Tag Archives: Pilbara

BHP, BlueScope and Rio Tinto to investigate Australia low-carbon steelmaking options

Environmental, Mining industry recognition, Steel and iron ore, Sustainable mining, , , , , , , , , , ,

Australia’s two largest iron ore producers, Rio Tinto and BHP, and its biggest steelmaker, BlueScope, have partnered in their efforts to accelerate the decarbonisation of steelmaking by agreeing to jointly investigate the development of the country’s first iron making electric smelting furnace (ESF) pilot plant.

Under a new framework agreement, the companies will consolidate the work each party has completed to date, leveraging both BHP’s and Rio Tinto’s deep knowledge of Pilbara iron ores with BlueScope’s operating experience in ESF technology.

The collaboration provides a platform to develop and potentially invest in a pilot facility and aims to demonstrate that production of molten iron from Pilbara ores is feasible using renewable power when combined with direct reduced iron (DRI) process technology, they said. If successful, it could help open a potential pathway to near-zero greenhouse gas emission-intensity operations for steelmakers that rely on Australian iron ore to meet global steel demand.

The parties will assess several locations in Australia for the proposed pilot facility, and will consider factors like supporting infrastructure, available workforce, access to target industry and supply chain partners, and suitability for operational trials. The prefeasibility study work program is expected to conclude at year-end. If approved, the pilot facility could be commissioned as early as 2027.

Rio Tinto Iron Ore Chief Executive, Simon Trott (right), said: “The carbon intensity of iron and steelmaking requires profound change to meet the needs of our planet and our climate objectives. We must find better ways to enable these materials to be made more sustainably through leveraging technology.

“We firmly believe the best way to tackle a challenge of this scale is through collaboration with industry and importantly this new agreement will leverage the more than two years of work we have already completed with BlueScope on this technology. We are excited to add this partnership to the suite of projects we have underway with our customers and suppliers to find better ways to accelerate their efforts to meet their decarbonisation targets.”

Incoming BHP Western Australia Iron Ore (WAIO) Asset President, Tim Day (left), said: “We are thrilled to partner with Rio Tinto and BlueScope to progress what we see as a potential breakthrough in reducing carbon emissions from steel production. Collaborations like this are so important for the success of these technologies and build on our work on blast furnace abatement projects, and our ongoing research and development projects with leading steelmakers, research institutes and technology providers around the world.

“Combining our expertise, we hope to help fast track near-zero emission-intensity pathways for steelmakers using Pilbara ores. Technology pathways compatible with renewable energy and scalable to the order of hundreds of millions of tonnes of steel production would be a major step forward in setting up Pilbara ores, and the world, for a low greenhouse gas emission future.”

BlueScope Chief Executive Australia, Tania Archibald (centre), said: “We have a clear vision for BlueScope in Australia as a vibrant, modern and sustainable manufacturer with a clear role to play in enabling Australia’s energy transition. Building a pathway to low emission-intensity iron and steelmaking in Australia is a key priority for our business. We’re excited to be partnering with Rio Tinto and BHP to explore the decarbonisation of the ironmaking process, and leverage the natural advantages of Australia – namely our iron ore resources and the abundant potential for renewable energy.

“We believe DRI is the most prospective technology to decarbonise our Australian business, and the development of ESF technology is key to unlocking Australia’s unique advantages in this decarbonisation journey – and, more importantly, has the potential for wider adaptation across the global steel industry. We believe that this collaboration where we can contribute BlueScope’s unique experience in operating an ESF will be key to cracking the code for Pilbara ores in low emission-intensity ironmaking.”

Schlam to provide specialised maintenance services through new Fixed Plant Maintenance division

Equipment maintenance, Mining maintenance, Mining services, , , , , ,

On the back of growing demand for specialised maintenance services, Schlam has launched its new Fixed Plant Maintenance division.

This expansion is being spearheaded by Kaze Richardson, an experienced fixed plant professional determined to drive operations in the Pilbara and the Goldfields regions to new heights, Schlam says. Having been involved in multiple fixed plant projects and shutdowns sector since 2010, Richardson developed his skillset from a Leading Hand to Site Manager.

Schlam says: “With a deep understanding of the unique challenges faced by industries in the regions, Kaze brings a wealth of knowledge and expertise to the table. His vision for the Fixed Plant Maintenance division is to provide exceptional services to Schlam’s valued partners, ensuring that their operations run seamlessly and efficiently.”

Richardson added: “Our goal is to become the go-to provider for all fixed plant maintenance needs in the Pilbara and Goldfields regions. We aim to do simple things well, with an ‘Adapt – Achieve – Repeat’ ethos.”

The establishment of the Fixed Plant Maintenance division reflects Schlam’s commitment to meeting the evolving needs of its clients, it says. By offering expert services, Schlam aims to provide its partners with a comprehensive end-to-end solution for all their fixed plant requirements. Whether it is routine inspections and repairs or complex refurbishments and upgrades, Schlam says its Fixed Plant Maintenance division has the capability to handle projects of any scale or complexity.

One of the key strengths of the new division lies in its team of highly skilled professionals. These individuals possess extensive knowledge and experience in working with a variety of materials, including steel, aluminium and various alloys. Their expertise allows them to fabricate custom components, structures and assemblies that meet the highest industry standards, Schlam says.

The Fixed Plant Maintenance division follows rigorous testing procedures to ensure every project meets the highest standards of precision, durability and compliance with industry regulations. This dedication to quality control reflects Schlam’s commitment to delivering exceptional results to its clients, it says.

Safety is of paramount importance to Schlam, and the Fixed Plant Maintenance division prioritises the implementation and adherence to robust safety protocols and best practices. By creating a secure working environment, Schlam says it ensures the wellbeing of its employees, clients and stakeholders, aligning its values with theirs.

The company concluded: “With the launch of the Fixed Plant Maintenance division, Schlam is poised to revolutionise the maintenance services industry in the Pilbara and Goldfields regions. Through exceptional expertise, unwavering commitment to quality, and a focus on safety, Schlam aims to become the trusted partner for all fixed plant maintenance needs.”

Wabtec-RoyHill

Wabtec premieres Roy Hill FLXdrive battery locomotive

Environmental, Mining equipment, Mining services, Power supply for mines, Steel and iron ore, Sustainable mining, , , , , , , , ,

Wabtec and its launch customer, Roy Hill, have celebrated the debut of the FLXdrive battery locomotive, the world’s first 100% battery-powered, heavy-haul locomotive for mainline service.

The ceremony unveiled the unique, striking pink-coloured locomotive at Wabtec’s design and development centre in Pennsylvania in front of employees, customer executives, and government and community officials.

“This FLXdrive locomotive represents a major step in the journey to a low-to-zero-emission future in the rail industry,” Rafael Santana, President & CEO of Wabtec, said. “The FLXdrive is driven from within by our battery technology and the innovative spirit of our employees. Roy Hill is an ideal customer to partner with given their leadership and excellent operational record.”

Roy Hill’s FLXdrive battery-electric locomotive will feature an energy capacity of 7 MWh. Based on the route and company’s rail operations, the FLXdrive is anticipated to provide a double-digit percentage reduction in fuel costs and emissions per train. Once Wabtec completes the final battery installations and track testing, the locomotive will begin its 17,000 km journey in 2024 for delivery to its new home in the Pilbara region of Western Australia, one of the world’s premier mining precincts.

Gerhard Veldsman, Chief Executive Officer, Hancock Prospecting Group Operations, owner of Roy Hill, said: “The foresight of our Executive Chairman, Mrs Gina Rinehart AO, has been instrumental in establishing an environment in which we can successfully leverage the ingenuity of our people alongside key partners like Wabtec to transform our rail and mining operations through nextgeneration technologies.

“The FLXdrive locomotive represents not only a first for the Pilbara, but a first for the mining industry. The technological smarts that have gone into the development of the loco makes it well suited for our rail network. By using regenerative braking, it will charge its battery on the 344 km downhill run from our mine to port facility and use that stored energy to return to the mine, starting the cycle all over again. This will not only enable us to realise energy efficiencies but also lower operating costs.”

Today, Roy Hill uses four Wabtec ES44ACi “Evolution Series” diesel-electric locomotives in a consist to pull trains that are typically 2.7 km in length carrying more than 33,000 t of iron ore. The addition of the FLXdrive will form a hybrid locomotive consist with Wabtec diesel-electric locomotives, and recharge during the trip through regenerative braking. The FLXdrive manages the overall train energy flow and distribution through its state-of-the-art energy management software. It is also designed with a unique battery thermal management system using liquid cooling to withstand the Pilbara heat, where ambient temperatures can exceed 55°C (131°F).

Roy Hill’s iconic pink livery symbolises the company’s commitment to assisting research and those suffering from breast cancer. To commemorate the FLXdrive’s premiere, Roy Hill, and Breast Cancer Awareness Month, Wabtec donated $50,000 to Linked By Pink, a non-profit organisation consisting of Erie area survivors diagnosed with breast cancer before the age of 45.

Rio Tinto, Yindjibarndi Energy Corp sign renewable MoU for Pilbara operations

Environmental, Mining services, Power supply for mines, Steel and iron ore, Sustainable mining, , , , , , , , , ,

Rio Tinto and Yindjibarndi Energy Corporation (YEC) have signed a memorandum of understanding (MoU) to explore opportunities to collaborate on renewable energy projects on Yindjibarndi country in the Pilbara region of Western Australia.

The two companies will study and evaluate a range of opportunities including wind and solar power as well as battery energy storage systems. The initial focus is on rapidly exploring the potential development of a solar power generation facility for the supply of energy to Rio Tinto.

Rio Tinto operates four gas-fired power stations in the Pilbara. About 600 MW to 700 MW of renewable generation is estimated to be required to displace the majority of gas use across its network. The company is currently assessing the development of approximately 300 MW of solar projects. The collaboration opportunities currently being explored by Rio Tinto and YEC, if progressed, would be complementary to renewable energy developments on Rio Tinto Iron Ore’s electricity grid.

YEC was established in June following an agreement between Yindjibarndi Aboriginal Corporation (YAC) and renewable energy developer ACEN Corporation (ACEN) to progress the development of major renewable energy projects on Yindjibarndi Ngurra (country) – an area covering approximately 13,000 sq.km within the Yindjibarndi Native Title Determination Areas.

YEC’s initial plans include a Stage 1 target of 750 MW of combined wind, solar and battery storage with construction to commence within the next few years. The collaboration opportunities being considered by Rio Tinto and YEC relate to some of these Stage 1 projects.

YAC Chief Executive, Michael Woodley, said: “Yindjibarndi Ngurra is ideally suited to developing renewable energy generation and our people are encouraged by Rio Tinto’s interest in building this capacity with us. This will strengthen our existing partnership and provide long term benefits for our community, while also ensuring that we can protect and preserve the areas of cultural, spiritual and environmental significance within our Ngurra.”

ACEN International CEO, Patrice Clausse, said: “This MoU signifies more than just a partnership; it’s a testament to the shared vision of sustainable energy development on Yindjibarndi Ngurra. It is the perfect blend of traditional significance and modern technology, designed to harness the limitless potential of the Pilbara’s sun and wind, while respecting the deep-rooted connection of the Yindjibarndi people with their land.

“Together, we are crafting an energy future that is not only renewable, but also renewing, by empowering local communities and contributing to a greener future.”

Rio Tinto Iron Ore Chief Executive, Simon Trott, said: “We are focused on repowering our Pilbara operations with renewable energy through the end of this decade and beyond by replacing gas and diesel with clean energy alternatives. The Pilbara is blessed with abundant year-round sunshine and strong winds at night, making it one of the most attractive places in the world to harness solar and wind power for energy generation. We’re excited to be deepening our partnership with the Yindjibarndi People through this agreement and look forward to working closely with them.

“We recognise we have a large carbon footprint in the Pilbara and are exploring a number of innovative solutions to help address this, including future collaborations with other Traditional Owner groups in the region.”

Rio Tinto has committed to reducing its Scope 1 and 2 emissions by 50% by 2030 across its global operations, with an estimated $7.5 billion planned to be spent on decarbonisation projects, predominantly in the second half of the decade. These projects will support a longer-term ambition of net-zero emissions by 2050.

Rio Tinto’s rail network, which connects its Pilbara mines to ports at Cape Lambert and Dampier in Western Australia, traverses Yindjibarndi Country. Rio Tinto has held a Participation Agreement and Indigenous Land Use Agreement with YAC, the representative body for the Yindjibarndi people, since 2013.

Last year, Rio Tinto and YAC signed an updated agreement aimed at strengthening ties and delivering improved social and economic outcomes for the Yindjibarndi people. The agreement reflects a joint commitment to work together to create more opportunities for the Yindjibarndi people to participate in Rio Tinto’s operations, including direct and indirect employment opportunities, and build sustainable long-term benefits to the community.

Iron Ore Company of Australia selects Rapid Crushing for Hancock crushing and screening ops

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Alien Metals Ltd’s wholly-owned subsidiary, Iron Ore Company of Australia Pty Ltd (IOCA), has selected Rapid Crushing & Screening Contractors Pty Ltd as its preferred supplier to undertake the crushing and screening operations at the flagship Hancock iron ore project in the Pilbara of Western Australia.

IOCA says it has conducted a competitive market engagement over the previous six months to identify commercially and technically-adept contractors to undertake works as part of the Hancock development and operations. This process has involved pre-qualified and targeted proponents, submitting bids for specific scopes of works and agreeing to key commercial terms.

Rapid Crushing is a market leader in iron ore, having previously worked with Fortescue Metals Group and being the incumbent contractor at Galaxy Lithium for the past six years, with that work continuing. The selection of Rapid Crushing for crushing services reinforces the assumptions made within the scoping study to deliver a C1 cost of approximately $60 per tonne, Alien Metals says.

The 2021 scoping study on Hancock showcased a 1.25 Mt/y production profile that would sustain an eight-year life of mine with current resources. The company has said it plans to make its first shipments in 2023, leveraging its direct shipping ore options.

Earlier this month, IOCA named REGROUP Australia as its preferred primary contractor to undertake the construction works, mining operations and haulage services for Hancock.

The selection of Rapid Crushing – which remains subject to the completion of a positive definitive feasibility study – paves the way to finalise the updates to the financial model as the IOCA continues to progress the remaining studies and regulatory workstreams required for a final investment decision for the Hancock project, it says.

Troy Whittaker, Chief Executive Officer, said: “We are pleased to announce that Rapid Crushing has been selected as the preferred tenderer for crushing and screening operations at our Hancock project. Rapid Crushing’s significant hard-rock mining knowledge and experience, particularly in iron ore, will be of great benefit to our overall operations.

“We will be working closely with Rapid Crushing to finalise optimisation activities that support the accelerated DFS work streams related to price opportunity as we prepare and execute the contractual documents.

“The selection of Rapid Crushing finalises the material procurement efforts for the project. This will result in a high level of validated and secured costing for the Hancock project.”

Fortescue kicks off battery-electric truck testing in the Pilbara

Environmental, Mine operation news, Mining equipment, Power supply for mines, Steel and iron ore, Sustainable mining, , , , , , , , , , , , ,

Fortescue Metals Group has started testing a battery-electric truck at its operations in the Pilbara of Western Australia as part of its latest decarbonisation efforts.

Having floated the idea of a battery-electric haul truck some three years ago – and started a physical build process 12 months ago – the company is now testing a battery-electric converted MT4400 AC truck at its Christmas Creek iron ore operations, Fortescue confirmed last week.

WAE and Fortescue Future Industries, part of Fortescue’s newly branded Fortescue Energy division, have been spearheading developments on this truck, referred to as the “Roadrunner” (pictured). The 221-t payload vehicle is fitted with a 1.4 MWh battery from WAE. It has already been run through more than 20 hours of dynamic testing that has included, among other things, downhill recharging scenarios, Fortescue said last week.

The vehicle is thought to be the largest battery-electric haul truck running in Pilbara operating conditions.

The converted MT4400 AC is expected to be joined by a 3 MW charger prototype – developed by WAE and a third party – by the end of the year. “This will help us to understand and develop haul truck duty and charging cycles,” Mark Hutchinson, CEO of Fortescue Future Industries, said in a conference call last week.

In June, Fortescue, through WAE, announced the expansion of its battery and electric powertrain production operations in the UK with an additional state-of-the-art facility in Oxfordshire. The facility, which will open in 2024, will focus on the production of a wide range of zero emission products for the off-road sector, including trucks and trains.

Alongside these battery-electric developments, Fortescue said it will have its first “green hydrogen fuel cell haul truck” on site for similar testing next year. This truck is being delivered through the company’s partnership with Liebherr and will be based off a 240-t-payload T 264 haul truck.

In June 2022, Fortescue announced a partnership with Liebherr for the development and supply of green mining haul trucks for integration with the “zero emissions power system” technologies being developed by FFI and WAE. Under the partnership, Fortescue agreed to purchase a fleet of 120 haul trucks from Liebherr; a commitment that represents approximately 45% of the current haul truck fleet at Fortescue’s operations.

In answer to an analyst question last week, Christiaan Heyning, FFI’s Head of Decarbonisation, said: “We are…putting both battery-electric trucks as well as a fuel cell electric trucks on-site this calendar year to do extended testing to figure out the ramp-up efficiency of both battery-electric and fuel cell. We will use those insights to make the final decisions about what our fleet will be.

“As you appreciate, it’s really dependent on whole routes and, therefore, we need to do more testing before we can make up our mind.”

A 100-day “sprint” FFI project focused on converting a legacy 221-t class Terex Unit Rig MT4400 AC electric drive, diesel-powered haul truck to run on a ‘green’ hydrogen 180 kW fuel cell system and a 300 kW/h battery was previously completed and run at Fortescue’s Hazelmere facility in Western Australia.

Fortescue celebrates first shipment of Iron Bridge magnetite

Mine operation news, Mineral project development, Steel and iron ore, , , , , , ,

Fortescue’s first shipment from its newly built, majority-owned Iron Bridge operations, in Western Australia, will soon be on its way to Vietnam marking the first time the company has exported a high-grade magnetite product.

It follows first production earlier this year, which saw the plant surpass expectations with a first run grade of greater than 67% Fe.

Iron Bridge, Fortescue says, is a demonstration of the company’s pioneering innovation. It signifies the first time the company has produced a wet concentrate product, which is transported to Port Hedland through a 135 km specialist slurry pipeline where dewatering and materials handling occurs to create a high grade magnetite product.

Fortescue Metals Chief Executive Officer, Fiona Hick, joined Nyamal Traditional Custodians and representatives from Fortescue’s Iron Bridge Joint Venture partner, Formosa, in Port Hedland as the first shipment was loaded.

Hick said: “Today is a truly special day for Fortescue. Last week we celebrated 20 years since Fortescue was founded and, today, we celebrate our first shipment of high-grade magnetite product from our most complex and innovative project yet.

“Iron Bridge is a game changer for Fortescue and builds on our track record of safely and successfully developing and operating iron ore projects in the Pilbara.

“High grade magnetite product will play an important role in lowering emissions in the steel industry, and Fortescue is moving at pace to ensure we are at the forefront of developing green steel technologies.

“I congratulate the entire Fortescue team for delivering this project while maintaining strong safety performance. We remain focused now on achieving a safe and efficient ramp up.”

Iron Bridge is an Unincorporated Joint Venture between FMG Magnetite Pty Ltd (69%) and Formosa Steel IB Pty Ltd (31%).

At full capacity, Iron Bridge is expected to deliver 22 Mt/y of high grade 67% Fe magnetite concentrate.

BHP Pilbara villages safety and accessibility upgrade complete

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BHP says work is complete on its A$300 million ($200 million) investment to improve safety and accessibility for residents and guests at its Pilbara villages in Western Australia.

The accommodation safety and security upgrade project began in 2020 and was completed earlier this year by the WA Iron Ore Non-Process Infrastructure (NPI), Engineering and Asset Projects teams.

Kate Holling, WA Iron Ore NPI General Manager, said the initiative involved a significant amount of work by a big number of people, however the results were outstanding.

“In total, 10,756 rooms were upgraded across our 13 WAIO villages with more than 10,000 doors, 8,000 lights, 1,500 CCTV cameras and 4.75 km of fencing installed,” she said.

“The work was delivered using 100% Australian manufacturers and local contractors, including many Traditional Owner businesses.

“Safety continues to be our number one priority and I’m happy to see this work complete to make our villages feel safer and more accessible for everyone who visits them.”

K2fly and BHP extend Ground Disturbance solution agreement

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K2fly Limited says BHP has extended its existing one-year contract related to K2fly’s Ground Disturbance solution covering its Western Australian Iron Ore (WAIO) operations in the Pilbara region of Western Australia.

The new three-year agreement comes with a total contract value of A$1.99 million ($1.35 million), according to the ASX-listed company, and follows an initial one-year engagement signed in May 2022.

BHP’s WAIO is an integrated system of four processing hubs and five mines, connected by more than 1,000 km of rail infrastructure and port facilities in the Pilbara region of northern Western Australia. It produces over 245 Mt/y of iron ore, making it one of the top five producers of iron ore globally.

Sitting within K2fly’s Natural Resource Governance area, K2fly Ground Disturbance solution is a cloud-based Software as a Service platform for applying, approving, tracking, reporting and submitting closure of permits and rehabilitation commitments surrounding ground disturbance activities, K2fly explained.

Nic Pollock, CEO of K2fly, said: “Our Ground Disturbance solution is the only commercial off-the-shelf solution available in the market globally and speaks to how our customers are increasingly attributing value to the importance of proper resource governance on land and protecting their license to operate. We are delighted to extend our contract into a three-year term with another global Tier 1 client.”

WSP grows presence in Western Australia with Calibre acquisition

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WSP says it is strengthening its position as a leading provider of services across the full mining asset life cycle with the addition of Calibre Professional Services and its 800 professionals in Australia.

The company’s mining team now represents over 5,200 professionals globally, including 1,400 experts in Australia, and benefits from an enhanced ability to support blue-chip mining clients in Western Australia, WSP says.

“We are eager to leverage the full potential of our combined teams and work together to support mining clients with strong ESG commitments,” Alexandre L’Heureux, President and CEO of WSP, said. “We have the opportunity to play a pivotal role at a time when mining companies are making bold commitments towards decarbonising their operations and infrastructure, while providing the critical minerals required for the green transition.”

Guy Templeton, WSP’s President and CEO, Asia Pacific, said: “With the acquisition of Calibre, we are significantly growing our presence in Western Australia, and in the mining sector, while further building on our Earth and Environment capabilities. We also look forward to creating significant value for our clients in the Pilbara Region and across the country.”

Adrian Chapman, Executive General Manager at Calibre, said: “Over the past two decades, we have focused on building Calibre as a consultant of choice for major mining projects. Joining WSP enables our talent to leverage the scale, capabilities, and expertise of a global company with 67,000 professionals.”