Tag Archives: Iron ore

Rio Tinto to roll out K2fly’s Ground Disturbance solution across Pilbara ops

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K2fly Ltd says Rio Tinto has signed a five-year contract for its Ground Disturbance solution, with the miner planning to roll it out across its iron ore operations in the Pilbara of Western Australia.

The contract will generate annual recurring revenue of A$620,000 ($450,676) over the initial five-year term, the ASX-listed company says.

The addition of Ground Disturbance expands the number of K2fly solutions used by Rio Tinto to five out of K2fly’s nine existing solutions which already include: Resource Inventory & Reconciliation, Dams & Tailings, Community & Heritage and Mine Geology Data Management, K2fly says.

K2fly says its Ground Disturbance solution provides a single source for applying, approving, tracking, reporting and submitting closure of permits and rehabilitation commitments surrounding ground disturbance activities.

Nic Pollock, CEO of K2fly, says: “We are delighted to continue to expand our relationship with Rio Tinto into ground disturbance. Effective ground disturbance systems are the glue for operations that want to ensure technical assurance around land management, maintain licence to operate and ensure high environmental, social and governance (ESG) standards. We are pleased to be working closely with Rio Tinto across a number of key ESG solutions globally.”

Metso Outotec to provide ‘unique’ sustainable screening tech to iron ore project

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Metso Outotec says it will supply unique sustainable screening technology for an iron ore project in the Southern Hemisphere.

The order for the product screening and scalping application covers 12 Metso Outotec BSE Series™ (Banana Screen Elliptical) tandem screens and 4 MF Series™ screens, all equipped with 305PS screening media. In addition, the contract covers Metrics monitoring system for screens, expert support and installation services, the company says.

Metso Outotec explained: “The need to reduce water in iron ore production and other minerals processing is a critical global challenge. The innovative and patented BSE Series screens enable iron ore processing even with higher natural moisture content without adding water.”

The order value, which is not disclosed, has been booked in Minerals segment’s September quarter orders received. The start-up of the project is scheduled for the first half of 2024.

Jouni Mähönen, Vice President, Screening business line, Metso Outotec, says: “We are pleased that the customer chose Metso Outotec for sustainable screening solutions for their process. The BSE screen is an outstanding option for their needs. The elimination of process water ultimately results in lower processing costs, increasing the customer’s competitiveness and profitability in the iron ore global markets.”

Results the customer can expect after implementation, according to Metso Outotec, include:

  • BSE Series screens, which are part of the company’s Planet Positive solution, enable elimination of process water in the screening process;
  • A 93% reduction of the plant’s overall water consumption, elimination of the need for tailing dams;
  • Reduced energy consumption from the entire plant compared with the wet screening process: 18,000 MWh/y electricity saving;
  • 30% increase in screening capacity compared with traditional screening;
  • Increased safety during media change-outs using the Hammerless Attachment system; and
  • Reduced capital expenditure due to the adoption of high-performing BSE screens.

Swedish universities on board with LKAB’s carbon-dioxide free mission

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

LKAB says it is investing SEK80 million ($9.3 million) in a multi-year collaboration focused on research for sustainable mining of the future.

In close collaboration with LKAB personnel, prominent researchers at, among other partners, Luleå University of Technology, Örebro University and Mälardalen University will develop solutions to enable the company’s transition to carbon dioxide-free processes and products by 2045, LKAB says.

Jordi Puig, Head of Mining Technology, LKAB, says: “This initiative supports our strategy to set a new world standard for mining. Researchs findings will be shared ‘open source’ with our partners ABB, Combitech, Epiroc and Sandvik and eventually also with other companies.”

As part of LKAB’s collaboration project to create a digitalised, automated and carbon-dioxide-free mine, the company has engaged in regular dialogue with academia and announces that, earlier in the year, the decision was taken to fund 10 different research assignments. Now an agreement has been signed with Luleå University of Technology, Örebro University and Mälardalen University, and discussions with several other universities have been initiated.

Daniel Johansson, Professor and Acting Head of Mining and Rock Engineering, Luleå University of Technology, says: “Since the start of Luleå University of Technology, and especially during recent decades, LKAB has been our strongest partner. We are very pleased to be entrusted to participate in the green transition which LKAB has now begun. This is also well in line with the university’s strategy for future autonomous, efficient and sustainable mine operation. We look forward to successful research collaboration.”

Amy Loutfi, Pro-vice-chancellor AI and Innovation, Örebro University, says: “The initiative presents a fantastic opportunity. This represents a collective ambition to focus on basic and applied research and to use AI and autonomous systems in an improved mining sector. We have been looking strategically at the mining industry for some time and we view it as a growing application area for AI and robotics. LKAB’s initiative leads us into further collaboration with industry and academic partners and we are delighted to be a part of this.”

Erik Dahlquist, Professor in Energy Technology, Mälardalen University, says: “Mälardalen University has worked with risk management, energy and production optimisation within many industries, and we are very pleased to be able to be working towards the realisation of LKAB’s ambition to set a new world standard for sustainable mining. This is really driving the industry towards a future with electrification and AI systems for automated operation.”

Research assignments will commence immediately and continue until the close of 2024. Research work will be conducted mainly within the areas of underground transportation and energy efficiency, as well as risk management for increased safety awareness

Puig added: “To improve safety, reduce carbon dioxide emissions and to increase productivity in our mines is vital for LKAB to be able to continue to deliver climate-efficient iron ore products. This is one of many steps toward the achievement of our objectives.”

Fortescue and Wintawari establish ‘culturally safe’ JV for Solomon Hub operations

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Fortescue Metals Group and members of the Wintawari Guruma Aboriginal Corporation, the prescribed body corporate for the Eastern Guruma People, have today announced a co-management framework to oversee the development of new mines at Fortescue’s Solomon Hub operations in Western Australia.

Under the framework, Fortescue and members of Wintawari will establish a “culturally safe” mining joint venture to mine the East and West Queens deposits on Eastern Guruma country. The 10-year mine services contract to be awarded to the new joint venture is estimated to be worth over A$500 million ($367 million), making the contract the largest ever awarded to an Aboriginal business by Fortescue.

A working group will be formed to collaboratively work together on all stages of the mine development from heritage and environmental approvals, resource drilling and definition and mine planning to operations and rehabilitation, Fortescue says. The agreement builds on the decade-long relationship between the parties, which was formalised in a Land Access Agreement in December 2009.

Wintawari Chair, Glen Camille, said: “The establishment of this new co-management joint venture represents the next step in our journey with Fortescue. We are glad to work with Andrew Forrest and Fortescue to improve the economic outcomes for Aboriginal people and thank Andrew for his demonstrated commitment.

“Working collaboratively, we will ensure that Eastern Guruma people are active participants in the future development of mines on our country, enabling deeper consultation around the protection of culturally significant sites while building a better future for our people.”

Fortescue Chief Executive Officer, Elizabeth Gaines, said: “Fortescue is proud of our longstanding relationship with Wintawari Guruma Aboriginal Corporation. We are confident that this new collaborative framework will strengthen our ties with the Eastern Guruma People, through the unique opportunity to have a seat at the table to share cultural knowledge and guide the growth of Fortescue’s operations on their country.”

Fortescue Senior Manager Indigenous Communities, Heath Nelson, said: “In line with our approach to ensuring our Native Title Partners benefit from our growth and development, this joint venture will also deliver significant economic opportunities through employment and contracting opportunities.”

Fortescue Chairman and Founder, Dr Andrew Forrest AO, said: “It gives me enormous pride to bear witness to this framework, which will shape a new shared direction for Fortescue and the Eastern Guruma People. Together, we will provide enduring benefit for future generations, while preserving their unique culture and heritage.”

Wabtec FLXdrive battery-electric loco to work at Roy Hill rail network in the Pilbara

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Roy Hill, in Western Australia, has announced the purchase of a Wabtec FLXdrive battery-electric locomotive, the world’s first 100% battery, heavy-haul locomotive for the region and the mining industry.

“We are committed to transforming the next generation of transportation by adopting advanced technologies that improve energy efficiency, lower operating costs and improve our rail and mining network,” Gerhard Veldsman, CEO of Roy Hill, says. “The FLXdrive locomotive will be the first for the region and the first for the mining industry and will improve our rail operations from the mine to Port Hedland.”

Roy Hill will receive the newest version of the FLXdrive battery-electric locomotive in 2023 with an energy capacity of 7 MWh. It is an upgrade from the 2.4 MWh prototype that was successfully tested in revenue service with a Class 1 railroad in the USA earlier this year.

Based on the route and Roy Hill’s rail operations, the FLXdrive is anticipated to reduce the company’s fuel costs and emissions in percentage by double digits per train. The ongoing use of the FLXdrive will also reduce ongoing operational costs through maintenance spend.

Simon Pascoe, General Manager of Engineering for Roy Hill, says: “Our analysis with Wabtec confirms the FLXdrive locomotive is ideally suited for our rail network. It has the horsepower to operate in a heavy haul train consist pulling loaded wagons with 35,000 t of iron ore, while at the same time reducing the entire train’s fuel consumption. The FLXdrive also is designed to function in the extreme heat of the Pilbara region.”

Today, Roy Hill uses four Wabtec ES44ACi “Evolution Series” diesel-electric locomotives in a consist to pull trains that are typically 2.7 km in length. The FLXdrive will replace one of the diesel locomotives to form a hybrid consist, and recharge during the trip through regenerative braking.

The FLXdrive manages the overall train energy flow and distribution through its Trip Optimizer system, an intelligent cruise control system programmed through artificial intelligence to respond to every curve and grade of the track in the most energy-efficient way possible, Wabtec says. It is also designed with a special liquid cooling system to withstand the Pilbara heat, where temperatures can reach 55°C.

Wendy McMillan, Regional Senior Vice President Australia and New Zealand for Wabtec, says: “This order demonstrates Roy Hill’s progressive and forward-thinking approach to the mining industry. By adopting this revolutionary technology in region, Roy Hill is pioneering new approaches to its operations that will benefit the company’s bottom line. The FLXdrive is a continuation of our growing partnership and shared vision to bring more efficient solutions to mining and rail industries.”

Wabtec’s goal is to develop the next generation of zero-emission locomotives. The company says it has a clear path to power new locomotives – and repower existing locomotives – with batteries, hydrogen internal combustion engines and hydrogen fuel cells. It is part of Wabtec’s vision for the rail industry to play a key role in building a clean energy economy and will enable the reduction of up to 300 Mt of global carbon emissions.

Rogerio Mendonca, President of Freight Equipment for Wabtec, says: “Controlling emissions is critical in the fight against climate change. The FLXdrive battery-electric locomotive is a bold step toward a low-to-zero-emission locomotive future. We continue working on solutions that cut the overall carbon footprint of the industries we serve through the development of low-emitting locomotives like the FLXdrive, and the use of alternative fuels such as bio-diesel, renewable diesel and hydrogen.”

ArcelorMittal to expand iron ore mining and logistics operations in Liberia

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The Government of the Republic of Liberia and ArcelorMittal have signed an amendment to the Mineral Development Agreement (MDA) which paves the way for the expansion of the steel major’s mining and logistics operations in Liberia.

With the MDA amendment coming into effect, ArcelorMittal Liberia will significantly ramp up production of premium iron ore, generating significant new jobs and wider economic benefits for Liberia, it said.

The expansion project – which encompasses processing, rail and port facilities – will be one of the largest mining projects in West Africa. The capital required to finalise the project is expected to be approximately $800 million, as it is effectively a brownfield expansion.

The expansion project includes the construction of a new concentration plant and the substantial expansion of mining operations, with the first concentrate expected in late 2023, ramping up to 15 Mt/y. Under the agreement, the company will have reservation for expansion for at least up to 30 Mt/y. Other users may be allowed to invest for additional rail capacity, it said.

As the largest foreign investor in Liberia, ArcelorMittal Liberia says it has invested over $1.7 billion in the country over the past 15 years.

More than 2,000 jobs are expected to be created during the construction phase, with Liberians envisaged to fill the majority of the roles created, the company said.

ArcelorMittal operates a Vocational Training Centre and provides two-year residential certificate training in mechanical and electrical trades. As part of the expansion, ArcelorMittal Liberia has also launched a training and development program for high potential Liberian employees who will gain on the job experience and knowledge in ArcelorMittal Mining operations globally.

The employees will receive advanced training in the fields of mining production and operation optimisation, plant maintenance, planning and execution, plant electrical operation systems and electrical maintenance. Other training areas include plant fitting and heavy-duty mobile equipment maintenance, as well as mine production and operations.

Lakshmi Mittal, Executive Chairman, ArcelorMittal, said: “The expansion of mine, processing, rail and port facilities is the largest iron ore project in West Africa and will draw international attention to Liberia as an attractive country to invest in. The current planned expansion is part of a long-term commitment by ArcelorMittal to Liberia that includes undertaking planning for the further expansion of our iron ore asset to at least 30 Mt per annum.”

Epiroc drills, bolters to help Dazhong Mining expand Chinese iron ore mines

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Epiroc says it has won a large order for mining equipment and service from Dazhong Mining Co Ltd in China as part of a plan to expand two of its underground iron ore mines in the most “safe and productive manner possible”.

Dazhong Mining has ordered a variety of rigs for face drilling, production and rock reinforcement for use at the Zhouyoufang and Zhongxinji mines in the Anhui Province. The order is valued at about SEK200 million ($23 million) and was booked in the September quarter of 2021. In addition to the equipment, the order includes on-site service and training including sophisticated simulators, which provide a safe and realistic environment to enhance the skills of machine operators, Epiroc says.

The machines ordered include Boomer face drilling rigs (including the Boomer S2 Face Drill), Simba production drilling rigs, and Boltec and Cabletec rock reinforcement rigs.

Dazhong Mining is rated as a national Green Mine Enterprise, meaning it is recognised for its sustainable way of mining, according to the OEM. The company also purchased a large number of machines from Epiroc in 2020.

“Epiroc is happy to team up again with Dazhong Mining so it can expand its operations further while strengthening safety, sustainability and productivity,” Helena Hedblom, Epiroc’s President and CEO, says.

The Head of Dazhong Mining said: “Our operations have truly become more safe, environmentally friendly and efficient through Epiroc’s equipment and service. We are happy that this model will continue to be applied to the expansion of two mines. We have a good long-term partnership with Epiroc as this supports us with a high-level technical resource which promotes the sustainable development of the mining industry.”

The machines for Dazhong will be equipped with Epiroc’s telematics system, which allows for intelligent monitoring of machine performance and productivity in real time, and most of the units will have Epiroc’s Rig Control System, RCS, installed, which makes them ready for automation and remote control. The equipment will be delivered in 2021 and 2022.

ERG’s BAMIN signs pact with Brazil Government to complete and operate FIOL railway

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Eurasian Resources Group (ERG) says its wholly-owned Brazilian subsidiary, BAMIN, has signed a concession agreement with the Brazilian Federal Government to complete and operate a section of the FIOL (East-West Integration) railway in the country.

BAMIN will advance the construction works, which until recently were carried out by the state-owned railway engineering and construction company Valec.

The sub-concession has been granted for a 35-year period, which includes an allowance of five years for the construction of the railway and 30 years for its operation. BAMIN’s investment into the railroad and the rolling stock will amount to around BRL3.3 billion ($683 million).

In April 2021, BAMIN won the auction on the B3 (São Paulo Stock Exchange) to complete and operate the first 537 km stretch of the FIOL. The concession agreement has now granted BAMIN 120 days to evaluate the progress of the construction and other related works. This preliminary phase precedes the preparation of a plan to resume the construction, which is scheduled for the second half of 2022.

Tarcio Gomes de Freitas, Minister of Infrastructure of Brazil, said: “The importance of this infrastructure project in the state of Bahia cannot be overstated. The project is very well structured and includes an iron ore plant, a railway and a seaport. The railway, which is undergoing construction, will serve the mining industry, as well as the agricultural sector, which is growing at an unprecedented pace, particularly in the west.”

BAMIN has already hired professionals in the rail industry to oversee the management of the FIOL railway. BAMIN will also leverage ERG’s international expertise as the largest transport operator in Central Asia with extensive experience in rail transportation, ERG says. Each year, ERG transports over 50 Mt of freight using 10,000 vehicles, while also maintaining and repairing 2,500 wagons and over 1,000 locomotives.

Benedikt Sobotka, CEO of Eurasian Resources Group, said: “All across the globe, railways play a crucial role in urban development, enabling people to gain access to new opportunities. In Brazil, we are confident that FIOL will act as an important connecting point between regions, cities and people, contributing to economic growth, and creating a strong link between the west and the east of the country. The logistics and exportation corridor that BAMIN will create will transport millions of tonnes of iron ore, agricultural products, as well as other goods.”

With the resumption of construction, the project is expected to boost the country’s economic growth at both the federal and the local level: FIOL will strengthen the rail network across 20 municipalities in Brazil, while also boosting foreign trade, ERG says.

BAMIN plans to install over 30 loading stations along the route, creating opportunities for regional producers, enhancing production chains, and helping establish new businesses.

Once completed, FIOL will be able to carry 60 Mt/y of freight, with BAMIN’s products accounting for a third of this capacity. More than 40 Mt of cargo will be made available for other businesses in both the mining and agricultural sector, as well as other industries in the Bahia region.

ERG said: “The importance of the FIOL railway cannot be overstated, as the railway will be part of an integrated logistics project that will connect the Pedra de Ferro mine in Caetité with the Porto Sul, currently under construction in Ilhéus, Bahia. Following the commencement of commercial operations in January 2021, the Pedra de Ferro Mine is expected to produce 1 Mt by the end of this year. Once the South Port and FIOL are completed (expected in 2026), the mine should produce 18 Mt of iron ore per year.”

Eduardo Ledsham, CEO of BAMIN, said: “The Pedra de Ferro mine, Porto Sul, and FIOL projects are an important milestone for the country’s economic development, and a source of pride for the Bahia State and all Brazilians. We are creating a new logistics corridor to integrate the west with the east of Brazil, creating a new, important exportation pathway.

“The state of Bahia will occupy a new and important place in the national economy, becoming the third largest iron ore producer in the country, generating wealth and prosperity, while also increasing the population’s income and improving the quality of life.”

Metso Outotec to deliver stirred mill technology to greenfield iron ore plant in China

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Metso Outotec says it will deliver several energy-efficient stirred mills to a greenfield iron ore processing plant in Liaoning Province, north-eastern China, marking one of its “Planet Positive” mineral processing orders.

The stirred mill installation, which corresponds to 11 MW of power, will be the largest of its kind in China, according to the OEM.

While the value of the delivery has not been disclosed, the order has been booked in the company’s Minerals segment September quartr orders received.

Christoph Hoetzel, Head of Grinding business line at Metso Outotec, said the company previously agreed on the delivery of a PG4265™ primary gyratory crusher and three HP900™ cone crushers for the same project, however the customer soon realised the benefits that could come with using its stirred mill technology.

“Our stirred milling technology, with its excellent performance and ability to increase both iron ore concentrate and recovery, has proven itself multiple times in the Chinese market,” he said. “The new installation will also benefit from class-leading energy efficiency and wear life.”

Metso Outotec claims to be the only manufacturer worldwide offering several stirred mill technologies (Vertimill®, HIG™ mill, and SMD).

The Metso Outotec Planet Positive portfolio focuses on the most environmentally efficient technologies – of which there are more than 100 – in the company’s current portfolio, responding to the sustainability requirements of its customers in the aggregates, mining and metals refining industries. The customer requirements relate to energy or water efficiency, reduction of emissions, circularity and safety, the company says.

ABB extends and expands hoist service agreement with LKAB at Kiruna

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ABB has signed a long-term agreement with LKAB to provide service to 12 mine hoists and, now, hoisting motors at the Kiruna iron ore mine in northern Sweden.

ABB has provided LKAB Kiruna with maintenance and hoist cycle optimisation to maximise efficiency and increase capacity at the mine since 2010. The new contract extends these services to the end of 2023, plus adds hoisting motors into the mix, with an agreement that LKAB may sign up for a further three years on a rolling basis, ABB says.

Most of the ore mined at Kiruna is at depths of more than 1 km, with large solid slabs of iron ore extending several hundreds of meters down into the ground. Local ABB engineers, supported by ABB globally, have worked on site at Kiruna to increase hoist capacity through a reduced hoist cycle time to optimise production. They have improved equipment use, balancing capacity and wear and tear of the hoist equipment, the company said.

Peter Ylivainio, Senior Maintenance Engineer at LKAB, said: “LKAB places great emphasis on refining every element of the underground mining process, in order to make it as efficient as possible. Mining ore at great depths is a logistical challenge that places demands for a well-functioning infrastructure and safe and resource-efficient production, with well-developed production methods and processes vital. We have a long successful relationship with ABB and their local presence, global expertise and remote operations technology support our goals.”

Erik Kjellgren, Strategic Account Manager, ABB, said: “This new agreement means ABB will ensure optimal capacity, greater efficiency, lower energy consumption and extended equipment lifecycles across control systems, motors, drives as well as the hoists up to 2023 and beyond. Our experienced team of engineers provides regular support to LKAB and we look forward to seeing increased benefits for our customer in terms of insights and actions to optimize equipment performance.”

The hoists are the main artery of the production flow at the Kiruna mine as they raise the ore hundreds of meters from the sublevel to ground level. Their continuous operation is critical for safety and to prevent costly interruptions to production, according to ABB. LKAB’s extended service agreement with ABB is designed to ensure the maximum reliability and availability for the hoist control system, motors and drives located both above and below ground.