Tag Archives: magnetite

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

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

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

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

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

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

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

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

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

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

Weir adds aftermarket and service contract to Iron Bridge remit

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

The Weir Group says it has won a £95 million ($127 million) order to provide aftermarket components and service to the Iron Bridge magnetite project in Western Australia.

The aftermarket contract follows Weir’s success in winning a record £100 million order for original equipment for the Iron Bridge project in 2019, including its Enduron® High Pressure Grinding Rolls (HPGRs, pictured) that, it says, will enable dry processing of ore and use at least 30% less energy than traditional alternatives.

The Iron Bridge magnetite project is a $2.6 billion joint venture between Fortescue Metals Group’s subsidiary FMG Magnetite Pty Ltd and Formosa Steel IB Pty Ltd located in the Pilbara region, around 145 km south of Port Hedland.

Both the aftermarket order and revenues will be recognised over the seven-year period of the agreement, which starts in 2022, in line with the 22 Mt/y project’s initial production.

Ricardo Garib, President of Weir Minerals, said: “This is another landmark order for Weir. Having helped design an energy and water efficient magnetite processing plant, we are delighted to provide operational support for Iron Bridge from 2022. It is an excellent example of the value that Weir’s innovative engineering and close customer support can create for all our stakeholders and reflects the key role we have to play in making mining operations more sustainable and efficient.”

Weir’s Enduron HPGRs are increasingly replacing conventional mills in comminution circuits, Weir says. In addition to their energy and water savings, they also reduce grinding media consumption, while their wearable components last longer, reducing maintenance costs. Additionally, HPGRs contribute significantly to carbon dioxide emission savings.

Stuart Hayton, Managing Director of Weir Minerals Netherlands, where the Enduron HPGRs are designed and manufactured, said: “This is an important project for Weir and for the broader mining industry. We know comminution is one of the most energy intensive parts of the mineral process and, with our Enduron HPGRs, we have a unique ability to offer significant cost, energy and water savings to customers around the world. As the mining industry evolves, we are commited to continuing to innovate, reducing miners’ costs and environmental impact.”

This latest contract award means Weir now has more than £200 million of orders from the Iron Bridge project including its Enduron HPGRs, GEHO® and Warman® pumps, Cavex® hydrocyclones and Isogate® valves.

To support the project and future growth, Weir says it will build a new service centre in Port Hedland, Western Australia, thereby providing employment and training opportunities in the area, with a particular emphasis on supporting greater Aboriginal representation in the broader mining workforce.

Pindan lands design and construct contract at Iron Bridge

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

Integrated property and construction group, Pindan, says it has been awarded another contract for works linked to the Iron Bridge Magnetite project in the Pilbara of Western Australia.

Iron Bridge, an unincorporated joint venture between Fortescue Metals Group subsidiary FMG Iron Bridge and Formosa Steel IB Pty Ltd, have awarded Pindan a A$3.6 million ($2.6 million) contract to design and construct the $2.6 billion project’s landside airport, it said.

Pindan Executive Director, Tony Gerber, said this new scope of work would kick off in October and was due to be finished by the end of the year.

“We have a long and successful history of working in this part of Western Australia and are already on the ground at Iron Bridge, having been awarded a A$3.4 million contract in June this year to design, supply and install a number of office buildings, as well as deliver associated infrastructure, at Fortescue’s Herb Elliot Port facility in Port Hedland,” Gerber said.

“This contract sees us manage civil works, design, and roadworks, and supply all resources, support facilities, labour and materials for this part of the project. It also includes the construction of a communications tower for the airport terminal building, as well as fitting out the airport.”

Iron Bridge is a new magnetite ore processing facility located 145 km south of Port Hedland. The project is on track to create around 3,000 jobs during construction and 900 full-time operational positions, and will deliver a premium product of high grade 67% Fe magnetite concentrate product with the first ore on ship scheduled for mid-2022.

Decmil captures NPI contract at Iron Bridge Magnetite project

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

Decmil Group says it has been awarded a circa-A$41 million ($30 million) contract to undertake non-mining process infrastructure works at the Iron Bridge Magnetite project in the Pilbara region of Western Australia.

Construction is scheduled to commence in September 2020 and be completed by May 2021.

Under the scope of works, Decmil will design and construct a bulk fuel storage and transfer facility, a mobile maintenance complex, including workshops, warehouses and related satellite office and site services facilities.

The bulk fuel storage and transfer facility will provide a refuelling facility for heavy vehicles, while the mobile maintenance complex includes a heavy vehicle workshop that incorporates locker storage, tool storage and an administration area, Decmil said.

The $2.6 billion Iron Bridge Magnetite project, owned by Fortescue Metals Group subsidiary FMG Iron Bridge Ltd and Formosa Steel IB, is expected to see a new magnetite mine developed to support production of 22 Mt/y of high grade concentrate, according to Fortescue. First concentrate is expected to be produced by mid-2022.

Decmil’s agreement is the latest in a stream of contracts the JV has issued recently, including the award of a wet processing plant build to CPB Contractors, a civils contract awarded to Civmec to build the structural concrete components for the dry plant at the project, and PROK’s contract for the design, manufacture and supply of conveyor pulleys at Iron Bridge.

Decmil CEO, Dickie Dique, said the company was delighted to secure works at one of Australia’s most significant mining projects.

“Crucially, this award at such a major project enhances our credentials to potentially secure more work in a resurgent iron ore and magnetite sector,” Dique said.

Fortescue Metals granted approval to expand iron ore capacity at Herb Elliott

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

Fortescue Metals Group says it has received approval from authorities to increase the material handling capacity of its Herb Elliott Port facility, in Western Australia, from 175 Mt/y to 210 Mt/y on a staged basis.

The approval, under the West Australian Environmental Protection Act 1986, includes provisions for 188 Mt/y of hematite ore and 22 Mt/y of magnetite concentrate. The high-grade magnetite product will be produced from the Iron Bridge magnetite operations, with first ore on ship from Iron Bridge scheduled for mid-2022.

The revised licence uses the capacity of Fortescue’s existing port infrastructure, comprising five berths and three ship loaders, and supports its 2021 financial year iron ore shipments guidance of 175-180 Mt.

Chief Executive Officer, Elizabeth Gaines, said: “Fortescue’s port operations are world leading and we have continually demonstrated our capacity to optimise the efficiency and productivity of our port infrastructure to deliver iron ore to our customers.

“The increase in the licensed capacity of Fortescue’s Herb Elliott Port from 175 Mt/y to 210 Mt/y is in line with our strategy to deliver growth through investment, including the $2.6 billion investment in the Iron Bridge project. This significant project will deliver 22 Mt/y of high-grade magnetite product, enhancing the range of products available to our customers through our flexible integrated operations and marketing strategy.

“We will continue to ensure that Fortescue remains a significant long-term contributor to the state and national economies through growth and development of our iron ore assets, job creation and investment.”

Fortescue says it maintains a high level of vigilance over its management of dust in Port Hedland, with installation and implementation of additional controls ensuring no net increase in dust emissions as a result of the progressive increase in throughput capacity at Herb Elliott.

Civmec to build foundations for key Iron Bridge processing equipment

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

Civmec’s Metals and Minerals division has been awarded a standalone civil contract to build the structural concrete components for the dry plant at the jointly-owned Iron Bridge magnetite project in the Pilbara of Western Australia.

The “Dry Plant Detailed Earthworks and Concrete” package was awarded by the owners of the project, Fortescue Metals Group subsidiary, FMG Iron Bridge Ltd, and Formosa Steel IB.

The project will see a new magnetite mine developed to support production of 22 Mt/y of high grade, magnetite concentrate product.

Civmec’s scope includes constructing the structural concrete components for the primary, secondary and tertiary crushing areas, screening areas, air classification and primary grinding areas, course ore stockpile, dry rejects, conveyors and all related earthing. It will involve over 350,000 cu.m of earthworks, the fixing of some 5,000 tons (4,536 t) of steel reinforcement and the placement of around 38,000 cu.m of concrete.

These works will employ over 200 of Civmec’s skilled workforce at peak, plus a commitment to engage with Local Aboriginal Enterprises, Civmec said, adding that the works will commence immediately with an expected completion in the March quarter of 2022.

Civmec’s Chief Executive Officer, Patrick Tallon, said: “Through our current delivery of works for Fortescue in the Pilbara, we have formed a strong working relationship built on transparency, trust and collaboration and reliable execution. Hence, we are extremely pleased to be given this further opportunity to continue to work with Fortescue on the Iron Bridge project.

“This is an exciting project of a very significant scale with a declared value for the overall project being $2.6 billion. The Iron Bridge joint venture has demonstrated and refined each step of the magnetite ore processing system and conducted full-scale trials to ensure the effectiveness of the process and gain confidence in the overall project success.”

This most recent contract award, combined with some other recent awards and scope increases on existing contracts, take the group’s current order book to circa-A$901 million ($625 million).

PROK conveyor pulleys to feature at Fortescue’s Iron Bridge magnetite project

Bulk handling, Equipment maintenance, Mineral project development, Mining consumables, Mining equipment, Mining services, Steel and iron ore, , , , , , , , ,

Global conveyor components manufacturer PROK has been awarded a major contract for the design, manufacture and supply of conveyor pulleys at the Iron Bridge Magnetite project, a joint venture between Fortescue Metals Group subsidiary FMG Iron Bridge and Formosa Steel IB Pty. Ltd, near Port Hedland in Western Australia.

PROK will produce around 170 complete pulleys from its Bayswater production facility in Perth, Western Australia. The pulleys will be installed across 25 new conveyors at the Iron Bridge site.

PROK says it is an expert in conveyor equipment and specialises in solutions that help mining companies across the globe keep their conveyor systems running efficiently and safely.

PROK General Manager, Wade Guelfi, said the Iron Bridge contract award highlighted PROK’s high level of technical capability and manufacturing experience.

“As a recognised leader in large engineered pulleys, we were a perfect fit for this type of project,” he said. “Our advanced in-house engineering team worked closely with the client to design a pulley solution that meets all project requirements.”

The pulleys range in sizes from 500-1,200 mm diameter and will be delivered in six stages starting in January 2021, the company said.

The contract forms part of Stage 2 of the Iron Bridge project, which involves construction of a large-scale process plant and port infrastructure to support 22 Mt/y (wet) of magnetite production. Stage 1 (pictured), completed successfully, was achieved by building and operating a full-scale pilot plant at the North Star mine site. This pilot project included the use of a dry crushing and grinding circuit, which FMG plans to leverage in stage two.

In FMG’s March quarter results, released late last month, the company said the $2.6 billion project was progressing on schedule and budget, with first concentrate production planned in the first half of calendar year 2022.

“We are excited to be part of this project and proud to be supporting Fortescue with heavy-duty engineered pulleys manufactured right here in Western Australia,” Guelfi added. “We look forward to working closely with FMG as the project progresses.”

Cundaline Resources to work on Iron Bridge magnetite project

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

Fortescue Metals Group has awarded 100% Aboriginal owned company, Cundaline Resources Pty, with the contract for the West Canning Basin earthworks at its majority owned Iron Bridge magnetite project, in Western Australia.

The award, which continues FMG’s longstanding commitment to supporting local and Aboriginal businesses, will see the group carry out the earthworks, access preparation and rehabilitation services associated with the hydrogeology drilling program for the Iron Bridge project.

The Iron Bridge project will deliver 22 Mt/y (wet) of high grade 67% Fe magnetite concentrate product, according to FMG, with the first stage completed successfully by building and operating a full-scale pilot plant at the North Star mine site. This pilot project included the use of a dry crushing and grinding circuit, which FMG plans to leverage in stage two.

The second stage of the project comprises the construction of a large-scale process plant, and port infrastructure to support the production of 22 Mt/y (wet) of iron ore.

In FMG’s March quarter results, released late last month, the company said the $2.6 billion project was progressing on schedule and budget, with first concentrate production planned in the first half of calendar year 2022.

Key milestones in the three-month period included detailed engineering passing the halfway mark, procurement of major long lead process equipment committed and the first blast at the ore processing facility site, enabling bulk earthworks to commence.

Fortescue’s Chief Executive Officer, Elizabeth Gaines, said Fortescue’s Aboriginal procurement initiative, Billion Opportunities, has awarded over A$2.5 billion ($1.6 billion) in contracts and sub-contracts to Aboriginal businesses and joint venture partners since the program began in 2011.

“We are committed to building on this proud track record through our growth projects, Eliwana and Iron Bridge, which have already awarded over A$60 million in contracts to Aboriginal businesses,” she said.

“Importantly, Billion Opportunities is focused on building the capability and capacity of Aboriginal businesses, and it is very pleasing to see Cundaline, a business which commenced operations as a labour hire company, now expand into earthworks and mechanical maintenance contracting areas.”

Cundaline’s Managing Director, Brenden Taylor, said: “The West Canning Basin Earthworks contract is a milestone project and the first of a number of potential opportunities on the Iron Bridge magnetite project for Cundaline.

“We have worked hard to transition our company from a labour hire specialist to a contracting entity managing and delivering our own projects. I am particularly proud of my team for their professionalism and ‘can do’ attitude and not giving up during the tough times.

“Along this journey we have worked together with other Aboriginal businesses and I especially want to acknowledge Fortescue, through the Billion Opportunities initiative, for making a real difference for a local and Aboriginal business like Cundaline to continue to grow our capacity and capability into the future.”

NRW Holdings wins bulk earthworks assignment from Iron Bridge project partners

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

NRW Holdings is about to mobilise a team to carry out bulk earthworks at Fortescue Metals’ majority-owned Iron Bridge magnetite project in Western Australia.

The contractor confirmed it had received a notice of award for the bulk earthworks assignment from the Iron Bridge joint venture (between FMG subsidiary FMG Iron Bridge and Formosa Steel IB) and, while the award remained subject to finalisation, it had been directed to commence mobilisation.

The $2.6 billion Iron Bridge project will see the development of a new magnetite mine (including processing and transport facilities) and associated infrastructure. It will support production of 22 Mt/y (wet) of high grade (67% Fe), magnetite concentrate product, according to the partners. Production is expected by mid-2022. The Iron Bridge site comprises the North Star, Eastern Limb, Glacier Valley and West Star magnetite iron ore deposits and is 145 km south of Port Hedland.

The contract scope for NRW includes the bulk earthworks and drainage for roads, processing plant and infrastructure for the new mine site development. The contract value is around A$70 million ($47 million) and is expected to have a duration of around 45 weeks, NRW said. At its peak, there will be some 200 site based personnel required for the project.

NRW’s CEO and Managing Director, Jules Pemberton, said: “NRW is pleased to be involved in this exciting new project with Fortescue and looks forward to its successful execution.”

Fortescue continues to invest in power options for Iron Bridge development

Environmental, Mineral project development, Power supply for mines, Steel and iron ore, , , , , , , , ,

Fortescue Metals Group is to invest $450 million as part of a program that will see hybrid solar gas energy delivered to the under-construction Iron Bridge magnetite project in the Pilbara of Western Australia.

The Pilbara Generation project – as it is called – is the next stage of its Pilbara Energy Connect program, the company said. This complements the $250 million Pilbara Transmission project, announced in October 2019, and will provide low cost power to the energy efficient Iron Bridge project.

The $2.6 billion Iron Bridge Magnetite project is expected to deliver 22 Mt/y of high-grade 67% Fe concentrate production by mid-2022.

The Pilbara Transmission project consists of 275 km of high voltage transmission lines connecting Fortescue’s mine sites, while the Pilbara Generation project will include 150 MW of gas-fired generation, together with 150 MW of solar photovoltaic generation. This will be supplemented by large scale battery storage and will be constructed, owned and operated by Fortescue, the company said.

Together, the transmission and generation projects, totalling $700 million of investment, form the Pilbara Energy Connect program of works providing Fortescue with a hybrid solar gas energy solution that will enable low cost power to be delivered to Iron Bridge. “This allows Fortescue to leverage its existing energy infrastructure including the Fortescue River Gas Pipeline and generation capacity at the Solomon power station and support the incorporation of large scale renewable energy,” the company said.

The Pilbara Energy Connect project builds on the Chichester Solar Gas Hybrid project which was announced last year. This landmark agreement with Alinta Energy will see up to 100% of daytime stationary energy requirements of the Chichester Hub iron ore operations powered by renewable energy.

Alinta will build, own and operate the 60 MW solar PV generation facility at the Chichester Hub and 60 km transmission line linking the Christmas Creek and Cloudbreak mining operations with Alinta Energy’s Newman gas-fired power station. On completion, this will integrate with the Pilbara Energy Connect program, via the Pilbara Transmission project.

Chief Executive Officer, Elizabeth Gaines, said: “Mining is a 24/7 operation and efficient, reliable, competitive energy generation remains an important consideration for the mining sector in Western Australia. The lack of an integrated transmission network in the Pilbara has been a key barrier to entry for large scale renewables and Fortescue’s investment will address this issue.

“Fortescue’s commitment of $700million in electricity generation and transmission infrastructure will complete the integration of Fortescue’s stationary energy requirements in the Pilbara into an efficient network, while lowering the overall cost of electricity to existing and future sites.

“By installing 150 MW of solar PV as part of the Pilbara Generation project, the modelling indicates we will avoid up to 285,000 t of CO2/y in emissions, as compared to generating electricity solely from gas.

“Importantly, Pilbara Energy Connect allows for large scale renewable generation such as solar or wind to be connected at any point on the integrated network, positioning Fortescue to readily increase our use of renewable energy in the future.”

Pilbara Energy Connect builds on Fortescue’s previous energy initiatives, including the construction of the Fortescue River Gas Pipeline, the conversion of the Solomon Power Station from diesel to gas generation, as well as a partnership agreement with the Commonwealth Scientific and Industrial Research Organisation (CSIRO) to develop and commercialise hydrogen technology.