Tag Archives: Pilbara

Novo looks to scrap metal industry for Egina gold nugget separation options

Novo Resources says it has completed encouraging processing trials on gravels extracted from its joint venture Egina gold project, in the Pilbara of Western Australia, at Steinert’s testing facility in Cologne, Germany.

Phase one of the company’s joint venture with Sumitomo Corp at the Egina gold project centres around gaining a better understanding of geology (grade, continuity, controls, gold particle size distribution, gold location within gravels, gold genesis, etc.) but also involves high level desktop studies and trials to develop potential future processing and mining methodologies.

Preliminary tests of eddy current separator (ECS) technology indicate promising potential to directly extract gold nuggets from gravel, the company said. This is one of several dry processing methodologies being considered by Novo for gold recovery at the project.

Tests conducted on a spectrum of nugget sizes ranging from 1-10 mm demonstrated consistently high gold nugget recovery via ECS technology. Nuggets that underwent testing were recently extracted from gravels at Egina, the company said.

ECSs are predominantly used to recover select metals in the scrap metal industry. Material is fed onto a conveyor, the head pulley of which contains an adjustable high-powered magnet spinning at very high rotation rates, 4,000 rpm in Novo’s tests, independent of the speed of the conveyor, Novo said. This spinning magnet induces an alternating magnetic field that differentially repels non-magnetic metals such as gold.

This magnetic repulsion causes gold nuggets to lift, or fling, off the end of the conveyor belt where they can be separated from waste material by a steel plate. These trials were designed to establish whether Egina gold nuggets react sufficiently to reliably be separated from waste material.

Novo said: “Gold at Egina predominantly occurs as free nuggets of which most are above 1 mm in size. This presents opportunity to explore innovative technologies, some used commercially in other applications such as ECS technology, to assess their efficacy for use at the Egina gold project.”

In addition to ECS technology, Novo conducted initial testing of Steinert mechanical sorting technology to detect small gold nuggets utilising an Argos EM electro-magnetic sensor, it said. Fine gold nuggets, around 1 mm, were consistently and readily detected indicating potential for direct mechanical sorting of gold nuggets, Novo said.

As a result, a combination of mechanical sorting and ECS technology is also being considered as a potentially viable means of dry processing at Egina, the company said.

Rob Humphryson, CEO and Director of Novo, said: “We are very encouraged by these initial laboratory test results utilising ECS technology. Our mantra when testing new technology and its application to our projects is to ‘test quickly and test cheaply’, and we now have in hand sufficient encouragement from these tests to consider ECS technology highly prospective for application in the field.”

The company said this preliminary testing shows ECS technology can play an important role at Egina, with potential application as a processing solution or an exploration tool, or both. “This technology generates significant inherent advantages: it requires no water, no chemicals, is of low capital cost and is readily mobile. It can also be employed along with other technologies and is scalable,” the company said.

Novo thinks field tests are warranted at larger scale to better understand recovery efficiencies, operating costs and throughput rates and the Company plans further work with Steinert to study schemes in which ECS machines, or ECS machines in combination with mechanical sorting technology, can achieve efficient recovery of gold nuggets at Egina.

The company concluded: “As Novo learns more about gold size particle and mass distribution of gold in Egina gravels, the company can then begin to estimate gold recovery.”

Battle for greenfield mining autonomy

The big two global giants in autonomous mining truck solutions continue to battle it out in chasing new contracts, especially for greenfield mines that offer a chance to supply more profitable “new” autonomous fleets as opposed to retrofitting autonomous capability onto existing fleets.

The main battle grounds remain Australian iron ore in Western Australia’s Pilbara region and Canadian oil sands in the Alberta production hub centred on Fort McMurray, though there are also surface haul truck autonomy trials ongoing in other mine types such as iron ore in other parts of the world, gold, coal and copper.

In iron ore the competition has turned traditional norms on their head.

Rio Tinto, traditionally a Komatsu truck user, announced earlier in 2019 that it had agreed to work together with Caterpillar to create an automated mine operation at the Koodaideri iron ore project, in Western Australia. The agreement will see Cat® and dealer WesTrac supply and support mining machines, automation and enterprise technology systems for the new mine. Rio, in a separate release, said this would see the supply of a fleet of 20 new autonomous 793F trucks.

Then in September, BHP, traditionally a Caterpillar truck user, turned the tables again by announcing that it will deploy 41 new Komatsu 930E-5 ultra-class autonomous haul trucks at its new South Flank iron ore mine in the Pilbara region of Western Australia, commencing in October 2019.

But OEM battles aside, autonomy comes with its own issues. This includes the mine having sufficient network capacity in place but also other practicalities like how it ties in with haul road design and how it affects OTR tyre performance.

This tyre angle is being delved into in some detail by Tony Cutler, Principal at specialist consultancy OTR Global, at the forthcoming inaugural Truck & Shovel Conference from International Mining Events, running 19-20 September in Singapore at the InterContinental, Middle Road.

His talk, “Factoring tyres into autonomous haulage”, will point out that since 2008, over 400 autonomous haul trucks have entered commercial operation on open-pit mines and, while autonomous haulage offers improved productivity, safety and operating cost, he argues that the main constraint to maximising these benefits is tyres. This presentation identifies the limitations associated with tyres – some inherent to the tyres, others to the autonomous systems and operating environments – and suggests solutions.

Cutler will be joined in an autonomy related session by Drew Larsen, Director of Business Development, ASI Mining, in a presentation titled: ‘Autonomous Mining – more feasible than you might think’.

The company, 34% owned by global mining OEM Epiroc, began work on a project with Barrick Gold to retrofit and automate a fleet of Komatsu 930-E Ultra Class haul trucks at the Arturo joint venture operation in Nevada, last year, and judging from Barrick’s commentary in its June quarter results, the gold miner is happy with how things are going.

Interestingly, Barrick said initially none of the OEMs wanted to engage in the project, “due to the mammoth task of retrofitting an autonomous system to a 20-year-old fleet of ultra-class trucks and the technological limitations that come with that age of machine”.

Barrick found another partner in ASI that specialises in autonomous solutions both inside and outside the mining industry and has now successfully completed a proof of concept (POC) utilising five haulage units “that have delivered over 5.5 Mt faster than any other similar POC in the industry”, it said.

These autonomous solutions require a lot of data to be effective and while there are no shortages of nodes on equipment nowadays, the haulage and loading industry is still coming to terms with how best to leverage this data.

Speakers from Komatsu will be confronting this issue head on at the event, with Jason Knuth, Senior Manager – Data Solutions, and Simon Van Wegen, Product Manager – Data Solutions, presenting a keynote titled, “Data-driven designs for dynamic mining environments”.

The two intend to reveal how OEMs are leveraging the plethora of data nodes on smart equipment to adapt equipment and design solutions for the modern mine environment.

To hear from more speakers like this, register for Truck & Shovel by clicking here.

Weir secures largest-ever individual mining order from Fortescue

The Weir Group says it has been awarded a £100 million ($123 million) order to provide industry-leading energy saving solutions to the Iron Bridge magnetite project, a joint venture between Fortescue Metals Group and Formosa Steel IB.

The order, which includes a range of Weir crushing and pump equipment including Enduron® high pressure grinding rolls (HPGRs) and GEHO® pumps, will reduce energy consumption and wet tailings waste by more than 30% compared with traditional mining technologies, according to the equipment manufacturer.

The Iron Bridge project, 145 km south of Port Hedland in the Pilbara region of Western Australia, is a $2.6 billion investment in premium magnetite iron ore reserves with annual production, when the mine is fully operational, of 22 Mt/y of 67% Fe concentrate. Delivery of the first ore is expected in 2022.

When the mine build was approved back in April, Fortescue CEO, Elizabeth Gaines, said the innovative design for the project, which included the use of a dry crushing and grinding circuit, “will deliver an industry-leading energy efficient operation with globally competitive capital intensity and operating costs”.

A pilot project to verify the Iron Bridge project design involved processing 1 Mt of ore through a full scale HPGR and air classifier, according to Fortescue.

Weir Group Chief Executive Officer, Jon Stanton, said: “We are delighted to have secured this landmark contract, which is Weir’s largest-ever individual mining order.

“Fortescue challenged us to help create one of the most energy and cost-efficient magnetite ore processing facilities in the world. Our engineers have worked relentlessly to design a solution that is truly innovative – delivering significant energy, water and cost savings. This is a great example of working in close partnership with an ambitious customer who shares our passion for using innovative engineering to make mining more productive and sustainable.”

Ricardo Garib, President of the Weir Minerals division, added: “Our team are really enjoying working with Fortescue. Our engineers relish a challenge and it has been great to work on a project that demonstrates the substantial cost and environmental savings that our range of solutions can offer.

“As more mines look to increase productivity, we look forward to even more opportunities to leverage our combination of passionate people, innovative solutions and comprehensive global service capability.”

Weir’s Enduron HPGRs are increasingly replacing conventional mills in comminution (crushing, screening and grinding) circuits because of their substantially lower energy consumption and potential for significant total cost of ownership reduction, Weir says.

“Not only do they require as much as 40% less energy than traditional alternatives, but their wearable components last much longer and the maintenance time required to replace worn out parts is significantly lower.”

The company outlined the reasons why companies are turning to Enduron HPGRs in a blog post earlier this week.

Monadelphous, BGC win West Angelas iron ore work off Rio Tinto

Engineering firms Monadelphous Group and BGC Contracting will help construct new facilities for Rio Tinto’s West Angelas iron ore mine, in the Pilbara of Western Australia, after the major miner awarded the two companies contracts.

Monaldelphous said its contract at West Angelas Deposits C and D, valued in excess of A$100 million ($68 million), includes the supply and installation of structural, mechanical, piping and electrical and instrumentation works associated with the construction of new iron ore facilities, as well as modifications to existing plant.

The work will commence immediately and is expected to be completed in April 2021.

BGC Contracting, meanwhile, will deliver civil infrastructure work as part of the same project. This includes carrying out bulk earthworks and civil works necessary to construct the heavy and light vehicle road networks that will connect the existing processing plant with the new C and D deposits.

In addition, BGC Contracting will construct the concrete foundations for the planned facility, as well as a HDPE water pipeline and install 17.5km of PVC conduit. BGC said work was due to commence on site in early October, with completion in less than a year. Detailed planning and mobilisation are already underway, it added.

Back in October, 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 to sustain production of its Pilbara Blend products, with first ore anticipated from 2021.

Once operational, both projects will feature the latest technology with 34 existing haul trucks to be retrofitted with autonomous haulage system technology, it said.

Monadelphous Managing Director, Rob Velletri, said his company’s contract award highlighted Monadelphous’ strong reputation and proven capability in delivering large-scale construction projects.

BGC Contracting CEO, Greg Heylen, said: “The West Angelas project will display the multidisciplinary capability of our construction team to deliver this large earthworks and civil works project.

“This latest contract award is a further step in the company’s diversification strategy. We look forward to working with Rio Tinto and all stakeholders to deliver this large-scale project.”

Rio Tinto continues to invest in Pilbara haul truck automation

Rio Tinto, in its half-year results, provided an update on its haul truck automation efforts at its iron ore mines in the Pilbara of Western Australia, saying it expects to hit some significant milestones by the end of 2019.

The company, one of the first adopters of autonomous haulage systems through a commercial trial at its West Angelas operation all the way back in 2008, said it had continued investing in productivity and automation in the first six months of 2019 and expected 50% of its iron ore truck fleet to be fully autonomous by the end of the year.

The company said: “Deployments are complete at seven of our sites, with Hope Downs 1 and Marandoo in transition.”

Last week, Fortescue Metals Group (FMG) said its plan to automate all haul trucks across its Pilbara iron ore network was going to plan, with 128 trucks running in autonomous mode as of the end of June.

Meanwhile, Rio said its AutoHaul project, which sees 2.4 km long trains travel across a network of 1,700 km of track, all monitored remotely from an operations centre in Perth, was now fully operational. These trains have safely travelled more than 4.5 million kilometres autonomously since they were first deployed last year.

BHP extends FIFO agreement with Alliance in Western Australia

Alliance Aviation Services says it and BHP’s Western Australia Iron Ore division have agreed to extend their air charter services agreement for a further two years.

The extension solidifies a relationship that started with the first flight for BHP WA Iron Ore in 2009, Alliance said.

BHP’s WAIO division 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. At each processing hub – Newman, Yandi, Mining Area C and Jimblebar – the ore is crushed, beneficiated (where necessary) and blended to create high-grade hematite lump and fines products. Iron ore products are then transported along the Port Hedland–Newman Rail Line to the Finucane Island and Nelson Point port facilities at Port Hedland.

Lee Schofield, Alliance’s Chief Executive Officer, said: “Alliance is delighted to be continuing the provision of these charter services into Coondewanna and Barimunya. Our commitment to safety and providing our clients with industry leading on time performance has played a significant role in being awarded this extension.”

Schofield, added: “In May this year, BHP acknowledged Alliance’s exceptional safety and operational record when BHP presented Alliance with an Aviation Safety Award in recognition of the safe carriage of 3.5 million BHP staff and contractors on charter and scheduled services throughout Australia from April 2002 to April 2019.”

WA government, EPA approves BHP’s strategic 50- to 100-year Pilbara mining plan

The Western Australia Government has approved a 50- to 100-year strategic mining proposal for the Pilbara by BHP, which outlines bold plans for new and existing mines, the state said.

BHP’s Pilbara Expansion Strategic Proposal details a cumulative picture of the miner’s planned and potential operations across the Pilbara, including mining operations, rail, storage areas, dams and associated mine infrastructure.

It mentioned new potential mining operations at Caramulla, Coondiner, Gurinbiddy, Jinidi, Marillana, Mindy, Ministers North, Mudlark, Munjina/Upper Marillana, Ophthalmia/Prairie Down, Rocklea, Roy Hill and Tandanya; alongside future expansions of existing mining operations at Jimblebar, Mining Area C, Newman and Yandi (pictured).

This type of “strategic proposal”, which the Environmental Protection Authority (EPA) has approved with conditions, “helps reduce red and green tape, allowing the EPA to consider the cumulative impacts of future proposals, rather than assessing impacts on a case-by-case basis, as individual mines or developments are proposed”, according to the government.

The EPA assessed the impacts to flora and vegetation, fauna, water quality and quantity, air quality as well as social surrounds, with the ministerial statement for BHP’s strategic proposal including conditions that may be applied to each development, including environmental management plans, a cultural heritage management plan, a mine closure plan and offsets through contributions to the Pilbara Environmental Offsets Fund where significant residual impacts remain.

“BHP is required to refer future individual proposals outlined in the ministerial statement to the EPA to determine if they meet the high environmental standards set by the strategic assessment,” the government said.

WA Premier, Mark McGowan, said BHP’s plan has the potential to deliver tens of thousands of jobs for Western Australians.

“We expect this Australian-first plan will reduce environmental approval times by up to 50%, while maintaining the highest environmental standards,” he said.

“Industry has been crying out for this type of plan. It recognises the need to reduce unnecessary ‘green tape’ to increase investor confidence, and pave the way for more jobs. It is another sign our economy is improving with the major miner taking a long-term view of its proposals in the state.”

Environment Minister, Stephen Dawson, meanwhile, said: “The Pilbara region holds immense environmental value and a key focus of the EPA assessment was to ensure the proposal did not significantly impact on important regional environmental values, including Karijini National Park and Fortescue Marsh.

“Strategic proposals allow the EPA to take a bigger picture view of the potential environmental impacts the proposals may have, considering the cumulative impacts rather than on a case-by-case basis, as individual mines or developments are proposed.”

Fortescue breaks ground at $1.275 billion Eliwana iron ore development

Fortescue Metals Group says it has officially broken ground on the Eliwana iron ore mine and rail project in the Pilbara of Western Australia.

FMG Founder and Chairman, Andrew Forrest, was today joined by Mark McGowan, Premier of Western Australia, FMG CEO, Elizabeth Gaines, and the company’s core leadership team, for the official sod turning.

The $1.275 billion project includes the construction of 143 km of rail, a new 30 Mt/y dry ore processing facility (OPF) and infrastructure. First ore on train is expected in December 2020, the company says.

FMG says contracts to the value of A$330 million ($232 million) to date have been awarded to more than 250 Australian business entities as part of the Eliwana development, of which 80% are Western Australia-owned businesses. As further approvals are progressed, it is expected over A$500 million in additional contracts will be awarded by the end of 2019, FMG said.

Contract recipients include BGC Contracting for bulk earthworks and roads, NRW Holdings, also for bulk earthworks, and SIMPEC for electrical, communications and dry fire systems testing.

“Eliwana underpins the sustainable production of West Pilbara Fines and provides the flexibility for Fortescue to deliver products at greater than 60% Fe grade,” FMG said. “The development will utilise the latest technology, autonomous trucks and design efficiency, further cementing Fortescue’s world leading use of innovation across its mining operations.”

Forrest said: “This is a proud day for Fortescue as we celebrate the largest project since the Kings Valley mine in 2014.

“Since Fortescue was founded 16 years ago, we have held community and family at our core and continued to deliver on our commitment to be the safest, lowest cost company. Eliwana is the next great step into the Western Hub, enhancing our profitability and extending our mine life.”

The project will generate up to 1,900 jobs during construction and 500 full-time site positions once operational, according to Forrest.

Gaines said: “The Eliwana project will build on Fortescue’s unparalleled track record and capability in safely developing and operating major iron ore projects in the Pilbara. Eliwana is core to the next phase of development in Fortescue’s world class, innovative operations. The project will see us maintain our low-cost status, provide us with greater flexibility to deliver on our integrated operations and marketing strategy and, when combined with the Iron Bridge Magnetite development, it will increase Fortescue’s average product grade and provide the ability to deliver the majority of our products at greater than 60% Fe, consistent with our long term goal.”

Vossloh to keep Rio Tinto’s Koodaideri iron ore plans on track

Vossloh Tie Technologies says it has won its first major order in Australia for the delivery of concrete ties for Rio Tinto’s in-development Koodaideri iron ore project in the Pilbara of Western Australia.

The production and supply of the ties will be performed by Vossloh’s Australian subsidiary, Austrak Pty Ltd, which was acquired in late-2018. The order encompasses approximately 280,000 concrete ties, expected to be delivered in 2020.

Koodaideri will include construction of an additional rail line to connect the new mine to Rio Tinto’s existing network. This is where Vossloh’s concrete crossties come in, providing improved track surface, alignment and gauge holding performance; strong, stable track structures to support high speed and heavy haul rail applications; smooth running surface to lower overall costs by increasing rail life and reducing locomotive fuel consumption; and longer lifecycles by providing exceptional durability and resistance to weathering and corrosion, according to the company.

Production at the $2.6 billion Phase 1 Koodaideri project is planned to start in late 2021, before ramping up to the nameplate 43 Mt/y capacity.

Austrak will perform the deliveries from a factory in Western Australia, which will also serve as a production site for further upcoming mining projects in the Pilbara region, Vossloh said. This will provide the potential to offer further growth opportunities for the company in Australia.

Andreas Busemann, Chief Executive Officer of Vossloh AG, said: “We are excited to see that our recent acquisition Austrak succeeded in this tender, contributing substantial value to Vossloh shortly after acquisition. This perfectly underlines the company’s strong position in Australia’s concrete tie market and once again confirms Vossloh’s outlook for the 2020 fiscal year, seeing an increase in sales and profitability.”

Rio and Hitachi Rail STS celebrate AutoHaul achievements

Rio Tinto and its lead technology partner on the AutoHaul™ project, Hitachi Rail STS, joined together today to celebrate the successful deployment of the world’s first automated heavy-haul long distance rail network.

AutoHaul trains, which deliver safety and productivity benefits for Rio Tinto’s iron ore business, have also firmly positioned Western Australia and its heavy-haul rail industry as a global leader in the joint development and application of rail technology, Rio said.

Today, 2.4 km long trains, monitored remotely from an operations centre in Perth, travel across a network of 1,700 km of track, delivering iron ore from 16 mines to ports in Dampier and Cape Lambert in Western Australia. These trains have now safely travelled more than 4.5 million kilometres autonomously since they were first deployed last year.

“This world-first was made possible by the close collaboration with project partners from Japan, US and Australia,” Rio said. “These include Hitachi Rail, Calibre, New York Air Brake, Wabtec and others who provided the necessary expertise, innovation and software to make AutoHaul a success. Several of these partners maintain a strong presence in Western Australia and have committed to continuing to invest locally.”

Rio Tinto Iron Ore Managing Director Rail, Port & Core Services, Ivan Vella, said: “The success of AutoHaul would not have been possible without the expertise, collaboration and dedication of teams within Rio Tinto and our numerous partners. I’d also like to commend our train driving workforce for their support and professionalism during the transition period.

“This project has cemented Western Australia as a leader in the heavy-haul rail industry and has attracted interest from around the world. The successful deployment of the world’s first heavy-haul long distance rail network demonstrates the potential for significant further improvement in such operations with others around the world looking to replicate.”

Western Australia Minister for Mines and Petroleum Bill Johnston, who also joined in with the celebrations, said the AutoHaul project is a world-first and an example of the strength of Western Australia’s resources industry, which continues to excel in technology and innovation.

“I’d like to congratulate Rio Tinto, Hitachi and all the other project partners for their hard work and dedication over the past decade to delivering this project, which really cements our State as a global leader in rail technology,” he said.

“AutoHaul has brought the rail freight industry in this country into the 21st century and is rightfully the subject of global interest. I’d also like to mention that the development of the world’s biggest robot is such a success because of the contribution from Western Australia’s skilled engineers and innovative workers.”

Michele Fracchiolla, President Americas and APAC Business Unit, Hitachi Rail STS, said: “Hitachi Rail STS is extremely proud of the lead technical and delivery role it played in enabling the deployment of the world’s first fully-autonomous heavy haul, long distance rail operation.

“This is a new technical benchmark for the freight rail industry worldwide and the result of a long-established and collaborative partnership between Rio Tinto and Hitachi Rail STS. Now that the trains are running autonomously, the levels of continuous improvement that can be achieved in safety, operational efficiency and sustainability are endless, and we look forward to continuing to collaborate with Rio Tinto to enhance the AutoHaul system.”

Early results from the deployment of the $940 million AutoHaul program highlight the technology’s potential to improve productivity, increase flexibility and reduce bottlenecks in Rio Tinto’s iron ore system, the miner said. “Rio Tinto’s Pilbara operations are being transformed to flex in line with market conditions and AutoHaul is a vital component in increasing flexibility and safety in the system.”

Rio operates about 200 locomotives on what is the largest privately-owned rail network in Australia and, in December, the deployment of software on Rio Tinto’s locomotives was completed.

“Autonomous trains improve safety through reduced risk at level crossings and automated responses to speed restrictions and alarms,” Rio says. “AutoHaul also removes the need for almost 1.5 million km of road travel per year previously required to transport drivers to and from trains mid-journey.”

All locomotives are fitted with AutoHaul safety systems including collision detection systems, automatic train protection technology – which controls train speed to ensure adherence to speed limits – and an on-board video camera to record the front view from the train.

The average return distance of these trains is about 800 km with the average journey cycle, including loading and dumping, taking about 40 hours. All public rail crossings on the network are fitted with CCTV cameras and have been upgraded to the highest safety standards, according to Rio.