Magazine
Barrick Gold: Projecting a golden future
2015 Issue 9
World Mining
• Mining • Oil • Construction • Industrial
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• The Editor
Photo: Antonio Cruz / ABr
The sweet and sour river
Editor
The
I
t saddens me that this year looks set to end on a sour note for some of our mining colleagues, not least those associated with two of the industry’s major forces, Vale and BHP Billiton. Both of these distinguished industry leaders have appeared on the cover of this magazine this year, and we are proud of our relationship with them. It is an unfortunate and poignant irony, however, that the company we now know as Vale was once called Companhia Vale do Rio Doce, which translates roughly as Valley of the Sweet River. Sadly, the Rio Doce is now far from sweet downstream of the Samarco Mineração iron ore mine in Brazil’s Minas Gerais province, after the collapse of two dams on 5 November 2015, spilling millions of gallons of mineral waste into the countryside the dams were designed to protect. The Brazilian authorities have declared a state of emergency, with the death count now into double figures and more than 200 towns in the Rio Doce basin affected. As I write this, it’s not yet known what caused the dams to burst, or what the long term consequences might be, but it’s easy for a whole brand to be tarnished and its share price savaged after an incident that attracts global media attention.
Martin Ashcroft
Just ask BP after the Gulf of Mexico disaster, or VW in the wake of the recent emissions scandal. Within a few days of the Samarco incident, reports were coming in that costs and fines could reach as much as $1 billion. This is by no means the only fatal incident in mining recently. If only it were. Harmony Gold reported the death of an employee last week in a fall of ground accident at its Masimong mine in the Free State province, South Africa. A worker was killed in October at Glencore’s Nickel Rim South mine in Sudbury, Ontario after being struck by a piece of equipment and so far this year there have been three deaths in the Pilbara region of Western Australia alone. We all know mining is inherently dangerous, and safety is the first concern in every company’s mission statement and values, but even so, there are still too many people killed or injured at work in this industry. Our first thoughts and feelings are naturally directed towards the people immediately impacted by these tragedies. Regaining their faith will not be easy. It’s hard to find anything positive to say about incidents like this, but clutching at straws, it may help that Samarco is a joint venture between Vale and BHP Billiton. No matter how big you are, some things are better shared. •
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Contents.......... Page 24
Cover storyBarrick Gold: Projecting a golden future
3
The Editor: The sweet and sour river
24
Barrick Gold: Projecting a golden future
40
Information modelling for the mining industry
49
Dr David Blond: The end of globalization
52
Rio Tinto: Advanced mining
64
United Mining Rentals: Working with you
Page 6: Monthly news & features: Newmont Mining BHP Billiton Golden Minerals Anglo American Iron Ore Barrick Gold Aquila Resources Australian uranium Martin Engineering Santacruz Silver Mines and Money, Toronto Marigold Mine milestone General Steel Holdings Atlas Copco Timetric survey
World Mining Magazine media information can be found at
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ADVERTISERS Page: 2 Industrial Vacuum Systems 8 TerraMar Networks 9 Wolseley Industrial Group 10 Conductix-Wampfler 12 GEA Barr-Rosin 14 Hawk Measurement 16 Polar Mobility Research 18 Mining Expo China 2016 20 Canary Systems 21 Dok-Ing 22 Monaflex 34 CleanTeQ Water 37 Virginia Transformer Corp 38 IDS Corporation 39 Seeing Machines 44 Puritech 48 QuERI International 59 Motive Traction 61 Richwood / AKW 64 United Mining Rentals 66 Greenfield Handlers 67 Kentz 68 Rockwell Automation
........................... News & Features Editor:
Martin Ashcroft martin@ogsmag.com
Page 38
Editor
Vanessa Ward editor@ogsmag.com
A new model: Information modelling
Sales
sales@ogsmag.com General email contact
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Design and Artwork
artwork@ogsmag.com Managing Director
Simon Ward
Company Information
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Monthly news & features
World Mining Magazine 2015 World Mining Magazine is published by Worldwide Business Media Limited, London, EC1V 2NX United Kingdom. Registered No. 6809417 England/ Wales. VAT No. 972 7492 76. All rights reserved. Reproduction in whole or any part without written permission is strictly prohibited. Liability: while every care has been taken in the preperation of this magazine, the publishers cannot be held responsible for the accuracy of the information herein, or any consequence arising from it. All paper used in this production comes from well managed sources.
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Monthly news & features •
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• News & features
News in Brief Newmont Mining has completed the sale of Newmont Waihi Gold in New Zealand to OceanaGold Corporation for US$101 million in cash. The sale agreement also includes a $5 million contingent payment and a one percent net smelter royalty on a recent discovery. Over the last two years Newmont has generated $1.7 billion through non-core asset sales, allowing the company to further pay down debt, invest in profitable production and return capital to shareholders. * * *
BHP Billiton shares sank to a ten year low earlier this month in the wake of the dam burst at its jointly-owned Brazilian iron-ore mine operation, Samarco. BHP stock fell to below $20 in Australia, a price last seen in late 2005. In a recent update, BHP and coowner Vale revealed that mine tailings had now spread 440 kilometers (273 miles) downstream through remote mountain valleys from the mine site in Brazil’s Minas Gerais state. * * * Golden Minerals has acquired the mining rights for the Santa Rosa vein in the San Luis del Cordero silver project in Durango State, Mexico, after signing an exploration and exploitation agreement with the wholly-owned Mexican subsidiary of Prospero Silver Corp. Golden Minerals plans to commence drilling in early 2016, once permits are received. The company aims to increase the size of the resource and to upgrade inferred resources to measured and indicated resource categories. * * * Paulo Castellari is stepping down as CEO of Anglo American’s iron ore business in Brazil at the end of the year, after leading the Minas-Rio project through its most critical stages over the last 3½ years. “Minas-Rio is now progressing through its 18-month ramp-up phase and I understand Paulo’s decision to move on to other opportunities at this stage,” said Anglo American CEO Mark Cutifani.
Barrick to sell non-core assets in Nevada for $720 million
B
arrick Gold Corporation is selling a number of non-core assets in Nevada for $720 million in cash. Included in the sale is 100 per cent of the Bald Mountain mine, 100 per cent of the Ruby Hill mine, Barrick’s 50 per cent interest in the Round Mountain mine and the company’s 70 per cent interest in the Spring Valley project. Barrick has announced asset sales, joint ventures and partnerships worth $3.2 billion since the start of 2015 and is on track to meet its stated debt reduction target of $3 billion for 2015, which, when completed, will represent a 23 per cent reduction in total debt since the start of the year. “The sale of these assets is consistent with our strategy to create longterm value for our shareholders by strengthening the balance sheet and further focusing our portfolio on core mines that will drive free cash flow growth,” said Barrick President Kelvin Dushnisky. “As we move into 2016 and beyond, we will continue to take steps to strengthen our balance sheet, but we will balance debt repayments with investments to drive future growth in free cash flow and EBITDA.” Barrick has reached an agreement to sell the company’s 50 per cent interest in the Round Mountain mine and 100 per cent of the Bald Mountain mine to Kinross Gold Corporation. Barrick
and Kinross have also agreed to form an exploration joint venture that will own a large land package on the Bald Mountain property. Each company will own 50 per cent of the joint venture and will fund exploration activities and advance new mine development opportunities on a 50-50 basis, with Kinross acting as the operator. The consideration for these assets is $610 million in cash. “We are excited to form a new partnership with Kinross that allows us to maintain significant exposure to a highly prospective exploration land package at Bald Mountain,” said Dushnisky. Barrick has also reached an agreement to sell the company’s 70 per cent interest in the Spring Valley project and Barrick’s 100 percent interest in the Ruby Hill mine to subsidiaries of Waterton Precious Metals Fund II Cayman, LP for $110 million in cash. “Through this sales process we have developed a strong working relationship with Waterton and we look forward to collaborating with them in the future should the right opportunities arise,” added Dushnisky. Both transactions are subject to customary closing conditions. The transaction with Waterton is expected to be completed by the end of 2015 and the Kinross transaction in January 2016. •
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• News & features
Aquila Resources submits mine permit application
Aquila Resources has submitted a formal application with the Michigan Department of Environmental Quality to secure the necessary permits and approvals to build and operate its goldand zinc-rich Back Forty Project. “This is a major step forward for Aquila, and represents the beginning of a transparent process that we expect will culminate with the building of an important economic development project that will grow the local economy, create good jobs and generate new tax revenue for local and state governments,” said Barry Hildred, CEO of Aquila Resources. “I would like to congratulate our expanded team, including our consultants, on delivering a comprehensive and quality application to the state within the timeline we established earlier this year.” Aquila’s mine permit application was completed with the assistance of Foth Infrastructure & Environment LLC, an engineering firm based in Green Bay, Wisconsin. Foth has worked on the Back Forty project since 2006, conducting a series of technical studies,
including geochemistry of waste rock and tailings, bedrock hydrogeology, water treatment, groundwater modeling, air quality and deposition modeling, reclamation planning, and tailings and waste rock storage facility design. Foth also managed a consulting team that conducted baseline environmental studies at Back Forty.
“Aquila is firmly committed to move this project to commercial production, and we look forward to working with local and state governments, area businesses and other stakeholders to develop a positive working relationship while building a reputation as a solid corporate citizen in Lake Township and Menominee County.” Aquila’s application is based on the company’s updated preliminary economic assessment (PEA) filed in September 2014. The PEA, which included an optimized mine plan and updated resource estimates, indicated that Back Forty has a pre-tax net present value of $282.2 million and a pre-tax investment rate of return of 38.8%. Back Forty is Aquila’s 100%-owned development-stage project delineating a zinc- and gold-rich volcanogenic massive sulfide (VMS) deposit located along the mineral-rich Penokean Volcanic Belt in Michigan’s Upper Peninsula. Over the past 10 years, Aquila and various joint venture partners, including Hudbay Minerals, have spent more than $70 million exploring and advancing Back Forty.
“Aquila is firmly committed to move this project to commercial production” “We have prepared a comprehensive Mine Permit application that underscores our commitment to mining in an environmentally responsible manner and to meeting or exceeding all of Michigan’s regulations,” said Andrew Boushy, vice president of project development at Aquila Resources. •
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• News & features
Australia agrees to sell uranium to India
T
he Australian government has agreed to sell uranium to India for civilian purposes, making India the first country to buy Australian uranium without being a signatory to the international nuclear nonproliferation treaty. The two countries have been working towards an agreement on uranium supply since a state visit to India in 2012 by then-Australian PM Julia Gillard. Two years later Gillard’s successor, Tony Abbott, signed a memorandum of understanding for “Cooperation in the Peaceful Uses of Nuclear Energy” whereby Australia would become a long-term supplier of uranium to India. Current PM Malcolm Turnbull and
Bulk material handling specialist Martin Engineering has gained the EAC Mark of Conformity (aka, Eurasian Conformity Mark) for the export of conveyor products and material flow aids, including the company’s full line of impact cradles, belt cleaners, sealing systems, air cannons and sonic horns. The certification allows the Martin
Indian Prime Minister Narendra Modi met on the sidelines of the G20 summit in Turkey last week and finalized the deal on Sunday 15 November. Vikas Swarup, spokesman for the Indian Ministry of External Affairs, described the agreement as a “milestone achievement”. India faces severe shortages of electricity and has limited nuclear capacity. According to the World Nuclear Association, there are currently 21 operating reactors in the country with a capacity of 4,780 megawatts, supplying a mere 2 per cent of its total power supply. The Hindustan Times reported that India plans to increase its nuclear capacity to 63,000 MW by 2032
by adding up to 30 reactors at a cost of $85 billion, India has nuclear energy agreements with 11 countries and currently imports uranium from France, Russia and Kazakhstan. Australia sits on around 40 per cent of the world’s uranium reserves and ranks third in terms of production, behind Kazakhstan and Canada, with exports of almost 7,000 tonnes of yellow cake annually. But Australia does not have its own nuclear power plants, so uranium production is basically for export. The deal to supply India will be good news for producers including BHP Billiton’s Olympic Dam, Ranger, Beverley, Four Mile and Honeymoon.
Engineering business units in Germany and Russia to offer the company’s extensive product family to the Customs Union (Russia, Belarus and Kazakhstan) and assures that the equipment is compliant with the EAC’s strict safety and quality standards. “The EAC Mark of Conformity is essential in order to sell and install bulk material handling components
in the three member countries,” said Russian Division Branch Manager Oleg Meister. “It will be instrumental in assuring ready availability and reasonable lead times. This certification allows us to offer more complete and versatile solutions that could help make systems across the region safer, while at the same time reducing operating costs.” •
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• News & features
Santacruz Silver to mine properties in central Mexico
S
antacruz Silver Mining has been granted a 30-year licence to mine and operate Contracuna’s Veta Grande and Minillas silver-gold-zinclead mineral properties in the state of Zacatecas in central Mexico. The company has entered into a definitive agreement with Minera Contracuña I and Vetalinda Compania Minera (together Contracuña). Santacruz paid US$200,000 on execution of the agreement and has agreed to make an additional payment of US$300,000 upon registration of the agreement with the Deputy of Mines, which is expected to occur in 2016. The operations are located in one of Mexico´s most prolific silver, lead, zinc and copper regions, which includes the Fresnillo Silver Mine, the Madero Mine (operated by Peñoles) and the Cozamin Mine operated by Capstone Mining
T
oronto, Ontario will host and co-sponsor the Mines and Money Americas mining investment forum in September 2016 and again in September 2017. The Mines and Money trade conference is one of world’s largest mining investment meetings, attracting over 3,000 investors and 900 exhibitors. This will be the first time in the event’s 13-year history that the conference
from the Contracuña properties reacted favourably on a metallurgical basis.” “In addition, the agreement will allow us to operate the Contracuña mill at 500 tpd capacity after a nominal capital expenditure upgrade,” he continued. “Further, the company will be in position to evaluate the possibility of upgrading the Contracuña mill throughput capacity and if the economics are favourable we can explore the opportunity to increase the mining operations.” The agreement is for an initial term of 15 years, with an additional 15 year extension at the discretion of Santacruz. The properties will be operated on a 60/40 net profits interest basis (NPI) with Santacruz holding 60% and Contracuña holding 40%. If the price of silver is greater than US$22.00/ounce, the NPI will change to 55/45.
Corporation. The Contracuña historical records indicate that the properties consist of extensive vein systems that average 4 to 4.5 metres in width with average head grades of 170 g/t silver, 1.5% lead, 2% zinc and 0.4 g/t gold including some mineralized stockwork zones associated to the structures. Santacruz already has a producing mine (Rosario) a little over 100 miles from the Contracuña properties, which will allow for future streamlining of operating and management functions. “This agreement allows us to immediately leverage on the extra milling capacity available at our Rosario Mine, which will help us realize certain economies of scale,” said Arturo Prestamo, President and CEO of Santacruz. “In this regard we note that mineralization previously processed
will be hosted in the Americas. It has previously been held in other global mining hubs such as London, Hong Kong and Australia. The Toronto Stock Exchange is a global leader in raising mining equity capital and there are approximately 1,500 mining companies listed on it. Last year, that translated into $229 billion in mining market capitalization and $8.9 billion in new mining equity raised.
Showcasing Ontario’s mining sector is part of the government’s plan to build up Ontario. The four-part plan includes investing in people’s talents and skills, making the largest investment in public infrastructure in Ontario’s history, creating a dynamic, innovative environment where business thrives, and building a secure retirement savings plan. •
WORLD MINING MAGAZINE www.ogsmag.com
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• News & features
S
ilver Standard Resources has announced that its Marigold mine produced its three millionth ounce of gold on 6 October 2015. The Marigold mine has been in continuous operation since 1988 and is forecast to produce between 195,000 and 205,000 ounces of gold this year at cash costs below $750 per ounce. Marigold is located in Humboldt County, Nevada, on the Battle Mountain-Eureka trend. In production since 1988, it is a large run-of-mine heap leach operation with several open pits, waste rock stockpiles, leach pads, a carbon absorption facility and a carbon processing and gold refining facility. Silver Standard acquired the Marigold mine in April 2014 and a technical report was released in November 2014. “Three million ounces of gold from continuous production at Marigold is a testament to the scale and quality of the deposit and the commitment of the Marigold team,” said Paul Benson, President and CEO. “Since the mine began operating in 1988, it has consistently replaced mineral reserves and mineral resources and today it has similar mine life as when it opened. “We are advancing several exploration targets and the Marigold assay program, which have the potential to increase production throughout the planned mine life and to add to mineral resources. The team remains focused on efficient, reliable and safe production at the lowest possible cost and we continue to advance our exploration and operational excellence programs to drive shareholder value.” Recent drill success in the 8 South pit area added new mineral resources, while deep sulphide exploration drilling confirmed the presence of permissive rock units at depth. Exploration activities are focused on mine life extension.
Marigold mine produces three millionth gold ounce
General Steel Holdings Inc, a nonstate-owned steel producer in Beijing, China, has completed the previouslyannounced acquisition of an 84.5% equity interest in Catalon Chemical Corp, a US corporation headquartered in Virginia, that develops and manufactures De-NOx honeycomb catalysts and industrial ceramics. Catalon’s honeycomb technology is an integral part of the selective catalytic reduction process widely used in steel mills, thermal power stations, waste
of General Steel. “We are excited to welcome aboard Catalon’s talented senior management team to General Steel and expect a seamless integration. As we merge Catalon’s proven technology, comprehensive suite of products and services, and talented team with General Steel’s vast resources, strong market presence and broad distribution platform, we are even more excited about the myriad of new business opportunities and synergies brought forth through this acquisition.
incinerators, stationary diesel motors, industrial plants and heavy-duty trucks. Catalon was valued at approximately $20 million by an independent third party. The acquisition is expected to enable General Steel to pursue the large and rapidly growing cleantech business in China to facilitate its business transformation. “We believe that acquiring Catalon is a strategic keystone for General Steel’s business transformation,” said Ms. Yunshan Li, chief executive officer •
WORLD MINING MAGAZINE www.ogsmag.com
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• News & features
Atlas Copco improves safety in underground drilling
A
tlas Copco has introduced core drilling rigs that eliminate many of the hazardous operations for mines involved in underground core drilling. Handling inner tubes and drill rods while extracting core samples is a risky operation for drillers around the world. A three metre long inner tube with core samples can weigh about 100 kg and despite safety regulations, accidents with severe injuries still occur. Atlas Copco’s Diamec Smart core drilling rigs have an advanced control system that automates functions such as drilling and adding and removing of rods. By using the unique rod handler, the operator can perform the work from a safe distance. Adding and removal of in the hole (ITH) equipment is all done automatically. The automatic functions not only increase the safety of operators, but also improve the working environment and increase productivity by eliminating operator fatigue. “There is an increasing focus on safety within the mining industry and the new Diamec Smart series sets a new standard
In a recent survey of over 100 decision-makers at Latin American mines by Timetric’s Mining Intelligence Centre (MIC), respondents were asked to outline their investment plans over a range of mine-site technologies in the coming two years. The results showed that out of 12 technologies involved, the category with the highest share of respondents intending to invest was remote control equipment and machine automation.
for underground core drilling rigs,” said Martin Sommers, VP marketing, Exploration Equipment at Atlas Copco. “Customers who have tried automatic drilling and rod handling never want to go back to the old way of drilling.” The new improved control system on the Diamec Smart is based on the Rig
Control System (RCS) that is used for all drilling rigs from the Mining and Rock excavation business area at Atlas Copco. More than 20 important improvements have been made in both hardware and software compared to the previous control system, making it even more robust and reliable.
The 12 categories spanned minemanagement and vehicle-related technologies that are used at an operational level. More than 50% of mines had already invested in all of the 12 mine-site technologies. Remote control/machine automation technologies had the highest share of respondents (50%) who either had it already in place but were intending to make further investments; or did not have it in place and were looking to
invest. This is followed by 46% planning investments in productivity monitoring systems, 44% in equipment health monitoring, 42% in mine management software (scheduling/optimization), and 41% in communications products and systems. “Mines in Latin America are set to exploit the advantages that remote controlled equipment and machine automation provides,” said senior mining analyst, Nez Guevara. •
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Barrick Gold: Projecting a golden future Barrick maintains its prime position in the gold market by focusing on the responsible mining of high quality assets.
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• Barrick Gold
B
arrick Gold, one of the world’s top gold producers, has been named to the Dow Jones Sustainability World Index for the eighth consecutive year; the company was also included in the Dow Jones Sustainability North America Index for the ninth year in a row. “We are honoured to be included in this respected index again this year,” said Barrick President Kelvin Dushnisky. “It tells us that we are continuing to live up to the values that, from day one, have driven Barrick’s success, values like trust and transparency, social responsibility and accountability and the pursuit of excellence in all that we do. When we stay true to these values and build strong partnerships with host communities, governments and our employees, we position ourselves for long-term success.” Each year, the Dow Jones Sustainability Index independently evaluates more than 2,500 companies using rigorous sustainability criteria to identify the top 10 per cent of performers. Companies are evaluated on a range of sustainability metrics, including governance, social performance, environment and economic contributions — taking into account both industry-specific trends as well as sustainability issues facing multiple sectors. Operating in a responsible manner creates significant value for Barrick’s shareholders, employees, local communities and host countries. In 2014, Barrick contributed $9.7 billion in the form of wages and benefits, royalties and taxes, purchases
of goods and services and community investments in its host countries and communities. This includes $3.6 billion in the developing and emerging countries where Barrick operates. Barrick has within its portfolio a number of the world’s largest undeveloped gold deposits, including Pascua-Lama, Donlin Gold and Cerro Casale. These projects offer leverage to higher gold prices, with more than 37 million ounces of gold in reserves and more than 48 million ounces of gold in measured and indicated resources. They provide the company with a platform for long-term growth in a higher gold price environment. Barrick maintains a strong competitive advantage in Nevada and the Andes, with a pipeline of projects that have the potential to grow free cash flow per share. Prefeasibility studies on growth projects in Nevada and the Andes will be complete by the end of 2015, into early 2016. These prefeasibility studies are focused on the Goldrush, Turquoise Ridge and Cortez sites in Nevada, on the Quantum Pacific Exploration and Alturas discoveries in Chile, and on the possible extension of the Lagunas Norte mine in Peru.
Goldrush
The Goldrush project, located six kilometers from Barrick’s Cortez mine, is one of the largest and highest grade gold discoveries of the last decade. Measured and indicated resources stood at 10.6 million ounces and inferred resources were 4.9 million ounces at the end of 2014. The prefeasibility study is expected to be complete by the end of 2015. Infill drilling in 2014 continued to demonstrate high grade continuity and led to resource upgrades, with nearly 70% of the overall resource now in the measured and indicated •
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• Barrick Gold
“Inclusion in the Dow Jones Sustainability Index tells us that we are continuing to live up to the values that have driven Barrick’s success from day one” •
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“A prefeasibility study for expanded underground mining at Cortez below currently permitted levels is due for completion any time now” 30
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• Barrick Gold
category. Permitting is progressing for twin exploration declines that will allow the company to better explore the northern limits of the known deposit.
“The Turquoise Ridge mine contains 4.5 million ounces in reserves at an average grade of 16.9 grams per ton — the highest reserve grade in Barrick’s operating portfolio and among the highest in the entire gold industry” Turquoise Ridge
The Turquoise Ridge mine, which is 75% owned by Barrick, contains 4.5 million ounces in reserves at an average grade of 16.9 grams per ton — the highest reserve grade in Barrick’s operating portfolio and among the highest in the entire gold industry. Turquoise Ridge has considerable untapped potential and could become a core operation. Barrick is advancing a project to develop an additional shaft, which could bring forward more than one million ounces of production, roughly doubling output to an average of 500,000
ounces per year at all-in sustaining costs of about $625$675 per ounce. The joint venture partners have approved a feasibility study and detailed engineering for the project. Pending receipt of permits and joint venture approval, initial production could commence in 2019. Preliminary estimates indicate capital expenditures of approximately $300-$325 million for additional underground development and shaft construction, and an attractive payback period of about two and a half years at a gold price assumption of $1,300 per ounce. Drilling has continued this year at the northern extension of the deposit where the ore body is still open to the north and east with higher grades than the average reserve grade.
Cortez
A prefeasibility study for expanded underground mining at Cortez below currently permitted levels is due for completion at any time. Mineralization in this zone is primarily oxide and higher grade compared to the current underground mine, which is refractory in nature. The limits of the Lower Zone have not yet been defined, and drilling has indicated the potential for new targets at depth.
Chile: Quantum Pacific Exploration
Barrick’s focus is gold and it is not actively seeking to expand its existing copper position. Yet the company does seek to maximize the value of those assets it already owns, including large land positions in Chile in some of the world’s most prolific districts for copper. In pursuit of this, Barrick has formed a strategic partnership with Quantum Pacific •
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• Barrick Gold
“In 2014, Barrick contributed $9.7 billion in the form of wages and benefits, royalties and taxes, purchases of goods and services and community investments in its host countries and communities”
•
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NO!PREIFILTRATION! CIF®!removes!the!need!for!complex!and!expensive!preFfiltration.!Water!is!fed! directly!into!the!CIF®!absorption!sorption!module!where!the!positive!ions! such!as!sodium,!calcium!and!magnesium!are!exchanged!with!a!counter!ion! such!as!hydrogen.!Negative!ions,!such!as!sulphate!and!chloride!are! exchanged!for!hydroxyl!ion.!There!is!no!barrier!used!in!the!technology!so! exchange!flux!is!extremely!high!and!the!potential!for!scaling!and!fouling!are! eliminated.!Any!particles!which!enter!with!the!feed!water!do!not!interfere! with!the!primary!desalination!operation!of!the!technology.! SELFICLEANING! The!continuous!movement!of!resins!within!our!CIF®!process!means!that!the! process!is!not!subject!to!scaling!and!fouling!failure!modes!associated!with! membrane!technology.!The!working!heart!of!the!CIF®!process,!the!ion! exchange!resins,!are!continually!cleaned!and!chemically!regenerated!before! being!reused!to!ensure!that!the!primary!treatment!process!remains! operating!at!optimum!conditions!
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• Barrick Gold
Exploration (QPX) to explore for copper deposits in a number of highly prospective areas of northern Chile. QPX is a company that focuses on exploring for one mineral commodity – copper - in one country - Chile. It is a part of the Quantum Pacific Group, an international business that includes some of the most innovative companies in natural resources, energy and commodities. Consistent with that theme, QPX is pioneering a new, multidisciplinary approach to exploration.
“Barrick has formed a strategic partnership with Quantum Pacific Exploration to explore for copper deposits in a number of highly prospective areas of northern Chile” The company has built a world-class team of experts who have a proven track record of copper discoveries and expertise in machine learning and big data analysis, among other disciplines. Their internal R&D lab uses proprietary technology to develop new strategies and tools designed to increase the probability of discovery, faster than conventional approaches and at lower costs. They combine world-class technical expertise with cutting-edge computer science, and
they bring in learning from other industries to develop nontraditional approaches. QPX shares Barrick’s spirit of collaboration and regularly seeks out joint ventures with companies that are complementary in assets and expertise. Under the terms of the agreement, QPX will manage the exploration program. Any gold deposits located on Barrick land will remain 100% Barrick owned. If a copper project is identified on either Barrick or QPX land, it will be 50% owned by each company. Certain properties where Barrick is already actively exploring, including zones around Zaldívar, Pascua-Lama, Cerro Casale and El Indio, are excluded from the agreement. The agreement runs for five years, with an option to extend for another three years and the partners will each contribute up to $30 million per year for exploration, with each bearing 50 per cent of the total costs. It is an exciting and mutually beneficial partnership for Barrick and QPX.
Alturas
Alturas is located in the Andean region of Chile, approximately 30 kilometres south of the former El Indio mine. It’s part of a large mineralized system, which extends well beyond the limits of Barrick’s current drilling area. To date, 35 core holes have been completed in an area one kilometre square. Mineralization appears to be oxide in nature and geologically similar to Veladero, with the potential to be significantly higher grade. Intercepts have been thick (typically ranging from 50-150 meters) and continuous. This region of the Andes is home to some of the world’s largest gold deposits, including Veladero, Pascua-Lama, •
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“Since it began operations in 2005, Lagunas Norte has outperformed production expectations”
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• Barrick Gold
Mining, a vital part of industry that truly functions on reliable power. This sector of industry depends on power to harness natural resources such as aggregates, precious metals, iron ore, oil, gas, coal and gold mining. All the machinery involved in this process uses power, both surface and underground mining operations use power to extract minerals and load trucks. There are different uses for transformers in the mining industry, so both liquid-filled and dry type are used. Depending on the application, there are some performance advantages that have been accepted. Virginia Transformer Corp has the engineering expertise and refined manufacturing processes to build some of the most dependable, long lasting units available. VTC offers transformers for drag lines, blast hole drilling and shovels (mil 167).
Virginia Transformer provided four 10 MVA transformers for Barrick Gold and is a Top Tier supplier for custom transformers.
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El Indio and Tambo. Barrick controls almost all of the prospective ground on the 140-kilometer long El Indio belt. The new discovery at Alturas is the result of a methodical re-evaluation of the El Indio belt led by Barrick’s exploration team, including members of the teams behind the Goldrush and Lagunas Norte discoveries. Drilling at Alturas finished at the end of the summer season in May. With mineralization open in multiple directions, the focus going forward will be on defining the full extent of the deposit, as well as exploring for additional targets nearby. Barrick’s other undeveloped gold deposits, including Pascua-Lama, Donlin Gold and Cerro Casale offer leverage to higher gold prices, with more than 37 million ounces of gold in reserves and more than 48 million ounces of gold in measured and indicated resources. They provide the company with a platform for long-term growth in a higher gold price environment.
Lagunas Norte mine life extension
sales@vatransformer.com
$543 per ounce. In its early years, production peaked at more than one million ounces per year. To date, Lagunas Norte has operated as an oxide heap leach mine and Barrick is currently evaluating a plan to significantly extend the life of Lagunas Norte by mining the refractory ore below the oxide ore body in the current pit. Barrick is initiating a prefeasibility study to evaluate this opportunity. As part of the study, it intends to evaluate the installation of a new grinding-flotation-autoclave processing circuit to treat the refractory ore, including the potential relocation of one autoclave from the Goldstrike mine to Lagunas Norte. All this potential can only strengthen Barrick’s primary position in the gold market, adding to other high quality assets across the world, including Pueblo Viejo in the Dominican Republic, Kalgoorlie in Australia, Jabal Sayid in Saudi Arabia and Kabanga in Tanzania. As a business it is managing its balance sheet in a difficult market by reviewing and selling off non-core assets so that it can focus on future potential.
Since it began operations in 2005, Lagunas Norte has outperformed production expectations. In 2014, the mine produced 582,000 ounces of gold at all-in sustaining costs of
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Reduce fatigue & distraction events. Save lives.
Seeing Machines’ Driver Safety System (DSS) is proven to dramatically reduce driver fatigue & distraction events. Today, in over 3,000 mine-site vehicles around the world, costly downtime is minimised while safe operations are maximised. DSS supports your fatigue management plans, improving productivity and keeping your vehicle operators safe. Supported globally through the CaterpillarŽ Dealer Network, the Seeing Machines DSS will protect your people and save lives. Learn more at www.seeingmachines.com
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A new model Information modelling can be a catalyst for change in the mining sector, says George Mokhtar, Associate Director, Turner and Townsend
I
t is critical that mining organisations seize the opportunity during this period of sluggish activity to improve on how they work, and in doing so, get fit for the upturn. The recent adoption of building information modelling (BIM) is impacting the infrastructure and property sectors. It can and will have the same effect in mining. The question is, which mining organisations will be ready for the disruption? What is BIM? Building information modelling (or simply, information modelling, as it is more commonly described outside of the property sector), can offer real opportunities for mining 40
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organisations to gain a competitive advantage on projects going forward. So what is BIM? Simply put by Iain Miskimmin of Crossrail Bentley Information Academy “about 80% of what BIM is about is passing on information and data associated with models in a structured way.” The definition agreed by buildingSMART, the Construction Project Information Committee (CPIC) and the Royal Institute of British Architects (RIBA) is that BIM is “a digital representation of physical and functional characteristics of a facility, creating a shared knowledge resource for information about it, forming a reliable basis for decisions during its life
• Information modelling on the ineffectiveness and inefficiencies of the industry. The UK Government was funding 40% of construction at the time and from its perspective as the client it was essential that improvement plans were put in place and. These were captured in the Government Construction Strategy (2011). Over the past five years the UK construction industry has made significant investment, and taken significant steps forward to focus on: • Providing centrally accessible project data with transparency and certainty • Setting clear criteria to measure value in service and align the supply chain • Upskilling and challenging clients to help them realise the best outcomes • Aligning design and construction with operational asset management • Streamlining waste through procurement and standardisation • Exploring procurement models to create competitive tension and align the capital phase with operational phase. One of the key mandates - which has its deadline in April 2016, is the BIM Level 2 mandate. From that point onward, the UK Government as the client will require fully collaborative 3D BIM (with all project and asset information, documentation and data being electronic) as a minimum. Is mining ready for BIM? On recent business travel to Africa and the US to engage with executives in the mining sector, it became clear to me that the more pertinent question should be ‘is BIM ready for mining”? A major benefit BIM offers is better cost certainty through the quantification and clash detection process. With a history of 3D modelling and robust project controls in mining already, the move to BIM earlier - although still beneficial, might not have produced the impact it can have today.
“About 80% of what BIM is about is passing on information and data associated with models in a structured way”
cycle, from earliest conception to demolition.” Importantly, within this definition, BIM is described as a digital representation of the building, and not as the actual 3D BIM model itself. This digital representation is more than just the 3D model, but rather a representation of an “information model”, which consists of “all documentation, non-graphical information and graphical information which the project team is required to provide”. The growing adoption of BIM In 2008-2009 the UK economic output for the overall construction sector took a significant dip, shining a spotlight
However, the 2016 BIM mandate in the UK focuses on a move to BIM for facilities management and asset management, where processes and data strategies have been significantly progressed. The result is that information is being maintained and matured through design, construction and into operation without losing significant knowledge. This allows for a more in-depth understanding of the levels of time recovery on projects and programmes. This concept is undoubtedly transferable to the mining sector and gives a strong indication of the evolution of BIM in mining. Like other capital projects, mining projects consist of an initial capital phase, followed by continuous development for the life of the mine. There is an obvious opportunity with BIM to use the data captured from the earlier phases in a mining project to forecast future expenditure, planned maintenance •
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and operational processes. In addition, the ongoing maintenance during construction of the ‘whilst built’ model in a BIM platform provides an accurate, complete and reliable source of truth to host information on operations and maintenance, and on full lifecycle data.
“There is an obvious opportunity with BIM to use data captured from earlier phases in a mining project to forecast future expenditure, planned maintenance and operational processes” Transferable concepts In addition to taking data into the operational phase of a mining project, BIM once applied should also promote other beneficial behaviours and opportunities within the mining sector. Five specific examples are: 1. People can become more involved, and the design can be tested more thoroughly at the early stages, thus providing better certainty of the ultimate value demonstrated by the supply chain. Taking a more integrated approach to project 42
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delivery, and increasing the density of early stage decisions can also improve progress through the feasibility stage to mitigate some changes later in the process. 2. By using rule based model checking, the confidence in the information that underpins the client decision making processes increases. Model checks have primarily been used for quality assurance, to ensure the quantities from models are sound, but are now also being used heavily to assess compliance with design standards, build-ability, access and health and safety. This is now a reality for the most complex BIM projects and the increase in useable information and continued usability of the information has led to reduced risk of design-related issues. 3. BIM-derived information can now be accessed and verified faster. In problem solving or progress meetings and workshops this information is readily accessible to report on status against the agreed goals, identify discrepancies and mediate to a satisfactory resolution. 4. Intelligent portfolio management and client insight is now achievable. Approaching the operational phase of a development project, the move from subjective decision making, which relies on user feedback and fragmentary data from disparate and unconnected asset management systems, towards objective decision-making takes place through the application of BIM. Building management systems are linked with other forms of data capture to create a more accurate, holistic picture of how the asset is performing and where the investment needs to go. 5. Model validation also represents a big change in the way we can work. Consistent, rich and accurate data is our greatest weapon for dealing with uncertainty. Asset knowledge and the ability to closely track how the operational team is sweating
• Information modelling
the asset are essential for continued optimisation whatever economic, social and environmental challenge is to be met. Challenges What challenges will the mining sector face with driving the adoption of BIM? Putting it bluntly, the technology (generally) works. The biggest challenge for the mining sector will be
“Mining organisations that spend time now to rethink business processes will be best placed to gain a competitive advantage in the long-term” around building up confidence and belief in the system, skills development in the market place and decision making. Implementing a BIM, or information modelling process requires input from mine owners’ teams including the design team, starting from the willingness to adopt, and ability to adapt. Culturally, owners’ team members and their supply chain need to recognise the importance of transparency of process, collaboration in design and information exchange and applying more rigour to data standards from the outset. One of the impacts is that the adoption of BIM has created a vacuum of talent; the market simply does not have enough people with skills to cope with the mandate. This has raised
some interesting questions and approaches and as a solution to this problem, some of the larger projects have opted to develop academies to induct and integrate team members into the BIM process, providing a shared understanding of requirements and expectations, as well as highlighting the importance of information within the landscape of the project information model. This has obvious repercussions for emerging markets within the sector. To support the client transition into a BIM environment we have seen the emergence of new roles. The Information Manager - a newly defined role - is responsible for the strategy, validity and direction of the production of asset information. Best practice dictates that this needs to be an organisational function with an understanding of the whole lifecycle. Adopting consistent and coherent client standards is key to driving this innovation. The first step is to make the decision and commitment to adopt. With that in mind, the opportunity currently presenting itself within the mining sector as we see it, is to get fit for a future where technologies such as BIM will play a bigger role in project delivery. Those mining organisations that spend time now to rethink business processes, consider technology innovations like BIM, and understand the cultural change within the organisation in order to drive adoption, will be best placed to gain a competitive advantage in the long-term. For more information, please contact: George Mokhtar Associate Director t: +44 (0) 7931 516 363 e: george.mokhtar@turntown.com •
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ION-IX
TM
Advanced ION EXCHANGE Technology Why use ION - IX ? TM
ION-IXTM is the ideal new system for: ●
●
●
●
Highest recovery of precious metals Steady product & efluent stream Reduced chemical and water usage Lowest O&M costs
Major benefits of the ION-IXTM System are: ●
●
●
●
●
Reduced chemical & water usage Lower waste volumes, higher concentration of metals recovered Compact footprint Reduced resin inventory Flow rates of up to 500 m3/h per valve possible
Elution profile with metals separated by ION-IXTM
Dikberd 14 unit 10A ● B-2200 Herentals ● Belgium Tel & Fax: +32 (0) 14 70 50 41 sales@puritech.be ● www.puritech.be
ION-IX Hydrometallurgy TM
Advanced ION EXCHANGE Technology Nickel / Cobalt
Zinc Recovery
Uranium
Copper Recovery
Nickel Laterite
Rare Earth
What Puritech does... Plant design The engineering of continuous countercurrent ion exchangers CCIX includes: ● ● ● ● ● ● ● ●
PFD & mass balance Process & Instrument Diagram Technical data sheets 3D design Piping & vessel drawings Electrical & instrumentation Commissioning Start-up
Pilot trials & Process Development Puritech has developed a process design simulation package. This software package allows us to calculate process performance before pilot trials. We have several pilot systems available for: ● ● ● ● ●
Optimising of existing process applications Developing new hydrometallurgy applications Obtaining data for a full size production plant Testing of different types of resin Providing proof of high performance
Copper Recovery Advantages of ION-IXTM System over solvent extraction for copper recovery are: ● ● ● ● ●
Lower capital and operating cost No fire hazards No crud formation or handling Much smaller footprint No strong electrolyte post-treatment
After electrolyse, copper can be extracted from the solution.
ION-IX
What Puritech builds... Nickel Laterite Nickel is a hard, silver white metal. It is mainly used in the manufacturing of stainless steel, steel alloys and superalloys. Nickel laterite can be found in large amounts in the tropics and comprises 73% of the world nickel resources.
Nickel - Cobalt Separation A 200 m3/h Ni/Co Separation plant has been designed and installed in Africa by Puritech. By using a split elution, the Nickel is separated from the Cobalt stream. A double or triple adsorption zone allows removing the desired metal almost completely.
Zinc Recovery The Zinc chloride can be removed from pickling acid. ZnCl2 will form a stable complex which is removed by anion resin. The resin is afterwards eluted with water.
Uranium & Rare Earth Applications Hydrometallurgy is used more and more as the first choice to recover precious metals. Some of the applications are: Uranium Lithium Rhenium Germanium Gold & silver ● ● ● ● ●
TM
74
I
ARTS CULTURE & PEOPLE
bne November 2015
Let me introduce you to QuERI How can we use QuERI? The mining and extractive industry faces challenges in light of current economic conditions worldwide, QuERI’s integrated approach to demand for primary products from coal to mining support activities and investment demand can provide the insights that only a globally integrated model of industrial activity can provide. Let us help with your forecasting and strategic insight needs. Drill down to the underlying factors driving demand for primary products. Let us develop a unique plan to provide the type of data useful for companies that need short, medium and long-term data in support of costly capital investments. Only QuERI’s integrated global model provides the links between industrial activity in one country and market demand (intermediate and final demand separately forecast) and international trade in commodities. ISIC3 Aggregates Coal Mining Metal Ore Mining Metal Ore Mining Metal Ore Mining Nonmetallic Minerals Mining Nonmetallic Minerals Mining Nonmetallic Minerals Mining Mining support activities Mining support activities Refined petroleum products Coke oven products Coke oven products Coke oven products Refined petroleum products Basic chemicals, except fertilizers Machinery for mining and construction Machinery for mining and construction
What does QuERI include? Standard packages offer access to complete databases covering more than 400 industries for 72 countries with updates quarterly. Databases cover production, market demand (intermediate, consumption, investment, and governments), imports and exports, prices, employment, and productivity. Given the complexity of the mining and extractive industry, specially developed company unique packages can be developed to provide more insightful analysis including drilling down to likely demand for key industry groups for single commodities using the integrated input-output models included in the forecasting model. Let us craft a package that meets your needs for both data and consulting.
NAICS 6 Detail Coal mining Iron ore mining Copper, nickel, lead and zinc mining Gold, silver and other metal ore mining Stone mining and quarrying Sand, gravel, clay and ceramic and refractory minerals mining and quarrying Other nonmetallic mineral mining and quarrying Support activities for oil and gas operations Support activities for other mining Petroleum refineries Asphalt paving mixture and block manufacturing Asphalt shingle and coating materials manufacturing Petroleum lubricating oil and grease manufacturing All other petroleum and coal products manufacturing Petrochemical manufacturing Construction machinery manufacturing Mining and oil and gas field machinery manufacturing
For further details please contact jmin@queridata.com
• Globalization
Decline of the global village Globalization has run its course, says Dr David Blond…but what comes next?
G
lobal Trade collapsed in 2015 as European recession worries and a significant devaluation of the euro led to a sudden drop in nominal European trade, having a negative impact on the worldwide trading system. The combination of euro fatigue with the long, drawn out crisis in Southern Europe after the financial crisis and the continued retrenchment in country after country – from Asia to Latin America – has left the world trading system in a state of crisis. Globalization, the panacea for the failure of countries to internalize development, has run its course. The opposition to the TPP (Trans-Pacific Partnership) and the counterpart agreement being forged across the North Atlantic, is due to the apparent failure of globalization to raise all boats evenly. Economists bear much of the blame for the failure of the system to produce the kind of results promised. The economics profession, ever since the emergence of imbalances in global
trade, has tried to brush these “issues” under the rug. They argue that the market system of checks and balances will eventually right the imbalances. But they ignore the damage done as we wait patiently for the correction. Technological and capital obsolescence means that as factories in one country or area of the world close and are replaced with imports, the lost trade rarely returns even after wages have been pushed down to below economic sustainability. Major imbalances in world trade with just a few countries running surpluses – China, Japan, Germany and the OPEC countries of the Middle East – with most others running sizable or just niggling deficits, has led to the crisis in Europe with the euro. Countries like Spain, Portugal and Greece, dependent as they are on tourism for much of their income and employment, needed flexible exchange rates to reign in imports (thus promoting domestic production of competing •
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• Globalization
goods). Without that ability, vacationing in Greece became as expensive as vacationing in Germany, so German tourists went farther afield to find warm weather, cheap food and lodging. The financial crisis in 2008 came at a time of massive global imbalances due, in part, to the euro allowing debtor countries to run up large and unsupported real trade deficits. Imbalances destabilized domestic industries, increased unemployment and made bankers nervous as imbalances indicated weak economies and bad credit risks. Governments facing rising unemployment borrowed against future prosperity, making it difficult to contemplate leaving the euro zone as the borrowed money would have to be paid back with devalued currencies adding to the outstanding debt. In short, European policies had turned what was a good idea – targets for debt to GDP as well as other rules – into time bombs that forced austerity on economies already weakened by the collapse of global confidence. The northern-dominated Central Bank chose to promote austerity as the general policy rather than stick to Keynesian style pump priming. The result has been to prolong the recession, making any uptick a signal to the Bank to either raise rates or push for more austerity in the debtor countries. With the change in leadership in the bank from German-Dutch to Italian, the European Central Bank began, belatedly, to purchase the non-performing debt in hope of rekindling the European economy. One result was a collapse in the value of the euro that had remained relatively strong throughout the crisis. As a result, when coupled with a global slow down starting in 2013 and continuing today, world trade measured in US dollar terms declined dramatically with the full effects of the downturn felt at the end of 2014 and on into 2015. QuERI’s internalized estimates of world GDP are based on a combination of EIU (Economist Intelligence Unit) estimates for the next ten years with model-determined demand and supply side measures of output. These are internalized in a
cross-country model along with other factors – trade, prices, and employment – to produce independent forecasts for GDP, private consumption, government spending, and international trade. These are based on dynamic models that integrate production and consumption through input-output models. The QuERI approach is dynamic and bottom-up and possibly the most sophisticated data driven model available from any company or government agency. Global output or production equalled $154 trillion in 2015. Growth has closely followed global GDP, but diverges during periods of extreme stress in the world trading system. Output growth in 2015 is expected to be close to zero, but GDP growth will be higher as it relies upon value-added, measured by continuing growth in demand. We approximate our GDP estimates by using a mixture of demand and supply determined GDP. As you can see in 2015 the supply-side GDP was near zero, while demand continued as people have to live, even if world output of factories, farms and services barely grows from the previous year. World trade almost collapsed, both in nominal and real terms. We have tried to modify the extent of the decline because at least some of the trade is non-dollar denominated (inter-European trade) so that the nominal dollar declines which are larger are less when measured in real volumes. Still, we can’t deny that 2015 was a turning point in the global trading system. We don’t expect future growth rates to approximate the high rates of the previous two decades, as more countries turn away from open borders towards more protection of domestic industries – both infant and mature.
Dr. David L Blond is President of Quantitative Economic Research International
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Rio Tinto: Advanced mining
Advances in technology have helped Rio Tinto make its operations safer, reduce costs and respond to environmental imperatives. •
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ining giant Rio Tinto’s main business is the production of raw materials including copper, iron ore, coal, bauxite, diamonds, uranium and industrial minerals including titanium dioxide, salt, gypsum and borates. Rio Tinto performs processing on some of these materials, with plants dedicated to processing bauxite into alumina and aluminium, and smelting iron ore into iron. The company also produces other metals and minerals as byproducts from the processing of its main resources, including gold, silver, molybdenum, sulphuric acid, nickel, potash, lead and zinc. Rio Tinto continues to make advances in technology that are being implemented into its biggest operations and will help it to cement its position as a world leader. 54
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Pilbara
Rio Tinto’s Pilbara operations include a world-class, integrated network of 15 iron ore mines, four independent port terminals, a 1,700 kilometre rail network and related infrastructure, designed to respond rapidly to changes in demand, supported by Rio’s operations centre in Perth, Western Australia. Rio Tinto is expanding its operations in the Pilbara to epic proportions, while introducing next generation technologies to deliver greater efficiency, lower production costs and improve health, safety and environmental performance. Two of Rio Tinto’s Pilbara mines have recently become the first in the world to start moving all of their iron ore using fully remote-controlled trucks. The pits at its Yandicoogina and Nammuldi mine sites have workers controlling the driverless trucks largely from an operations centre in Perth, 1,200 kilometres away. Josh Bennett manages the mining operations at Yandicoogina mine north west of Newman and is closely involved in the running of 22 driverless trucks on the site. The two pits are
• Rio Tinto
the largest of their kind in the world, he said. “To the naked eye it looks like conventional mining methods. I guess the key change for us is the work that employees and our team members are doing now,” he added. “What we have done is map out our entire mine and put that into a system; the system then works out how to manoeuvre the trucks through the mine.” The company is now operating 69 driverless trucks across its mines at Yandicoogina, Nammuldi and Hope Downs 4. The trucks can run 24 hours a day, 365 days a year, without a driver who needs bathroom or lunch breaks, which has industry insiders estimating each truck can save around 500 work hours a year. The technology takes away dangerous jobs while also slashing operating costs. “We have taken away a very high risk role, where employees are exposed to fatigue,” said Bennett. “It is quite challenging to get repeatability out of a human; one of the advantages we have had with autonomous haulage, particularly in the truck fleet, we notice we are getting consistency in terms
of the way the machines are operating. “One of the biggest costs we have is maintaining mobile assets, so we spend a lot of time on our operator training, education. So, there are obvious capital savings in terms of setting up camps, flying people to site; there are fewer people so there are less operating costs, but there are some costs that come into running the system and maintenance of the system as well.” Rio’s plans do not stop at trucks. It is also trialling unmanned trains and mining with robot drills with the aim of rolling out the machines across as many of its mine sites as possible. Eventually, most of the company’s supply chain from the pit to the port will be remotely controlled from Perth. That will involve the creation of new, highly skilled positions. “We have a whole dedicated team based in Perth that is looking at how to optimise the system, looking at maintenance, productivity... those are jobs that did not exist five years ago,” said Bennett. “We have roles which are being created such as a central controller and a pit controller which are essential to running the autonomous system.” At a recent investor seminar in Sydney, Rio Tinto outlined the next phase in its long-term strategy to capitalise on the growing global demand for high-quality iron ore through a relentless focus on productivity and efficiency, technology, and people development to drive costs lower at its Pilbara operations. Rio Tinto also revealed new detail on the data underpinning its projections for 2.5 per cent average annual growth for steel demand across China and the rest of the world over the next 15 years. This rigorous analysis confirms that Chinese crude steel production is expected to reach around one billion tonnes by 2030. Emerging markets will also play an increasingly significant role in the iron ore market, with non-Chinese steel demand expected to increase by 65 per cent by 2030. Rio Tinto Iron Ore chief executive Andrew Harding said, “As we move into our 50th year of exports from Australia, Rio Tinto is embarking on a new phase in our iron ore business. We have spent the past decade building the best iron ore business in the world - a project that has come in on time and below initial cost estimates. We intend to optimise these new assets to deliver maximum value for shareholders and stakeholders as markets transition. “Our long-term strategy is supported by comprehensive market analysis, leadership in people, world-class technology and an unrelenting pursuit of productivity improvements. Rio Tinto has some of the best tier one mining assets in the world and our workplace culture of chasing new efficiencies will ensure we remain the best iron ore producer in the industry. We are also focused on realising further costs savings through some 400 efficiency initiatives across the Pilbara.” Rio Tinto Technology and Innovation chief executive Greg Lilleyman said, “Our sector-leading Mine of the Future programme is already delivering significant groupwide productivity improvements. Rio Tinto’s first-mover status in autonomous equipment has resulted in significant productivity gains while our use of big data analytics has allowed us to safely extend maintenance cycles. These productivity gains, combined with our asset management programme, have us on a pathway to safely reduce maintenance costs by about $200 million a year over the next three years. The Technology and Innovation team is also ensuring that Rio Tinto not only undertakes the right projects but when we do them, we do them right.” •
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“One of the advantages we have had with autonomous haulage is getting consistency in the way the machines are operating”
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Oyu Tolgoi
Oyu Tolgoi is situated in the southern Gobi desert of Mongolia. Since 2010, Rio Tinto has been the manager of the Oyu Tolgoi project and has a percentage ownership share. Oyu Tolgoi is one of the most exciting developments in copper and gold mining for several decades. As well as containing reserves and resources that make it one of the world’s largest coppergold deposits, Oyu Tolgoi will have a transformative effect on the nation and the people of Mongolia and is an important long-term partnership with the Government of Mongolia. By the time it reaches full production in 2021, the International Monetary Fund estimates that Oyu Tolgoi will generate up to a third of Mongolia’s GDP. Oyu Tolgoi is expected to produce an average of 430,000 tonnes of copper and 425,000 ounces of gold per year, as well as by-product silver and molybdenum, over its mine life. Ore from Oyu Tolgoi will be processed into concentrate on-site and, in its initial years, be shipped by road to international markets. In 2013, Oyu Tolgoi reached a major milestone when shipping commenced with trucks carrying copper concentrate leaving the mine bound for customers in China. The 100,000-tonne58
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per-day concentrator began processing ore at the beginning of 2013, from Oyu Tolgoi’s open pit. The underground section of the mine, which Rio Tinto expects to develop in the next phase of the project, contains up to 80 per cent of the value of the project. Oyu Tolgoi is designed to be one of the most water-efficient mines of its kind in the world. As well as using water only from a previously-undiscovered, deep and saline aquifer that is unconnected to surface water, the operation will continuously recycle 80 per cent of the water used in operations and all of the water used for domestic purposes.
Bowen Basin
Rio Tinto says the automation technology being rolled out in driverless trucks and trains in the Pilbara will soon move to the Bowen Basin. Rio Tinto has real productivity concerns, with Australian miners hard to find and expensive to pay, and so is spurring the spread of automation to Queensland. The Bowen Basin contains the largest coal reserves in Australia. This major coal-producing region contains one of the world’s largest deposits of bituminous coal. The Basin contains much of the known Permian coal resources in
• Rio Tinto
“We have a dedicated team based in Perth that is looking at how to optimise the system, looking at maintenance, productivity... those are jobs that did not exist five years ago”
Queensland, including virtually all the known mineable prime coking coal. The Bowen Basin covers an area of over 60,000 square kilometres in Central Queensland running from Collinsville to Theodore. Rio Tinto’s operations in the region are comprised of the Hail Creek and Kestrel mines. Together the mines supply more than 10 million tonnes of coking and thermal coal for export annually. Hail Creek is an open cut mine that has been operating since 2003. In October 2013, Rio Tinto opened the Kestrel Mine Extension. This US$2 billion dollar extension added 20 years to the mine’s life and is one of the most advanced and sophisticated underground coking coal operations ever built in Australia.
Cape Lambert
Expansion at the Nammuldi iron ore mine and Cape Lambert port continues ahead of schedule. Rio Tinto has ramped up production at its West Australian iron ore sites as a result of being ahead. $1.1 billion was allocated to increase the size of the company’s Cape Lambert port and rail facilities. The second phase of expansion, which will increase iron ore production to 360 million tons a year by the end of this year,
has been the most recent focus for the company. The extra capacity has added tremendous value to the business, Andrew Harding, iron ore boss, announced. The expansion in both phases will allow Rio Tinto to move iron through the region at a low cost. Rio Tinto has also said that the use of autonomous technology was already helping the company keep its costs down. Not only do the automated trucks mean that fewer trucks are required at the new mines, but that innovative sourcing and procurement have also delivered considerable savings, with much of the construction equipment coming from emerging supplier powerhouses, such as China, Indonesia and Thailand.
Weipa Bauxite Mine
Last month Rio Tinto and the Australian Renewable Energy Agency (ARENA) announced Australia’s first commercial diesel displacement solar plant has commenced commercial operation at Rio Tinto’s Weipa bauxite mine. The Weipa Solar Plant will generate electricity for the mine, processing facilities and township on the Western Cape York Peninsula in Queensland. Rio Tinto general manager, Weipa Operations, Gareth •
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• Rio Tinto Rio Tinto quick facts: Rio Tinto’s Pilbara operations include 15 iron ore mines, four independent port terminals, a 1,700 kilometre rail network and related infrastructure. The company is now operating 69 driverless trucks across its mines at Yandicoogina, Nammuldi and Hope Downs 4. When it reaches full production in 2021, the International Monetary Fund estimates that Oyu Tolgoi will generate up to a third of Mongolia’s GDP. Oyu Tolgoi is expected to produce an average of 430,000 tonnes of copper and 425,000 ounces of gold per year. Oyu Tolgoi will continuously recycle 80 per cent of the water used in operations and all of the water used for domestic purposes. The Bowen Basin in Queensland contains one of the world’s largest deposits of bituminous coal. Australia’s first commercial diesel displacement solar plant has commenced commercial operation at Rio Tinto’s Weipa bauxite mine. The modernisation of the aluminium smelter will increase production capacity by 48 per cent and result in Kitimat becoming one of the lowest cost smelters in the world.
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• Rio Tinto “The Technology and Innovation team ensures that Rio Tinto not only undertakes the right projects but when we do them, we do them right”
Manderson said, “This power purchase arrangement is an opportunity to trial the introduction of an alternative power source such as a solar plant into a remote electrical network like the one here in Weipa.“ At peak output, the 1.7-megawatt capacity solar plant has the capacity to generate sufficient electricity to support up to 20 per cent of the township’s daytime electricity demand. “We expect the energy from the solar plant will help reduce the diesel usage at Weipa’s power stations and save up to 600,000 litres of diesel each year. This will reduce Weipa’s greenhouse gas emissions by around 1,600 tonnes per year, equivalent to removing around 700 cars.” The solar plant is expected to produce an average of 2800-megawatt hours of electricity per year.
Kitimat
Rio Tinto is preparing its first shipments of metal from its world-class Kitimat aluminium smelter in Canada following an extensive modernisation of the facility. The modernisation of the aluminium smelter will increase production capacity by 48 per cent and result in Kitimat becoming one of the lowest cost smelters in the world. Rio Tinto is now focused on safely ramping up towards its annual production rate of 420,000 tonnes. The modernised smelter, which was delivered in line with the revised schedule and budget, is powered exclusively by Rio Tinto’s wholly owned hydro power facility and uses the company’s proprietary AP40 smelting technology, which will effectively halve the smelter’s overall emissions. Aluminium chief executive Alf Barrios said, “The modernisation of Kitimat will fundamentally transform its performance, moving it from the fourth quartile to the first decile of the industry cost curve. At full production, Kitimat will be one of the most efficient, greenest and lowest-cost smelters in the world. Positioned in
British Columbia on the west coast of Canada, Kitimat is well placed to serve rapidly growing demand for aluminium in the Asia-Pacific region and to serve the North American market.”
Mine of the Future
Launched in 2008, the Rio Tinto Mine of the Future programme is not a single mine site but a programme developed by Rio Tinto that plans to change the face of mining with step change improvements in productivity and efficiency. Rio Tinto is now rolling out a number of technological advancements across its operations to meet the three key themes of the programme: Autonomy: to achieve massive efficiency in surface bulk mining Recovery: to increase efficiency by sorting waste before it gets to process plants Tunnelling: to access deep orebodies faster. Technology is an increasingly important success factor in the mining and minerals industry. Improvements in technology have changed the way Rio Tinto looks at mineral deposits, have made its operations safer, helped it manage costs and respond to environmental imperatives.
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