the professional mindset of his employer, skilled and committed personnel and new equipment as Tapojärvi’s strengths. These factors enable Tapojärvi to respond quickly to the client’s needs.

“We were forced to let the production stand idle when the temperature dropped low in early January,” Miettinen said. “There were also some struggles involving the machinery. Despite everything, our operations have been launched successfully and the client has been happy with our performance.”

To support its operations, Tapojärvi has developed processes and systems that are constantly collecting online production data. Data and analytics help enhance Tapojärvi’s performance, safety and maintenance processes.

“We are able to provide the client with comprehensive and complex production data, which allows us to influence the mine’s operations and performance together with the client,” Miettinen said. “I am glad that our cooperation with Kaunis Iron has gone smoothly from the very beginning and that we are already involved in developing the operations.”

The service contract with Kaunis Iron is Tapojärvi Sverige’s first major open-pit mine contract in Sweden. The company has previously worked in underground mines on the sites of LKAB and Zinkgruvan, for example.

Metso to deliver Nordberg cone crushers to WCS’ Simandou iron ore project

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Metso says it has received an order exceeding €10 million ($10.9 million) from Winning Consortium Simandou (WCS) for the supply of key crushing equipment for its concentrator plant at Simandou Iron Ore Blocks 1 and 2 in the Republic of Guinea.

Metso’s scope of delivery consists of 16 Nordberg® HP900™ secondary and tertiary cone crushers, a crusher series that has over 10,000 installations worldwide in the aggregate and mining industries.

Xun Fang, Head of Metso’s Minerals Sales in Greater China, said: “We are pleased to be chosen as the supplier of the state-of-the-art crushing equipment for the Simandou iron project by WCS. We will leverage our global knowledge and resources to support the success of this project.”

Winning Consortium Simandou has been set up by the founders of SMB Winning Consortium, namely Winning International Group from Singapore, China Hongqiao and UMS Guinea. WCS won the public tender to develop Simandou Iron Ore Blocks 1 and 2 in November 2019 and signed a Base Convention agreement with the Guinean Government in June 2020.

Simandou Blocks 3 and 4 are held by Simfer S.A., which is owned by the Guinean State (15%) and Simfer Jersey Limited (85%). Simfer Jersey Limited is a joint venture between the Rio Tinto Group (53%) and Chalco Iron Ore Holdings Ltd (CIOH) (47%), a Chinalco-led joint venture of leading Chinese SOEs (Chinalco (75%), Baowu (20%), China Rail Construction Corporation (2.5%) and China Harbour Engineering Company (2.5%)).