Tag Archives: Ma’aden

Ma’aden and Hexagon partner on Middle East’s first ‘digital mine’ at Mansourah Massarah

Mine operation news, Mineral project development, Mining services, Mining software, Precious metals, Sustainable mining, , , , ,

Ma’aden and Hexagon have partnered to launch what they say is the Middle East’s very first digital mine, with Hexagon’s life-of-mine technology solutions being deployed at Mansourah Massarah mine, combining sensor, software and autonomous technologies to enhance efficiency, productivity, quality and safety across the mine’s operations.

Duncan Bradford, Executive Vice President Base Metals and New Metals, Ma’aden, said: “This partnership strongly aligns with our digitisation strategy, as we work to use the vast amounts of data that we mine to make our mine safer and more efficient. We look forward to working closely with Hexagon to implement and utilise the region’s first digital mine to elevate Mansourah Massarah’s operations.”

Nick Hare, President of Hexagon’s Mining division, said: “We are excited to help bring to life this important shift toward digitisation of the mine, one that holistically leverages intelligent data and automation across workflows to minimise the impacts of mining while simultaneously improving safety, productivity and operational efficiency.

“This is about co-authoring the next chapter of mining in this region with a partner who shares in our drive toward a sustainable future.”

Mansourah Massarah, Ma’aden’s newest, largest, and most technologically advanced gold mine, is in Al Khurmah governorates in Makkah Region. The mine consists of the Mansourah and Massarah resources, which are being developed as conventional open-pit mines. The 4 Mt/y plant employs carbon-in-leach and pressure oxidation processes and autoclave technologies for ore gold production. It reached a major milestone of producing first gold in September 2022, going on to produce 11,982 oz for the year.

Ma’aden receives DNV accreditation for low-carbon ammonia

Energy minerals, Environmental, Sustainable mining, , , ,

Saudi Arabian Mining Company (Ma’aden) has been certified by the international assessor DNV as having produced 614,000 t of ultra low carbon ammonia, representing the largest quantity accredited in the world to date, it claims.

This is a significant step forward in Ma’aden’s plans to grow and transform its business to become an ESG role model in the Kingdom, the company said.

This accreditation highlights Ma’aden’s commitment to operational excellence and increasing its portfolio of premium products as the company positions itself in key global markets at the same time as driving the decarbonisation of supply chains across the fertiliser industry and supporting sustainable food production.

Ma’aden says there is significant potential for it to consolidate its presence as a leading producer of ultra low carbon ammonia. This follows Ma’aden’s ambitious program to ship over 138,000 t of “blue ammonia” to major global markets, including the European Union and China, signalling the company’s growing activity in global value chains.

Robert Wilt, CEO, Ma’aden, said: “We are now at the forefront of supplying the world with a lower carbon fuel source that has potential to support the global energy transition. It’s great to see our plans for growth and transformation not only being realised and putting Ma’aden on a sustainable path for the future, but also having the potential to help drive Saudi Arabia’s green ambitions.”

Geir Fuglerud, CEO of DNV SCPA, said: “This accomplishment stands as a testament to Ma’aden’s dedication to environmental stewardship and its commitment to a sustainable future. This achievement not only aligns with global sustainable developments goals but also demonstrates Ma’aden’s industry leadership position in the Kingdom of Saudi Arabia.”

Ma’aden teams up with Metso, thyssenkrupp Uhde for sustainable phosphate production

Energy minerals, Environmental, Mineral processing, Mining services, Sustainable mining, , , , , ,

The Saudi Arabian Mining Company (Ma’aden) has entered into an agreement with Metso and thyssenkrupp Uhde for the development and licensing of Ma’aden’s Integrated process concept, aiming for greenfield facilities at Ras Al Khair in Saudi Arabia, and the deployment of technology able to capture CO2 and recycle phosphogypsum.

The technology for CO2 capturing comes from the lime produced from the calcination of phosphogypsum using sulphur, leading to a reduction in CO2 emissions across Ma’aden’s phosphate business, making it more sustainable in the long term, it says.

The complex will enable the deployment of an innovative patented concept, which has been officially recognised by the United States Patent and Trademark Office. The patent will allow Ma’aden to use new technology to reduce carbon emissions and reuse phosphogypsum as a useful resource.

Ma’aden’s patented approach is dual purpose, not only contributing to global warming mitigation through sustainable CO2 capturing but also providing a viable solution for recycling phosphogypsum, addressing two of the most pressing environmental challenges facing the phosphate industry – the decarbonisation of polluted CO2 and the effective use of phosphogypsum, a by-product of phosphate production often left in large quantities.

Hasan Ali, Executive Vice President, Ma’aden Phosphate, said: “This pioneering patent, combined with our new CO2 capturing complex, underscores Ma’aden’s commitment to sustainability. We look forward to working with Metso and thyssenkrupp Uhde to develop this important project that will truly change and reduce the carbon footprint of our phosphate business. It puts us at the forefront of innovation, turning what was once leftover material into a valuable resource, while significantly reducing CO2 emissions. It’s a giant leap towards a sustainable future.”

Hannes Storch, Vice President for Metals and Chemicals Processing at Metso, said: “We are excited to see this unique project moving forward. The new concept for the phosphogypsum processing will be a major step forward in the fertiliser industry, contributing to sustainability targets, such as waste recovery and limiting global warming. Metso contributes to the project with our extensive know-how and experience in the field of fluid bed, gas cleaning and sulphuric acid solutions.”

Lucretia Löscher, COO thyssenkrupp Uhde, said: “We are honoured to be chosen from our esteemed customer to provide our technology and expertise. We are providing the innovative process to turn the phosphate industry into a circular economy. This project will be another important milestone for thyssenkrupp Uhde in enabling the green transformation for our customers.”

Ma’aden brings in Darkstone for Mansourah-Massarah TSF contract

Mineral project development, Mining services, Precious metals, Water management, , , , , ,

Saudi Arabian Mining Company (Ma’aden) has awarded Darkstone with a SAR105 million ($28 million) construction contract for the second phase of its Mansourah-Massarah gold mine tailings storage facility (TSF) construction project.

Darkstone Arabia Ltd, a company engaged in industrial mechanical and electrical maintenance, mechanical engineering, civil, construction and MEP works, was awarded the procurement and construction contract by Ma’aden this month, with the engineering portion assigned to ATC Williams, a leader in the provision of solutions for tailings, water and waste, to aid in designing the tailings and water management system.

Mansourah-Massarah is an open-pit mine in the Central Arabian gold region of the Kingdom of Saudi Arabia, approximately 500 km southeast of Riyadh. The project has expected production of 250,000 oz/y of gold over an estimated life of 12 years.

As part of the contract, Darkstone will perform several tasks, including:

  • Construction of the waste management system, including floor and perimeter embankment, piping, mechanical works and HDPE geomembrane;
  • Waste distribution system;
  • Water management system;
  • Conducting laboratory tests; and
  • Carrying out various related activities.

Metso builds out Ma’aden relationship with Mansourah & Massarah LCS contract

Comminution of minerals, Mine operation news, Mineral processing, Mining equipment, Mining services, Precious metals, , , , , , ,

Metso says it has signed a two-year Life Cycle Services (LCS) contract with Ma’aden’s Base Metals and New Minerals company’s new gold processing plant at the Mansourah & Massarah site in Saudi Arabia.

Metso will support the customer in commissioning, ramping up and optimising the new greenfield site, covering both maintenance and plant operations, it says. Other elements of the agreement are field services and recommendations for wear and spare parts management, and advisory and training services.

The agreement demonstrates Metso’s service expertise, and it is an important continuation of the greenfield mineral concentrator and gold processing plant agreement signed in 2019, it said. This contract, related to Outotec at the time, saw a consortium of Outotec and Larsen & Toubro awarded with an engineering, procurement and construction contract to build a greenfield mineral concentrator and gold processing plant in the Kingdom of Saudi Arabia.

The Mansourah & Massarah operation has been built in the Central Arabian gold region, with the processing plant capable of up to 4 Mt/y throughput. The concentrator and the gold processing plant has been designed to produce an average of 250,000 oz/y of gold over the life of mine.

The customer has the option to extend the contract by one year.

Kamal Pahuja, President Middle East and India market area, Metso, said: “We are very delighted with the customer’s continued trust in Metso. By choosing Metso’s Life Cycle Services contract, Ma’aden will receive comprehensive and top-notch service solutions as well as on-site technical expertise and support. We are committed to safety and sustainability objectives and will work with and support the customer in achieving their operational objectives. We are also committed to strengthening our service capabilities in the region to serve the growing customer base.”

Duncan Bradford, Executive Vice-President, Ma’aden Base Metals and Minerals BU, said: “Our aim is to lift the productivity of the new plant to the target level, strengthen the skills of our Saudi employees, and achieve our production and safety targets. The new plant will use three different methods of gold processing, including the first autoclave in Saudi Arabia; this requires a lot of know-how and proactive planning for trouble-free operation and maximum productivity. Metso already has a comprehensive range of key equipment for the plant flowsheet, and we will be able to benefit from Metso’s technological and service expertise.”

Ma’aden and Ivanhoe Electric to embark on milestone exploration program in Saudi Arabia

Mineral exploration, Mining services, , , , , , , , ,

Saudi Arabian Mining Company (Ma’aden) has finalised its agreement with Ivanhoe Electric Inc (IE) to purchase a 9.9% stake in the company and form a 50/50 joint venture to undertake what it says is one of the largest exploration programs ever conducted.

The deal will provide Ma’aden, through the joint venture, with access to IE’s Typhoon™ geophysical survey technology, which will accelerate the exploration of Saudi Arabia’s lands, estimated to hold $1.3 trillion of untapped minerals, the company says.

The two companies flagged this agreement back in January with a signing at the Future Minerals Forum in Saudi Arabia.

Ma’aden’s exploration program is driven by the Kingdom’s Vision 2030, which positions mining as a third pillar of the Saudi economy. Under its new corporate strategy, Ma’aden aims to grow 10-fold by 2040 and to move into strategic minerals to fuel the growth of downstream industries in the Kingdom.

The joint venture (JV) with Ivanhoe Electric will explore at least 48,500 sq.km of land, covering highly prospective licence areas with potential for major new copper, nickel, gold, silver and other strategic mineral discoveries, Ma’aden says. The JV will deploy IE’s proprietary Typhoon technology and CGI software that, it says, will strengthen Ma’aden’s exploration capabilities and grow its resource base and production pipeline.

As part of the agreement, Ma’aden will acquire approximately 10.2 million common shares in IE, representing 9.9% of Ivanhoe Electric Inc, for $126.5 million with a top-up option to maintain its 9.9% ownership. The JV will deploy $66 million of the $126.5 million to fund exploration activities and the purchase of three new generation Typhoon machines. Ma’aden has also been granted the right to appoint a nominee to the IE board of directors.

The formation of the JV and the acquisition of 9.9% shares in IE will only be effective after fulfilling certain conditions.

Robert Wilt, CEO of Ma’aden, said: “We are launching one of the largest exploration programs in the world in partnership with Ivanhoe Electric. It’s great to see companies like IE recognise the scale of the opportunity here. We have only scratched the surface of the potential in the Kingdom, and we need to explore faster, smarter and cover more ground to meet our long-term growth objectives. IE’s Typhoon technology will enable us to accelerate our exploration efforts by six times, and de-risk and advance the development of a significant exploration hub in the Kingdom. This is going to help put us on track to meet our 10x growth targets and fast track development of the Kingdom’s mineral riches.”

Ivanhoe Executive Chairman, Robert Friedland, added: “We are excited to finalise our transaction terms with Ma’aden and begin the important work of minerals exploration in the Kingdom of Saudi Arabia. Our joint venture will embark on the largest exploration program ever conducted using our highly powerful and disruptive Typhoon geophysical surveying system. With our Typhoon technology, our Computational Geosciences’ machine-based learning software, and the combined talents of our highly experienced team of women and men, we have all the tools necessary to conduct a transformational exploration program for electric and precious metals in the Kingdom of Saudi Arabia. The potential for future discoveries is extraordinary.”

TOMRA Mining tech to be used for the world’s largest lithium sorting plant

Energy minerals, Environmental, Mine operation news, Mineral processing, Mining equipment, Mining services, Sustainable mining, , , , , , , , , ,

TOMRA Mining says it is in the process of installing what will be the world’s largest lithium mineral ore sorting plant at Pilbara Minerals’ Pilgangoora project in Western Australia.

The installation has already started and is expected to reach completion in late 2023.

Pilbara Minerals says it owns the world’s largest, independent hard-rock lithium mine, producing a spodumene and tantalite concentrate. Through its P680 Expansion Project, the company has plans to step-up its production run-rate at the operation to a total of circa-680,000 t/y of spodumene concentrate. The sorting plant is part of this project.

Dale Henderson, Managing Director and CEO, Pilbara Minerals, said: “This new facility to be constructed at our Pilgangoora Project will be the world’s largest lithium mineral ore sorting plant. TOMRA’s experience in large global sorting installations, innovative technology and ability to provide local support were significant factors in our decision to work with them. From the start, the TOMRA team has been working side by side with us and our engineering partner DRA Global to deliver this important project.”

As part of this expansion project, Pilbara Minerals turned to TOMRA Mining for assistance to address the key industry challenge in the processing of spodumene feed ore contaminated with barren host rock.

TOMRA has 50 years’ experience in sensor-based sorting technologies and has designed and built 90% of the world’s large-scale mining sorting plants with a capacity above 300 t/h, it says. These include plants such as the Ma’aden Umm Wu’al project, which is operating at 1,850 t/h and the Lucara diamond operation which runs 15 sorters.

Specifically for the Pilbara Minerals project, TOMRA Mining highlighted that it offered effective ore sorting solutions with high sensor resolution and ejection accuracy that ensure high lithium recovery and waste removal with a stable and consistent performance at high capacity.

The TOMRA Mining team conducted a geological assessment of sample ores supplied by Pilbara Minerals. It revealed the pegmatite deposit did have non-lithium bearing host rock intrusions. Some of these minerals have a high density like that of spodumene, which means that it is also concentrated when using heavy media separation (HMS). This reduces the efficiency of the downstream flotation and contaminates the final product. Sensor-based sorting technologies, on the other hand, can measure the colour, density and mineralogical variations in individual particles, enabling the accurate detection and removal of this barren material, the company explained.

Working closely with the Pilbara Minerals metallurgical team, TOMRA conducted extensive test work at the TOMRA Test Center in Sydney, Australia, to check all the options and answer any questions arising during the tests.

The samples were run at capacity on production sorters and included repeatability and variation testing. The test work benchmarked the expected performance of the sorters and was used to establish the sort quality on each of the ore types that will be fed through the plant.

Primero Group, which was awarded the contract for construction of the project, has now started bulk earthworks for the sorting plant.

The TOMRA team was involved not only in the testing and supply of equipment, but also provided assistance with the plant layout and understanding of the implications of sorting on the upstream mining and downstream process of the ore. This involvement throughout the development process will add to efficient operational ramp-up and technical optimisation.

TOMRA’s capability to support the project with a dedicated Australia-based team and a global support structure has been a significant factor and is an important part of de-risking the installation of this new technology. The team is working closely with Pilbara Minerals through the installation process, commissioning and start-up, and will continue to provide on-site support once the sorting plant is up and running.

Metso Outotec, thyssenkrupp Uhde to develop phosphogypsum processing options for Ma’aden

Energy minerals, Mine operation news, Mineral processing, Mining equipment, Mining services, Sustainable mining, , , , , , ,

Metso Outotec says it and thyssenkrupp Uhde have signed a Memorandum of Understanding with Ma’aden in Saudi Arabia for developing a novel circular concept to improve the sustainability of Ma’aden’s phosphate operations.

The aim is to design a groundbreaking integrated complex for processing of phosphogypsum, a waste by-product from phosphoric acid production, to reduce the amount of solid waste and allow the capture of CO2 emissions.

The new circular process will be incorporated into Ma’aden’s phosphate operations to support the company in achieving its ambitious sustainability goals aligned with the Kingdom’s objectives, Metso Outotec said.

For the development of this process, Metso Outotec’s extensive know-how and experience in the field of fluid bed and sulfuric acid solutions will be used.

Hannes Storch, Vice President for Metals and Chemicals Processing at Metso Outotec, said: “We are honoured to be part of this unique initiative. Decarbonisation and circularity are relevant for all industries, and the new concept to be developed for phosphogypsum processing will be a major step forward in the fertiliser industry, contributing to efforts limiting global warming.”

Global Mining Guidelines Group welcomes Ma’aden to its membership

Base metals, Mining industry recognition, Mining services, Precious metals, Sustainable mining, , , , ,

Global Mining Guidelines Group (GMG) has welcomed Ma’aden to its membership, the first mining company from Saudi Arabia to do so.

A fast-growing enterprise that includes a mineral portfolio of phosphate, aluminium, gold, copper and other commodities, Ma’aden continues to diversify its portfolio to encompass a wide range of industries, GMG said.

It added: “The Saudi-based company pioneered the mining industry in the region by creating a fully integrated mining value chain. This has paved the way for the development of the Saudi Arabian economy well into the future, and mining is now the third pillar of Saudi industry, a key pillar in delivering Saudi Arabia’s Vision 2030 economic diversification plans.”

Since its IPO in 2008, Ma’aden has transformed from a small gold producing company to a much larger entity. Capitalising on this momentum, the company has set ambitious goals to continue its growth trajectory by leveraging the country’s mineral deposits, increasing production rates in existing value chains, increasing exploration and adding new strategic minerals to its portfolio.

Heather Ednie, GMG’s Chief Executive Officer, said: “Ma’aden’s growth has been truly remarkable. They’ve become a leading force in the mining industry not only in the region, but globally. Collaboration remains a key component to solving many of the challenges facing the industry today and we’re certain their team of mining experts will bring a vast wealth of knowledge and experience to the Global Mining Guidelines Group.”

Saud Al-Mandil, Vice President, Digitalization & Operational Excellence at Ma’aden, said: “We are pleased to join the Global Mining Guidelines Group and contribute to the advancement of the international mining industry. As we move forward, governance and sustainable reporting will be imperative for the global industry to advance and contribute to the development of industries from food and agriculture to electric vehicles. We will continue to work with our colleagues in the industry to ensure that the mining ecosystem operates in a sustainable and efficient manner.”

In addition to owning a number of mining assets outright, Ma’aden also has a joint venture with Barrick on the Jabal Sayid copper-gold mine in Saudi Arabia (pictured).

Bartram comes back to TOMRA Mining ready for sensor-based sorting demand uptick

Base metals, Comminution of minerals, Diamond mining, Energy minerals, Environmental, Mineral processing, Mining equipment, Mining people, Mining services, Sustainable mining, , , , , , , , , ,

Having left TOMRA Mining more than a decade ago only to return to the Germany-based company in November, Kai Bartram’s re-arrival at the sensor-based sorting firm represents a good time to take stock and reflect on how far the mining sector has come with its understanding and acceptance of this type of pre-concentration technology.

Bartram, now Global Sales Director of TOMRA Mining and a member of TOMRA’s Mining Management Team, was happy to answer some of IM’s questions after getting his feet back under the table in the company’s offices in Wedel, Germany.

IM: How has the mining industry’s appreciation of the benefits of sensor-based ore sorting changed since you left TOMRA in 2010? What trends have led to a wider take up of the technology?

KB: In 2010, sensor-based sorting (SBS) was still seen as a niche technology in the mining industry. Some smaller, more innovative mining companies had seen the potential and effectively implemented SBS, but the mining industry, as such, had not accepted the technology. While in the industrial minerals sector several optical sorters – and, in the diamond industry, mainly X-ray luminescence machines – were operating, the rest of the industry was cautious about integrating sorters into their flowsheets.

That changed slowly with the introduction of Dual Energy X-ray technology. The technology is so robust and perfectly suited to the harsh environment of the mining industry that the economic benefits of pre-concentration became obvious. Another point that has strongly supported the adoption of sorting technology is the fact that average ore grades keep decreasing while energy costs keep increasing.

IM: Diamond and industrial mineral operations were typically the first adopters in the mining sector; what commodity sectors do you expect to see dominate demand for sensor-based ore sorting systems into 2030? What changes to the technology or wider industry understanding have led to this belief?

KB: In the beginning, sorters were seen as small machines, which would never meet the capacity requirements of large hard-rock mineral processing circuits. Therefore, only small mines saw the opportunity to implement sorting as a pre-concentration step in their process. Today, we see that our 2.4-m-wide flagship sorter, TOMRA COM XRT 2.0, can process up to 500 t/h, so that large operations can also implement the technology. An example of such a trend is the Ma’aden Phosphate Umm Wu’al processing plant, where 2,000 t/h are processed with TOMRA XRT sorters.

I am sure we will see more of these bigger projects in many different commodities. Of course, the current market trend is towards ores that are required for the electric revolution, like lithium, copper, cobalt and rare earth elements. TOMRA has proven that we have the right solution to upgrade those ores efficiently and can contribute to more economical output. So, I expect to see more installations in the future.

The TOMRA COM XRT 2.0 units can process up to 500 t/h

IM: Are there any regions more willing to apply these solutions than others? Why is this the case?

KB: If you look at our global reference list, you can see that the larger installed base resides in Europe, Africa and the Americas. The Asian markets are a little behind, but this is easily explained by history. As a European company, we focused more on the better known and established markets. In general, the mining market is a very global industry with big players active in all continents.
I do not believe there are regions more willing to apply the technology than others. It is just a matter of supporting all regions in the same way. TOMRA is investing heavily to ensure we have a good global support network, to be there for and with our clients.

IM: Do you expect to see more collaboration with OEMs over the next decade when it comes to implementing ore sorting solutions with process flowsheets? How do you see the input of both TOMRA and OEMs benefitting the wider mining industry?

KB: Collaboration is essential in any industry. We need specialists who are experts in their field, and TOMRA is one of the global leaders in sensor-based sorting. In order to achieve the best results in one field, one must focus. Therefore, big projects can only be undertaken by a group of companies or experts who collaboratively work together. We, as a solution provider, are very dependent on well-engineered and integrated plant designs and believe we have to collaborate and have close relationships with plant builders to ensure the best possible solution for our clients.