Tag Archives: Iron ore

MACA on the road again at Iron Bridge magnetite project

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

MACA says it has been awarded a bulk earthworks contract at the Iron Bridge magnetite project, a joint venture development in the Pilbara of Western Australia between Fortescue Metals and Formosa Steel IB.

The contract is for access roads and infrastructure at the $2.6 billion project, 145 km south of Port Hedland.

MACA said this work is expected to generate revenue of A$26 million ($17.6 million) for the company, with the scope including general earthworks for camp expansion, construction of 26 km of mine access road, construction of the explosive facility and access road, and a further 23 km of road upgrade works.

MACA, which has already started work on the contract, becomes the latest mining equipment, technology and services contract to find work at Iron Bridge, which is expected to deliver 22 Mt/y of high-grade 67% Fe concentrate production following start up in 2022.

Just last month, Weir Minerals was awarded its largest ever individual mining order from the project.

 

Bis gets firm handle on GFG Alliance Whyalla contract

Bulk handling, Mine operation news, Mining equipment, Mining services, Steel and iron ore, , , , , , , , , , ,

Bis says it will become the single materials handling contractor for GFG Alliance in Whyalla, South Australia, as of October 1.

As part of GFG Alliance’s strategy to maximise efficiency at its Whyalla-based operations ¬– incorporating its Liberty Primary Steel and SIMEC Mining businesses (which includes a 10 Mt iron ore mine in the Middleback Ranges of South Australia) – several materials-handling work packages were consolidated into a single contract to be operated by a single contractor partner.

The contract will see Bis deliver a range of site services to Whyalla including steel services, scrap processing and handling, slag processing and handling, and bulk materials handling.

The award comes as Bis celebrates 60 years in Whyalla this year, where it currently employs 170 people. Bis will bring on another 80 employees as part of the expanded scope of works.

Liberty Primary Steel Acting Executive Managing Director, Jason Schell, said: “GFG Alliance is looking forward to partnering with Bis to help drive our continuous-improvement culture and turn our business around for a sustainable, long-term future.

“This consolidated contract will result in significant cost savings for our business, while providing greater opportunities to optimise Bis’ assets and workforce across multiple work-fronts.”

Bis Chief Executive Officer, Brad Rogers, said the announcement showed the strength of the company’s relationship with GFG Alliance, as well as Bis’ track record of safely and reliably delivering flexible, efficient solutions for its customers.

Hadyn Shepherd, Bis General Manager Mining Services South East, meanwhile, said the win was great recognition for Bis and the team in Whyalla.

Port Hedland’s iron ore export capacity receives ‘potential’ boost

Bulk handling, Mining services, Steel and iron ore, , , , ,

One of the world’s largest ports for iron ore exports, Port Hedland, in Western Australia, has had its  potential shipping capacity increased by 40 Mt/y.

The additional capacity, which was a result of Western Australia Government and industry investment at the port, will see Port Hedland’s potential shipping capacity go from 577 Mt/y to 617 Mt/y, a 6.9% increase.

Annual capacity allocations for each port user will remain the same, according to a media statement from Western Australia Ports Minister, Alannah MacTiernan. However, the increased capacity will allow all port users more capacity above their allocated tonnages by accessing D‑class shipping opportunities under the Port Hedland Vessel Movement Protocols.

Investments at the port to facilitate this new capacity modelling by the Pilbara Ports Authority included capital dredging, innovative marine technology and other port efficiencies, according to the statement.

This includes the recently completed three-year dredging works program, the Channel Risk and Optimisation Project. The A$120 million ($81 million) project included the removal of “high spots” in the channel, optimising navigable depths to allow deeper drafted vessels to safely navigate along the 42 km shipping channel.

Also driving this increase is the continued movement and facilitation of larger vessels in the channel. The sizes of ships coming into Port Hedland have increased significantly in recent years, with 45% of vessels now carrying more than 200,000 deadweight tonnage, compared with less than 10% in 2009, according to the Pilbara Ports Authority. Much of this increase can be put down to bigger vessels carrying iron ore from Port Hedland to Asia and elsewhere.

In August, Port Hedland achieved a monthly throughput of 46.1 Mt, of which 45.4 Mt was iron ore exports. The monthly throughput was a 7% increase from August 2018, according to the Pilbara Ports Authority.

Rio Tinto aims for carbon emission cuts across steel value chain

Environmental, Mineral processing, Steel and iron ore, Sustainable mining, , , , , ,

Rio Tinto has signed a Memorandum of Understanding (MOU) with China’s largest steel producer, China Baowu Steel Group, and Tsinghua University, one of China’s most prestigious and influential universities, to develop and implement new methods to reduce carbon emissions and improve environmental performance across the steel value chain.

The China Iron and Steel Association (CISA) invited all three to sign the MOU at its China International Steel and Raw Materials Conference, held in Qingdao.

The MOU will enable the formation of a joint working group tasked with identifying a pathway to support the goal of reducing carbon emissions across the entire steel value chain, which accounts for 7-9% per cent of the world’s carbon emissions, according to 2017 figures from The World Steel Association.

The working group will establish a joint action plan on how to best use the three entities’ complementary strengths in research and development, technologies, processes, equipment, logistics, industry coordination and policy advisory capacities to combat climate change and improve environmental performance, Rio, one of the world’s biggest iron ore producers with one of the largest operations in the Pilbara of Western Australia (pictured), said.

Rio Tinto Chief Executive, J-S Jacques, said: “This pioneering partnership across the steel value chain will bring together solutions to help address the steel industry’s carbon footprint and improve its environmental performance.

“The materials we produce have an important role to play in the transition to a low carbon future and we are committed to partnering with our customers and others to find the most sustainable ways to produce, process and market them. We are already doing this in aluminium and now, through this partnership, we will be doing it in the steel industry.

“We thank CISA for its support and look forward to collaborating with China’s largest steel producer, China Baowu, and Tsinghua University, a global leader in climate change research and collaboration.”

China Baowu Chairman, Chen Derong, said: “China Baowu is committed to ecological and sustainable development. We will promote sustainable production through intelligent manufacturing. We want to make a difference to the iron and steel ecosystem by developing greener factories and enterprises to deliver a cleaner, more sustainable steel industry.

“We hope to jointly address climate challenges with our partners, and create a model of harmonious coexistence between cities and steel mills.”

Tsinghua University Vice President, You Zheng, said: “Tsinghua is committed to providing solutions to climate change challenges and contributing wisdom to sustainable development. Initiating the Global Alliance of Universities on Climate is an important milestone, and just one example. The signing will enable us to work closely with the upstream and downstream of the steel industry value chain to jointly find the solution to the industry’s low-carbon transformation.”

Metalloinvest employs Derrick fine screening technology at Mikhailovsky GOK iron ore mine

Comminution of minerals, Environmental, Mine operation news, Mineral processing, Mineral project development, Mining equipment, Mining project news, Steel and iron ore, , , , , , ,

Metalloinvest says it has launched Derrick fine screening technology at its Mikhailovsky GOK mine, in Russia, as part of a major project to improve the quality of the operation’s iron ore concentrate.

The first technological phase of the ore concentrate project was launched at Mikhailovsky GOK beneficiation plant during an official ceremony (pictured) attended by Nazim Efendiev, First Deputy CEO, Sales Director, Management Company Metalloinvest; Mitchell Derrick, CEO of Derrick; Miron Boris, General Manager of Thrane Teknikk (exclusive representative of Derrick in Russia and CIS); Sergey Kretov, Managing Director of Mikhailovsky GOK; and Mikhail Aksenov, chairman of the Committee for Industry, Trade and Small Business Development of Russia’s Kursk region.

On the same day, an agreement was signed with Thrane Teknikk to supply Derrick equipment for the second stage of the project, which will see the construction of a new building for beneficiation of concentrate at the beneficiation plant.

Efendiev said the introduction of fine screening technology is an important part of the comprehensive program to improve iron ore products at Mikhailovsky GOK.

“Improvements in the quality of concentrate will enable the enterprise to produce premium quality pellets in line with international standards,” he said. “Mikhailovsky GOK products will enter the top league, allowing access to new sales markets. The enterprise will also reduce its impact on the environment and will increase production efficiency.”

Mitch Derrick said the company’s partnership with Metalloinvest began in 2005 and, since that time, the two have worked together at Mikhailovsky and Lebedinsky to ensure significant efficiency gains in the production of high-grade iron ore concentrate with Derrick’s 5-Deck StackSizer® screens.

“I am extremely happy that we are furthering this important alliance with Metalloinvest’s decision to utilise Derrick’s newly offered 8-Deck SuperStack™ High-Frequency Screens at Mikhailovsky,” he said. According to the Derrick chief, this solution offers over twice the capacity of traditional units in a similar footprint, which significantly reduces both the upfront installation costs and ongoing operating and maintenance costs.

During the first stage of the project, Derrick fine screening technology was introduced at four technological sections of the beneficiation plant. The design, supply and installation of the equipment, adjustment works and commissioning took place within a period of just one year. The capital expenditures for the first stage exceeded RUB1.2 billion ($18.7 million).

As a result of the first stage of implementation, over 3.7 million tonnes of iron concentrate with an increased iron level of 67% Fe from 65.1% will be produced in 2020 at the fine screening technology section, Metalloinvest says.

The second stage of the project, launched in August 2019, will see construction of a new building for beneficiation of concentrate using Derrick equipment (22 Derrick stack sizers and 44 water pumps, metal constructions, pipelines, supporting equipment).

As a result of the second stage, production of high-quality concentrate with an iron content of 68.7% Fe will amount to 16.9 Mt in 2022. The construction of the new beneficiation building and modernisation of production will enable the processing of complex ores with a higher iron content and will reduce overburden and production costs, according to the company.

Investments in the second stage are projected to be more than RUB12 billion.

WEG looks to attract iron ore miners with latest slip-ring motors

Equipment maintenance, Mineral processing, Mining consumables, Power supply for mines, , , ,

WEG has unveiled its new M Mining series of slip-ring motors that, it says, are intended for dusty environments in the iron ore or cement sectors.

Available in frame sizes IEC 355 to IEC 1000, the new M Mining slip-ring motors cover the power range from 250 kW-10 MW at 50 Hz or 60 Hz line frequency. These three-phase induction motors are between four and 14 poles and designed for voltages up to 13.8 kV, making them a reliable choice for mills, crushers, blowers, exhaust fans, conveyors, centrifuges, and other applications in the mining and cement industries, it said.

Andreas Schulte Mesum, Director European High Voltage Solutions, based at WEG Germany GmbH, said: “Their performance and robustness make the new M Mining series of motors, with their high IP rating, steel casing and two different brush systems, an excellent choice for applications in the mining and cement industries. The design is based on specific electromechanical properties that offer long life and high stability.”

The wound rotors of slip ring motors allow them to achieve high starting torques along with low start-up current. In contrast to squirrel-cage motors, the windings are connected to three slip rings to allow a variable resistance to be inserted in the rotor circuit. This has several major benefits for users including higher rotor circuit resistance to improve the motor’s start-up characteristics; the motor starting current and rated current are close to the same; and loads with high starting torque can be driven, as well as loads with high inertia. Further advantages include higher efficiency and simple installation, WEG said.

The new motor series has a brush compartment with a new design and transparent window for inspection and access. Commissioning is aided by combining the motor with a fully integrated control panel as an option, according to the company. At the same time, operating and maintenance costs are reduced and plant availability is increased.

The motor series is available in two versions: either with a brush lifting device, or with brushes in constant contact. “The lifting mechanism of the brush lifting device has been redesigned to make it even easier to maintain,” WEG said. “Compared to the version with fixed brushes, the brush lifting system requires less maintenance. In addition, brush wear is reduced by fitted pressure springs. An integrated control system is also available as an option for the brush lifting device.”

With its innovative design and new insulation arrangement, the system offers other advantages.

“For example, the cooling system of the brush compartment is independent of the motor cooling system, further boosting the efficiency,” WEG said. “The extended lifetime of the brushes is one of the main advantages, but user access to the brush compartment is also significantly easier with this version. The brush compartment achieves an IP rating of up to IP66.”

The M Mining motors are available with protection ratings from IP55 to IP66. They are also protected by WEG paint systems that enable operation in abrasive and humid environments with atmospheric sulphur dioxide.

SIMPEC to power up FMG’s Eliwana iron ore mine

Mine operation news, Mineral project development, Mining services, Power supply for mines, Steel and iron ore, , , , , ,

SIMPEC has been given another assignment at Fortescue Metals Group’s Eliwana iron ore mine and rail project in Western Australia, with a circa-A$5 million ($3.4 million) contract to construct the 25 MW diesel power generation facility at the operation set to keep it busy until July 2020.

The contract, which commences this month, was awarded to the WestStar business by Energy Power Systems. It is SIMPEC’s first full vertical installation package comprising of civil, structural, mechanical, piping, electrical and instrumentation works, the company said.

Under the agreement, SIMPEC will supply (partially), install, test and commission the 25 MW facilities for Eliwana, with the delivery executed over three separable portions.

Back in April, SIMPEC was awarded its largest single contract to date, with ATCO Structures and Logistics granting it a circa-A$10 million contract to design, supply, construct, test and commission the electrical, communications and dry fire systems for an 800-room mine camp at Eliwana. The contract was scheduled to commence in the middle of the year and take nine months to complete.

The Eliwana project will involve the building of 143 km of rail, a new 30 Mt/y dry ore processing facility and infrastructure. Production is expected to commence in December 2020 with a life of mine strip ratio of 1.1. The project underpins the introduction of a 60% Fe grade product (Fortescue Premium) in the second half of the company’s 2019 financial year.

Weir secures largest-ever individual mining order from Fortescue

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

The Weir Group says it has been awarded a £100 million ($123 million) order to provide industry-leading energy saving solutions to the Iron Bridge magnetite project, a joint venture between Fortescue Metals Group and Formosa Steel IB.

The order, which includes a range of Weir crushing and pump equipment including Enduron® high pressure grinding rolls (HPGRs) and GEHO® pumps, will reduce energy consumption and wet tailings waste by more than 30% compared with traditional mining technologies, according to the equipment manufacturer.

The Iron Bridge project, 145 km south of Port Hedland in the Pilbara region of Western Australia, is a $2.6 billion investment in premium magnetite iron ore reserves with annual production, when the mine is fully operational, of 22 Mt/y of 67% Fe concentrate. Delivery of the first ore is expected in 2022.

When the mine build was approved back in April, Fortescue CEO, Elizabeth Gaines, said the innovative design for the project, which included the use of a dry crushing and grinding circuit, “will deliver an industry-leading energy efficient operation with globally competitive capital intensity and operating costs”.

A pilot project to verify the Iron Bridge project design involved processing 1 Mt of ore through a full scale HPGR and air classifier, according to Fortescue.

Weir Group Chief Executive Officer, Jon Stanton, said: “We are delighted to have secured this landmark contract, which is Weir’s largest-ever individual mining order.

“Fortescue challenged us to help create one of the most energy and cost-efficient magnetite ore processing facilities in the world. Our engineers have worked relentlessly to design a solution that is truly innovative – delivering significant energy, water and cost savings. This is a great example of working in close partnership with an ambitious customer who shares our passion for using innovative engineering to make mining more productive and sustainable.”

Ricardo Garib, President of the Weir Minerals division, added: “Our team are really enjoying working with Fortescue. Our engineers relish a challenge and it has been great to work on a project that demonstrates the substantial cost and environmental savings that our range of solutions can offer.

“As more mines look to increase productivity, we look forward to even more opportunities to leverage our combination of passionate people, innovative solutions and comprehensive global service capability.”

Weir’s Enduron HPGRs are increasingly replacing conventional mills in comminution (crushing, screening and grinding) circuits because of their substantially lower energy consumption and potential for significant total cost of ownership reduction, Weir says.

“Not only do they require as much as 40% less energy than traditional alternatives, but their wearable components last much longer and the maintenance time required to replace worn out parts is significantly lower.”

The company outlined the reasons why companies are turning to Enduron HPGRs in a blog post earlier this week.

Tacora puts Scully iron ore mine back on the map

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

Tacora Resources says it has made its first seaborne vessel shipment of iron ore concentrate produced at the Scully mine located in Wabush, Newfoundland and Labrador, Canada.

Last week, the MV RIO TAMARA departed the Port of Sept-Iles, Quebec, with a payload of 69,770 t (wet) of Tacora Premium Concentrate bound for a customer in Europe. The vessel was loaded at dock 30 of the Société ferroviaire et portuaire de Pointe-Noire (SFPPN), at the Port of Sept-Iles on Quebec’s north shore.

Tacora purchased substantially all the assets associated with the Scully mine on July 17, 2017. In the subsequent months, it completed a feasibility study that confirmed the viability of Tacora’s restart plans for the mine, secured life of mine access to rail transportation services and ship loading infrastructure, including access to a deep water port with SFPPN and the Port of Sept-Iles, and concluded various regulatory matters with the Government of Newfoundland and Labrador, including consultations with local indigenous peoples.

Larry Lehtinen, Executive Chairman and CEO, said: “We are very pleased to have the Scully Mine back in production producing a premium quality sinter feed for the global iron ore market containing in excess of 65.5% iron and less than 2% manganese, 3.0% silica with ultra-low levels of alumina and phosphorous.”

He added: “Congratulations to our teammates at the Scully Mine in Wabush, NL, who are off to a great start building a high-performance organisation based on innovation, variable compensation and productivity. We are grateful to all the stakeholders involved in the Scully Mine restart with a special thanks to our valued logistics partners at SFPPN, Quebec North Shore and Labrador Railroad and the Port of Sept-Iles.”

Primero to work on stacker/reclaimers for BHP South Flank iron ore project

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Primero Group Limited says it has been awarded a “significant contract” at the BHP-owned $4.6 billion South Flank iron ore project in Western Australia.

The ASX-listed company will carry out the pre-assembly of The South Flank Balance Machines for thyssenkrupp Industrial, it said.

thyssenkrupp was awarded the supply and installation of the Balance Machines by BHP in November 2018, Primero said.

Primero’s scope is the pre-assembly of the two stackers and one “off-reclaim machine” at the AMC (Australian Marine Complex), located in Henderson, south of Perth.

The machines will be the largest rail mounted stacker/reclaimers machines to be installed in the world, with a loading capacity of 20,000 t/h.

The contract is set to commence immediately and is expected to be completed in the current financial year, ending June 30, 2020.

Primero said: “The contract award represents another significant win for the company’s Non-Process Infrastructure division and will create up to 60 direct positions locally over the contract period.”