Tag Archives: Western Australia

Port Hedland’s iron ore export capacity receives ‘potential’ boost

One of the world’s largest ports for iron ore exports, Port Hedland, in Western Australia, has had its  potential shipping capacity increased by 40 Mt/y.

The additional capacity, which was a result of Western Australia Government and industry investment at the port, will see Port Hedland’s potential shipping capacity go from 577 Mt/y to 617 Mt/y, a 6.9% increase.

Annual capacity allocations for each port user will remain the same, according to a media statement from Western Australia Ports Minister, Alannah MacTiernan. However, the increased capacity will allow all port users more capacity above their allocated tonnages by accessing D‑class shipping opportunities under the Port Hedland Vessel Movement Protocols.

Investments at the port to facilitate this new capacity modelling by the Pilbara Ports Authority included capital dredging, innovative marine technology and other port efficiencies, according to the statement.

This includes the recently completed three-year dredging works program, the Channel Risk and Optimisation Project. The A$120 million ($81 million) project included the removal of “high spots” in the channel, optimising navigable depths to allow deeper drafted vessels to safely navigate along the 42 km shipping channel.

Also driving this increase is the continued movement and facilitation of larger vessels in the channel. The sizes of ships coming into Port Hedland have increased significantly in recent years, with 45% of vessels now carrying more than 200,000 deadweight tonnage, compared with less than 10% in 2009, according to the Pilbara Ports Authority. Much of this increase can be put down to bigger vessels carrying iron ore from Port Hedland to Asia and elsewhere.

In August, Port Hedland achieved a monthly throughput of 46.1 Mt, of which 45.4 Mt was iron ore exports. The monthly throughput was a 7% increase from August 2018, according to the Pilbara Ports Authority.

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.”

SIMPEC to power up FMG’s Eliwana iron ore mine

SIMPEC has been given another assignment at Fortescue Metals Group’s Eliwana iron ore mine and rail project in Western Australia, with a circa-A$5 million ($3.4 million) contract to construct the 25 MW diesel power generation facility at the operation set to keep it busy until July 2020.

The contract, which commences this month, was awarded to the WestStar business by Energy Power Systems. It is SIMPEC’s first full vertical installation package comprising of civil, structural, mechanical, piping, electrical and instrumentation works, the company said.

Under the agreement, SIMPEC will supply (partially), install, test and commission the 25 MW facilities for Eliwana, with the delivery executed over three separable portions.

Back in April, SIMPEC was awarded its largest single contract to date, with ATCO Structures and Logistics granting it a circa-A$10 million contract to design, supply, construct, test and commission the electrical, communications and dry fire systems for an 800-room mine camp at Eliwana. The contract was scheduled to commence in the middle of the year and take nine months to complete.

The Eliwana project will involve the building of 143 km of rail, a new 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. The project underpins the introduction of a 60% Fe grade product (Fortescue Premium) in the second half of the company’s 2019 financial year.

Cummins HSK78G gas generator gets a runout at Blackham’s Matilda-Wiluna gold mine

Blackham Resources has enlisted the help of Cummins and its new HSK78G gas generator to power up production at the Matilda-Wiluna gold operations in Western Australia, according to the engine manufacturer.

Blackham’s power supplier, Perth-based Contract Power Group, selected the newly launched Cummins HSK78G generator to supply prime power for the next stage of expansion at the mine. The new gas-powered generator will provide up to 20% of the mine’s power as the company strives to increase its production.

Located 500 m above sea level, Matilda-Wiluna is subject to extreme temperatures, ranging from -2° C to 50° C throughout the year. Considering these conditions, the HSK78G’s capability to deliver power in remote areas and extreme climates – generating up to 1,800 kWe in ambient temperatures of 55°C – was a crucial requirement behind the choice to select the generator, Cummins said.

With a power density of 2 MW from the new Cummins 78-litre, V12 gas engine, the HSK78G provides high electrical efficiency up to 44.2% on a wide range of pipeline natural gas down to 70 methane number (MN) without impacting power and efficiency output, according to the company.

Craig Wilkins, Director of Cummins Prime Power Segment and Global Sales Support, said: “It’s an exciting time in the power solutions sector and we’re delighted to deliver the latest innovations in gas generator technology to Blackham Resources. The company operates on a massive scale and required a sizeable dependable power generation solution to operate in difficult conditions. Cummins’ HSK78G offered the required performance levels as well as one of the industry’s longest major overhaul service cycles of 80,000 hours.”

Marc Grosser, General Manager of Contract Power Group, said: “We are happy with the performance of the unit so far and the associability of maintenance items. It’s a compact unit and very well designed. Cummins have ensured there is fast service and support when called upon, despite our extremely remote location.”

Blackham expects to produce 70,000-80,000 oz of gold in its 2020 financial year and aims to progress its Sulphide Expansion project to unlock the large sulphide reserves and resources it has delineated at Wiluna.

RCT deploys ControlMaster at Westgold mine sites

RCT says it is finalising a major automation project for Westgold Resources at five of its gold mine sites in Western Australia’s Murchison region.

The package of works involved the autonomous solutions provider installing and commissioning its ControlMaster® Guidance Automation technology to 10 of Westgold’s underground loader fleet across its mining operations, including CAT R2900Gs and Sandvik LH517 LHDs.

RCT will also deliver its latest surface-based ControlMaster Automation Centres equipped with Multiple Machine Selection and Multiple Machine Control options aimed at driving further mining production efficiencies at each site.

Guidance Automation encompasses a fully automated tramming cycle between production level locations, which includes proportional braking and automated steering and speed control, RCT says.

“The technology also includes features such as G-Dash which empowers operators by presenting a graphical dashboard of the machine telemetry and diagnostic features to ensure optimal loader performance,” the company said.

Implementing the ControlMaster Guidance Automation solution across Westgold’s Big Bell, Paddy’s Flat, Comet, South Emu and Starlight operations standardised the company’s production technology and will deliver significant efficiencies and synergies, according to RCT.

RCT Business Development Manager Mining – APAC, Ryan Noden, said each delivery is being tailored to site-specific requirements.

“Over the past few months, RCT has been working in a staged approach to upgrade Westgold’s existing systems and consolidate the operating system across all operations to ControlMaster,” he said.

“The introduction of RCT’s technology will offer Westgold a proven and successful pathway to mine digitalisation, with the ability to adopt the latest technology offerings as and when required and applying shared learnings across its operations.”

He continued: “RCT is excited to be working closely with Westgold as a technology provider to achieve operational excellence.”

David Noort, Executive General Manager – ACM at Westgold Resources, said he was delighted to be working with RCT.

“We made the decision to implement the ControlMaster Guidance Automation solution due to RCT’s proven productivity and technological reliability and proactive support services,” he said.

“Being able to implement Multiple Machine Selection/Multiple Machine Control is an added advantage as it will support staged growth and specialised applications where geotechnical constraints require a period of standoff before re-entry after blasting.”

RCT has been upskilling Westgold site personnel by implementing operator and maintenance training courses and will carry out after sales support and field servicing on an ongoing basis, it said.

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.”

Northern Minerals backs XRT ore sorting pilot plant plan with Steinert order

Northern Minerals has capped off its ore sorting project enhancement initiatives at the Browns Range rare earths project, in northern Western Australia, with the selection of a Steinert ore sorter for use at its pilot plant.

The selected machine is in stock in Perth and a deposit has been paid in order to secure it and avoid any lead time lags or delays, the company said.

Nexus Bonum, which previously completed the feasibility study for the x-ray transmission ore sorter system at the pilot plant, has been engaged to undertake the front-end engineering and design work required for the inclusion of the sorter into the pilot plant beneficiation circuit.

The company said: “As previously announced, the findings from initial test work and studies indicate that the inclusion of ore sorting at Browns Range has the potential to double the mill feed grade potentially leading to an increased production rate of heavy rare earth carbonate and a potential lowering of operating costs.”

The company is currently working with stakeholders and regulators on obtaining the approvals required for the installation of the ore sorter at Browns Range and is aiming to have the system installed and commissioned by mid-2020, subject to receiving these approvals in a timely manner.

Northern Minerals’ Managing Director and CEO, George Bauk, said: “Following the recent capital raising, we have moved quickly to progress this critical piece of equipment that has the potential to be a game changer for the project.

“Higher grades going into the plant would result in higher production rates and lower operating costs, a double win in terms of proving the economics of the Browns Range project.”

Northern Minerals commenced production of heavy rare earth carbonate at the Browns Range pilot plant back in October. This followed plant commissioning in June.

The project is designed to assist the company in evaluating the economic and technical feasibility of mining at Browns Range and will provide the opportunity to gain production experience and surety of supply for its offtake partner. This could see the company become the first significant producer of dysprosium outside of China.

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.”

Newmont Goldcorp weighing haul truck automation at Boddington

Newmont Goldcorp President – and soon to be CEO – Tom Palmer, told investors on a conference call this week that the miner was looking into the feasibility of implementing autonomous haulage at the Boddington gold-copper mine, in Western Australia.

The mine produced 709,000 oz of gold for Newmont Goldcorp last year and is currently undergoing a stripping campaign in the South Pit in order to reach higher-grade ore.

Palmer said the company recently advanced its “autonomous haulage study” at the mine and there could be a funding decision made on this project before the end of 2019.

“If approved, the project is expected to improve cost and mining productivity, by converting the fleet of 39 haul trucks to autonomous operation, using the Cat command system,” Palmer said.