Tag Archives: Mineral Technologies

Chemours cuts ribbon on Trail Ridge South mineral sands mine

The Chemours Company has held a ribbon cutting event for key community stakeholders and legislators to officially recognise the startup of its newest mineral sand mine, Trail Ridge South, in Florida, USA.

The new mining operation, which kicked off commissioning in August, represents a $93 million investment that will create approximately 50 new jobs in the three-county area.

The project to expand its mining operations will allow Chemours – the only domestic producer of titanium and zirconium minerals and one of only two domestic producers of rare earth minerals – to have additional access to these high-quality concentrated deposits used to produce Chemours’ Ti-Pure™ brand of titanium dioxide (TiO₂).

“A reliable supply of quality ilmenite and other minerals is critical to our ability to serve customers,” Mark Smith, Vice President of Operations for Chemours Titanium Technologies, said. “Sourcing those resources from a community we’re already so deeply connected to makes it even better – it’s a win-win. We’re incredibly proud to call Clay County home and look forward to many years of safe operations and partnership.”

Chemours’ sand mining approach uses environmentally responsible processes that have minimal impact on the environment and provides for full land reclamation when mining is complete, the company says. Constructed in approximately 13 months, the Trail Ridge South facility was designed using a modularisation concept, where modules were built off-site and then shipped to the site for assembly. Modularisation allows the facility to be more easily moved in a shorter timeframe at the end of the mining life of the site, which is anticipated to be approximately eight years.

The new mining facility took 150,000 man-hours to construct with zero recordable injuries. In addition, the site’s leaders worked closely with regulatory agencies to obtain required permits and ensure there was no adverse impact to the environment.

In addition, Trail Ridge South will incorporate Mobile Mining Units (MMUs) designed by Carrara, Queensland, Australia-headquartered Downer company Mineral Technologies that address environmental concerns with traditional dredge mining. The MMUs allow the site to have much lower emissions, reduced dust levels, and improved safety by removing conventional hauling trucks. In addition, the facility will recycle 98% of the water used in the manufacturing process – providing sustainable solutions while still meeting the Chemours’ commitment to process minerals. Trail Ridge South process water and water treatment ponds are all constructed above ground, with approximately 39 million gallons (177.3 million litres) of storage capacity.

Chemours kicks off commissioning at Trail Ridge South mineral sands mine

The Chemours Company has begun commissioning its newest mineral sand mine, Trail Ridge South, in Florida, USA.

The new mining operation represents a $93 million investment that will create approximately 50 new jobs in the three-county area, and will incorporate Mobile Mining Units (MMUs) that were previously tested out at the company’s Jesup, Georgia mining site, allowing for reduced dependency on traditional dredge or truck and shovel mining processes.

Commissioning work to test operational aspects of the new mine has begun, with startup anticipated later this year. Expansion of its mining operations will allow Chemours – the only domestic producer of titanium and zirconium minerals and one of only two domestic producers of rare earth minerals – to have additional access to these high-quality concentrated deposits used to produce Chemours’ Ti-Pure™ brand of titanium dioxide (TiO₂).

“The commissioning of our new Trail Ridge South mine is much more than an operational milestone – it represents a huge win for our customers, community, and our country,” Jody Sciance, co-Director of Minerals Operations for Chemours, said. “This secure, domestic mineral supply means more tonnes of TiO₂ for our pigment customers, more jobs for Clay County residents, and access to critical materials identified by the U.S. Department of the Interior as vital to our nation’s security and economic prosperity – all with minimal impact on our local environment. We are extremely proud to expand our footprint in Florida and look forward to partnering with this community for years to come.”

The MMUs to be used at Trail Ridge South, an expansion of its existing Trail Ridge operation, allow the site to have much lower emissions, reduced dust levels and improved safety by removing conventional hauling trucks, Chemours says. In addition, the Trail Ridge South facility will recycle 98% of its water used in the manufacturing process – providing sustainable solutions while still meeting the company’s commitment to process minerals. Trail Ridge South process water and water treatment ponds are all constructed above ground, with approximately 39 million gallons (177 million litres) of storage capacity.

A high-performance solution, the MMUs for both Jesup and Trail Ridge South have been designed by Carrara, Queensland, Australia-headquartered Downer company Mineral Technologies (MT). MT told IM in 2021 that these units are aimed at mining sites where traditional dredging is not an option, or not cost effective. The technology delivers improvements in availability, orebody yields, throughput and overall mineral recovery. Suited to sand environments that include organics such as tree roots, light clay and soft or friable rock, MMUs can reduce operating costs by also eliminating the need for conventional truck and shovel mining. MT said the Chemours MMUs are extracting difficult-to-reach mineral sand deposits where traditional mining methods don’t stack up as the best business case. The MMUs provide a far safer and substantially reduced cost per tonne solution compared with other options.

MT says the MMU has a 750 t/h nominal operation with peak at 900 t/h. It offers complete remote control via a tablet device eliminating the need for on-board personnel. Dozers push run of mine ore to the unit where a hopper is loaded via hydraulic excavator, with the material then crushed to a suitable size for pumping of slurried ore to downstream processes.

Mineral Technologies adds to MD spirals range with WW7

Mineral Technologies, a Downer company, has added a new spiral separator to its MD range with the Australia-made WW7.

The WW7 are manufactured in the company’s ISO9001:2015-accredited Australian manufacturing facility and shipped to customers worldwide.

Designed with improved wash-water diverters, the new WW7 is great for operations requiring a simpler method of wash-water addition and control, according to the company. It does this with the introduction of a new diverter and secondary wash-water distributor.

Mineral Technologies says customers across North America and Europe are installing banks of WW7s for fine iron ore beneficiation, with the image above showing one of the latest shipments ready to leave the company’s facility.

Primero, Mineral Technologies enlisted for Strandline’s Coburn mineral sands project

Primero Group has been awarded preferred EPC status on a substantial contract with Strandline Resources on the Coburn mineral sands project in Western Australia.

The total volume of awarded engineering procurement and construction (EPC) works totals around A$150 million ($107 million), according to Primero, and follows an initial eight-week Early Contractor Involvement (ECI) process that provided further definition of the delivery strategy and project deliverables between the groups. It also coincided with the appointment of Mineral Technologies (MT), a global services provider and leader in the design and supply of mineral sands processing facilities (and a subsidiary of Downer Group), as the strategic technology partner alongside Primero for the project delivery.

Strandline said the contract involved the engineering, procurement, construction, commissioning and performance testing of the Wet Concentration Plant (WCP), Mineral Separation Plant (MSP) and associated processing circuits at the operation.

The Coburn WCP is designed to beneficiate the heavy minerals (ilmenite, leucoxene, rutile, zircon and monazite) and reject the non-valuable, lighter minerals through multiple stages of high capacity gravity separation and classification, according to Strandline. The rich heavy mineral concentrate produced from the WCP will be transported to the MSP and stockpiled ready for processing.

“The WCP infrastructure is relocatable and is planned to be moved several times during the mine life as the mine advances along the orebody,” Strandline said. “The MSP design comprises conventional electrostatic separation, gravity and magnetic fractionation to recover a range of premium-quality final products, including chloride ilmenite, rutile, premium zircon and zircon concentrate.”

The full project award is subject to Strandline Resources approving a Final Investment Decision in the coming months, Primero said. The ECI process came after Strandline’s recent A$18.5 million equity raising.

Primero Managing Director and CEO, Cameron Henry, said: “This award is an excellent example of Primero’s ECI phase in action and adds to our growing book of projects in preferred contractor status. We have worked intensively with Strandline over the past two months in designing a delivery solution that best meets the key project objectives and value drivers, while also minimising execution risks.”

Strandline has also already appointed Piacentini & Son to design and construct three mobile dozer mining units for the project, while Macmahon has been named as the principal contractor to provide site-wide civil and bulk earthworks construction services for the project.

UMCC banks Mineral Technologies’ MD Spiral Separators at Irshansk

United Mining and Chemical Company (UMCC), in Ukraine, has recently commissioned eight banks of Mineral Technologies’ MD Spiral Separators (models MG6.3 and HG10i) as part of the refurbishment of its Irshansk mineral sands operation, the Australia-based company reports.

Business Development Manager, Dale Henderson, said Mineral Technologies had worked with UMCC for several years and during this time had developed a solid understanding of the unique requirements of the Ukrainian site.

“We were delighted to welcome UMCC leaders to our head office earlier this year to inspect our spiral production facilities and discuss future plans for the mine site,” he said.

As a follow-up to delivery of the spirals, Henderson and Craig Vadeikis, Principal Process Consultant, visited the Irshansk site in September this year to review the equipment installation and commissioning.

General Manager, Metallurgy, Equipment and Technology, Alex de Andrade, said that by developing a deep understanding of customer operations and process objectives Mineral Technologies is well placed to identify the best process, equipment selection and key know-how to assist project success.

de Andrade said: “We congratulate UMCC on achieving final commissioning for their new mineral sands plant. It has been a pleasure working with UMCC throughout this process and we look forward to assisting in future operations.”

Robotics and automation projects among latest METS Ignited funding recipients

Australia’s Minister for Industry, Science and Technology, Karen Andrews, has announced seven mining supply businesses as the recipients of A$4.1 million ($2.9 million) in innovation funding under the METS Ignited Collaborative Project Funds.

The recipients of the funding will now be able to launch eight collaborative industry projects delivering highly-advanced solutions to a variety of mining challenges and contribute to the growth and capability of the METS sector, according to METS Ignited.

This funding is part of a four-year, A$15.6 million commitment made by the Australian Government to incentivise collaboration and address METS sector priorities. The funding established the METS Ignited Collaborative Project Funds, which support industry-led projects to improve the productivity, competitiveness and innovative capacity in the METS sector.

Today’s announcement at Mineral Technologies, on the Gold Coast of Australia, is the third tranche of funding. METS Ignited received 26 grant applications and has awarded the funds to businesses specialising largely in robotics and automation, data analytics, data platforms, Internet of Things and business and professional services. The recipients are: Mineral Technologies, Premron, Austmine, Roobuck, Process IQ, AMOG (x2) and Magotteaux.

Acting CEO of METS Ignited, Ian Dover, said: “Active collaboration across the ecosystem is core to accelerating commercialisation of innovation and has been lacking in the METS and mining sector, where historically relationships have been in the main transactional.”

“Facilitating such innovation is part of the mandate for METS Ignited. It’s vital we support the application of influential future technologies across the METS sector and maintain Australia’s competitiveness.”

Recipients of the Collaborative Project Funds are required to secure equal or greater investment from an industry partner. As a result, the total value of the eight projects is A$11 million.

The largest fund recipients were Queensland-based Mineral Technologies and Premron, awarded A$1 million each. Mineral Technologies’ automation of the Roy Hill Iron Ore beneficiation plant project automates the gravity separation spiral process used in the mine to optimise the concentration of lower-grade ore into higher value ore for export, METS Ignited said.

Roy Hill CEO, Barry Fitzgerald, said: “I am delighted the government is supporting our partnership with Mineral Technologies – a project that seeks to enhance the operational efficiency of our mine, delivering more high-grade product while reducing waste for the same operational cost.”

The automation of spiral control in the Roy Hill beneficiation plant will materially improve the concentration of ore into high value product for export, according to Roy Hill. More high-grade product and less waste will be produced for the same feed and processing cost, delivering value to both the environment and Roy Hill’s bottom line, the company said. Once proven effective at Roy Hill, the technology can be commercialised and rolled out at similar operations across the world.

“This innovation project will deliver a step-change improvement through real time control of our 720 spirals, enabling our processing plant to dynamically respond to the natural variability of the material it is treating,” Fitzgerald said.

Premron’s Continuous Haulage System (CHS) project, meanwhile, will revolutionise coal mining in underground mines, according to METS Ignited. It eliminates the use of shuttle cars, used to take the coal cut from the wall of the mine to a transfer point further away in the mine (dead time). CHS will see the coal go straight to a conveyor belt and out of the mine.

Other projects that received funding in this round include: sensor technology to monitor the location of people and equipment underground; artificial intelligence technology to emulate the role of a grinding expert; automated sensor detection for oversized rocks; a predictive analytics tool that pinpoints the best time for equipment descaling; a METS career pathway programme; and a device to give more detailed information on the chemistry inside the grinding mill while it is operating.

METS Ignited said: “Collectively, the projects will benefit the mining sector by optimising the value chain, increasing productivity for mining and mineral processing, supporting and enhancing environmental management, and improving operational safety.”

The project fund recipients include:

Automation of the Roy Hill Iron Ore beneficiation plant

  • Recipient: Mineral Technologies
  • Partners: Roy Hill
  • Collaborative project funds: A$1 million
  • Industry investment: A$1 million
  • This project automates the gravity separation spiral process used in the mine to optimise the concentration of lower-grade ore into higher value ore for export.

CHS

  • Recipient: Premron
  • Partners: Gauley Robertson Australia, Kestrel coal mine
  • Collaborative project funds: A$1 million
  • Industry investment: A$1.13 million
  • Continuous haulage will revolutionise coal mining in underground mines. It eliminates the use of shuttle cars, which are used to take the coal cut from the wall of the mine to a transfer point further away in the mine. CHS will see the coal go straight onto a conveyor belt and out of the mine.

Austmine METS career Pathway Program

  • Recipient: Austmine
  • Collaborative Project Funds: A$240,000
  • Industry investment: A$1.76 million
  • This project places university students as interns in METS companies around Australia, increasing the interest level and uptake of graduates into the METS sector

The OVERwatch Platform

  • Recipient: Roobuck
  • Partners: Redpine Signals, Northparkes Mines, University of Wollongong
  • Collaborative project funds: A$600,000
  • Industry investment: A$1.5 million
  • This project develops sensors and software to track the location of people and machinery working in underground mines and ensure that collisions are avoided. This is a complex project as there is limited communication options underground (eg no Wi-Fi).

Remote grinding optimisation and support centre

  • Recipient: ProcessIQ
  • Partners: Orway Mineral Consultants, Jamieson Consulting, Curtin University
  • Collaborative Project Funds: A$620,000
  • Industry investment: A$780,000
  • This project enables grinding experts to interact directly and in real time with grinding circuits on remote mine sites to ensure they are operating at their most productive levels. The project will develop automated artificial intelligence software to emulate the experts as there is very limited supply of this specialist expertise, leading to increased processing efficiency globally.

Automated Oversize Detection

  • Recipient: AMOG
  • Partners: Omniflex
  • Collaborative Project Funds: A$150,000
  • Industry investment: A$220,000
  • This project involves developing sensor equipment that alerts the mine when rocks are too big to process through the crushing and grinding equipment. Blockages in the crushing and grinding circuits are costly and time consuming. Haulage trucks with oversized rocks will be diverted to a separate location in the mine, which avoids stoppages.

Smooth Operator leach circuit process optimisation

  • Recipient: AMOG
  • Partners: Lithium Consultants
  • Collaborative Project Funds: A$220,000
  • Industry investment: A$220,000
  • This project involves developing a predictive analytics tool that allows copper and nickel mines to pinpoint when they should close equipment for descaling. Closing equipment too late or early is very costly. There is a very large global market for this product.

Commercialisation of pulp chemistry monitor for the mining industry

  • Recipient: Magotteaux
  • Partners: Hydrix, Manta Controls, Newcrest Mining
  • Collaborative Project Funds: A$250,000
  • Industry investment: A$310,000
  • This project involves developing a device to give more detailed information on the chemistry inside the grinding mill while it is operating. Grinding and flotation circuits use many chemical inputs in order to extract minerals from the ore. Getting the chemical balance right in the mill and the next stage of floatation is critical to removing as much of the valuable mineral as possible. The percentages of the yield vary between 85% and 95% and a 1% improvement in yield will deliver a very large financial benefit to the mine.