Tag Archives: Iron ore

LKAB selects IFS enterprise asset management solution as part of digital transformation plan

Automation, Communications in mining, IoT, Mining services, Mining software, Steel and iron ore, Sustainable mining, , , , , , , , ,

LKAB has asked IFS to deliver an enterprise asset management (EAM) solution capable of helping the company set a new world standard for data-driven mining, the enterprise applications company says.

To achieve carbon dioxide-free sponge iron production by 2045, LKAB recently launched one of the largest industrial investment plans in Swedish history.

To reach its productivity and environmental goals, the company has embarked on a holistic digital transformation journey to ensure business process transparency, consolidation and harmonisation of processes and data, as well as access to high-quality insights to drive improved decision making, IFS says.

“Launching a comprehensive evaluation process, LKAB scanned the market for a best-in-class EAM solution that could support its mission-critical mining operations while offering an open architecture for easy integrations,” the company explained. “Another key consideration was to equip its workforce with intuitive, easy-to-use mobile technology to ensure a positive user experience.”

Based on its capabilities in key areas such as maintenance and logistics, as well as its RESTful APIs based on the OData standard and browser-based user interface, the IFS cloud-based solution was selected by LKAB, IFS explains.

“The journey LKAB has embarked on will transform the global iron and steel industry and set new standards for how mines are digitised and managed,” Markus Petäjäniemi, Senior Vice President, Market and Technology, said. “To lead the industry toward more responsible, resource-efficient mining practices, we need the very best technology to make sure our people and assets are working efficiently and safely. IFS is an open solution that will connect to our technological backbone and support our current and future needs.”

Elni Kullmer, IFS Managing Director, Nordics, added: “This is a landmark agreement for IFS and we are honoured to have been chosen by LKAB to help usher in a new era of efficient mining. We have been supporting EAM processes in asset-intensive industries since the 1980s and we are thrilled to be able to bring our experience to bear on this exciting project.”

The IFS solution will be used by some 4,000 LKAB employees working in Sweden, England and Norway, according to the EAM vendor.

Schlam to provide MEM support to Rio’s Pilbara iron ore ops

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

Schlam says it has been selected to sit on a panel to provide mining equipment maintenance (MEM) support for Rio Tinto Iron Ore (RTIO) across its operations in the Pilbara of Western Australia.

The company is one of three firms tasked with providing support to the major, with the three-year contract incorporating various trades, including heavy-duty mechanics, auto electricians, light vehicle mechanics, boilermakers and more.

Schlam Chief Executive Officer, Matt Thomas, said being invited to the panel was a fantastic opportunity for the company.

“Being invited to sit on this panel would not have been possible without our team putting in the hard work on-site that they have done up until now to show what we’re capable of,” he said.

“Over the past six to 12 months, our team has demonstrated a commitment to safety and quality, world-class trade skills and excellence in customer service. I thank everyone who has contributed to this win for the company and hope that it’s one of many more to come soon.”

Weir Minerals wins large comminution order from Nigeria iron ore mine

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

Two of the largest screens built by Weir Minerals Africa are being designed and manufactured in South Africa as part of a process solution for an iron ore mine in Nigeria.

According to Tiisetso Masekwameng, General Manager Comminution at Weir Minerals Africa, the flowsheet accepted by the customer includes equipment for screening, washing, and grinding supplied by Weir Minerals.

“Within our scope of work are the two largest Enduron® double-deck banana screens built by Weir Minerals,” Masekwameng says. “This is made possible by the depth of design expertise in our Separation Technology Group, an eight-strong team conducting research and development.”

Steven Hunter, Separation Technology Group Leader at Weir Minerals Africa, says the two 51 t Enduron double-deck banana (DBHG 43/97) screens (one pictured) for this project were built upon the designs of the existing Weir Minerals screens range. These large machines measure 4.3 m wide and 9.7 m long and can process 1,750 t/h.

“The customer’s production requirements demanded this considerable size, so we optimised the design by minimising mass without compromising structural integrity,” Hunter says. “We conducted extensive finite element analysis on the whole machine but focused on the main structural elements, ensuring that the units were fit-for-purpose while still being light enough to be driven by the exciters.”

The size of the units still demanded the design and manufacture of Weir Minerals Africa’s largest exciter yet – the Enduron LTX 10. With 120 t of excitation force (at maximum setting), these units will drive the screens at a stroke of 9.4 mm and a gravitational force of 4.6 G.

Hunter said the screens are ready to be fitted with Weir’s IIoT platform, Synertrex. “This allows the machines to be monitored remotely; the system can measure the machine’s performance and any deviations arising that may require proactive attention,” he explained.

The order for Nigeria also includes two Trio® jaw crushers, two Trio cone crushers, two large 2 m by 8 m Trio apron feeders, two Trio pan feeders, eight Enduron vibrating screens and an Enduron HPGR.

For the clay washing circuit, Weir Minerals Africa will supply the mine with a Trio twin-shaft blade mill and Trio twin-shaft coarse washers as well as Warman® slurry pumps.

Kwatani branching out from South Africa roots

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

Vibrating screen and feeder specialist Kwatani says it is transitioning from equipment supplier to solutions provider, as it attracts customers from well beyond its South Africa headquarters.

According to Kwatani General Manager Sales and Service, Jan Schoepflin, the company’s strong in-house expertise and design capability – combined with the manufacturing quality it consistently achieves – ensures its customised solutions deliver optimal performance at the lowest possible lifecycle costs.

“Our recent orders show that our customer base in Southern Africa remains strong, while there is growing recognition of our cost-effective offerings in West Africa, East Africa and North Africa,” says Schoepflin. “At the same time, orders from countries like Canada and Russia indicate that our markets abroad continue to grow.”

Kwatani says it remains the market leader in the supply and servicing of vibrating screens and feeders on iron ore and manganese mines in South Africa’s Northern Cape province. It also counts platinum, coal, diamond and gold mines in its customer base. Its West Africa orders have been mainly to gold mines, and there is growing potential for gold mining in East Africa, Schoepflin says.

Over its four decades of operation, Kwatani has produced about 16,000 custom-designed screens, and is building, on average, 30 to 40 units a month in its ISO 9001:2015 certified facility close to OR Tambo International Airport in Johannesburg.

“Our reputation has been built on prioritising what our customers need, and doing business with integrity and trust,” Schoepflin says. “This means delivering on what we promise and making sure that customers achieve the expected value from our products.”

The company’s solution focus is underpinned by its significant and ongoing investment in local skills, ensuring that its designs leverage strong mechanical and metallurgical engineering expertise, according to Schoepflin.

“This confidence in our products allows us to offer a process guarantee to customers, to deliver the tonnage, throughput and fractions that they expect,” he says. “Depending on which country our customers operate in, they may also have different industry and quality standards/certification expectations and we work closely with them to understand these clearly and meet their requirements.”

Schoepflin also emphasises the company’s service capabilities, which include its local service centres closer to customers, and its support partners in other countries.

“The careful selection of these partners is vital to meet customers’ stringent technical expectations,” Schoepflin says. “In some countries, our partners can also manufacture components according to our drawings and specifications, should there be an urgent requirement from a customer.”

Samarco iron ore pellet operations restart five years after Fundão tailings dam spill

Mine operation news, Mineral processing, Mining safety, Steel and iron ore, Water management, , , , , , , , , ,

BHP and Vale have confirmed their joint venture Samarco iron ore business has restarted operations in Brazil, more than five years after the failure of the Fundão dam led to its suspension.

Samarco’s gradual restart of operations incorporates concentrator 3 at the Germano complex in Minas Gerais and pelletising plant 4 at Ubu in Espírito Santo, as well as a new system of tailings disposal combining a confined pit and tailings filtering system for dry stacking, BHP said.

With the new filtration process, Samarco expects to be able to substantially dewater sand tailings, which represent 80% of total tailings by volume, and safely stack these filtered sand tailings in piles, Vale said. The remaining 20% of tailings are planned to be deposited in the Alegria Sul pit, a bedrock self-contained structure. Additionally, Samarco is progressing in the decommissioning of the Germano tailings dam to improve safety standards.

“Independent tests have been carried out on Samarco’s preparations for a safe restart of operations,” BHP added.

Samarco expects initially to produce around 7-8 Mt/y of iron ore pellets from the use of one of three concentrators to beneficiate iron ore from the Germano complex and one of four pellet plants in the Ubu complex, representing 26% of Samarco’s productive capacity.

Vale explained: “The integrated restart of operations occurs after an extensive commissioning test, ensuring a safe resumption after five years.”

Following the Corrective Operation Licence received in October 2019, Samarco expects to be able to restart a second concentrator in around five years to reach a range of production of some 14-16 Mt/y. The restart of the third concentrator could happen in around nine years, Vale said, when Samarco expects to reach a production volume of around 22-24 Mt/y.

The extensive work undertaken by the Renova Foundation, a collaboration between Vale, BHP Billiton Brasil Ltda and Samarco, to remediate and compensate for the damages of the failure of the Fundão dam in November 2015 continues, BHP said. The foundation is responsible for carrying out programs to repair the social and environmental impacts.

By November 2020, Renova had spent approximately $2.1 billion on its remediation and compensation programs. By November 2020, around $620 million had been paid in indemnities and emergency financial aid to approximately 325,000 people.

Vale given the go ahead to start Capanema iron ore construction

Bulk handling, Environmental, Mineral project development, Steel and iron ore, , , ,

Vale says it has received the required licences to start construction of the Capanema iron ore project in Minas Gerais, Brazil.

The project involves the development of the Capanema mine, acquisiion of new equipment, implementation of a long-distance 2.4 km conveyor belt (TCLD, pictured) and adjustments in the Timbopeba stockyards. This is expected to amount to multi-year investments of $495 million.

With the start-up expected for the second half of 2023, the project will have a production capacity by natural moisture (without tailings generation) of 18 Mt/y and, in the first years, will bring a net addition of 14 Mt/y of capacity to Vale with the “expedition” through the Timbopeba site, Vale said.

The start of the construction works of Capanema marks another important step in productive capacity buffers creation, ensuring greater operational flexibility with low capital intensity, Vale said.

Vale has previously identified that Capanema could be one of its new operations to use “dry processing” techniques.

ERG’s BAMIN iron ore project kicks into gear

Mine operation news, Mineral project development, Steel and iron ore, , , , , ,

Eurasian Resources Group says it is continuing to advance its BAMIN integrated iron ore mining and logistics project in Brazil with the planned commercial start-up this month of its Pedra de Ferro mine in Bahia.

Pedra de Ferro has an initial capacity of 2 Mt/y of high-grade iron ore with 65% Fe content, but, in full production, will be able to produce 18 Mt/y of ore.

At the same time as this, plans for the implementation of Porto Sul, a deep-water port complex that is part of BAMIN, also continue to advance.

Carried out by the State of Bahia and BAMIN, the initial works at the port (pictured) focus on the construction of the requisite infrastructure and access to the site. This phase of the work will generate 400 direct jobs and another 1,200 indirect jobs, according to ERG.

Overall, the BAMIN project is expected to see Bahia become the country’s third largest iron ore producer.

Benedikt Sobotka, CEO of ERG, said: “The start of operations at Pedra de Ferro is a fundamental step towards the full implementation of the project. Porto Sul, in addition to its strategic importance, will strengthen the local economy and support the growth of other sectors. While implementing the BAMIN project, we also aim to positively contribute to the economic and social recovery and help mitigate the long-term impact of the pandemic.”

JSW, BBURG HD2500RC drill rig impresses at Fortescue’s Solomon iron ore mine

Automation, Mineral exploration, Mining equipment, Mining services, Steel and iron ore, , , , , , , , , , , , ,

JSW Australia’s ambition to leverage the latest drilling and automation technology is coming to fruition with the deployment of a new high powered, small footprint drill rig to Fortescue Metals Group’s Solomon iron ore mine in the Pilbara of Western Australia.

The planned arrival of the HD2500RC was announced around a year ago.

Leveraging IDAT (Intelligent Drilling Applications & Technology) technology, developed by German manufacturer BBURG and customised in conjunction with IDAT, the rig underwent site commissioning in July and its initial production performance to date has been impressive, according to JSW.

The HD2500RC was designed especially for the challenging terrain at Solomon where the preparation of drill pads is difficult and expensive, the company says.

“With JSW’s years of experience on-site and first-hand knowledge of the challenges, along with IDAT’s technology expertise and BBURG’s engineering capability, we had a powerful collaboration for the development of the new rig,” JSW CEO, Warren Fair, says.

He said overall the rig was proving to be more productive, safer and quieter than the existing technology on site.

The HD2500RC joins other new technologies in JSW’s fleet including the Equus green drills developed specifically for bauxite mines and new drilling technology for magnetite mines being developed by IDAT in partnership with German manufacturer Bauer.

Fair concluded: “IDAT brings the technology, JSW brings the operational know-how. So far, it’s proving to be a winning formula.”

BRE enlists Hardox HiAce for Super Quad iron ore transport

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

Bruce Rock Engineering (BRE) says it is integrating SSAB’s new wear steel for corrosive environments such as mining in its new Hardox® HiAce.

Servicing this industry is one of BRE’s star products, the 60 m Super Quad road train with a payload up to 141 t. This vehicle is made up of four trailers pulled by a powerful truck travelling vast distances on dirt roads. Designed for heavy industry and the mining sector, a majority of these vehicles transport iron ore from the mines in the Pilbara region of Western Australia to the nearest port.

Such transportation exposes the trucks’ steel to acid corrosion caused by the environment, BRE says. This increases maintenance cost, and wear and tear.

Hardox HiAce steels are able to prolong the service life by up to three years at lower pH environments, making it cost effective and, consequently, increasing profitability, it says.

Hardox HiAce is used on the entire floor plates and the trailer sides of BRE’s new Super Quad trailers for transporting corrosive loads, with SSAB’s research and wear corrosion tests indicating a conservative estimate of a 20-30% increase in service life compared with Hardox 450.

Brenton Verhoogt, Operations Manager at Bruce Rock Engineering, said: “We did not hesitate for a minute before introducing Hardox HiAce into a Super Quad trailer combination for iron ore transport. When SSAB develops a new product, we know it has been tested thoroughly before being launched. Therefore, we are confident it will perform as Hardox 450, with the added benefit of being corrosion resistant.”

BRE’s relationship with SSAB, the manufacturer of Hardox wear plate, dates back 15 years.

LKAB leveraging Sandvik, Epiroc autonomous loading solutions at Kiruna

Automation, Explosives and blasting, IoT, Mine operation news, Mining equipment, Mining safety, Mining services, Mining software, Steel and iron ore, , , , , , , , , ,

Autonomous operations are stepping up at LKAB’s Kiruna asset, in northern Sweden, with the underground iron ore mine adding another two autonomous loaders to its fleet this month.

The company says new technological solutions leveraging automation and digitalisation are needed as mining proceeds to ever greater depths at Kiruna.

“We are already operating three automated loaders, and, in December, we will scale up to five units,” Mikael Winsa, Production Manager at Kiruna, said.

LKAB is well acquainted with automated and remote loading, having started using this technology all the way back in 2000.

Magnus Lindgren, Production Manager for Remote Operations, says: “The infrastructure is much better today and there are better conditions for doing it really well. All of the components to make this work, for example, the network, are now more mature and stable.” Lindgren has been with LKAB since 1994 and worked with the first driverless loaders when they were introduced.

Today three 21 t Sandvik LH621i loaders are operated from a control room at level 1365 in the mine. Sandvik also provides the software that makes it possible to control the machines at some distance from the production area.

Winsa added: “The traffic system has revolutionised automated loading. It allows us to run several machines at the same time, in the same area, and back and forth to the same destination. This is a great leap forward in terms of technology and development.”

The automation system, Sandvik’s AutoMine® Multi-Lite, enables greater flexibility by creating better prerequisites for increasing production, LKAB says.

“We can boost production in one area from around 3,000 t to 5,000 t, since we can run more machines, even at night time,” Winsa says.

This mean significantly more buckets of ore can be hauled over a 24-hour period; something not possible after blasting with conventional loaders, since personnel cannot be exposed to blasting gases.

Lindgren says: “In some ways, this is a completely new approach to loading and production. It is very exciting to take part in this journey and contribute to a solution for mining at greater depth.”

Lindgren said the company is also in the initial phase of launching Epiroc’s remote loading system: “The system is now being fine-tuned and we plan to commission the traffic system early in the new year.”

The automated loaders navigate through the drifts safely and efficiently, according to LKAB. Cameras are installed at the front and back of the machine, which means the operator can follow the loading progression in real time. In addition, one operator can run several machines simultaneously.

“We are able to increase both availability and production by operating more automated loaders,” Lindgren said. “But this doesn’t mean that the manually-operated machines have outlived their usefulness. It just means that we have more tools in our toolbox.”

And the flexibility this enables is the key to mining the Kiruna orebody at greater depth, not least after the seismic event that occurred on May 18, which affected several of the production areas. This has meant fewer areas must produce more ore. In that context, automated loaders are a necessity.

Winsa concluded: “We are always taking small steps forward. It feels like we’ve crossed a threshold and can see many new possibilities leading into the future.”