Tag Archives: stacker

Bedeschi stacker, conveyor being commissioned at Shougang Hierro iron ore ops

Close to eight months after announcing the contract award, Italy-based Bedeschi S.p.a. has delivered a stacker and conveyor to Peru-based iron ore miner, Shougang Hierro Peru SAS.

The STK33/1000 stacker and conveyor have been designed to operate at a 1,800 t/h rate, and are being used as part of an expansion project. They have been installed in the San Nicolas beneficiation area where the mineral is processed and stocked before being dispatched.

Both pieces of equipment are in the commissioning phase ready to be handed over to the mine operators, Bedeschi said.

Back in December, the company announced the order from Shougang Hierro, saying it would be responsible for engineering, manufacturing and delivery of one conveyor (width 1,000 mm and total length of 710 m) and one stacker STK33/1000 designed for a nominal stacking rate of 1,500 t/h of iron ore.

It was also supporting Shougang Hierro in the optimisation of existing equipment, implementing DEM analysis and optimised design on interfaces with the new supplied equipment.

Shougang Hierro’s open-pit mine uses Chinese TYHI WK12 rope shovels loading Komatsu HD1500-7 and Caterpillar 785C trucks to transport ore to primary crushers, from where ore is conveyed to San Nicolas via a belt approximately 15.3 km long and with a capacity of 2,000 t/h.

The secondary crushing plant at San Nicolas sees the iron ore reduced in size by approximately 95% then fed to a magnetic separation plant for mill grinding and concentration via cyclones, magnetic separation and flotation, separated into two types of products, high-grade iron concentrate for sintering and the other used to feed the pelletising plant, after going through a filtration process. In the filter plant, thickening, homogenisation and filtering of the pulp received from the magnetic plant are carried out, leaving the ore ready to be made into pellets.

Terra Nova to supply new stacker to Karara Mining’s magnetite operation

Terra Nova Technologies Australia (TNT Australia) says it has been awarded the replacement tailings stacker contract by Karara Mining Ltd at its magnetite mine, 200 km southeast of Geraldton in Western Australia.

Karara Mining is the largest mining operation and the first major magnetite mine in the Mid-West of the state. It produces a premium, high-grade concentrate product for export to steelmakers with an expected mine life in excess of 30 years.

The scope of supply will be to replace an existing stacker, TNT Australia said.

In partnership with TNT’s sister company, e2o, a subsidiary of Clough, the contract will include the supply of a new “fit for purpose” heavy-duty stacker able to withstand the rigours of a high-capacity mining environment along with the associated civil works, installation, commissioning and removal of the existing stacker.

This contract will be completed by TNT Australia and e2o, working in partnership as part of the Murray & Roberts ownership group.

The replacement stacker project, which commenced last month, is required to be concluded within 2022 in order to meet Karara’s schedule requirements.

thyssenkrupp rail-mounted stacker handed over to BHP South Flank

thyssenkrupp says it has handed over the world’s largest rail-mounted stacker to its client BHP for the South Flank iron ore development in Western Australia,

The first stacker among a “trio of giants”, ST-04 took more than three years of research and design development in six countries, and two years of significant local fabrication, construction and commissioning processes, thyssenkrupp said.

Over the next few months, it will gradually ramp up its operating capacity of 20,000 t/h.

The engineering company was awarded this contract − one of its largest ever fabrication and construction projects in Western Australia − by BHP back in late 2018.

Under the €150 million ($181 million) contract, thyssenkrupp was to supply two stackers that deposit iron ore into stockyards for loading, and a reclaimer for loading the ore onto trains for transport to Port Hedland. The machines’ capacity of 20,000 t/h made them the largest rail-mounted stackers and reclaimers in the world, according to the company.

Primero has been helping thyssenkrupp in this pursuit, carrying out pre-assembly of the machines at its Australian Marine Complex, in Henderson, Western Australia.

In BHP’s half year results to December 31 released earlier this week, it said South Flank remained on budget and on track to deliver first production by mid-2021. The company expects the operation to ramp up to 80 Mt/y of output, helping replace production from the existing Yandi mine, which is reaching the end of its economic life.

thyssenkrupp reaches new milestone on Rio EII facility

Just over a month after declaring the first ore aboard a new stacker at the bulk handling facilities of Rio Tinto’s East Intercourse Island (EII) facility, thyssenkrupp says it has achieved another milestone at the sustaining capital project in the Port of Dampier, Western Australia.

First ore has now arrived on Stacker ST2EN, according to the company, with two of the three stackers now installed as part of the project, which involves the manufacture, installation and commissioning of three replacement stackers and associated equipment as part of an almost A$70 million ($39.8 million) upgrade.

When the upgrade was announced back in August 2017, Rio said design and fabrication work was expected to commence in 2018, with installation and commissioning anticipated in late 2020.

Rio also said at the time that thyssenkrupp Australia would manufacture, assemble and fabricate the stackers required for the refurbishment before transporting the 1,860 t of stacker weight to the Pilbara.

thyssenkrupp helps keep BHP South Flank iron project on track

thyssenkrupp Industrial Solutions (Australia) says it is on track to deliver the world’s largest rail-mounted stackers and reclaimer on schedule for BHP’s South Flank iron ore project, in the Pilbara of Western Australia.

The company was, in November 2018, awarded the contract to design, supply, construct and commission two stackers that will deposit iron ore into stockyards for loading, and a reclaimer for loading the ore into trains for transport to Port Hedland.

These large machines will each have a capacity of 20,000 t/h, making them the largest rail mounted stackers and reclaimer in the world.

thyssenkrupp developed the two fully autonomous stackers and reclaimer with the latest statutory requirements for functional safety as defined in AS4024 and AS61508. For machine collision avoidance, a combination of GPS, SIL-rated encoders and limits are used. The fully autonomous machines are digitally connected and monitored from a remote centralised control room, according to thyssenkrupp.

Offsite pre-assembly of these locally designed and manufactured machines is well underway in Perth, according to the company, with many of the large pre-assembled modules already complete. These modules are to be transported from their current location at the AMC complex in Henderson, to the BHP South Flank site with construction likely to commence in late January 2020. The first machine will be commissioned and ready for first ore in line with BHP’s 2021 target.

Zoran Matijevic, Project Director – South Flank Project at thyssenkrupp Industrial Solutions (Australia), said: “It has been a great privilege to lead thyssenkrupp’s team through design, procurement, fabrication and preassembly phases so far, and achieve 50% overall project progress milestone ahead of the plan. I look forward to logistics, construction and commissioning phases and final handover of this equipment.”

thyssenkrupp’s Industrial Solutions global Business Unit (BU) Mining has recently streamlined its operations and are now fully focusing on mining equipment, with the engineering centre of excellence for materials handling located in Perth.

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.