Tag Archives: Pilbara

Verton’s Everest 6 does the heavy lifting at Roy Hill

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

Verton Australia says iron ore miner Roy Hill has purchased its remote-controlled load orientation system, the Everest 6.

Designed to dramatically improve safety in crane operations, the Everest is a load management system designed to control and rotate a load to its target destination.

Everest eliminates the need for human held taglines to control suspended loads, thereby improving safety and productivity for crane operations, Verton says.

The Everest 6 and R5 models that are being employed at Roy Hill’s iron ore operations, in the Pilbara of Western Australia, can manage loads of up to 20 t and 5 t, respectively, while significantly improving workplace safety and efficiency, according to Verton.

Verton CEO, Trevor Bourne, said: “The Everest series is a great example of how mining companies are committed to reducing the risk of crane incidents by ensuring no human contact is required for managing suspended loads, with tag line use and associated workloads removed.”

Roy Hill has provided positive feedback on how the Everest performed during a recent mine shutdown when they replaced an 18 t transformer, according to Bourne.

“The Everest responded perfectly in smooth rotation with the load on the hook without causing the crane rope to twist and there was no need for taglines during the lift so Roy Hill was able to keep the riggers out of the line of fire during lifting operations,” he said.

Located 340 km southeast of Port Hedland, Roy Hill has an integrated mine, rail and port facilities and produces 55 Mt/y of iron ore, with approval to increase to 60 Mt/y.

Scott Technology to automate Koodaideri sampling and analysis process

Automation, Metallurgy, Mineral project development, Mining equipment, Mining services, Steel and iron ore, , , , , , ,

Scott Technology says it has been awarded a significant contract by Rio Tinto to design and build the automated mine site laboratory for the Koodaideri iron ore project, in the Pilbara region of Western Australia.

The automation and robotics solutions provider’s contract involves the building construction and equipment supply for the robotic sample preparation and analysis laboratory (graphic above), it said.

The project will be undertaken across multiple Scott manufacturing sites and is scheduled to be installed by mid-2021.

Scott Technology said: “The project leverages recent advancements in automation and digitisation, helping to deliver a safer and more productive mining operation. Once completed and in production in 2021, the Koodaideri laboratory will be the safest, most productive, highest quality iron ore facility in the world.”

Koodaideri, billed by Rio as an “intelligent mine”, will deliver a new production hub for Rio’s iron ore business in the Pilbara, incorporating a processing plant and infrastructure including a 166 km rail line connecting the mine to the existing network.

Construction on Koodaideri Phase 1 started in 2019 with first production expected in late 2021. Once complete, the mine will have an annual capacity of 43 Mt, underpinning production of the company’s flagship iron ore product, Pilbara Blend.

The contract award highlights Scott’s evolution in the mining sector from a leading supplier of sample preparation equipment, to a complete end-to-end automation and analysis solution provider, it said.

“The company’s commitment to R&D is helping to drive efficiency and output of some of the world’s largest mines, and Scott is currently working with multiple global mining companies and commercial laboratories on large scale automation projects, particularly in the Asia Pacific region,” it said. “In recent years, the company has implemented solutions in the mining sector such as robotic refuel, robotic idler change, sampling systems, and automated sample preparation facilities.”

Scott CEO, John Kippenberger, said: “Demand for industrial automation continues to intensify, driven by a continuing focus on health and safety, and to improve productivity, quality and profitability.

“As a global leader in automation and robotic solutions, Scott is well positioned to take advantage of this growing demand and we are progressing a number of opportunities across a range of sectors. With these latest developments in our technology platform, we see the mining sector continuing to play an increasingly important role as a contributor to Scott’s future growth.

“We are looking forward to partnering with Rio Tinto on this innovative project that once complete will set the new benchmark for safety and operational excellence in Iron Ore sample preparation and analysis.”

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.

BHP’s South Flank on course for 2021 first iron ore deadline

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

Fluor says BHP’s $3.6 billion South Flank iron ore project, in the Pilbara of Western Australia, is on track for first ore in 2021, with the engineering firm having erected the first 1,500 t of modules in the ore handling plant.

This construction milestone is in the critical sequence to first ore and comes after achieving 50% project completion, announced by BHP in October 2019, Fluor said.

Fluor is providing engineering, procurement and construction management services on South Flank.

In December, Mammoet said it had started transporting the first heavy components for the under-construction mine, with around 1,900 items including prefabricated and modular mine processing plant units of various sizes set to be moved from Port Hedland to the new mine site.

When operational, South Flank will be one of the largest iron ore processing hubs in the world. The project will include an 80 Mt/y crushing and screening plant, an overland conveyor system and rail-loading facilities. The mine will replace production from BHP’s Yandi mine, which is nearing the end of its life.

South Flank engineering and procurement work is being performed from BHP’s office in Perth, with Fluor working together with BHP as an integrated project team, it said.

Tony Morgan, President of Fluor’s Mining and Metals business, said: “We are extremely proud of what we have been able to accomplish with BHP on this project including our commitment to achieve diversity through the hiring of indigenous and local team members.

“The pioneering integrated team approach on this project is truly a collaborative effort. We look forward to continuing our long and successful relationship with BHP on this project and beyond.”

Richard Gerspacher, Project Director, said: “Based on the project routines and culture we’ve created, I am confident that the project will continue to proceed in a positive manner as we work towards first ore.”

Fluor previously performed the feasibility study for the project before it was awarded the follow-on construction and project management scope. Over the life of the project, it is expected that more than 9,000 people will be engaged in the South Flank work force.

Construction began in July 2018 and first production of iron ore is anticipated in 2021.

Mondium secures WTS2 iron ore contract from Rio Tinto

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

Rio Tinto has awarded Perth-based Mondium a A$400 million ($276 million) contract to design and construct the Western Turner Syncline Phase 2 (WTS2) mine in the Pilbara of Western Australia.

Mondium, a joint venture involving Monadelphous and Lycopodium, will undertake all engineering and design, procurement and site construction works associated with the WTS2 development, including the process plant, overland conveyor and non-process infrastructure.

Back in November, Rio said it would invest $749 million in the development of WTS2 at its Greater Tom Price operations, facilitating mining of existing and new deposits and including construction of a new crusher as well as a 13 km conveyor. In addition to this, the haul truck fleet at the mine will be fitted with Autonomous Haulage System technology to enable autonomous haulage from 2021.

Mondium’s work is expected to create 450 jobs starting in the March quarter, with completion slated for 2021. Rio said Mondium and it would work closely to ensure the contract provides local and Indigenous employment as well as business opportunities in the region.

Rio Tinto Iron Ore CEO, Chris Salisbury, said: “We’re committed to supporting WA businesses, buying locally and supporting our communities through the creation of jobs. We’re pleased to award this contract to Mondium who share those values.”

NRW receives BGC contract win at FMG’s Eliwana project

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

NRW Holdings’ newly acquired BGC Contracting business has been awarded an infrastructure contract with Fortescue Metals Group at its Eliwana iron ore mine and rail project, in the Pilbara region of Western Australia.

The new contract, which came just two weeks after NRW announced the completion of the BGC acquisition, will support the development of 143 km of rail for the Eliwana project, according to the contractor.

The scope includes the construction of circa-65 km of rail formation, including earthworks, roadworks, drainage works and construction of bridges and pre-cast structures. The contract is valued at close to A$138 million ($96 million) with mobilisation expected to commence soon (completion is scheduled for late 2020). At its peak, the project will employ an expected workforce of 400, utilising over 140 pieces of major plant in the process.

Jules Pemberton, NRW’s CEO and Managing Director, said: “Following the successful acquisition of the BGC Contracting business, NRW’s operational delivery capabilities in the Pilbara are further enhanced, through the addition of the highly skilled BGC workforce into the group, together with the strong technical skillset to safely and successfully deliver the large bridges and concrete structures required on the project.”

In addition to the building of 143 km of rail, Eliwana will include a 30 Mt/y dry ore processing facility and infrastructure. Production is expected to commence in December 2020 with a life of mine strip ratio of 1.1.

CIMIC’s CPB Contractors seals A$150 million contract for Rio Tinto in Pilbara

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

CIMIC’s CPB Contractors has been selected by Rio Tinto to deliver three separate packages of work at the miner’s Robe Valley iron ore operations, in the Pilbara region of Western Australia.

The projects, worth approximately A$150 million ($103 million), include earthworks; construction of roads, bridges and pits; water supply infrastructure and drainage; fencing; and site establishment and demobilisation. The projects will be completed by the end of 2021, according to CIMIC.

Back in October 2018, Rio, together with joint venture partners Mitsui and Nippon Steel & Sumitomo Metal, approved an investment of $1.55 billion to sustain production capacity at two projects forming part of the Robe River joint venture in the Pilbara. Around $967 million was set to go towards developing the Mesa B, C and H deposits at Robe Valley, with $579 million for developing Deposits C and D at West Angelas operation.

The investments were to enable Rio Tinto to sustain production of the Pilbara Blend and its Robe Valley lump and fines products.

CIMIC Group Chief Executive Officer, Michael Wright, said: “CIMIC Group companies have a strong track record of delivering significant projects to the iron ore industry. With our decades of experience in the Pilbara we offer major mining clients certainty and confidence in construction, mining and industrial services.”

thyssenkrupp to deliver jaw gyratory crusher to Roy Hill iron ore mine

Comminution of minerals, Mine operation news, Mineral processing, Mining equipment, Steel and iron ore, , , , , , ,

thyssenkrupp is to install the first above ground jaw gyratory crusher in Australia at the Roy Hill iron ore mine, in the Pilbara of Western Australia, following an agreement signed with the mining company.

Located 340 km southeast of Port Hedland, Roy Hill has integrated mine, rail and port facilities and produces 55 Mt/y of iron ore, with approval to increase to 60 Mt/y.

The new crusher will be designed for high performance and cost-effective operation, ie low servicing and maintenance costs, according to thyssenkrupp.

Ben Suda, Head of Sales at thyssenkrupp Industrial Solutions (Australia), said: “We are excited and grateful for the opportunity to be supplying Roy Hill with a new primary jaw gyratory crusher. This is the third order for such machine within a short time in Australia. It shows once again the confidence our customers in the country place in crushing equipment from thyssenkrupp.”

The jaw gyratory crusher is characterised by an especially enlarged feed opening, according to thyssenkrupp. It is normally serrated and, together with the upper part of the mantle, forms the initial crushing zone. The coarsely crushed material is then reduced to the desired product size in the crushing chamber below.

Jaw gyratory crushers can handle much bigger chunks of material than comparable gyratory crushers of the same mantle diameter and feature a higher crushing ratio, with less tendency to become clogged in the feed zone as a result of bridging, the company concluded.

Primero Group to take on EPC contract at Rio’s Koodaideri iron ore mine

Mine operation news, Mineral processing, Mineral project development, Mining services, Precious metals, Steel and iron ore, , , , , , , , , ,

Primero Group has secured a A$115 million ($79 million) contract with Rio Tinto’s iron ore division that will see it design, fabricate, supply, deliver, construct, install, test and commission the Mine Infrastructure Area and associated facilities at the Koodaideri iron ore project in the Pilbara of Western Australia.

The scope includes the complete engineering, procurement and construction (EPC) contract of the facilities for this project, which will commence immediately and is scheduled to be completed in mid-2021.

Primero says it expects to employ a workforce of over 150 personnel at its peak.

Koodaideri, billed by Rio as an “intelligent mine”, will deliver a new production hub for Rio’s iron ore business in the Pilbara, incorporating a processing plant and infrastructure including a 166 km rail line connecting the mine to the existing network.

Construction on Koodaideri Phase 1 started this year with first production expected in late 2021. Once complete, the mine will have an annual capacity of 43 Mt, underpinning production of the company’s flagship iron ore product, Pilbara Blend.

In addition to mine infrastructure and the accommodation camp, an airport and mine support facilities will be built. Throughout the construction period, Rio expects to employ over 2,000 people with 600 permanent roles created once the mine is operational.

In addition to the Koodaideri work, Primero said it had been awarded Phase 2 of the proposed processing upgrade, on an engineering, procurement and construction management (EPCM) basis, for Northern Star Resources’ Pogo gold mine, in Alaska, USA.

The works will be conducted predominantly from Primero’s Americas Montreal (Canada) office with works progressively executed this winter to ensure construction windows are met in the summer period, it said.

The upgrade works will increase throughput of the current processing facility from 1 Mt/y to 1.3 Mt/y by January 2021, with the potential to move to a Phase 3 (1.5 Mt/y) over the coming years.

Primero said: “Works are set to progress over the next 12 months including detailed design and equipment procurement with the planning for on-site works commencing over the winter period to be executed in the warmer months, post winter.”

The award of the project is the first major contract with Northern Star Resources, Primero added.

Northern Star acquired Pogo, the company’s first mine outside of Australia, from Sumitomo Metal Mining late last year for $260 million.

REMA TIP TOP Australia belts up at BHP South Flank project

Bulk handling, Equipment maintenance, Mining consumables, Mining maintenance, Mining services, Steel and iron ore, , , , ,

REMA TIP TOP Australia has been selected by Monadelphous to install more than 50 km of conveyor belting for the BHP-owned South Flank iron ore project, in the Pilbara of Western Australia.

A key component of the project to build the $3.6 billion mine, the conveyor belting will be delivered with splice kits and the installation and splicing of steel cord and fabric belt on five conveyors systems, three of which are overland conveyors, with 77 rolls of belt to be installed and 77 splices to be completed in total. REMA TIP TOP Australia will assist Monadelphous in this work.

The conveyor solutions specialist has worked with Monadelphous on a range of major projects in the past and it is this proven track record that was critical in securing the project for the business, it said.

Steve Hipwell, REMA TIP TOP Australia Projects Manager, said: “This project represents a significant win for the business and is a testament to the commitment we have shown to delivering quality projects.

“Monadelphous have a substantial pipeline of works in the resources, energy and infrastructure sectors so it’s great to continue to build on our successes with this leading engineering company.”
Hipwell said mobilisation was set to begin in the June quarter.

Earlier this year, Fenner Dunlop secured the contract to manufacture and deliver the overland conveyor belt package to South Flank.

BHP is targeting first ore extraction at the operation in 2021 and expects to ramp up to 80 Mt/y of output. This will replace production from the existing Yandi mine, which is reaching the end of its economic life.