Tag Archives: Iron ore

Vale and Port of Açu sign HBI Mega Hub MoU

Bulk handling, Environmental, Mine operation news, Mining services, Steel and iron ore, Sustainable mining, , , ,

Vale says it has signed a MoU with the Port of Açu to study the development of a Mega Hub at the port located in São João da Barra in the state of Rio de Janeiro, Brazil, to produce HBI (hot briquetted iron) using the direct reduction route.

The Mega Hub will initially receive pellets from Vale and could, in the future, include an iron ore briquette plant at site to supply the direct reduction route at the industrial complex.

According to the agreement, both companies will seek to attract investors and clients to build and operate the direct reduction plant using natural gas which will be available at the port, with the possibility of eventually converting to green hydrogen, producing HBI with near-zero carbon emissions.

It is a pioneering initiative that considers a technical study coordinated by the Port of Açu and sectorial academics which proposes the use of HBI as partial burden in blast furnaces, reducing greenhouse gas emissions and increasing steelmaking productivity without needing to substitute existing assets, such as the blast-furnaces and steelworks. Currently, HBI is mostly used in electric arc furnaces. Using HBI in this type of furnace will enable a smoother decarbonisation process for the Brazilian steelmaking industry.

The agreement with the Port of Açu marks another step in the development of Mega Hubs in Brazil. Mega Hubs are industrial complexes designed to produce low-carbon steel products and Vale has already begun implanting such hubs in three countries in the Middle East (Saudi Arabia, UAE and Oman).

Marcello Spinelli, Executive VP of Iron Ore Solutions, said: “We believe that Brazil has great potential to be a hub for low-carbon steelmaking. We have high-quality iron ore, abundant natural gas reserves and the potential to develop green hydrogen. As a Brazilian company, Vale seeks to partner with ventures that contribute in this direction. We want to be the driving force behind Brazil’s ‘neo-industrialisation’, which will be based on green industry.”

José Firmo, CEO of the Port of Açu, said: “The signing of this partnership demonstrates the full industrialisation potential of the Port of Açu, confirming its vocation as the port of energy transition in Brazil. We believe that the Port of Açu, with its unique port infrastructure in the country, strategic location and potential for the most competitive Brazilian natural gas prices, brings together unique characteristics to, together with Vale, contribute to the decarbonisation of the domestic and international steel industry.”

Albano Vieira, Consultant for steel and mining issues at Prumo, the holding company that develops the Port of Açu, said: “Brazil is one of the most important iron ore and steel producers in the world and Vale is a leading player in this market. The use of HBI in blast furnaces can reduce greenhouse gas emissions by around 25%, with even greater potential reductions along the chain, which would put the industry in line with the goals of reducing emissions by 2030. With the Port of Açu as the gateway to zero-carbon industrialisation projects, all the conditions and analyses point to the country becoming a major producer of HBI, supplying steel mills all over the world.”

Metso to deliver two Vertimill 4500 grinding mills to Canadian iron ore producer

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

A Canadian iron ore producer has awarded Metso an order for two powerful Vertimill® 4500 grinding mills to be delivered in the September quarter of 2024. The value of the order, which exceeds €10 million ($10.6 million), has been booked in Minerals segment’s 2023 September-quarter orders received.

Graham Davey, Director, Stirred Mills at Metso, said: “We are very pleased to collaborate on projects that support decarbonisation of the steel industry through production of high-grade and high-purity iron ore with sustainable processes. The Vertimill stirred grinding mill technology is globally recognised as a leading solution for energy-efficient grinding. Compared to traditional technology, operators can typically save up to 30-35% of the electrical energy and grinding media consumption. A small footprint and easy installation are also big advantages.”

Vertimill technology is an example of Metso’s Planet Positive offering. It is capable of handling feed sizes of up to 6 mm and grinding to product sizes of 30 microns or less. Vertimills are available in standard mill sizes ranging from 11 kW to 3,352 kW.

Since the introduction of the technology in the 1990s, Metso says it has sold over 540 Vertimill units to nearly all types of minerals.

Metso says it is the only manufacturer worldwide that can offer several stirred mill technologies (Vertimill, HIGmill™ and SMD), enabling it to support customers with the most suitable and efficient mill for their application.

Vale gears up for low-carbon iron ore briquette production in Brazil

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Vale has started load tests of its iron ore briquette plants at the Tubarão Unit in Vitória, Brazil, as part of a project it believes could eventually reduce steel industry CO2 emissions by up to 10%.

The load tests are part of the plant’s commissioning and are one of the last stages before production begins, it said.

Vale’s CEO, Eduardo Bartolomeo, said: “This is a historic moment for the steel industry. After several years of development in Brazil, we are offering an innovative product that will support our clients in the challenge of decarbonising their operations and we are meeting demands from society to fight climate change.”

The briquette is produced from the low-temperature agglomeration of high-quality iron ore using a binder technology solution, which gives the final product high mechanical strength.

Announced by Vale in 2021, the briquette has the capacity to reduce greenhouse gas emissions in steel production by up to 10% compared with the traditional blast furnace process by eliminating the carbon-intensive sintering stage. This reduction is significant when considering that the steel industry is responsible for around 8% of the world’s emissions.

The product also reduces the emission of particulates and gases such as sulphur dioxide and nitrogen oxide, as well as eliminating the use of water in its production. The briquette can also be used in the direct reduction route, replacing the pellet.

The first briquette plant in Tubarão (pictured, photo: Rafael Coelho) is scheduled to start up this year and the second plant at the beginning of 2024. They will have the capacity to produce 6 Mt/y of briquette. The two units were originally dedicated to the production of pellets and were converted for briquettes. Investment in the project amounted to $256 million and generated 2,300 jobs during construction.

Vale began developing briquettes around 20 years ago at the Ferrous Technological Center in Nova Lima (Minas Gerais). It is part of the evolution of iron ore products offered by the company throughout its history, the result of significant investments in research and innovation. Until the 1960s, the basic product was high-iron lump. As the supply of lump fell, the first pelletising plants were set up in Brazil, which allowed the use of fine ore (pellet feed) and continue to be important for the steelmaking chain. The briquette, as well as pellets, are part of Vale’s portfolio of high-quality products. The company expects to expand its production capacity to 100 Mt/y of briquettes and pellets after 2030.

The briquette is also included in Vale’s strategy to reduce its Scope 3 emissions, related to the value chain, by 15% by 2035.

The company also aims to reduce its net direct and indirect carbon emissions (Scope 1 and 2) by 33% by 2030, as a first step towards becoming a zero-carbon company by 2050. Vale has already signed more than 50 agreements with clients to offer decarbonisation solutions, which account for 35% of the company’s Scope 3 emissions. Among the proposed solutions is the construction of briquette plants co-located on the premises of some customers.

Among the agreements signed, three aim to set up “Mega Hubs” in Middle Eastern countries (Saudi Arabia, the UAE and Oman) to produce “hot-briquetted iron” (HBI), in order to supply the local and transoceanic markets, with a significant reduction in CO2 emissions. It is expected Vale will build and operate iron ore concentration and briquetting plants at the hubs, supplying the raw material for the HBI plants, which will be built and operated by investors and/or clients. Vale is also studying the creation of similar hubs in Brazil, though no location has yet been defined.

Iron Ore Company of Australia selects Rapid Crushing for Hancock crushing and screening ops

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Alien Metals Ltd’s wholly-owned subsidiary, Iron Ore Company of Australia Pty Ltd (IOCA), has selected Rapid Crushing & Screening Contractors Pty Ltd as its preferred supplier to undertake the crushing and screening operations at the flagship Hancock iron ore project in the Pilbara of Western Australia.

IOCA says it has conducted a competitive market engagement over the previous six months to identify commercially and technically-adept contractors to undertake works as part of the Hancock development and operations. This process has involved pre-qualified and targeted proponents, submitting bids for specific scopes of works and agreeing to key commercial terms.

Rapid Crushing is a market leader in iron ore, having previously worked with Fortescue Metals Group and being the incumbent contractor at Galaxy Lithium for the past six years, with that work continuing. The selection of Rapid Crushing for crushing services reinforces the assumptions made within the scoping study to deliver a C1 cost of approximately $60 per tonne, Alien Metals says.

The 2021 scoping study on Hancock showcased a 1.25 Mt/y production profile that would sustain an eight-year life of mine with current resources. The company has said it plans to make its first shipments in 2023, leveraging its direct shipping ore options.

Earlier this month, IOCA named REGROUP Australia as its preferred primary contractor to undertake the construction works, mining operations and haulage services for Hancock.

The selection of Rapid Crushing – which remains subject to the completion of a positive definitive feasibility study – paves the way to finalise the updates to the financial model as the IOCA continues to progress the remaining studies and regulatory workstreams required for a final investment decision for the Hancock project, it says.

Troy Whittaker, Chief Executive Officer, said: “We are pleased to announce that Rapid Crushing has been selected as the preferred tenderer for crushing and screening operations at our Hancock project. Rapid Crushing’s significant hard-rock mining knowledge and experience, particularly in iron ore, will be of great benefit to our overall operations.

“We will be working closely with Rapid Crushing to finalise optimisation activities that support the accelerated DFS work streams related to price opportunity as we prepare and execute the contractual documents.

“The selection of Rapid Crushing finalises the material procurement efforts for the project. This will result in a high level of validated and secured costing for the Hancock project.”

Metso books filter and pump orders from India iron ore projects

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

Metso has been awarded orders to deliver concentrate dewatering filters and pumps to two iron ore projects in India. The combined order value exceeds €10 million ($11.01 million) and was booked in the Minerals segment’s June-quarter 2023 orders received.

Metso’s scope of delivery consists of the engineering, manufacturing and supply of several VPA pressure filters and filter feed pumps as well as spare parts.

Vijay Dhar, Vice President for Minerals Sales in the Middle East and India market areas at Metso, said: “We are pleased having been chosen to deliver the pressure filters to the two sites. The VPA filters are one of the most sustainable filters available and are classified as Planet Positive products because of their water and energy efficiency.”

Metso says its filtration portfolio consists of 15 different filter types and a comprehensive service offering for various mining and industrial applications, with more than 5,000 installations globally. The Larox® legacy is carried over in five filters in the portfolio. Over 80% of the Metso filters are part of the company’s Planet Positive portfolio.

Weir Group marks Minerals and ESCO progress in H1 results

Base metals, Comminution of minerals, Equipment maintenance, IoT, Mining equipment, Mining finance, Mining services, Mining software, Steel and iron ore, Sustainable mining, Water management, , , , , , , , , , , , , , , , , , ,

The Weir Group has issued its half-year results to June 30, 2023, noting some significant achievements across its Minerals and ESCO divisions.

Headline numbers for the six-month period included a 19% year-on-year jump in revenues to £1.3 billion ($1.67 billion) and a 26% rise in operating profit to £212 million.

Weir Minerals continued to execute on key strategic growth initiatives, and during the first half gained market share in its core mill circuit product categories, it said.

The company said: “We converted 100% of our competitive field trials for large mill circuit pumps, and also rolled-out our latest cyclone technology.”

One highlight in the period came at a large Brazilian iron ore mine, where Weir Minerals upgraded the cyclones to its latest Cavex® 2.0 solution. The new cyclones, which are Synertrex®-enabled, have improved separation and increased mineral recovery by more than 400,000 t/y, according to the company.

Cavex 2 cyclones were launched in 2020, introducing new geometric features to offer performance unmatched by any cyclone in operation at that point, the company claimed. The advanced LIG+ design (patent pending) enables the Cavex 2 hydrocyclones to classify up to 30% more feed slurry, while occupying the same footprint as competitor hydrocyclones, according to Weir.

Weir Minerals says it also made good strategic progress in sustainable solutions during the six-month period and delivered year-on-year growth in comminution. New orders included a pebble crushing plant for a large copper mine in South America and a crushing solution for a potash mine in Canada.

The company also said it saw “very encouraging interest” from customers for its Redefined Mill Circuit, securing orders from large copper mines in South America for coarse particle flotation (CPF) pilot circuits, in partnership with Eriez.

“Through this strategic alliance, we have integrated CPF technology with our latest generation Warman® mill circuit pumps and Cavex cyclones to provide significantly improved recoveries and process efficiencies for our customers,” it said. “Once operational in the September quarter, these plants will be important reference sites for the industry.”

Around a year ago, Weir Minerals and Eriez Flotation announced a cooperative agreement to design and develop CPF systems. This allows both companies to better connect the Eriez equipment with the slurry classification and conveying expertise of Weir Minerals, according to Ricardo Garib, Division President of Weir Minerals.

Weir Minerals also launched its new, proprietary digital intelli-solutions for pumps, cyclones and high pressure grinding rolls which, coupled with its Synertrex 2.0 platform, captures critical machine health data and enables remote condition monitoring.

It concluded: “We continued to invest in research and development of our core technologies including new materials and polymers, and upgrades and range expansions for our industry leading Warman slurry pumps.”

Weir ESCO, meanwhile, reported that the number of mines using Motion Metrics™ AI-enabled vision technology increased during the first six months of the year, with new orders including a package of five ShovelMetrics™ and five LoaderMetrics™ systems to be deployed across all large mining machines at an iron ore mine in Western Australia.

“The division made excellent progress in growing market share in mining attachments, with a 37% year-on-year increase in orders,” it said. “A particular highlight included converting four cable shovel buckets from competitor products to ESCO technology for a large North American copper miner.”

The division also provided an update on trials of its proprietary ore characterisation technology, which has been leveraging the BeltMetrics™ solution from Motion Metrics positioned above a conveyor directly after the crusher in the flowsheet at an unnamed mine. As well as using the rugged vision technology Motion Metrics has previously used, the company is also incorporating hyperspectral imaging into the mix for this trial.

It reported: “Field trials of our proprietary ore characterisation technology were successfully completed during the first half. Tests enabled critical data to be collected and validated the performance of the technology in a real-world environment.”

Development has now progressed to the next phase focused on exploring “novel illumination” technologies to enhance minerals characterisation, it added.

New Motion Metrics capabilities and functions were launched during the six-month period, including an upgraded lens cleaning solution that enhances machine vision capability and improves response times.

“Other technology investments included development of a new series of mining attachments that, once launched, will expand our addressable market,” it said.

Vale hits ICMM’s GISTM target for tailings storage facilities

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Vale says it has implemented the Global Industry Standard for Tailings Management (GISTM) in 48 of its 50 tailings storage facilities (TSFs), with plans to bring the two remaining TSFs into conformance by August 2025.

The GISTM was developed after the tragic failure of a tailings facility at Brumadinho, Brazil, in 2019, through an independent process convened by ICMM, the United Nations Environment Programme and Principles for Responsible Investment.

The standard sets a high bar and contains 77 requirements integrating social, environmental, local economic and technical considerations which strive to achieve the goal of zero harm to people and the environment, according to ICMM.

Vale says of the 48 TSFs now in conformance with the GISTM, 35 are in the Iron Solutions business unit in Brazil and 13 in the Energy Transition Metals business unit (11 in Canada and 2 in Brazil).

“The two remaining Iron Solutions TSFs in Brazil have a lower consequence classification and will be in conformance with the standard by August 2025, following the criteria of the Conformance Protocols defined by ICMM,” Vale said.

The 48 TSFs in conformance meet the GISTM requirements, and some of them have action plans in place according to the Conformance Protocols, according to the company. In addition to meeting the 77 standard requirements, a TSF in conformance with the GISTM means that the oversight, monitoring and transparency of information have been and will continue to be improved, according to Vale. The focus is on the safety of people and the environment throughout the entire TSFs life cycle.

When the GISTM was published in August 2020, ICMM members committed to conform with the standard for tailings facilities classified as ‘extreme’ or ‘very high’ consequences by August 2023, and all other facilities by August 2025. Members are due to publish their progress towards conformance with the GISTM by August 5, 2023, for tailings facilities with the highest potential consequences in the event of a failure.

The ICMM said earlier this week that it anticipated some companies will not achieve full conformance with the standard’s requirements.

Implementing GISTM for Vale’s TSFs represents only one part of the company’s efforts to become safer and more sustainable, the miner says. Vale has been improving the management of its mining dams by conducting an in-depth technical analysis of the historical, current condition and performance of each structure. The preventive, corrective and monitoring actions have also been intensified, being increasingly integrated with social movements and updated according to legislation.

Vale also continues to progress de-characterisating its upstream tailings dam structures in Brazil. As of 2019, out of the 30 dams of this kind included in the program, 12 have already been de-characterised, representing 40% of the total. The program is expected to be completed in 2035. The de-characterisation of upstream facilities in Brazil is Vale’s commitment, in addition to being part of the current Brazilian federal and state legislation on dam safety.

Hexagon, MinRes to ‘transform mining’ with autonomous road train developments

Automation, IoT, Mineral project development, Mining equipment, Mining services, Mining software, Steel and iron ore, , , , , , , , , , , , ,

Hexagon AB has signed a major agreement with diversified mining company Mineral Resources (MinRes) to provide an autonomous haulage solution for a fleet of road trains to run at the Onslow iron ore project in Western Australia, which, the companies say, will transform safety, productivity and sustainability in the region.

The world-first, fully autonomous road trains are a full-site, truck-agnostic solution, leveraging positioning, onboard autonomy and by-wire, fleet management, collision avoidance, world perception and autonomous mission management solutions from Hexagon.

These solutions will be added to Kenworth 330 t road trains (coming with three trailers each), which will run autonomously on MinRes’ 150 km private haul road.

This agreement builds on two major milestones the companies achieved over the last two years in anticipation of rolling out the fully autonomous road trains at Onslow.

In late 2021, Hexagon and MinRes signed an agreement to develop an autonomous road train solution as part of a plan to unlock “stranded tonnes” in the Pilbara of Western Australia. Then, in April 2022, the companies announced a world-first had been achieved with the successful demonstration of a triple-trailer, automated road train platoon in the Yilgarn of Western Australia – each autonomous road train, in this case, hauling 300 t of iron ore.

Andrew Crose, Vice President, Autonomous Mining, Hexagon’s Mining division, told IM that the speed of adoption of this automated solution – from agreement to demonstration, to planned commercial deployment, in a little over two years – was aided by the abilities and efforts of a global team of Hexagon experts.

“Hexagon has staffed a large multi-national team across the Hexagon technologies stack across Perth (Australia), United States, Brazil, Switzerland and Canada to deliver this technology,” he said.

The companies also worked within the framework of the established Code of Practice for Safe Mobile Autonomous Mining in Western Australia to gain the necessary regulatory approvals to move the project forward at such a pace.

Mike Grey, Chief Executive, MinRes, said in the press release: “Automation will remove the risk of driver fatigue, lower operating costs and reduce fuel use and emissions. There’s enormous potential for these vehicles to transform mining across the world.”

Commissioning of the autonomous road trains is expected to fall in line with the go-live date for Onslow – currently estimated for the first half of 2024.

The road trains form an important part of the 35 Mt/y project, ensuring this tonnage is moved from the mine to the Port of Ashburton.

MinRes has said previously that the autonomous road train technology will initially be adopted for its own mining operations, with a view to offering the solution to its Tier 1 customer base as it grows its Mining Services division.

Hexagon recently expanded its autonomy offering with the acquisition of HARD-LINE; a deal that, Nick Hare, President, Hexagon’s Mining division, says allows the company to provide a scalable automation platform that all mining companies can use and grow with.

Mineral Resources’ achieves energy strategy milestone with Wonmunna solar installation

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Mineral Resources (MinRes) says it has marked an important milestone in its energy strategy with the successful installation of a 2.1 MW solar-battery system at its Wonmunna iron ore project in the Pilbara region of Western Australia.

Located 80 km northwest of Newman, the Wonmunna mine was purchased as an undeveloped project in the 2021 financial year. First ore was achieved just five months after construction began at the site and during the 2022 financial year, production from Wonmunna ramped up to 5 Mt/y.

Installation of the 5B Maverick solar technology at the Wonmunna site – complete with more than 4,000 solar panels – was completed during the 2023 financial year. Following successful testing and optimisation works, the technology is now providing significant benefits for site operations and reducing dependency on diesel fuel, MinRes says.

The combined solar-battery system will produce more that 30% of the mine’s power requirements and ultimately cut diesel consumption by approximately 760,000 litres each year, while reducing the site’s carbon emissions by around 2,000 t/y of carbon dioxide equivalent.

In addition, the crusher at the site is powered 100% by the system during the middle of the day when renewable output meets peak plant load.

During the warmer summer months, the system can achieve more than 40% displacement on any given day – and, with a 20-year life span, it can be redeployed to other operations once Wonmunna reaches its end-of-life, MinRes says.

Chief Executive Energy, Darren Hardy, said the Wonmunna solar and battery array at Wonmunna was a positive step forward in the company’s renewable energy strategy.

“MinRes is committed to pursuing renewable energy opportunities where we can and our team has been working hard to deliver a solar array and battery solution that delivers optimum output at Wonmunna,” Hardy said. “Together with natural gas, renewables will play an important role in our energy future, and MinRes continues to pursue off-grid solar power and energy storage solutions to support our remote locations.”

Gas and LNG power stations currently supporting MinRes’ lithium operations at Mt Marion in the Goldfields and Wodgina in the Pilbara are delivering significant emissions savings, according to the company. This includes a 64 MW capable power station at Wodgina, which is the largest of its kind on a mine site in the southern hemisphere, the company says.

At the upcoming Onslow Iron project, also in the Pilbara, MinRes will install a range of energy solutions designed to offset diesel with alternative fuels and renewable energy options, energy storage, and electrification of mobile equipment and transport.

MinRes says it recognises the need for meaningful action to address climate change and is committed to investing in activities that reduce the carbon intensity of its operations and maintaining best-practice environmental, social and governance performance.

The company’s Roadmap to Net Zero Emissions outlines MinRes’ pathway towards a transition to gas, renewable energy and other emerging technologies to support its operations and reduce its carbon intensity – including the company’s goal to achieve of net-zero emissions by 2050.

Eriez Magnetic Mill Liners boost safety, energy efficiency and durability at Nexa Resources mine

Comminution of minerals, Mineral processing, Mining equipment, Sustainable mining, , , , , , ,

A new report from Eriez® reveals how a set of Magnetic Mill Liners (MML) are significantly improving safety standards, energy efficiency and operational longevity at a Nexa Resources operation in Peru.

The MML is a wear-resistant steel-encased magnet that combines the best qualities of steel and magnetic liners, according to Eriez.

The report highlights the superiority of MMLs over conventional liners by describing the numerous benefits these advanced liners offer. Each MML is composed of individual sections that are much lighter than traditional liners, facilitating safer and easier installation procedures, Eriez says. Weighing only 20-40 kg per section, the MML eliminates the requirement for specialised cranes within the mill, streamlining operations and enhancing safety protocols. Nexa even credits the MML installation with contributing to the company’s achievement of a major Peruvian safety award.

There are considerable environmental advantages associated with the implementation of MMLs, according to Eriez. Heavier steel liners require significant fuel consumption for transportation and material handling while lightweight MMLs can be installed by hand. Additionally, Nexa reports a significant reduction in noise levels with the MML, creating a more favorable work environment overall.

The case study also highlights the energy-efficient aspects of MMLs. In traditional ball mills, small ball chips do not contribute to the grinding process, leading to wasted energy. However, MMLs effectively eliminate the presence of small ball chips, resulting in energy savings of up to 11% during the grinding process, according to Eriez.

The exceptional durability of MMLs is another standout feature discussed in the report. Unlike conventional liners that necessitate frequent replacement, the Eriez MML has garnered a track record of success through many installations in diverse mining operations worldwide, including iron ore, copper, nickel and gold mines, as well as other non-ferrous mines. These installations provide evidence that MMLs outlast rubber or metallic liners by two to three times, Eriez states.