Posted by Paul Moore on twenty sixth April 2024
Vale has reported its Q1 2024 outcomes, the place the stand out figures are for iron ore whose manufacturing elevated from 66.8 Mt in Q1 2023 to 70.8 Mt in Q1 2024. A giant bonus was seen in its Northern System, specifically at S11D in Para state, Brazil, the place iron ore manufacturing was up by 1.4 Mt yr on yr from 16.32 Mt to 17.71 Mt. This was S11D’s highest Q1 output since 2020, with Vale stating that continued asset reliability initiatives had secured higher operational stability through the wet season.
Eduardo Bartolomeo, Vale CEO, gave some clues to the explanations for the improved efficiency within the webcast dialogue on the outcomes: “At S11D, elevated geological data permits extra correct mining plans, whereas the truckless system mixed with a cell mining fleet supplies additional working flexibility. Our long-term capability to cope with jaspilite depends on the set up of the brand new crushers, as you understand, however these surgical measures have allowed us to function S11D with extra effectivity, with the very best manufacturing for a primary quarter since 2020.”
What are the surgical measures? Bringing vehicles again right into a beforehand all truckless mine is a serious a part of this. The mine because it started operation has used a truckless idea with an IPCC system for waste and ore. There are 4 cell crushing methods working at the side of conveyor belts that transfer alongside the benches because the mining face advances in beneficial zones. These methods had been initially suppled by Sandvik as 4 PF200-9500 absolutely cell IPCC methods; with FLSmidth assuming duty for the undertaking when it acquired Sandvik Mining Techniques in 2018. The crushing stations are loaded by a Caterpillar 7495 rope shovel. The PF200 conveyor masses a cell Sandvik beltwagon with 11,500 t/h capability which in flip masses a foremost pit conveyor.
Initially the crushing stations used Sandvik CR810/18-40 so-called hybrid roll crushers however later FLSmidth ABON sizers had been deployed – 16/400 sizers with a brand new enamel interlacing chevron sample to cut back the granulometry of the ultimate product with out impacting the feed price of 9,000 t/h with high dimension as much as 1,600 x 1,600 mm. In the end after a number of fingers on expertise these methods have labored effectively however the place the absolutely cell and belt methods aren’t possible, the mine has additionally more and more been utilizing conventional truck-shovel strategies for extraction of ore and waste so as to add a lot wanted flexibility. Vale is now calling this a hybrid method.
A serious concern S11D has had from the outset is the referenced jaspilite in locations – a tough rock from the Carajas formation containing bands of jasper and iron minerals with 42% common Fe and 36% common SiO2. It’s a problem on account of its excessive abrasiveness and compressive power. To attempt to deal with the compact materials higher in addition to to mine extra marginal areas of the deposit Vale at the beginning of the undertaking additionally sourced three absolutely cell crushing rigs from TK Mining outfitted with a big jaw crusher of kind EB 20×15 which had been hydraulic excavator loaded. These are understood to be nonetheless in use however primarily as stationary crushers.
Vale has now opted for a devoted resolution involving a separate funding of US$755 million for the Compact Crusher Challenge at S11D which can allow the environment friendly processing of tougher jaspilite and transition materials. The scope entails the implementation of major crushing, secondary crushing and a belt conveyor system with a capability of 45 Mt/y. Vale has mentioned it’s based mostly on gyratory crusher expertise. So far, the undertaking is 33% full. Concrete has been laid for the primary flooring of the constructing of the first crushing construction. Civil building for the second crusher has began. Work on the related conveyor belts of the Western Hall are anticipated to be accomplished in H1 2024.
General S11D capability is now 90 Mt/y however a serious enlargement is underway often called Serra Sul 120, referring to the truth that the undertaking will see manufacturing attain 120 Mt/y by 2026. The undertaking consists of the opening of latest mining areas and consists of the set up of a semi-mobile crusher in Space 5.
