Tag Archives: Vale

Vale and Wabtec to optimise maintenance processes for EFC loco fleet in Brazil

Environmental, Mine operation news, Mining services, Steel and iron ore, Sustainable mining, , , , , ,

Vale and Wabtec have announced a master service agreement (MSA) to further increase the efficiency and operations of the Evolution Series (EVO) Locomotive fleet on the Estrada de Ferro Carajás (EFC), in Brazil.

The strategic 10-year deal, valued at R$1.8 billion ($341 million), will optimise the maintenance services for Vale’s fleet increasing availability, reliability and the potential for expanded freight transport on the EFC connecting the southeast of Pará to the capital of Maranhão, São Luís, Vale says. The EFC is around 1,000-km-long, covering 28 municipalities. The railway branch is around 100-km-long and connects EFC to the S11D project, in Canaã dos Carajás.

Carlos Medeiros, Vice President of Operations at Vale, said: “This long-term strategic agreement means a new standard of reliability, availability and safety for EFC locomotives, reinforcing our commitment to consistently invest in the quality and technology of our railway operations and promote the technological development of the railway sector in Brazil.”

Wabtec will analyse locomotive performance data from the last three years at EFC. The company also will provide real-time monitoring on 5,000 parameters of the EVO locomotives operating on the railway. Wabtec’s Global Performance Optimisation Centers will evaluate the data and identify opportunities for continuous performance improvement and optimization of maintenance cycles, reducing towing and failure rates.

Danilo Miyasato, President and Regional Leader of Wabtec in Latin America, said: “Wabtec has a proven history of providing integrated services designed to maximise reliability and availability of customers’ locomotives at optimal operating costs. This contract reinforces our long-standing working relationship with Vale to drive sustainable and efficient growth of EFC’s railway operations.”

In addition to planning and supplying parts for preventive maintenance, the agreement foresees the creation of specialised jobs in São Luís, contributing to the local economy and strengthening regional infrastructure, Vale says.

Vale and Wabtec have worked together for almost three decades to supply locomotives, materials and components for the EFC. In July 2023, the two companies also announced an agreement for the purchase of three FLXdrive battery locomotives, which will operate for the EFC, which represents an important step in its journey towards decarbonisation.

Vale hits renewable power milestone ahead of 2025 deadline

Environmental, Mining services, Power supply for mines, Sustainable mining, , , ,

Vale has announced that all the electricity used in its operations in Brazil in 2023 came from renewable sources, such as hydroelectric, wind and solar power plants. Thus, the company has achieved its goal of having 100% renewable electricity consumption in Brazil two years ahead of its original 2025 schedule.

The information is highlighted in the 2023 edition of the Vale Integrated Report.

Having reached the target, Vale has zeroed its indirect CO2 emissions in Brazil, which correspond to Scope 2 emissions. The company still has the challenge of achieving 100% renewable energy consumption in its global operations by 2030. At the moment, this indicator stands at 88.5%.

Vale Director of Energy and Decarbonization, Ludmila Nascimento, said: “We are announcing an important milestone in Vale’s decarbonisation strategy, which aims to reduce its Scope 1 and 2 CO2 emissions (direct and indirect) by 33% by 2030 and to become net-zero by 2050. As we are progressing on our targets, we are helping to make Brazil’s energy matrix even cleaner, contributing to society’s fight against climate change.”

The start-up of the Sol do Cerrado solar complex in November 2022 was key to achieving the target two years ahead of schedule. Located in Minas Gerais, Brazil, the solar complex represented an investment of $590 million by Vale. It is one of the largest solar energy parks in Latin America, with an installed capacity of 766 MW (peak), equivalent to the consumption of a city of 800,000 inhabitants. In July 2023, the complex reached its maximum capacity. It has the potential of contributing to around 16% of all the electricity consumed by Vale in Brazil.

The path towards 100% renewable consumption began to be traced by Vale back in the 1990s, when the company acquired its first hydroelectric plants. Today, Vale is supplied by a renewable energy portfolio of 2.6 GW of installed capacity, equivalent to the consumption of more than 3 million inhabitants. There are 14 assets held through direct and indirect participation in consortia and companies (ten hydroelectric plants, three wind farms and Sol do Cerrado). If it were a power generator, Vale would be the 15th largest in the country.

In its global operations, Vale is also moving towards 100% renewable energy consumption by 2030. The company invests in joint venture partnerships, renewable generation certificates in contracts and innovation initiatives for better efficiency in the use of batteries.

Vale is also working to reduce its direct Scope 1 emissions. In the mines and railroads, where diesel is currently intensively consumed, the company is studying the adoption of alternative fuels, such as ethanol for trucks and green ammonia for locomotives. In the pelletising furnaces, the strategy is to replace anthracite with zero-emission biocarbon, made from the carbonisation of biomass.

Last year, Vale signed an agreement with Wabtec for the supply of three electric locomotives and the start of studies into the development of a green ammonia-powered locomotive engine. The company also produced pellets with 100% biocarbon for the first time in an industrial test.

Vale Base Metals targets pyrrhotite with latest recovery innovation challenge

Base metals, Environmental, Mineral processing, Sustainable mining, , , ,

Vale Base Metals has launched the Pyrrhotite Resource Recovery Innovation Challenge to, it says, facilitate and enhance recovery of valuable metals and minerals contained in pyrrhotite.

The challenge reflects a commitment to driving innovative environmental solutions with a goal to identify and accelerate development of novel approaches to process low-grade pyrrhotite tailings, the solid remnants resulting from the mineral processing of sulphide ore.

Adam McMillan, Director of Research and Innovation for Vale Base Metals, said: “We’re committed to safely delivering critical minerals essential for the world’s energy transition and continued sustainable economic development. Open innovation is a key enabler that allows us to rapidly identify and trial innovative solutions that can help us unlock value from waste and we look forward to reviewing the innovative solutions this challenge inspires.”

Through this challenge, Vale Base Metals says it is inviting researchers, innovators and entrepreneurs to propose innovative technological solutions that can help to unlock value through circular mining while ensuring environmental responsibility.

Proposals will be evaluated until August 2024, with innovation laureates announced in September. Selected solutions will be awarded a prize of C$25,000 ($18,420) from Vale Base Metals.

For more information about the challenge and how to participate, click here

SpectraFlow wins second Crossbelt Analyzer order from Vale

Bulk handling, Mineral processing, Steel and iron ore, Sustainable mining, , , ,

SpectraFlow Analytics says it has received a second order from Vale for a Crossbelt Analyzer as part of the mining company’s quality monitoring processes at its iron ore dispatch terminal of Ponta da Madeira (TMPM), in Maranhão, Brazil.

While it is the second order from Vale, it is the third order for a minerals Crossbelt Analyzer in South America.

The company said: “After the very successful installation of a SpectraFlow Crossbelt Analyzer for the same application in the Terminal Ilha Guaíba in Rio de Janeiro, this is now second installation of a SpectraFlow Analyzer within Vale to enhance the ship loading with real-time data.”

SpectraFlow analysers are already installed in the cement, iron ore, gold, platinum, copper, potash, bauxite and recycling industries. They leverage Near Infrared Sensors, providing measurements of dry raw material composition at key points in mining, processing and refining value chains.

Olitek ships first Remote Charge-up Unit to Newmont’s Cadia operation

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Olitek Mining Robotics says it has reached an important milestone in its Remote Charge-up Unit (RCU) project with the dispatch of a RCU to Newmont’s Cadia operation in New South Wales, Australia.

The RCU uses robust mining robotics and a modified Volvo Construction Equipment wheeled excavator platform to enable full face charge-up from the safety of the cabin, Olitek explains.

Mechanised charge-up of tunnel development faces significantly reduces exposure of charge-up crews to tunnel face hazards such as seismicity, rockfalls, thermal stress and repetitive strain injuries. The development face explosives loading and priming crews are most ‘at risk’ to these geotechnical hazards due to the lengthy exposure duration at the tunnel face to perform their tasks.

The RCU project was part of a Canada Mining Innovation Council (CMIC)-backed consortium involving Vale, Newcrest (now Newmont), Agnico Eagle and Glencore, which sought to deliver a TRL7 (Technology Readiness Level) fully functioning prototype unit that will move personnel at least 4-5 m away from the underground development face and provide faster manual charge-up options to reduce exposure time for existing operations.

The system leverages Olitek’s patented HELX initiation system, allowing full charge-up and tie in to be completed using low-cost conventional detonators, the company says.

Olitek said the dispatch represents a major commercialisation milestone.

Riino zero-emission monorail haulage system receives mining company backing

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Riino, a company incorporating technology influences from monorails, subway systems and the mechanised raise climber, is a step closer to bringing its zero-emission material movement concept to reality, having signed up three mining company backers for a technology scoping study, utilising a consortium approach, supported by the Canada Mining Innovation Council (CMIC).

Agnico Eagle Mines, Rio Tinto and Vale are now all part of a CMIC-backed consortium pushing the Riino project forward under CMIC’s Surface Mining Alternative Haulage project. In addition, Riino has also been successful in achieving funding as part of Canadian government backing through the Mining Innovation Commercialization Accelerator Network.

Riino is an innovative monorail haulage system targeting the reduction of the industry’s carbon emissions and achieving net-zero goals, CMIC says. It is designed to receive its power from internal, train-mounted motors as well as auxiliary on-board batteries for a complete electric and automated operation.

The Riino concept originated out of President and CEO Aaron Lambert’s experience as a contract miner in Sudbury – a role that saw him interact and engage with many different technologies.

The standard 120-t (18% grade) or 400-t payload numbers used by Riino have been influenced by existing underground or open-pit mining profiles

Lambert has been working on Riino for several years, with the initial plan to produce a system that is both capex- and opex-efficient. The headline numbers associated with this are a targeted 50-80% reduction in haulage operating costs.

As time has gone by, the zero-emission element has created a further selling point for Riino, encouraging mining companies to consider its use alongside a host of other ‘green’ haulage alternatives to the standard diesel-powered truck and shovel fleet.

All three of the mining companies attached to the ongoing scoping study have been interrogating the data and designs Lambert and his team have assembled over recent months, and are now pledging financial resources to wrap some in-depth numbers and technical data around what it will take to build a prototype to a sufficient technology readiness level.

To this point, the power requirements for Riino have been based off existing specifications for both open-pit and underground mines. The standard 120-t (18% grade) or 400-t payload numbers have also been influenced by existing underground or open-pit mining profiles.

“We’ve had great early engagement from mining companies since we started the Riino project, and the latest backing from Agnico, Rio and Vale is tangible evidence of that,” Lambert told IM.

The three mining companies and Riino are currently engaged in this four-month study, which will be concluded by the end of this year. The idea is to then engage in another staged development process that could result in a full-scale prototype being built for testing at a location in Sudbury, owned by Rainbow Concrete Industries.

Trevor Kelly, Innovation Manager at CMIC, said: “We see the scoping study as a good opportunity for the industry to look at this solution. It offers a low-cost entry point and definitive outcome to enable companies to get involved initially, quickly. As with many other CMIC projects, we work with entrepreneurs and mining companies to find the ‘sweet spot’ between what money and resources are available, matching that to a relevant technology scope.

“As a result, it gives Riino and the mining companies a view on the potential of this technology and the possible paths forward.”

Gary Molloy, Innovation Manager at CMIC, added on the scoping study: “At this stage, it is all about building confidence in your company and your product.”

Each Riino locomotive – of which there are several making up a system – has internal, train-mounted motors to offer optimal driveline power across the system. These locomotives also come with wheels that have full attachment to the rails – via load-bearing, side-attachment and under-attachment wheels – similar to that of a rollercoaster. This eliminates the potential for train derailments, according to Lambert, saving potential system damage as well as downtime.

The inclusion of a Busbar able to provide 750 V of DC power comes out of the subway and surface transit space, meanwhile.

On top of this, the system has auxiliary on-board batteries to eliminate a significant amount of electrical infrastructure such as power cables and additional sub-stations.

This makes for a system able to offer speeds of up to 80 km/h, transport material lump sizes up to -760 mm, carry 120 t on a standard 18% incline road/ramp and navigate road widths of 1.8 m.

The Riino system has auxiliary on-board batteries to eliminate a significant amount of electrical infrastructure such as power cables and additional sub-stations

Lambert concluded: “Riino’s ambitious journey to revolutionise material movement in mining has gained substantial momentum and is swiftly progressing toward realisation.

“This pivotal phase, marked by rigorous study and financial commitments, aims to propel Riino towards a prototype build, positioned for testing in Sudbury. With a scoping study drawing to a close by year-end and subsequent developmental stages on the horizon, Riino stands poised to redefine mining logistics, offering a glimpse into a greener, more efficient future.”

World Economic Forum members to discuss global energy transition at IMARC

Environmental, Mining events, Mining industry recognition, Sustainable mining, , , , , , , , , , , , , ,

The World Economic Forum (WEF) will bring together political and business leaders at a special forum focusing on the global energy transition, and Australia’s role in it, as part of the International Mining and Resources Conference (IMARC) being held in Sydney from October 31-November 2.

The event, consisting of an exclusive roundtable and a panel discussion, will explore the challenge of transitioning to renewable energy while managing the need for low-cost and reliable power generation.

The “Australia Energy Transition Community” roundtable will take place on November 1 for WEF’s mining, energy, finance and public sector members.

It will bring together major players from both the public and private sectors to discuss the opportunities, complexities and realities of the energy transition for Australia. Its aim is to set a clearer pathway forward between the government and the private sector on Australia’s energy transition and critical minerals strategy.

IMARC Conference Director, Sherene Asnasyous, says the WEF initiative highlights IMARC’s role as a key forum to enable the industry to address the issues facing not only Australia, but the global energy sector.

She says IMARC, unlike other industry forums, can bring together stakeholders from across the entire value chain to share their insights, perspectives and solutions on how to achieve a sustainable and prosperous energy future for Australia and the world.

She said: “We are proud that the WEF has chosen IMARC to host this important initiative on the energy transition in Australia. Over its 10 years, IMARC has become the leading forum in Australia to connect industry leaders, politicians, and the broader business community to facilitate conversations to address existential issues facing society.”

Jörgen Sandström, Head, Transforming Industrial Ecosystems at the WEF, will lead the discussion with the hope of better aligning the resource and energy sector across public and private sectors.

Sandström said: “The current paradigm, which we hope to change, is that the energy sector and resource sector, particularly from a government level, operate independently from one another, which results in less effective policy. The transition to renewable energy is a complex challenge that requires a collaborative effort between the public and private sectors and we believe that Australia can lead the world given it’s resource wealth, strong governance systems and highly trained workforce.”

The keynote panel discussion to follow, titled ‘Unlocking Australia’s Energy Transition: From a Global to a Country Perspective’ will feature Sandström and executives from leading mining, energy and finance companies:

  • Gillian Cagney: President, Australia and New Zealand (incl. PNG & Mongolia), Worley;
  • Andrew Hinchcliff: Group Executive Institutional Banking and Markets, Commonwealth Bank of Australia;
  • Sam Crafter: Chief Executive Officer, Office of Hydrogen Power South Australia; and
  • Mark Cutifani: Non-Executive Director, TotalEnergies; Senior Independent Director, Laing O’Rourke; and Chair, Base Metals, Vale.

The panel will explore the global trends and challenges of the energy transition, and how Australia can leverage its natural resources, innovation and collaboration to achieve its net-zero emissions target and become a global leader in the green economy.

International Mining is a media sponsor of IMARC 2023 and will be in Sydney to report on the event

Samarco sets monthly iron ore pellet production record with Metso unit

Environmental, Mine operation news, Mineral processing, Mining industry recognition, Steel and iron ore, Sustainable mining, , , , , , , , , ,

Samarco Mineração S.A. has set a monthly production record during August 2023 of 824,829 t of high-grade pellets in a single pelletising line with its 816 sq.m Metso Pelletizing Plant Indurating Machine #4 at its Ubu site in Brazil.

On an annalised basis, the production is equivalent to approximately 8.8- 9 Mt/y of pellets from a single machine. Samarco has installed three additional Metso Pelletizing Plants at its Ubu site.

Pedro Sousa, Sales Manager, Ferrous & Heat Transfer, South America, said: “We’re very excited to see Samarco breaking their monthly iron ore pellet production record and would like to congratulate the whole team for this great achievement. It makes us proud to see how our solutions are helping our customers improve their pelletising operations while simultaneously supporting the journey toward decarbonisation.”

Currently, only the Plant #4 is in operation, with Samarco and Metso discussing the revamp of the three other plants to continue increasing pellet production and decarbonising the steel industry processes using sustainable technologies, according to Samarco’s gradual production revamp plan. Related test work and studies are currently being performed at Metso’s R&D facility in Frankfurt, Germany.

Metso’s traveling grate pelletising process produces uniform pellets, ensuring high performance and quality with low investment and operating costs, as well as decreased energy consumption and emissions, according to the OEM.

Samarco is a joint venture owned by Vale and BHP. Samarco’s principal place of business is in Belo Horizonte, with units operating in Minas Gerais and Espírito Santo. The company’s main product is iron ore pellets, the raw material for steel production.

Vale introduces Agera, the Sustainable Sand business

Environmental, Mining services, Sustainable mining, Water management, , , , , ,

Vale has announced the introduction of Agera – a company created to develop and expand its Sustainable Sand business.

Based in the state of Minas Gerais, Brazil, Agera receives the sand produced from the treatment of tailings generated by Vale’s iron ore operations in the state and promotes its commercialisation and distribution. The new company also invests in research and development (R&D) of new solutions for the product.

Sustainable Sand began to be produced by Vale in 2021 after seven years of research, as a substitute for sand extracted from the environment. Since then, around 900,000 t of the product have already been sent to the construction sector and road paving projects. The expectation is to sell 1 Mt this year and 2.1 Mt by 2024.

Fabiano Carvalho Filho, Vale’s Business Development Director, said: “We created Agera with the aim of scaling a business that is helping us to reduce the use of dams and piles in Minas Gerais, as well as helping to replace natural sand, which is often extracted predatorily from river beds. The creation of Agera is strongly linked to our strategy of promoting circular mining, which means strengthening the concepts of the circular economy in mining, associating economic development with better use of natural resources.”

Established about a year ago under the provisional name of Co-Log, Agera projects annual sales revenue of BRL18 million ($3.6 million) by 2023. Today, it has seven customer service points and stocks material in the Brazilian states of Minas Gerais and Espírito Santo. The company has contracts with seven road hauliers and three rail freight providers. The company currently serves more than 80 manufacturing units in seven segments (concrete, precast, mortar, artifacts, cement, textured paints and pavement) and is investing in research to expand its operations in other applications, such as red ceramics.

Fábio Cerqueira, Agera’s CEO, said: “We are structured to accelerate the development of sustainable products and materials, meeting the specific requirements of the market. In addition, our logistical solutions enable end-to-end efficiency to guarantee agility in the supply of sustainable sand.”

In terms of the production of Sustainable Sand, the wet processing of iron ore, which is currently used for less than 30% of Vale’s production, generates tailings, which can be disposed of in dams or piles. These tailings are basically composed of silica, the main component of sand, and iron oxides. It is a non-toxic material, which is only processed physically.

Since 2014, Vale has been investing in research to find solutions for the reuse of sand from iron ore processing, with the aim of reducing the generation of tailings. In 2021, Vale began marketing Sustainable Sand, a product intended for civil construction with 100% legal origin, high silica content and low iron content, as well as high chemical and granulometric uniformity.

The sand has been produced at the Brucutu mine in Minas Gerais since 2021. Last year, the company began small-scale production at the Viga mine and in the coming months it plans to start production at the Cauê mine, in Itabira.

In Brazil, around 330 Mt of sand are used every year in construction and industrial processes. The extraction of natural sand from riverbeds often exceeds the rate of natural replenishment and can cause irreversible environmental impacts. With the production of Sustainable Sand, it is possible to carry out 100% circular extraction, transforming a material that would otherwise be discarded into various products for the benefit of society, without compromising biodiversity, Vale says.

In addition, Sustainable Sand generates greater profitability for the construction market and industries, since the process guarantees greater control and quality of the final product, avoiding material waste and reworking during construction, the company added. Also in concrete production, Sustainable Sand helps to reduce cement consumption and CO2 emissions.

Resourcing Tomorrow

Major miners join Resourcing Tomorrow lineup

Energy minerals, Environmental, Mining events, , , , , , , , , , , , , , , ,

Representatives from the world’s largest mining companies Anglo American, BHP, Glencore, Rio Tinto and Vale have confirmed their attendance for this year’s Resourcing Tomorrow event, in London, event organisers say.

These attendees will join other leading mining companies including AngloGold Ashanti, Antofagasta Minerals, Barrick, B2 Gold, Eldorado Gold, Endeavour Mining, Freeport-McMoRan, Newmont, Sibanye-Stillwater and Teck Resources.

As Europe’s largest mining event, Resourcing Tomorrow: Accelerating the Energy Transition takes place in London on November 28-30 and is poised to be yet another agenda-setting edition for the industry, fostering collaboration and knowledge exchange among professionals in the field, event organisers say.

Resourcing Tomorrow unites all stakeholders in the mining industry, including global mining and energy companies, investors, government delegations, researchers, educators, regulators, suppliers and operators. The conference program will provide 100-plus sessions in which all of the aforementioned miners will participate, giving attendees the opportunity to engage and network with leaders and industry specialists from around the world.

The event will draw participants from more than 100 countries, including Australia, USA, UK, Canada, India, Brazil, South Africa, Ghana, Chile, Nigeria, Peru and Germany, demonstrating its international appeal and the global significance of the mining industry, organisers say.

With the increasing pace of change and emerging technologies in the mining industry, Resourcing Tomorrow will focus on the future of our industry and presents a unique opportunity for international representatives of the world’s leading resource economies to meet, find new partners, discuss current challenges, and share the latest research, technology and best practice.

International Mining is a media sponsor of Resourcing Tomorrow.