Tag Archives: Karara Mining

NRW equips Karara magnetite mining fleet with two new Cat 6060 shovels

NRW Civil & Mining has recently invested in two new Cat 6060 hydraulic mining shovels to meet some unique challenges at Karara Mining’s magnetite project in Western Australia’s Midwest region, engaging Cat dealer WesTrac in the process.

Karara is the largest mining operation and the first major magnetite mine in the Midwest region, producing a premium, high-grade concentrate product which is exported from Geraldton port.
Unlike the more commonly mined hematite, magnetite is a hard and highly abrasive ore, which meant NRW needed machines that could cope with the rigours of operating in such harsh conditions.

NRW opted for the Cat 6060 Hydraulic Mining Shovel, a 600-t unit able to load 218 t trucks and above.

According to NRW Mining Operations Manager, Adam Harper, the buying decisions for a mining contractor are very much driven by client expectations.

“We’re obviously chasing safe machines, but they have to be able to perform to our clients’ expectations and do so efficiently,” Harper said.

According to WesTrac Product Manager, Greg Wear, the Cat 6060 is a premium Caterpillar® offering when it comes to hydraulic mining shovels and has traditionally been the shovel of choice for top tier miners.

“This is the machine that we promote for highly productive loading of 240 ton (218 t) trucks and up,” Wear said. “Tier One miners have had good success with that and, now with NRW onboard, it shows that mining contractors are also seeing the value of the Cat 6060.”

Wear explains that the 600-t models have a long history, having first been released to market under previous owner Terex as the RH340 in 2004. Since being acquired by Caterpillar, the machine has been progressively “Catified” through a series of phased improvements.

“Over the past 10 years, Caterpillar has made phased improvements,” he said. “Phase one was a lot of quick wins that could be applied to make the machine more reliable. Phase two looked at structural changes designed to provide stronger, heavier frames and more reliability. Phase three continued that with modifications around sticks and booms, and a completely new superstructure and larger slew ring.

“Today with all the next generation technology, the transformation is complete with all Cat electronics and parts, and there’s been a new cab installed. Now the 6060 has the complete Caterpillar feel and functionality.”

Part of the new cab design was increased visibility, allowing the operator clear views to the digging and loading areas as well as the tracks.

Caterpillar Product Application Specialist, Dirk Tegtmeier, said the transformation of the Cat 6060 brings the same level of commonality to the large shovel that is seen across other Cat equipment.

Tegtmeier says a key efficiency gain, thanks to the 6060 now incorporating all-Cat components and improved structures, is that service intervals and the total operating life of the machine can be extended.

“The updated Cat 3512E engine, coupled with the fuel burn saving features, thanks to new hydraulic optimisation, will certainly offer a longer life than with the previous version,” he said.

That longevity, coupled with the added strength and Cat Enhanced Motion Control as part of the Operator Assist functionality of the Cat 6060, is important given the harsh terrain in which the new mining shovels are operating and the need to meet high production targets – with a minimum feed rate to the primary crusher of 3,500 t/h.

“The 6060 FS comes with an extremely productive profile that enabled us to match the client’s production schedules perfectly,” Harper said. “We also chose the Cat 793 trucks that are perfectly matched for size and passing with the 6060, so it’s a highly productive match. But we needed to ensure we had the reliability as well.”

Karara’s proximity to Geraldton and Perth – two and four-hour drives from the mine, respectively – and the fact WesTrac has parts and service centres in those locations, was another key factor in NRW’s decision to go for the Cat 6060.

According to Harper, the hardness and abrasiveness of the magnetite ore means ground engagement tools can wear up to 20 times faster than in hematite mining operations, meaning regular access to spares is vital.

“The teeth on the bucket can need replacing within 24 to 70 hours, whereas in some hematite mines, it could be anywhere from 500 to 1,000 hours,” Harper said.

“Having the customer service centre four hours away in Perth that runs 24/7 is crucial as it means we are able to get access to parts as needed. Also, WesTrac Geraldton being two hours away for support was really a deciding factor for us in choosing the Cat 6060s.”

Harper says NRW’s previous experience working with Cat equipment and existing relationship with WesTrac was one factor that helped win the contract with Karara Mining.

“Karara Mining Limited had a long association with Cat products, in particular the 6060 face shovels and the 793 dump trucks, and that played a big part in helping win the contract,” he said.

Terra Nova to supply new stacker to Karara Mining’s magnetite operation

Terra Nova Technologies Australia (TNT Australia) says it has been awarded the replacement tailings stacker contract by Karara Mining Ltd at its magnetite mine, 200 km southeast of Geraldton in Western Australia.

Karara Mining is the largest mining operation and the first major magnetite mine in the Mid-West of the state. It produces a premium, high-grade concentrate product for export to steelmakers with an expected mine life in excess of 30 years.

The scope of supply will be to replace an existing stacker, TNT Australia said.

In partnership with TNT’s sister company, e2o, a subsidiary of Clough, the contract will include the supply of a new “fit for purpose” heavy-duty stacker able to withstand the rigours of a high-capacity mining environment along with the associated civil works, installation, commissioning and removal of the existing stacker.

This contract will be completed by TNT Australia and e2o, working in partnership as part of the Murray & Roberts ownership group.

The replacement stacker project, which commenced last month, is required to be concluded within 2022 in order to meet Karara’s schedule requirements.

NRW cements Karara Mining services contract

NRW has followed up on a letter of intent with Karara Mining Limited for mining services works at the Karara Iron Ore mine in Western Australia, sealing a formal contract with the company.

The contract value is circa A$702 million ($502 million) over a five-year duration, with the project workforce averaging an estimated 250 personnel.

Located 200 km southeast of Geraldton in the Shire of Perenjori, Karara is the largest mining operation and the first major magnetite mine in the Mid West. It produces a premium, high-grade concentrate product for export to steelmakers.

With an expected mine life of 30-plus years, Karara’s operation includes a large open-pit mine, complex ore processing and beneficiation plant and significant infrastructure and logistics networks.

The works to be performed include load and haul, drill and blast and run of mine re-handling with the drill and blast component to be undertaken by NRW’s wholly owned subsidiary, Action Drill & Blast Pty Ltd.

In addition, the work includes train loading and rehandling of the product stockpiles together with miscellaneous dayworks at the mine site, camp and access roads.

Key mining equipment required for the project including three 600 t excavators and a fleet of 220 t trucks is being progressively mobilised to site for commissioning, with works commencing in March 2022.

NRW Chief Executive Officer, Jules Pemberton, said: “I am delighted that NRW has now been formally awarded the contract and I look forward to a long and successful partnership with Karara Mining.”

Karara Chief Executive Officer, Changjiang Zhu, said: “NRW is an established Western Australia-based mining and civil contractor with extensive open-cut mining experience gained through a number of successful mining operations in the state. Offering new prime equipment, NRW has the capability to undertake the entire Karara scope of work comprising a broad range of mining, construction and engineering services. We look forward to commencement of mining services early next year.”

NRW in line for A$702 million Karara Mining iron ore gig

NRW has received a letter of intent from Karara Mining Ltd to carry out mining services works at the Karara iron ore mine in the Gascoyne region of Western Australia.

Subject to reaching agreement with Karara, the anticipated value of the contract is around A$702 million ($529 million) over a five-year duration with a project workforce averaging circa-250 personnel.

MACA, through its recently acquired Mining West business, currently holds the contract mining agreement at Karara.

The works to be performed include load and haul, drill and blast, and run of mine re-handling. The drill and blast component will be undertaken by NRW’s wholly-owned subsidiary, Action Drill & Blast Pty Ltd. In addition, the work includes train loading and re-handling of the product stockpiles together with “miscellaneous day works” at the mine site, camp and access roads.

Karara is the largest mining operation and the first major magnetite mine in the Mid West region. It produces a premium, high-grade concentrate that it exports to steelmakers.

“With an expected mine life of 30-plus years, Karara’s operation includes a large open-pit mine, complex ore processing and beneficiation plant and significant infrastructure and logistics networks,” NRW said.

NRW estimates an equipment capital expenditure of around A$170 million to be progressively spent over the term, which will include the purchase of three 600 t face shovel excavators and a fleet of 220 t trucks.

NRW CEO, Jules Pemberton, said: “With a strong local presence in the area through our Geraldton-based DIAB Engineering business and our mining contract with Gascoyne Resources at the Dalgaranga mine site, we look forward to continuing to support the existing and highly experienced workforce on site through this transition, as well as creating employment opportunities for the Gascoyne region community.”

Karara CEO, Changjiang Zhu, said: “NRW is an established Western Australia-based mining and civil contractor with extensive open-cut mining experience gained through a number of successful mining operations in the state. Offering new prime equipment, NRW has the capability to undertake the entire Karara scope of work comprising a broad range of mining, construction and engineering services.

“We look forward to negotiation of an agreement with NRW and commencement of mining services early next year.”

Karara Mining to stack tailings high to keep costs, water use and footprint low

Bis, FLSmidth and Karara Mining have developed a “unique mobile stacking conveyor” solution that has cut water use, costs and the environmental footprint at the iron ore miner’s operation in Western Australia.

If Karara’s iron ore mine had chosen a wet tailings storage facility, the tailings pond would have been roughly 8 sq.km based on its 30-year mine life, according to FLSmidth.

The operation is also in the Mid-West region of Western Australia, an area with scarce water reserves, so losing so much water to wet tailings would have been costly to both the environment and Karara’s bottom line.

With these factors in mind, Karara looked at implementing a dry-stacked/filtered tailings system to allow for significant water recovery and reuse. As well as reducing costs, dry stack technology would reduce the tailings footprint to around 4 sq.km, according to FLSmidth.

Bis worked with Karara and FLSmidth to develop a solution to build, own, operate and maintain a “unique mobile stacking conveyor”, FLSmidth said. This fixed infrastructure solution was developed by the three companies to integrate a walking conveyor and stacking technology normally used in large-scale copper mining operations.

Aside from the significant reduction of the physical footprint compared with the wet tailings alternative, Karara was looking for cost efficiencies in other areas, FLSmidth said. “For instance, the planning of a wet tailings storage facility needs to factor in an ongoing maintenance strategy. This comes with a perpetual cost that can only be guessed at while the decades pass,” the company said. “With dry-stack tailings, the total cost of ownership over the mine’s lifetime is easier to estimate and Karara were confident the dry stack solution would be cost competitive.”

Water usage was another key consideration for Karara. With environmental and cost factors in mind, Karara wanted to look at ways to have greater control over water assets on site. The ability to reuse and recycle water in the mining process would lead to substantial cost efficiencies by minimising the amount of makeup water needed for the mining operation, FLSmidth said.

The technology implemented into Karara’s tailings storage facility was also an important factor as Karara wanted the flexibility to continually update the equipment with the view of running it more efficiently as new technology became available. It engaged Bis to operate the facility machinery based on its deep industry experience with materials handling and bulk logistics, FLSmidth said.

FLSmidth, meanwhile, was identified by Karara as being able to meet the project’s requirements and mine-specific needs.

The mining OEM said: “A primary demand was the ability to supply a cost-effective dry stacking technology ideal for dry climate mining operations that reduced water requirements. With FLSmidth’s advanced stacking capability (machinery working off stacked pile) and ability to stack tailings at 15% moisture content, this meant tangible water savings for Karara.

“At Karara, the dry tailings will be stacked in four lifts to the maximum height approved by the Western Australia Government. The solution proposed by FLSmidth also created a smaller tailings storage footprint, which also meant improved site rehabilitation potential.”

Karara worked closely with Bis and FLSmidth to get the project off the ground and make Karara the first mine in Australia to take full advantage of this dry-stack technology, FLSmidth said.

The tailings storage facility is fast approaching the completion of Lift 1 and, together with Karara, Bis and FLSmidth are already in the planning stage to lift the equipment to the second level.