Tag Archives: Iron ore

Mineral Resources partners with Hexagon for ‘autonomous road train first’

Automation, Bulk handling, Mineral project development, Mining services, Steel and iron ore, , , , , , , , ,

Mineral Resources Ltd (MRL) says it has partnered with Hexagon to develop an autonomous road train solution as part of a plan to unlock “stranded tonnes” in the Pilbara of Western Australia.

Part of its mining services infrastructure supply chain solution, the autonomous road trains will form an essential part of the cost-efficient supply chain for the Ashburton Hub iron ore project, MRL said.

To support the development of the 30 Mt/y Ashburton Hub, the company plans to run a fleet of 425 t Gross Combination Mass (GCM), triple-trailer road trains operating across multiple convoys, with each road train convoy consisting of up to five prime mover trucks, with three trailers each, hauling the ore from the mine site to the Port of Ashburton.

The autonomous road train solution integrates Hexagon’s drive-by-wire technology with an autonomous management system to orchestrate vehicle movement, MRL explained. A successful pilot project is already underway at MRL’s Yilgarn operations (pictured) using 385 t GCM triple-trailer road trains, which have been tailored for the specific economic constraints of iron ore and other bulk commodities. During the next two years, the testing will continue, ramping up to 425 t GCM in time for the development of the Ashburton Hub project in the December quarter of 2023.

In this final configuration, a remote operations centre would monitor the trucks, with one operator in control of the platoon.

“An autonomous road train configuration of this scale is a world first and reflects MRL’s approach to continuous improvement and innovation,” it said. “We will initially adopt the technology for our own operations, with a view to offering the solution to our large Tier One customer base, further growing MRL’s mining services business.”

Mike Grey, MRL’s Chief Executive – Mining Services, said: “MRL has always been at the forefront of providing innovative and low-cost mining services solutions. In recent years, we have implemented a number of new technologies which have enhanced the safety and operational efficiency of our long-distance road train haulage fleet, reducing the risks of driver fatigue and increasing fleet availability. The autonomous road trains will take us to the next level again. They provide a safe, cost-efficient solution for hauling ore, which is key to unlocking stranded tonnes in the Pilbara.”

He added: “Being part of the MRL Group, our Mining Services division is in a really good position to trial all of our new technologies on our own mine sites prior to offering additional services to our customers. Our autonomous road trains, combined with our other innovations, are all part of our growth strategy to expand our capability to provide full pit-to-ship, low-cost infrastructure solutions.”

CSI to deploy ‘innovative’ screening solution at Roy Hill iron ore operations

Comminution of minerals, Mine operation news, Mining equipment, Mining services, Steel and iron ore, , , , , , , , ,

CSI Mining Services (CSI), a wholly owned subsidiary of Mineral Resources Limited (MRL), has been awarded a mining services contract by Roy Hill at its iron ore operation in Western Australia’s Pilbara region.

This new contract builds on CSI’s long-standing relationship with Roy Hill, which has seen CSI provide crushing and screening works since early project inception. The new contract will see CSI deliver an expanded scope of work which includes crushing, screening and haulage services.

CSI says it is uniquely positioned as a key service provider to Roy Hill given its strong track record of exceeding performance targets and detailed understanding of the mine and its operational processes and procedures.

In delivering the new contract CSI will deploy an innovative new screening solution to deliver industry-leading efficiencies to the project. The screening solution is an exclusive product to CSI and is not available on the market, giving CSI a distinct design advantage.

Mineral Resources’ Chief Executive Mining Services, Mike Grey, said: “We are very pleased to be selected as preferred mining contractor by Roy Hill to provide safe and efficient crushing, screening and haulage services, following the successful completion of our previous contract.

“Our track record at the operation demonstrates that we can mobilise quickly and exceed production targets, while maintaining an industry leading safety record.

“Our mining services business has delivered strong growth year-on-year and this new contract for Roy Hill reinforces CSI’s position as a market leading mining services contractor.”

Roy Hill Chief Operating Officer, Anthony Kirke, said: “CSI has been a valued partner to Roy Hill since February 2017, initially providing crushing services, followed by the addition of screening and associated haulage services for our Direct Shipped Ore. CSI’s agility in responding to changing operational requirements, commitment to innovation and continuous improvement and alignment with our values have resulted in positive outcomes for Roy Hill.

“The award of this new and expanded multi-year contract reflects the strong relationship between our two companies and we look forward to the deployment of CSI’s new screening solution at our mine site.”

Vale adapts iron ore processing route to make sand product for construction sector

Comminution of minerals, Environmental, Mine operation news, Mining equipment, Mining services, Steel and iron ore, Sustainable mining, Water management, , , , , , , , , , , , , , , ,

After seven years of research and investment of about BRL50 million ($8.9 million), Vale says it has developed a process for producing sand from its production processes with applications in the construction market.

After adaptation in the state of Minas Gerais’ iron ore operations, the sandy material, previously disposed in piles and dams, is now being processed and transformed into a product, following the same quality controls used in the production of iron ore. This year, around 250,000 t of sand has been processed and destined for sale or donation to be used in concrete, mortar, cement and road pavement.

According to Marcello Spinelli, Vale’s Executive Vice President for Iron Ore, the development of this product is the result of more sustainable operating practices.

“This action promotes a circular economy within our units and reduces the impact of tailings disposal for the environment and the society, in addition to being a reliable alternative for the construction industry, where the demand for sand is high,” he said.

Sustainable sand stock yard at Brucutu

Vale’s Sustainable Sand is considered a co-product of the iron ore production process. The material extracted in the form of rocks undergoes several physical processes in the plant, such as crushing, classification, grinding and concentration, until iron ore is obtained.

The innovation introduced by Vale lies in the concentration stage where the by-product of the iron ore processing is once more processed until it reaches the necessary quality to become sand for commercial use. In the traditional method, this material would become tailings and be destined to dams or piles. Every tonne of sand produced represents one less tonne of tailings being generated.

The sand resulting from the iron ore treatment is a 100% certified product, with high silica content and very low iron content, in addition to high chemical and granulometric uniformity.

According to Jefferson Corraide, Executive Manager of the Brucutu and Água Limpa Complex, the sand does not have hazardous characteristics in its composition.

“The mineral processing to obtain the sand is essentially physical, not altering the composition of the materials, so the product is not toxic,” Corraide said.

Recently, Vale’s sand had its application in concrete and mortar certified by three specialised laboratories in Brazil: Instituto de Pesquisas Tecnológicas, Falcão Bauer and ConsultareLabCon.

The properties of Vale sand are also being analysed by an independent study conducted by researchers from the University of Queensland’s Sustainable Minerals Institute (Australia) and the University of Geneva (Switzerland), who are investigating whether alternative construction materials produced from mineral ores could become a sustainable source of sand while significantly reducing the volume of waste produced by mining. These researchers introduced the term “ore sand” to refer to this type of processed sand sourced as a co-product or by-product of mineral ores.

Precast concrete produced with Vale’s Sustainable Sand

Production scale

Vale has already committed to allocating more than 1 Mt of sand for sale or donation in 2022. Buyers are companies operating in four different regions in Brazil: Minas Gerais, Espírito Santo, São Paulo and Brasília. It is estimated that, in 2023, production will reach 2 Mt.

Rogério Nogueira, Director of Ferrous Marketing, explained: “We are getting ready to scale up the sand destination even more from 2023. For this purpose, we have a team of professionals dedicated to this new business and adapting our operations to meet the market needs.”

Currently, Vale is producing sand for sale and donation at the Brucutu Mine, in São Gonçalo do Rio Abaixo (Minas Gerais).

Other mines of the company, also located in Minas Gerais, are in the process of obtaining environmental and mining approvals for sand production.

André Vilhena, Manager of New Businesses at Vale, said: “Our mines provide a sandy material that is rich in silica, which can be used in different industries. We are working with several institutions, including universities, research centres and Brazilian and foreign companies, to develop new solutions to give new destinations to iron ore tailings.”

In addition to using the existing infrastructure in the iron ore mines, Vale also has a railway and road network to transport the sand to markets in several Brazilian states. “With this activity, our main focus is on the sustainability of our iron ore operations, minimising the environmental liabilities, in addition to seeking to promote employment and income by means of new businesses,” Vilhena said.

Eco products

Vale has been carrying out tailings application studies since 2014. Last year, the company inaugurated the Pico Block Factory, the first pilot plant for construction products whose main raw material is tailings from mining activity. Installed at the Pico Mine, in the municipality of Itabirito (Minas Gerais), the factory promotes a circular economy in iron ore processing operation.

The Federal Center for Technological Education of Minas Gerais (CEFET-MG) provides technical cooperation with the Block Factory. Ten researchers from the institution are working on site during this period, including professors, laboratory technicians and graduates, undergraduates and technical course students. During the R&D period, the products will not be sold.

Another research initiative aims to develop the use of sand in pavement solutions in partnership with Itabira’s campus of the Federal University of Itajubá (Unifei). The focus is on the donation of sand for the pavement of local roads.

More sustainable mining

In addition to the Eco products line, Vale has other initiatives to make its mining more sustainable and reduce the generation of tailings. The company has been developing technology to increase the dry processing of its ores, which does not require the use of water. Currently, around 70% of Vale’s production is dry processed and this shall remain at this level when the production capacity of 400 Mt/y is reached and after the start-up of new projects. In 2015, this figure was 40%.

In Carajás, as the iron content is already high (above 65% Fe), the material is only crushed and screened to be classified by size (granulometry).

In Minas Gerais, in some mines, the average content is 40% Fe. By the conventional method, the ore is concentrated by means of processing with water to increase the iron content, with most of the tailings deposited in dams or pits. This is where another technology under implementation at Vale stands out: FDMS (Fines Dry Magnetic Separation). This technology sees the magnetic concentration of ores of low iron grade with no use of water, and therefore, with no need for dams.

Developed in Brazil by New Steel, a company acquired by Vale in 2018, this technology is already in use in a pilot plant in Minas Gerais. In 2023, the first commercial plant will start up in Vargem Grande, with a production capacity of 1.5 Mt/y and investment of up to $150 million.

Another technology which reduces the need of dams is tailings filtration and subsequent dry piling. Once the capacity of 400 Mt/y is reached, more than 60 Mt/y (or 15% of this total) will be processed in plants, where most of the tailings will be filtered and piled this way.

Vale has already opened a filtration plant in Vargem Grande and three more will be commissioned in the March quarter of 2022: one in Brucutu and two in Itabira. Only 15% of the production will continue to be processed by the conventional method, with wet concentration and disposal in dams or deactivated mine pits.

Hancock, Mineral Resources and Roy Hill consider Australia-first infrastructure sharing pact

Mineral project development, Mining equipment, Mining services, Steel and iron ore, , , , , , , , , , , ,

Hancock Prospecting Pty Ltd and Mineral Resources Ltd have entered into a legally binding agreement under which they will jointly investigate the potential to develop a new iron ore export facility at Port Hedland’s Stanley Point berth 3 in South West Creek.

The agreement would see Roy Hill Holdings, a Hancock subsidiary, provide services to both MRL and Hancock for development and operation of the project, including rail haulage and port services.

MRL said: “The project aligns with MRL’s strategy to unlock stranded deposits in the Pilbara by developing pit-to-port solutions and expanding its capability to be a long-term, low-cost sustainable supplier of iron ore to international markets.”

Hancock and MRL will conduct an expedited study to assess the economic and technical feasibility of the proposed project in the coming months, to usual market standards, they said.

In addition, Hancock and MRL will seek to undertake discussions with the Government of Western Australia and the Pilbara Ports Authority (PPA) in relation to the potential project. It is acknowledged that in order for the proposed project to proceed, the parties would need to first receive a development approval and a capacity allocation for the project from the PPA to jointly develop and operate Stanley Point berth 3 and other associated supporting port infrastructure.

MRL Managing Director, Chris Ellison (pictured in shot with Hancock Prospecting Executive Chair, Gina Rinehart on screen), said this partnership and infrastructure sharing proposal is the first-of-its-kind in the Australian resources industry and would enable significant value to be unlocked for the company in a sustainable manner.

“Our long-stated strategy is to transition from short-life, high-cost mines to lower-cost, long-life operations underpinned by innovative infrastructure solutions,” he said. “Developing our stranded assets will provide additional growth for MRL’s unique mining services build-own-operate model.”

The project  will be subject to a final investment decision by both parties, and other necessary approvals and agreements (including a lease, licence and an infrastructure development agreement or similar) from the PPA on agreed terms.

Dynamic Group drilling businesses capture iron ore, gold and lithium work

Energy minerals, Explosives and blasting, Mineral project development, Mining services, Precious metals, Steel and iron ore, , , , , , , , ,

Dynamic Group Holdings Ltd says its Dynamic Drill & Blast Pty Ltd and Orlando Drilling Pty Ltd businesses have been awarded new contracts set to generate between A$12-$14.15 million ($8.6-10.1 million) of additional revenue.

Of the six recently awarded contracts, three were awarded to Dynamic Drill and Blast, and are associated with a Tier 1 ASX-listed iron ore producer across projects in the Pilbara region of Western Australia for the purposes of mining, civil construction and specialised blasting, the company said.

In addition to the Pilbara projects, Dynamic Drill and Blast has been awarded a project in the Gascoyne region of Western Australia working with a Tier 1 ASX-listed earthmoving contractor, as well as an additional construction project in the Goldfields region of Western Australia.

Furthermore, Global Lithium Resources Ltd (team pictured) has selected Orlando to carry out Global Lithium’s planned RC drilling program in the March quarter of 2022 at its Marble Bar lithium project in Western Australia. Global Lithium’s drilling program is planned to comprise of some 60,000 m of RC drilling.

Global Lithium Managing Director, Jamie Wright, said: “The program is aimed at extending the lithium mineralisation by targeting the greenstones to the south of our Archer Deposit, down to our southernmost tenements.”

Dynamic Drill and Blast continues contract discussions, which are at various stages, with multiple parties. The company is experiencing a sustained and strong level of enquiry resulting in a significant pipeline of opportunities for short-, medium- and long-term projects, it said.

Austin’s milestone ULTIMA truck body delivered to Rio Tinto Iron Ore

Equipment maintenance, Mining consumables, Mining equipment, Mining services, Steel and iron ore, , , , , , , ,

Austin Engineering has announced the delivery of its 1,000th truck body to Rio Tinto Iron Ore in Western Australia.

The milestone was marked with a ceremony at Austin’s Kewdale-based manufacturing facility, attended by Western Australia Premier, Mark McGowan (right), Rio Tinto Iron Ore Chief Executive Officer, Simon Trott (centre), along with Austin’s Chairman, Jim Walker, and Chief Executive Officer, David Singleton (left).

The ULITMA truck body in question was unveiled on site today.

Over the past 30 years, Austin has supplied approximately A$300 million ($214 million) of its designed and engineered equipment to Rio Tinto’s iron ore operations. Austin also supplies equipment to Rio Tinto’s global operations from its manufacturing sites spread across four continents.

Austin and Rio Tinto’s partnership commenced in 1988 with Western Australia-based John’s Engineering and Cranes (JEC), which is now part of the Austin business, providing truck body components to Robe River, a Rio Tinto Group Company.

Austin’s Kewdale facility is one of two of the company’s major manufacturing sites in the Asia Pacific region. Austin is investing A$6.5 million to implement advanced manufacturing processes and capabilities at its Perth and Batam (Indonesia) sites, including increased automation and the use of custom jigs, fixtures, workstations and a standardised manufacturing approach to building products.

The Kewdale facility is currently receiving the first manufacturing upgrade, which will benefit major customers, such as Rio Tinto, and enhance the company’s supply of Western Australian-made dump truck bodies and other hauling and loading products, Austin said.

Singleton said: “In the dynamic and constantly evolving mining industry, it is becoming an increasing rarity to see a long-standing partnership, particularly one deeply rooted in the local community, going from strength-to-strength. This makes today’s milestone all the more extraordinary, and like the other 999 truck bodies we’ve made for Rio Tinto Iron Ore in Western Australia, it will be manufactured locally.

“Austin is proud of its role in helping Rio Tinto successfully deliver the iron ore that is the economic lynchpin of our great state.”

McGowan said: “Austin Engineering is one of WA’s key local manufacturers. It is providing mining companies like Rio Tinto with locally designed and manufactured equipment, but it is also creating an increasing number of local job opportunities here at its Kewdale facility.

“Rio Tinto’s commitment to purchasing Western Australian made truck bodies, that will be used right here in the state, reflects the WA State Government’s commitment to boost local manufacturing, local content, and local jobs, enabling our State to become more self-sufficient and prosperous into the future.”

Rio’s Trott said: “The manufacture of the 1,000th truck body for our iron ore operations here in Western Australia is a testament to the Austin-Rio Tinto relationship that spans three decades and covers the globe.

“The partnership is an example of our commitment to working with local business to create ongoing employment and to develop world-class products. We are committed to sourcing local content wherever possible to support our suppliers, our business and the communities in which we operate. I look forward to our longstanding partnership continuing to support the Western Australian economy.”

Crushing and washing plant inaugurated at Tata’s Khondbond iron and manganese mine

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Tata Steel’s Ores, Mines & Quarries (OMQ) Division has opened an 8 Mt/y crushing and washing plant at its Khondbond Iron and Manganese Mine (KIMM) near Joda in the Keonjhar district of Odisha, India.

The facility was inaugurated today by T V Narendran, CEO & Managing Director, Tata Steel, in the presence of D B Sundara Ramam, Vice President (Raw Materials), Tata Steel; Avneesh Gupta, Vice President (TQM and Engineering & Projects), Tata Steel; Atul Kumar Bhatnagar, General Manager (OMQ Division), Tata Steel; Mukesh Ranjan, Chief Projects OMQ Division, Tata Steel; Pervez Akhtar, Chief Projects Raw Materials, Tata Steel; and other senior officials and vendor partners of the company.

Speaking on the occasion, Narendran emphasised the need to focus more on resource efficiency, productivity and technology with the requirement of raw materials growing in line with the growth of the company. He congratulated the OMQ Division and the engineering and projects team for achieving this great milestone.

The iron ore processing plant will cater to the rapidly growing raw material requirements of Tata Steel and will provide raw material security. In line with the company’s core objective of building sustainable mining and manufacturing processes, the facility incorporates the latest technology for ore processing, enabling efficient resource usage and reduced wastage.

The plant design includes three stage crushing and screening. To reduce the inherent alumina from the ore, two rotary drum scrubbers have been installed, which can reduce the alumina of the incoming ore, thereby improving the ore quality.

The slurry from the scrubbing screens is processed through hydrocyclone clusters, maximising ore recovery and reducing wastage, the company said. The overflow from the hydrocyclone is fed to a high rate settling thickener which facilitates recovery of process water from the slime. To further minimise water use, the water recovered from the thickener is recycled back into the plant for recirculation, minimising the requirement of makeup water for plant operation.

An in-plant rainwater harvesting reservoir has also been created to store and reuse the rainwater runoff from the hill slopes for dust suppression, plant operations and ground water charging in and around Khondbond. A paste thickener facility is also being set up within the premises for further improving the recovery of water. The plant is equipped with a dry fog dust suppression system and water sprinklers for controlling fugitive dust emissions within the product stockpiles.

Monadelphous banks more work with Rio Tinto and BHP

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Monadelphous Group Limited says it has secured new contracts and contract extensions in the resources sector totalling approximately A$110 million ($80.1 million).

The company has secured a 12-month extension to its existing contract with BHP Iron Ore for the provision of general maintenance services for shutdowns, outages and minor capital works at the Mt Whaleback, Jimblebar, Eastern Ridge, Mining Area C and Yandi mine sites located in the Pilbara region of Western Australia.

Monadelphous has also been awarded several new contracts with Rio Tinto in the Pilbara under its sustaining capital projects panel agreement for:

  • The construction of new hawser rails and upgrades to the existing dolphins at Cape Lambert A and B wharves. The work, which includes design, fabrication, supply and installation, is expected to be completed by July 2023; and
  • The upgrade of conveyor gravity take-up systems at East Intercourse Island and Cape Lambert, with work expected to be completed in the September quarter of 2022.

In addition, Monadelphous has also secured a 12-month extension to its existing mechanical and electrical maintenance, shutdown and project services contract across BHP’s Nickel West operations in Western Australia.

Metso Outotec to help Ferrexpo boost iron ore pellet production at Poltava

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Metso Outotec has signed an agreement for the delivery of key equipment for the expansion of an existing production line at the Ferrexpo Poltava Mining iron ore grate-kiln pellet plant, in Ukraine.

The value of the equipment is €18 million ($20 million), and it has been booked in the company’s Metals Q4/2021 orders received, the OEM said.

Metso Outotec’s scope of delivery consists of equipment for major modifications to the traveling grate, rotary kiln and annular cooler. This will see the production line’s capacity increase to over 6 Mt/y of iron ore pellets, Metso Outotec said, adding that the two companies have recently worked together to complete the engineering.

Chris Urban, VP, Heat Transfer Products at Metso Outotec, said: “Metso Outotec and Ferrexpo have developed a strong relationship and common respect for each other while planning improvements for Ferrexpo’s Poltava site. During the past several years, Metso Outotec has been committed to supporting Ferrexpo in the expansion and upgrade of their Poltava plant to a world-class production facility featuring state-of-the-art technologies. Once the project is complete, Poltava will not only be able to substantially increase the plant production, but they will also realise considerable improvements in the plant’s fuel and power consumption as well as plant emissions.”

Earlier this year, the two companies agreed on the delivery of multiple energy-efficient Vertimill® VTM-3000 stirred mills to Ferrexpo, with the vertical grinding mills set to become the largest of their kind to be installed in the country.

Jim North, Interim CEO at Ferrexpo plc, said: “We are pleased to announce this latest development in our ongoing collaboration with Metso Outotec, which will help us realise further growth at our production base in Ukraine. Through our continued focus on investing in our pelletiser, we are deploying modern, energy-efficient technologies that will help us achieve greater volumes of our high-grade iron ore pellets, which are helping to facilitate decarbonisation in the global steel industry.”

Metso Outotec says it is the world’s leading supplier of grate-kiln pellet plants, with more than 50 installations globally totaling over 130 Mt/y of production.

Veris gets to work on Iron Bridge Magnetite Project pipeline contract

Comminution of minerals, Mineral processing, Mineral project development, Mining equipment, Mining services, Steel and iron ore, Water management, , , , , ,

Veris Australia, a provider of spatial data services, has been selected to provide surveying, pipeline design, data and GIS support services for a concentrate and return water pipeline associated with the Iron Bridge Magnetite Project in Western Australia.

The works, to be executed under subcontract with MPC Kinetic, are expected to generate A$2 million ($1.5 million) in revenue for Veris Australia. Works have already commenced and have an expected duration of 12 months.

The specific scope of works includes boundary staking, centreline set-out, feature and design surveys, level monitoring and as-built surveys for the pipeline route.

The Iron Bridge Magnetite Project, a joint venture between Fortescue Metals Group subsidiary FMG Magnetite Pty Ltd and Formosa Steel IB Pty Ltd, is set to deliver 22 Mt/y of high-grade magnetite concentrate product. The project, set to start up by the end of next year, is 145 km south of Port Hedland in Western Australia.

The contract award leverages Veris Australia’s position as the leading pipeline survey and spatial data service provider nationally and adds to the extensive portfolio of pipeline surveys previously delivered, the company said.

Michael Shirley, Chief Executive Officer, Veris Australia, said: “It’s pleasing to see our significant expertise in pipeline surveys once again recognised with the award of this contract, which follows other recent project wins in pipelines and linear infrastructure across Australia.

“MPC Kinetic is a key client of Veris and we have a well-established relationship, having worked together on numerous pipeline projects previously, and I look forward to our team once again delivering for MPC Kinetic on this key piece of infrastructure underpinning the development of the Iron Bridge project.

“We continue to take big strides forward as a business, with our recent and continued investment in leading-edge data capture technologies and visualisation platforms, which are well complemented by significant contract awards such as this.

“There continues to be a number of pipeline developments under consideration across Australia, and I am confident we are well positioned to take advantage of these opportunities and continue to provide innovative solutions through our technology.”