Tag Archives: Pilbara

BHP’s South Flank to receive world’s largest rail-mounted stackers and reclaimer from thyssenkrupp

thyssenkrupp Industrial Solutions has been awarded one of the largest fabrication and construction projects the company has ever handled in Western Australia, with an order from BHP’s South Flank iron ore operation.

Under the €150 million ($171 million) contract, thyssenkrupp will design, supply, construct and commission large-scale stockyard machines for South Flank, in the central Pilbara region.

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. The company carried out the first blast at the project in September.

thyssenkrupp will supply two stackers that deposit iron ore into stockyards for loading, and a reclaimer for loading the ore on to trains for transport to Port Hedland. The machines will have a capacity of 20,000 t/h, making them the largest rail-mounted stackers and reclaimer in the world, according to the company.

Torsten Gerlach, CEO Mining Technologies at thyssenkrupp Industrial Solutions, said: “South Flank will be one of the largest iron-ore operations worldwide. We look forward to contributing to this project by combining longstanding global expertise in the mining business with local experience.

“Our strong partnership with BHP extends globally, but the Pilbara region is a core area where we have provided material handling solutions for decades. With our field service teams, we are supporting our customer on a daily basis.”

The design of the machines incorporates the latest Australian design standard requirements and technology improvements centred on safe construction, operation and maintenance activities, according to the company.

 

Fortescue’s autonomous haul truck fleet at Christmas Creek still growing

Fortescue Metals Group has now seen 35 manned haul trucks converted to autonomous mode at its Christmas Creek operations in the Pilbara of Western Australia, with Caterpillar recently completing a Command for hauling installation on a Komatsu 930 E, according to the iron ore miner.

The company shared the news ahead of an investor and media tour of the company’s operations this week.

During the tour, attendees will take in details of the company’s new 60.1% Fe product, West Pilbara Fines, in addition to viewing the innovative relocatable conveyor that started operating earlier this year.

Visitors can also expect to see first-hand Fortescue’s roll out of autonomous haulage technology. This includes a global first where Cat Command for hauling, part of Caterpillar’s MineStar technology offering first used on a commercial scale at Fortescue’s Solomon Hub operation, has been retrofitted on a CAT 789D and a Komatsu 930E haul truck.

Chief Executive Officer Elizabeth Gaines said: “Fortescue has led the way globally in embracing automation at our operations. The 789D is the 35th manned truck to be converted to autonomous at Christmas Creek, demonstrating our progress to becoming the only iron ore operation in the world to have a fully autonomous haulage fleet.”

Gaines said the tour will also see the company discuss Fortescue’s new energy agenda, including the integration of renewable energy and its recently announced landmark partnership with CSIRO to commercialise hydrogen technology.

New generation Scania XT trucks go to work at Pilbara mine site

Scania’s first new truck generation XT mining chassis have arrived in Australia and are already in use at a Pilbara mine site in Western Australia.

The two Scania NTG G 450 8×4 twin steer chassis have been fitted with new, higher-capacity 40,000-litre Shermac water cart bodies for the customer.

Scania says the tailor-made Shermac bodies are more than double the capacity of those fitted to traditional road-going trucks used on mine sites and are designed to replace mine-specific road train combinations.

“The new Scania XT trucks offer the customer a more cost-effective solution to the requirement for dust suppression and road building assistance on-site,” Scania says.

Robert Taylor, General Manager, Mining at Scania Australia, said the mining customer has had experience operating a fleet of Scania trucks on-site as service vehicles, flatbeds and technical support vehicles for the past year.

“The trucks were in service 24-hours per day, seven-days per week and have clocked up around 70,000 km on-site in their first 12 months. They have been very reliable in service and the drivers enjoyed the comfortable and quiet Scania cab,” he said.

“When we were discussing the replacement of the customer’s existing water carts, we suggested a more flexible solution, in the form of the NTG 450 XT 8×4 as they could handle the higher payload of 40,000-litres for a GVM (gross vehicle mass) of around 66 t,” Taylor said.

The water carts are also on call 24/7 and reliability is very important to the customer, Taylor added.

“They work in an extremely harsh environment where there is a lot of dust and heat and so water cart availability is critical to the mine’s operations. The vehicles will be serviced on-site to maximise uptime,” he said.

This new high-capacity water cart underscores Scania’s ability to configure a vehicle exactly to a client’s needs, according to Taylor.

“Our client wanted a reliable, high-capacity vehicle that could be maintained easily and quickly and one that could do the job day-in, day-out. The new Scania XT range is designed for these conditions and, in addition to being able to source and fit a suitable body, we have been able to deliver a solution at a reduced capital cost to the client compared with their previous solution,” he said.

“One of our longer-term goals has been to be able to offer our customers the ability to replace their very high-cost capital equipment with Scania solutions that provide a greater degree of resource utilisation flexibility as well as cut their capital expenditure without compromising availability or productivity. And we are able to deliver solutions in a timelier manner as well.

“With these new XT water carts we believe we are taking another significant step towards delivering on that strategy,” he said.

Jim Ray, who controls sales and sales management at mining engineering equipment supplier Shermac, said Scania was confident the 8×4 chassis would be suitable for this 40,000 litre payload, having seen 66 t payloads used widely in tipper configurations in South America and Indonesia mine sites.

“All of our water carts are custom designed and extensively tested to ensure optimum weight distribution and performance no matter how tough the environment or challenge,” Ray said.

“With liquid loads you do get high dynamic forces, but our Roadserve 2000 model water cart is well baffled and on-site speeds will be low and there are few inclines, allowing the vehicles to do their jobs reliably. Scania also has a lower centre of gravity compared with the previous solution, which also aids stability and safety,” he said.

The Scania NTG XT range has been designed for challenging operating conditions and comes with a 150 mm protruding steel front bumper bar that protects the vehicle against significant frontal knocks.

With protective grilles for the LED headlights, a fold-down bumper-mounted step to allow safe access for windscreen cleaning on-site, and a 40 t capacity tow point, the XT is suited to the operating conditions of a mine site. Additionally, Scania has added extra tough door mirror covers for the XT, as they are often very vulnerable to accidental damage.

Within the NTG cabs, all drivers are seated more comfortably in new seats, positioned closer to the screen and door for enhanced visibility, while repositioned A-pillars and mirrors provide an even safer and enhanced view out to the front and side.

The G 450 B8x4HZ chassis selected by the customer has a 5,950 mm axle distance, and two 12 t front axles and two 21 t rear drive axles for a GVM of 66 t.

The 450 hp (336 kW), 13 litre, six-cylinder in-line engine drives through a Scania Opticruise automated gear-change and GRSO935R transmission, with specific off-road mode built into the management system.

The latest and highest output Scania hydraulic retarder system is fitted to provide safe braking, preserving the service brake linings on the drum brakes, which are backed by ABS.

Steel leaf spring suspension all-round provides a solution for the on-site driving environment, backed up by a heavy-duty mechanical suspension for the cab to chassis connections. A new electrically powered cab tilting mechanism is occupational health and safety friendly, as well, Scania says.

Within the low roof day cab, the Scania XT is fitted with a steering-wheel mounted airbag as well as driver and passenger side curtain airbags designed to protect occupants in the event of a rollover.

Caterpillar busy with Pilbara automation retrofit on Komatsu 930E haul trucks

Caterpillar says it is putting its commitment to retrofit solutions and mixed-fleet interoperability into practice by installing Cat® MineStar™ Command for hauling technology on Komatsu 930E mining trucks in the Pilbara of Western Australia.

The first commercial installation of the automation retrofit package will be completed before the end of the year, the company said, with 24 of the retrofitted, 290 t capacity 930E trucks working autonomously alongside the mine’s fleet of autonomous Cat trucks.

Craig Watkins, MineStar Solutions Manager, said: “Our interoperability initiative is driven by mining companies’ goals of making best use of their existing fleets.

“The Cat system makes it possible to operate different brands and sizes of trucks as well as manned trucks and autonomous trucks in the same space. Dynamic truck assignment optimises productivity. Our system also offers the flexibility to scale up fleet size to meet the mine’s needs.”

MineStar Command for hauling also allows trucks, no matter the payload or manufacturer, to operate at their full capabilities.

“The productivity gains attributed to Command for hauling are proven and growing,” the company said. For example, Caterpillar customer Fortescue Metals Group has measured a 30% improvement in productivity from its fleet of 70 Command-equipped trucks working at its Solomon Hub iron ore mines, also in the Pilbara, according to Cat.

In addition to the commercial launch of the 930E system, the first trial of autonomous Cat 797F mining trucks is underway at a mine in North America, Caterpillar said.

With nominal capacity of 363 t, the 797F is Caterpillar’s largest truck. It will join the 227 t capacity Cat 793F CMD, already operating in the Canadian oil sands, South America and Australia, in the autonomous truck line up.

Monadelphous wins more iron ore work off BHP

Australia-based engineering group Monadelphous has been awarded a contract with BHP’s iron ore division worth approximately A$240 million ($172 million) over a three-year period.

The contract, which contains an additional two one-year extension options, involves the provision of general maintenance services at BHP’s Mt Whaleback, Jimblebar, Eastern Ridge, Mining Area C and Yandi mine sites, in the Pilbara of Western Australia.

Monadelphous Managing Director, Rob Velletri said the contract built on the company’s long-standing relationship with BHP, on both construction and maintenance projects, over the past two decades.

“We look forward to further developing our relationship with BHP over the coming years, growing our operational footprint in the Pilbara and continuing to strengthen our long-term commitment to the region and the communities in which we operate,” he said.

In 1996, Monadelphous’ engineering and construction division ventured into the iron ore market with BHP on the Yandi II project to construct the crushing and screening plant, while, in 2008, it secured part of the structural, mechanical and piping works for BHP’s Rapid Growth Project 4 at the Newman Hub iron ore processing facility.

Civmec readies for first shutdown maintenance campaign at Roy Hill iron ore mine

Australia-based Civmec Ltd’s maintenance team is about to mobilise to Roy Hill Holdings’ iron ore operations in the Pilbara of Western Australia as it commences the first shutdown campaign of its long-term services contract with the company.

In July, Civmec was awarded a maintenance contract with Roy Hill and the company is now “working collaboratively on planning, drawing experienced personnel from its extensive resource pool to ensure this first phase of a long maintenance campaign is delivered seamlessly”, it said.

Civmec said the outcomes of this first phase of work, due to start this month, will dictate the client’s approach to ongoing maintenance.

The contract includes providing mechanical, scaffolding, electrical, conveyor and shutdown management services, according to the company.

Civmec said this contract, and others recently secured with the likes of Alcoa, Rio Tinto and Fortescue Metals Group, was the direct result of investing in dedicated maintenance facilities nationally, together with bolstering its maintenance management team capability, training and recruiting.

Patrick Tallon, Civmec’s CEO, said: “We see the commitment towards the continual growth of a maintenance division as a very strategic move to support the significant requirement to maintain the many new plants that have recently been constructed in the minerals and metals and oil and gas sectors across Australia.”

Civmec has traditionally been thought of as a multi-disciplinary heavy engineering construction company.

Roy Hill is a 55 Mt/y iron ore mining, rail and port operation in Western Australia’s Pilbara region. Civmec previously carried out four contracts as part of the build, included heavy engineering and structural, mechanical, piping and electrical instrumentation packages.

FMG backs Western Australia Aboriginal businesses in latest contract awards

Fortescue Metals Group has awarded more than A$6 million ($4.4 million) worth of contracts to two Western Australia Aboriginal businesses, as part of the iron ore company’s Billion Opportunities programme.

Aboriginal-Noongar owned business Kooya Australia Fleet Solutions, Australia’s largest indigenous fleet management and rental company, has been awarded a three-year contract for the supply of light and commercial leased vehicles across Fortescue’s operational sites, while majority owned Aboriginal business Thuroona Services has been given a contract for maintenance work at Fortescue’s rail operations.

Since the inception of Fortescue’s Billion Opportunities in 2011, 270 contracts and sub-contracts valued at A$2 billion have been awarded to 110 Aboriginal-owned business and joint ventures, Fortescue said.

Fortescue Chief Financial Officer Ian Wells said the contracts signified the company’s continued commitment to supporting local content as part of its procurement process.

“By partnering with Aboriginal businesses to build their capability and capacity, we are opening the doors to future work with other organisations which is fundamental to their economic sustainability and prosperity,” he said.