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The Gudai-Darri iron ore mine is Rio Tinto’s first greenfield mine in Pilbara, Western Australia in over a decade and has endured several setbacks. Already producing ore almost a year behind schedule and with a budget of over $3 billion, the mine could collapse as one of the most expensive and notorious failures in the company’s recent history. there is.
However, the swath of innovative technology being installed at Gudai-Darri means that hopes for the project remain high, and Rio Tinto believes the mine will produce the Pilbara Blend of iron ore, the company’s flagship product. We are optimistic that it will help us in the future production of our products. The miner’s total supply of ore.
Production is expected to continue increasing through the rest of the year, reaching full capacity in 2023. The mine has an expected life of more than 40 years, an annual production capacity of his 43 million tons (1 million tons), and a feasibility study to support the expansion of this new hub is also underway.
Rio Tinto Iron Ore Chief Executive Simon Trott said in a statement: Through the deployment of technology and innovation, Rio He sets new standards for Tinto mine development. “
Digital twins and self-driving trucks
Mark Davies, Chief Technology Officer, Rio Tinto, said: This array of autonomous assets will complement other planned state-of-the-art deployments. “
Chief among these new innovations is the complete digital replica of the processing plant, known as the ‘digital twin’. A digital twin is a virtual version of an asset that incorporates a process model and derives real-time feedback from process instrumentation, power and water usage. They allow reliable prediction of changes over the life of the mine and are sophisticated enough to consider how changes in ore quality and head grade affect operations.
It also collects geological data below the surface. This allows the team to monitor and act on the data collected from the plant. The autonomous assets will be monitored remotely from Rio Tinto’s operations center in Perth, 1,500 kilometers away, and digital data will be used to provide an interactive 3D environment for virtual reality training.
Similarly, the use of self-driving vehicles in mining has expanded rapidly since Komatsu’s first self-driving truck went into production in 2008, according to Komatsu’s technical director Michael Lewis.
Much of this is driven by worker safety concerns. The Global Mining Guidelines Group report calls for a “system safety approach” for mining companies that install and use automated systems. The group says there is an urgent need to address the use of autonomous systems within the mining industry, both above ground and below ground.
Chirag Sathe, co-leader of the project and principal manager of BHP’s mining system, commented in the paper: “
production profit
Lower-than-expected iron ore production put Rio Tinto under considerable pressure earlier this year. Labor shortages combined with problems in his supply chain prevented the Anglo-Australian mining giant’s Pilbara operations from starting up, and by 31 March he had three months to ship iron ore. It remained at 71.5 million tons.
However, by the second quarter, we saw a clear improvement and were ready to start production at Gudai-Darri. A total of 79.9 million tonnes were shipped from Pilbara, representing a 12% increase in the first quarter, and Rio Tinto Chief Executive Officer Kellie Parker spoke at the Melbourne Mining Club in August, explaining that Pilbara’s power supply He said further increases can be expected if the number recovers. authentic.
“Pilbara offers one of the best opportunities in the world to harness solar and wind power to generate energy on our property,” said Parker. “We are working to establish an integrated solar and wind network and are seeking large-scale solar and wind proposals of at least 4 gigawatts in Queensland.”
The Pilbara solar farm is expected to provide about a third of the mine’s average electricity from August. This is complemented by a new lithium-ion battery energy storage system.
Gudai-Darri is just one of four projects Rio Tinto has embarked on in recent years. This is because miners are looking to expand their business and increase production. Other projects such as West Angelas and Western Turner Syncline Phase 2 came online last year, and Robe Valley is due in his September quarter. Collectively, these are intended to replace his 130 million tonne capacity at other sites.
Cost of innovation in Gudai-Darri
But what could be one of the most sophisticated mines in the world was expensive. Production has been delayed for several months, and Trott defended it, although he admitted there was a $500 million cost overrun, adding that the impact of Covid-19 was “supply disrupted in his chain.” and inflation were foreseen in the original costing of the project.”
The mine was initially budgeted at $2.6 billion, with first ore scheduled for late 2021, but capital costs are now expected to be $3.1 billion. However, as a result of the Pilbara mine commissioning, Rio Tinto’s iron ore production and product mix are expected to improve in the second half of the year. Rio Tinto was under considerable pressure in the first quarter of this year as iron ore shipments fell short of expectations. ‘
Rising costs have been observed across the Australian mining sector, with constant innovation and production expansion coming with a hefty price tag. The West Australian has reported that Fortescue Metals Group has been forced to update the cost of Pilbara’s Iron Bridge magnetite project twice. Estimates for this project have increased by $1 billion to bring him from $3.6 billion to $3.8 billion.
Like Rio Tinto, Fortescue is determined to make the mining process ‘green’. The company has set up a research and development facility in Hazelmere, Perth, where a “green team” is working to develop the world’s first infinite train, which will use gravitational energy and require additional charging. Recharge the battery electrical system with and without.
Gudai-Darri: innovation and profitability
Automation and technology not only make workers safer, they can also lead to significant productivity gains and, in turn, higher profitability. Mining companies have reported cutting production costs by as much as 30% through automation, and companies such as Rio Tinto are looking to capitalize on these long-term savings to offset the burgeoning front-end costs of such innovations. I rely on
A recent report from Knowledge Sourcing Intelligence, “Mining Automation Market – Forecast 2022-2027,” states: Replacing human labor in operating equipment with technology and automation can significantly reduce the cost of the mining process.
“The application of automation in mining will significantly reduce the operating costs of large-scale devices and equipment involved in the mining process.”
But this change could ultimately threaten mining jobs in the long run. The impact of the Covid-19 pandemic, which has particularly affected migrant workers in Australia’s mining industry, could lead to a relative scarcity of employment opportunities in this most profitable sector.
It remains to be seen how mining will change as key players embrace technological innovation, with rising energy prices driving up costs even further and labor shortages, among many other issues.
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