Tag Archives: Pilbara Minerals

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

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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.

Pilbara Minerals and Calix commit to lithium calcination tech demo plant at Pilgangoora

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Pilbara Minerals and Calix have executed a joint venture (JV) agreement for the development of a demonstration plant using Calix’s patented calcination technology at the Pilgangoora project in Western Australia.

The aim of the joint venture is to produce lithium salts via an innovative midstream “value added” refining process leveraging this calcination technology. It will also explore the potential commercialisation of the process.

The objective of the “Mid-Stream Demonstration Plant Project” is to deliver a superior value-added lithium product enabling lower product cost, reduced carbon energy intensity, and reduction of waste product logistics.

The unincorporated JV will be a 55:45 agreement in favour of Pilbara Minerals, with each party funding their share of operating and capital costs and Calix licensing its patented technology and calcination knowhow into the JV. Pilbara Minerals will manage the demo plant at Pilgangoora, overseeing both the construction and operational phases.

A successful demonstration of the calcination technology via this plant may then lead to its commercialisation with the JV licensing the technology to the global spodumene processing industry, Pilbara Minerals says.

It follows a previous agreement signed back in June.

The project aims to demonstrate a superior value-added lithium product to the existing industry supply chain, while also potentially delivering a significant reduction in carbon intensity, with potential industry benefits including:

  • Product cost – the flash calcination technology developed by Calix has the potential to treat very fine spodumene concentrate at lower lithia grades and materially improve overall lithia recovery, thereby enabling a lower cost per lithia unit;
  • Carbon intensity reduction – substantial carbon emission reduction through the electrification of the Mid-Stream process, including spodumene calcining, enabling the potential to use up to 100% renewable sourced power; and
  • Waste reduction/handing – rationalisation of the carbon footprint via reduced waste movement across transport and logistics supply chains from a more lithium-dense, and near zero-waste final product.

Pilbara Minerals’ Managing Director and CEO, Dale Henderson, said: “The Mid-Stream project has the potential to be a game changer for our industry. If successful, we will be able to deliver a superior chemical intermediary product to market compared to spodumene concentrate.

“This intermediate product offers a higher concentration in lithium and less impurities whilst being produced through a new process that reduces CO2 emissions compared to the traditional process route for hard-rock spodumene chemical conversion.”

New Ishigaki filter press starts up at Pilbara Minerals’ Pilgangoora operation

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Pilbara Minerals Ltd says it has commenced concentrate production from its newly installed filter press at the Pilgan Plant. The development is part of the Plant Improvements Project being undertaken at its 100%-owned Pilgangoora lithium-tantalum operation in Western Australia’s Pilbara region.

The filter press in question is provided by Ishigaki and will handle approximately 1,500 t/d of concentrate, Pilbara Minerals’ Managing Director and CEO, Ken Brinsden, confirmed.

The Pilgan Plant Improvements Project is expected to de-bottleneck the facility to increase plant operating time and throughput, reduce final product moisture (minimising solar drying) and further manage product recovery performance. These improvements are ultimately expected to realise additional production capacity from the facility, and particularly from the fines flotation circuit.

A total of approximately A$22 million ($16 million) of capital will be invested, with the project expected to be fully ramped-up during the December quarter 2021 to 360,000-380,000 t (dry) of spodumene concentrate. When combined with Ngungaju Plant’s ramped-up capacity of 180,000-200,000 t (dry), which is expected from mid-2022, the total annual production capacity across the entire Pilgangoora operation is expected to increase to circa-560,000-580,000 t/y.

Brinsden said the commencement of production from the Pilgan Plant Improvements Project marked another significant and exciting milestone in the rapid growth of the Pilgangoora project.

“The team has done another amazing job in delivering this project on time and in line with budget,” he said. “Keeping it on track, in combination with the restart of the Ngungaju Plant, is testament to the delivery capability of our team – particularly considering that these works were achieved during a period when the resources industry is under considerable pressure in terms of securing people, resources and equipment.”

Pilbara Minerals enlists Contract Power Australia for Pilgangoora solar power plans

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Pilbara Minerals Limited has announced a Power Purchase Agreement (PPA) between its wholly owned subsidiary, Pilgangoora Operations Pty Ltd, and Contract Power Australia that could see a 6 MW solar array built at the Pilgangoora lithium project in Western Australia.

The solar array is, the company says, an important demonstration of its commitment to implementing environmentally friendly power solutions, as a part of its pledge to transition to net-zero emissions (scope 1 and 2) in the decade commencing 2040.

Pilbara Minerals said it looks forward to continuing its working relationship with Contract Power and the broader Pacific Energy Group, which began in 2018 when the first baseload power station was installed at Pilgangoora. The PPA involves a 15-year contract to construct, operate and maintain a 6 MW solar array, which is estimated to displace 3.8 million litres/y of diesel fuel, saving an estimated 9,900 t of CO2/y over the contract period.

“A key factor in awarding this exciting new renewable energy project to Contract Power was their established track record and ability to design and safely deliver turnkey energy projects,” the company added.

It is anticipated that procurement for the project will commence imminently with commissioning expected in late July 2022, and commercial operation from the end of August 2022. The design facilitates the future expansion of solar capacity and potential inclusion of battery storage at Pilgangoora, as Pilbara Minerals creates further efficiencies around its power supply and storage solutions at Pilgangoora, it said.

The installation of the first phase of the solar farm is just one part of the initial rationalisation of power assets at Pilgangoora, as the company further integrates the Ngungaju Operation. A local power network will be created to join the Ngungaju and Pilgan Plants, and the Carlindi camp facilities thereby creating further efficiencies, Pilbara Minerals explained.

Pilbara Minerals’ longer-term objectives include integration with other northern Pilbara power and/or gas and renewables sources with a view to creating further efficiency gains on the path to net-zero carbon.

IronMerge SIMPEC joint venture to work on Pilgangoora lithium operation

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SIMPEC and IronMerge have secured their first contract under a newly incorporated joint venture, with the IronMerge SIMPEC JV to work on Pilbara Minerals’ Pilgangoora lithium operation in Western Australia.

WestStar Industrial Ltd’s SIMPEC formed its first Aboriginal Business joint venture, IronMerge SIMPEC JV, with IronMerge Pty Ltd just last month.

The Stage 1 A$15 million ($11.7 million) improvement works contract at Pilgangoora involves a series of works to improve operating time and throughput as part of continuous improvement to operational performance of Pilgangoora’s Stage 1, 2 Mt/y processing facility.

SIMPEC has been contracted to perform all vertical installation works including earth works, civils, fabrication, structural, mechanical, piping, tanks, electrical and instrumentation works for the project. All works will be conducted with joint venture partner IronMerge.

The Pilgangoora lithium-tantalum project has a current resource of 222.5 Mt and existing JORC compliant reserves of 104.6 Mt.

SIMPEC Managing Director, Mark Dimasi (pictured on the right), said: “This newly awarded contract is a tribute to not only our SIMPEC delivery team but also Ian Taylor (Chairman of IronMerge, pictured in the middle next to Ken Brinsden, MD and CEO of Pilbara Minerals, on the left) and his IronMerge team. This is a very proud moment for all of us and I sincerely look forward to seeing this JV relationship growing and developing in the construction and mining sector. A big thank you to the Pilbara Minerals team for backing us throughout this tender phase.”

Pilbara Minerals and POSCO move a step closer to lithium chemical production JV

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The Pilbara Minerals Board has conditionally exercised its option to enter into an incorporated joint venture with POSCO (for up to 30% participation) for the development of a downstream lithium chemical conversion facility in South Korea.

Pilbara Minerals’ Managing Director and CEO, Ken Brinsden, said the company’s relationship with POSCO had developed over the last year as it has continued to work through the Pilgangoora lithium project joint venture.

“It has been really pleasing to see the positive results generated by the due diligence work to date. The significant investment by POSCO into their PosLX technology has paid off and they have proven their ability to produce an industry leading, battery-ready lithium product through their innovative lithium purification process,” he said.

On October 2, 2018, Pilbara Minerals produced its first spodumene concentrate shipment from Pilgangoora. A total of 8,800 t (wet) of spodumene concentrate grading approximately 6.1% lithia and 1.2% Fe2O3 set sail from Port Hedland bound for the company’s offtake partners in north Asia.

The company’s agreement with POSCO encompasses long-term offtake, funding and the downstream conversion plant joint venture opportunity.

Brinsden said the rapid growth in lithium chemicals consumption in South Korea could see the country’s battery manufacturing sector supply around 25% of worldwide capacity by 2028, according to Benchmark Mineral Intelligence.

The downstream lithium facility, to be located in the Gwangyang Free Economic Zone in South Korea, would have up to 40,000 t/y of lithium carbonate equivalent (LCE) capacity and process spodumene from Pilgangoora using POSCO’s patented PosLX purification process.

Since the December quarter, Pilbara Minerals has been undertaking technical due diligence to assess the proposed chemical plant development and work to date has delivered promising results, it said.

“Due diligence has included a visit of technical staff and assessment of POSCO’s existing commercial operations plant using their PosLX technology, based on Pilbara Minerals’ spodumene delivered from the Pilgangoora project,” Pilbara Minerals said.

POSCO has developed its first commercial-scale operation (after the initial development of a pilot scale plant) that produces up to 2,500 t/y of lithium chemicals on an LCE basis, according to Pilbara Minerals. Based on spodumene chemical conversion, the plant has the capacity and flexibility to produce both high grade lithium hydroxide, or, alternately, lithium carbonate products with low impurities in the final products produced.

Pilbara Minerals said: “The battery grade lithium hydroxide produced has to date been tested by major South Korean cathode makers and has passed their qualification process.”

Once a number of conditions surrounding the deal are complete, they will be put to the Board of Pilbara Minerals for a final decision and commitment to the joint development in mid- to late-May 2019. The parties would then aim to complete construction of the chemical conversion plant in late 2020 with commencement of ramp-up and production from early 2021.

Northern Australia Infrastructure Fund boosting mine development

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A new investment mandate for the Northern Australia Infrastructure Fund (NAIF) is helping more projects get off the ground sooner, NAIF Executive Director Peter Ross told delegates at the International Mining and Resources Conference 2018 (IMARC) in Melbourne.

Ross said the fund’s investment mandate, introduced in April, was proving significantly more flexible.

“We are now able to provide up to 100% of the debt finance for a project – up from 50% previously, and we can now also consider smaller projects below A$50 million ($35 million) in value, where they meet other criteria,” Ross said.

Since its establishment in 2016, the NAIF has grown its portfolio. It has moved from having five projects in due diligence in 2017 to making investment decisions on six projects in the last financial year.

“Our loan portfolio now stands at A$264 million, on Northern Australian projects valued at A$969 million,” Ross said.

“In addition, we have another A$750 million of loans that are conditionally approved. In total, the NAIF expects to soon be supporting projects valued at A$2.3 billion, which will provide thousands of jobs in Northern Australia and deliver long-term benefits for the region.”

As might be expected in Northern Australia, resource projects feature prominently in the NAIF portfolio. Since June 2017 a third of the projects considered for due diligence by the fund have been resources-related.

Of the six projects sanctioned, three are resource related.

Sheffield Resources’ Thunderbird mineral sands project (pictured) secured A$95 million in finance to develop its LNG power station and reticulation, and upgrade road and port infrastructure to support the project in WA’s West Kimberley Region.

The NAIF has also signed off on a A$95 million facility for the Onslow Marine Supply Base, and A$15 million for the upgrade of the Pippingarra Road, a 70 km public road to access the Pilgangoora lithium-tantalum mine being developed by Pilbara Minerals, near Port Hedland.

Ross said as word spread of the NAIF’s capacity, project enquiries were increasing. The NAIF has experienced a 320% increase in projects undergoing due diligence since September 2017.

Apart from being an infrastructure project in Australia’s north, to secure NAIF support a project must also have the capacity to repay or re-finance on commercial terms, be of public benefit, and demonstrate it has an effective indigenous engagement strategy.