All aboard Brockman 4

AN on-location look at Rio Tinto’s billion dollar modern mine, set to centralise its existing and future Pilbara operations and double iron ore output as it continues to expand. By Brooke Showers

Brockman 4 is the latest addition to Rio Tinto’s iron ore mining operations in Western Australia’s Pilbara region.
The $US1.5 billion mine was opened by Parliamentary Secretary to the Premier, Treasurer and State Development Minister Helen Morton MLC and Rio Tinto chief executive iron ore and Australia Sam Walsh.
Located 60 kilometres northwest of Tom Price, the mine is expected to have an initial output of 22 million tonnes per annum of high-grade iron ore with the potential to expand to 40Mtpa.
With a 30-year mine life, Brockman 4 is also ideally positioned to serve as an infrastructure service hub for the future development of nearby deposits.
“As we have made clear recently, growth in our Pilbara iron ore operations is back on the agenda and Brockman 4 features significantly in our future plans,” Walsh said.
“The mine has been planned very much for future expansion to double the initial capacity in mind, and we would expect that additional tonnage to form an important component of our planned expansion of Pilbara capacity to 330 million tonnes per annum.”
The mine workforce has 530 full-time employees, of which 16% are female and 8% are indigenous – both figures that Walsh intends to increase. He said Brockman 4 had attractive working conditions, including an 8 and 6 roster.
The camp facilities are first rate, a growing trend at many remote minesites. Brockman 4 has a swimming pool, fitness centre, tennis courts, wet and dry mess, and a netted enclosure to polish up the golf swing.
It has 1000 dongas, all including a phone, plasma television, fridge, air conditioning, spacious shower and vanity unit.
There are two different locks on the drawers and wardrobes, so employees can secure their personal items onsite while at home on a break. This allows each donga to be shared by two workers on opposing rosters.
Utilising the latest equipment, Brockman 4’s open cut mining operation hosts three 500t Hitachi shovels, a 350t Hitachi excavator and 15 Komatsu 830E 220t dump trucks.
Supporting infrastructure onsite includes a fixed plant maintenance workshop, tyre and light vehicle maintenance facility, and integrated process and potable water systems.
It has a two-stage dry processing plant, including primary and secondary crushing, sample stations and train load-out system.
The anticipated daily movement of materials is 160,000t and Rio Tinto expects to load 20 trains per week, linked by the 50km rail network.
The hub model has the potential to align all the Rio Tinto mine operations into one central train system for ship loading.
“Mesa A/Warramboo and Brockman 4 demonstrate our strategy of substantial investment in high-quality, long-life, low-cost assets,” Walsh said.
“They are outstanding deposits, close to existing infrastructure, and each promises excellent commercial returns.”
Brockman 4’s pit designs are expected to yield about 600Mt of high-grade ore of more than 60% iron and 450Mt of a lower 50-60% iron grade, which will be stockpiled for future processing.
Rio Tinto also has studies underway to take its Cape Lambert port from 80Mtpa to 180Mtpa to help bring its Pilbara total to 330Mtpa.
The company also will have five new mines or mine expansions to meet capacity.
Walsh expects the free on board price for iron to drop 13.3% in the December quarter of this year to $US127 per tonne.
Brockman 4 has land-use agreements in place with traditional owners, the Puutu Kunti Kurrana Pinikura and Eastern Guruma people.
Rio Tinto is committed to having all employees in WA complete cultural awareness courses with Aboriginal leaders to strengthen the company’s understanding of Aboriginal people.
The company has created better ways to support its Aboriginal neighbours in the workplace through this knowledge.
The strategy for Rio Tinto to focus donations into four key areas – education, health, the environment and culture – has helped the company address issues facing the community. In 2009 the company contributed $27.8 million in community investment activities in WA.
Brockman 4 has a swimming pool, fitness centre, tennis courts, wet and dry mess, and a netted enclosure to polish up the golf swing.

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