Magnetite Projects

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Southdown Project

Client
Grange Resources & Sojitz Corporation
Location
Southdown, Western Australia
Products
Magnetite
Project Capital Value
$1.6 Billion (for 7Mtpa (2009)
Project Summary
The Southdown Joint Venture is a joint venture between Grange Resources, an Australian publicly listed company (70%) and Sojitz Resources and Technology Pty Ltd (30%), a Japanese trading house. The Joint Venture proposes to mine and export 10 million tonnes of premium magnetite concentrate annually. The product will be exported from the Port of Albany and processed into pellets for international markets. The Southdown Magnetite Project mine life is estimated to be from 19 to 40 years.


EPMS was engaged by the Southdown Joint Venture as Owner’s Engineer and provided
engineering and design assistance when required. Some of EPMS’s senior management
team have had an involvement with the Southdown Project going back as far as 2006.
Scope
Development and Management of Comminution, Beneficiation and Pelletisation Testwork

Flowsheet Development

Management of Process Engineering and Process Plant Design

Balance of Plant Engineering and Design

Engineering and Design pertaining to the routing and easement requirements for the proposed slurry pipeline

Management of Tailings Management Studies being undertaken by Golders

Order of Magnitude Studies for Albany and Kemaman

Pellet Plant Layouts (Kemaman)

Port Layouts (Albany)

Investigation into Process water Options and Pricing

Early Water and Mass Balance Calculations

Document Management Support

Executive Summary Report

Project Controls Assistance

Technical Assistance
Project Achievements
EPMS maintained an involvement with the Southdown Project up until around 2010. In 2009 Grange developed their own in-house owner’s team and engaged a major EPCM consultant to finalise the PFS and undertake the DFS. EPMS are still engaged by Grange to provide technical assistance and undertake engineering studies for both Grange’s Southdown and Tasmanian operations, Savage River and Port Latta.

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Concentrate Dewatering and Storage Study

Client
Grange Resources (Tasmania)
Location
Port Latta, Tasmania
Products
Magnetite Concentrate and Pellets
Project Capital Value
Approx $93.5M (for Option B)
Project Summary
The project is located in Port Latta on the northwest coast of Tasmania where Grange Resources Tasmania Pty Ltd (Grange) owns a pellet plant and port facility. EPMS was engaged by Grange to undertake an Options Study for concentrate only production at Grange’s existing Port Latta site (Option B) and an alternative site (Option A). The sites are situated approximately two kilometres inland of exiting port facilities.




Favourable market conditions for concentrate and the need to invest heavily in the aging plant to meet operational and environmental requirements have been the impetus for this Study. The existing pellet and filter plants were installed over forty years ago and only designed for a twenty year mine life. A modern filtration plant would offer significant benefits in terms of reliability, efficiency and maintenance.

The Study concluded that the most cost-effective option would be to locate the proposed facilities filtration plant, concentrate storage shed, conveyors and all associated infrastructure on the existing port site (Option B).
Scope
Options Study including:


PFD’s (for both Options)


Development of equipment lists
(for both Options)


Development of equipment datasheets
and specifications for vendor pricing


Engineering and Design (of sufficient
detail to achieve a ±25% cost estimate)
for both Options


Compilation of Capital and Operating
Cost Estimates (for both Options)


Initial Risk Review (for both Options)
Project Achievements
EPMS was able to provide high-quality robust deliverables for inclusion into the Options Study report and the Capital Cost Estimate provided was to a level of accuracy that exceeded the industry standard for this stage of study.



EPMS’s past project experience gained on similar projects ensured that the work was completed efficiently and within the client’s extremely tight timeframe.

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Zapucay Project

Client
Gladiator Resources
Location
Isla Cristalina Belt in Uruguay
Products
Magnetite
Project Capital Value
TBA
Project Summary
The project area comprises 750 km2 in the Isla Cristalina Belt district of Uruguay, located approximately 400km north of Montevideo, the capital of Uruguay, and some 50km from the Brazilian border. EPMS was engaged by Gladiator Resources to provide technical assistance as well as design and engineering for development of their Zapucay Magnetite Project.
Scope
Development and Management of Metallurgical Testwork Program
Interpretation and Reporting on Testwork Results
Development of Flowsheets and Mass Balance
Development of Process Design Criteria
Development of Engineering Lists
Equipment Sizing and Selection
Development of Basis of Design
Development of Specifications and Datasheets
Development of Plant Layouts
Development of General Arrangement
Drawings, Plans and Elevations
Compilation of Capital Cost Estimate and Basis of Estimate Report
Development of Operating Cost Estimate
Project Achievements
EPMS provided high-quality, fit-for-purpose concept and preliminary designs that were used as the basis for detailed design.

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Wilcherry Hill Project

Client
Ironclad Mining Limited
Location
105 km northwest of Whyalla, South Australia
Products
Magnetite
Project Capital Value
Confidential
Project Summary
IronClad Mining’s tenements in South Australia are collectively known as the Wilcherry Hill Project. The tenements are located 30km north of the township of Kimba. The Wilcherry Hill Project comprises of four tenements and covers an area of 976 km2. The tenements are EL4162 Wilcherry Hill, EL4286 Vally Dam, EL4421 Peterlumbo, EL3981 Eurilla Dam.
Scope
Preliminary Plant Designs
Order of Magnitude Cost Estimates
Conceptual Design for the Dry Magnetic
Separation (DMS) Plant
Project Achievements
EPMS provided high-quality, fit-for-purpose concept and preliminary designs that were used as the basis for detailed design.

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Jogja Iron Project

Client
Indo Mines
Location
Java, Indonesia
Products
Iron Sands (Magnetite)
Project Capital Value
Approx $150M (2011 Feasibility Study)
Project Summary
Through its joint venture company PT Jogja Magasa Iron, Indo Mines Limited owns a 70% interest in the Jogjakarta Iron Project. The Project is located on a 22 km long by 1.8 km wide stretch of beach between the Kulon Progo and Serang Rivers in Indonesia.


The Feasibility Study for a 2 million tonne iron project was undertaken during 2011. The intention is to commence dry mining surface sands on the contract of work area. A probable ore reserve of 163.5mt at an average grade of 13.7% Fe for the surface sands has been defined. Mining is scheduled to produce 2.0mt of concentrate per annum at 55% Fe.
Scope
Feasibility Study including:

Process Plant Engineering and Design

Capital Cost Estimate

Implementation Schedule

Implementation Planning
Project Achievements
EPMS provided high quality robust deliverables for inclusion in the Feasibility Study report. The Capital Cost Estimate provided was to a level of accuracy that exceeded the industry standard for this stage of study. EPMS’s deliverables were provided well within the initial budget estimate and within the estimated timeframe. EPMS is currently providing project execution assistance to Indo Mines for the next stage of the Project.

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Sino Iron Project

Client
Citic Pacific Mining
Location
Cape Preston, 100km southwest of Karratha
Products
Magnetite
Project Capital Value
~ $5.9 Billion
Project Summary
The Sino Iron Project is the largest magnetite mining and processing operation under construction in Australia. The project is being developed at Cape Preston, 100 kilometres
southwest of Karratha in Western Australia’s Pilbara region.
Scope
Development of Technical and Functional Specifications for new mining fleet including, drills, shovels, trucks, mobile crushing plant, and light vehicles

Technical Evaluation of tenders

Design of temporary facilities
Project Achievements
All work was completed on time, within
budget and to the satisfaction of the client’s
project owner.

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Tonkolili

Client
Ausenco
Location
200 km NE of Freetown, Sierra Leone
Products
Magnetite
Project Capital Value
$1.2 Billion (phase 1)
Project Summary
The Tonkolili Iron Ore Project consists of mining and processing operations that will produce concentrate for export for approximately 45 years. There’s also potential for increased production subject to further exploration. The crushed ore will be concentrated in process plants located at the mine. The ore concentrate will then be transported approximately 200 km via new infrastructure to a new purpose-built port at Tagrin Point, near the mouth of the Sierra Leone river estuary.
Scope
Provision of Project Execution and Planning Expertise to Ausenco
Project Achievements
All work was completed to a high quality and finished within the cost and time constraints set by the client.