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Luc Bélanger from SNC Lavalin delivered this presentation at the 2012 Americas Iron Ore conference. Americas Iron Ore is one of the most respected annual gatherings for North and South American iron ore markets and its agenda features: iron ore industry and market developments; new project developments and expansions in North and South America; overview of steel demand; iron ore spot market price; infrastructure and transport challenges and investment opportunities. For more information on the annual event, please visit www.immevents.com
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HARD IRON ORE PROJECTSBy: Mr. Luc Bélanger, Sr. Vice President Iron Ore
& Dr. Marcus Sztrimbely, VP Iron Ore Technology
GLOBAL MINING & METALLURGY
Brazil, November 2012
Introduction to SNC-Lavalin:Global M&MGlobal Iron Ore Experience
Taconite Type Iron Ore Projects in the Labrador Trough {Plan Nord}:Lac Otelnuk – Adriana Resourses & WISCOMont Wright Expansion – ArcelorMittalTaconite Project – New Millenium & Tata Steel
Taconite Type Iron Ore Project in Mauritania, West Africa:GUELB II - Société Nationale Industrielle et Minière
Closing CommentsQuestions
PRESENTATION OUTLINE
Our Mission:
Contributing to the success of our clients through value-added services and continuous improvementGlobal leader in project delivery with worldwide project experience
Ongoing projects in some 100 countries International network for over 50 yearsOffices across Canada and in over 40 countriesOver 33,500 employees worldwide
Presence in CanadaWe have over 12,000 employees in Canada with offices in all provinces and territories
Presence in BrazilWe have over 1,200 employees in Brazil with offices in Belo Horizonte (Formerly Minerconsult)
SNC-LAVALIN AT A GLANCE
GLOBAL DELIVERY
Legend
M&M OfficeNickelCopper
OtherIron OreAluminum / Alumina
ZincGoldAcid Plant
Vancouver London
Perth BrisbaneJohannesburg
Santiago
Lima
NouméaBelo Horizonte
Bucharest
Toronto
Montreal
Saskatoon
JakartaIron ore PDC
London Office
ON 6 CONTINENTS
SNC-LAVALIN IN LATIN AMERICA
Open pit mining / materials handling
DSO and concentration, magnetite, hematite, taconite (hard, low-grade ores)
Large materials handling systems design
Port facilities designMaterials handling
Marine works
Heavy rail systems design
Infrastructure design
DISTINCTIVE TECHNICAL CAPABILITIES
IN IRON ORE TECHNOLOGYPIT - TO - PORT
MAP OF CANADA
LabradorTrough
MINES & PROJECTS-QUEBEC PLAN NORD
RECENT IRON ORE PROJECTS
Client and Project Location
Project Name and Capacity
Year ofCompletion
Services Provided
ArcelorMittal, Mont-Wright Mont-Wright, Spirals replacement Ongoing EPCM
ArcelorMittal, Mont-WrightMont-Wright, Concentrator Expansion 8 Mtpa
Ongoing EPCM
ArcelorMittal, Mont-WrightMont-Wright, Mont-Reed & Fire Lake, 24 Mtpa expansion
Ongoing Scoping & PFS
New Millennium, Labrador Taconite, 21.5 Mtpa (concentrator) Ongoing FS
IOC, Labrador Genesis, 25 Mtpa (concentrator) 2011 OoM & Pre-PFS
ArcelorMittal, Mont-WrightMont-Wright, Concentrator Expansion 8 Mtpa
2010 FEL2 & FEL3
ArcelorMittal, Fire Lake Fire Lake, 8 Mtpa (concentrator) 2010 FEL2 & FEL3
QUEBEC & NEWFOUNDLAND
IRON ORE PROJECTS -TRENDSIRON ORE IS A “LOW PRICED COMMODITY”
DSO becoming scarce and in challenging locationsSeveral new projects deal with low grade ores i.e., Itabirite, BIF’s and Taconite all requiring:
Higher volumes to be minedExtensive, costly grinding (for liberation)Advanced beneficiation technologies
Some concentrates produced have a fine particle size (Taconites) better suited for pelletizing. Transportation of fine product problematic
Increased number projects involving pelletizing plants
Projects must have a large output capacity to be profitableLarge Infrastructure requirement
HARD IRON ORE PROJECTS CAPEX intensiveImportant infrastructure componentRemote locations - Extreme climatesLower recoverable Fe grade – Some exceptions (Mary River,
Kiruna, Tazadit, others)Beneficiation required
SOME CHARACTERISTICS
IRON ORE HARDNESS SCALE
Harder Oresof Interest
Source: USIMINAS Mineração
HARD ORES BENEFICIATION• Magnetite and Hematite ores relatively easily
amenable to concentration• Hematite fines require flotation• Requires grinding, energy• Produces tailings• Adds a CAPEX component to the project• Enables control on product quality• Permits economical extraction of lower grades
ores ( Profitability below 30% Fe ?)
• Commands high mining tonnages
IRON ORE PROJECTS -CAPEX INTENSITYCOST PER TON OF INSTALLED CAPACITY:
Mine and equipment 10 to 30 $/tBeneficiation plant 45 to 70 $/tPelletizing Plant 60 to 80 $/tInfrastructures 50 to 120 $/tTOTAL ~ 165 to 300 $/t
Lac Otelnuk – Adriana Resourses & WISCO
Mont Wright Expansion – ArcelorMittal
Taconite Project – New Millenium & Tata Steel
TACONITE ORE TYPE PROJECTS IN THE LABRADOR TROUGH {PLAN NORD}
LAC OTELNUK PROJECT
Legend
Blue = Current Projects
Red = Prospects
MONT-WRIGHT EXPANSION
TACONITE PROJECT
LAC OTELNUK
Project Status: Feasibility Study
Define alternative options for key aspects of the Project and select a single preferred optionThis work includes the selection of:
The overall magnitude of the Project; between 32 to 50 Mt of product per yearThe preferred location for the pelletizing plantThe preferred location of the new concentrator
LAC OTELNUK – DEPOSIT TYPES & MINERALIZATION
The Lac Otelnuk deposits are of the moderately metamorphosed or weathered type ore referred to as Taconite
Mineralization of interest on the Lac Otelnuk property is the iron formation that consists mainly of magnetite (Fe3O4) and hematite (Fe2O3) in bands alternating with chert or jasper
The iron mineralization from Lac Otelnuk can be processed with stage grinding and low intensity magnetic separation
Fine grinding at 80% finer than 53 microns is required to achieve a good concentrate of 68.5% Fe with silica content of approximately 4%
The weight recovery averaged around 30%, while the magnetite recovery was around 96%
NI 43-101 TECHNICAL REPORT ON THE PRELIMINARY ECONO MIC ASSESSMENT FOR 50 MTPY – 4/08/11
LAC OTELNUK PROJECTThe overall Project will consist of three distinct areas of responsibilities:
Mine and Facilities:MinePrimary crushingOverland conveyingProcessing plantsTailings disposalMine area infrastructure including workshops, accommodation, utilities and air strip
Rail:Rail car loading, Rail alignment (815 km) and Rail car unloading
Port Facilities:Stockpiling of product and reclaiming from stockpilesPort facilities including jetty, wharf and shiploading facilitiesPort area infrastructure
NI 43-101 TECHNICAL REPORT ON THE PRELIMINARY ECONO MIC ASSESSMENT FOR 50 MTPY – 4/08/11
CONCENTRATOR FLOW –CRUSHING AND GRINDING
NI 43-101 TECHNICAL REPORT ON THE PRELIMINARY ECONO MIC ASSESSMENT FOR 50 MTPY – 4/08/11
CONCENTRATOR FLOW –CONCENTRATING
NI 43-101 TECHNICAL REPORT ON THE PRELIMINARY ECONO MIC ASSESSMENT FOR 50 MTPY – 4/08/11
MONT-WRIGHT EXPANSION PROJECT
Project Status: Under Construction
Specular Hematite Ore
Hard & abrasive grinding
Autogenous grinding; relative coarse liberation 80% above 150 microns
Gravity separation process (Spirals); product below 75 microns difficult to recover
TACONITE PROJECT – NEW MILLENIUM CORPORATIONProject Status: Feasibility Study under completion
Involves two adjacent deposits: one in Newfoundland & Labrador and another in QuebecThe study will evaluate whether to develop one or both of the ore deposits to meet the design capacity of 22 MtpaThe principal components of each project scenario are:
Mine and infrastructure planning and designConcentrator near the depositElectric transmission line640 km Slurry pipeline, and Pellet plant and associated facilities
RECENT IRON ORE PROJECTS –AFRICAClient and Project Location
Project Name and Capacity
Year ofCompletion
ServicesProvided
SNIM, Mauritania Guelb II, 4 Mtpa (concentrator) Ongoing EPCM
ArcelorMittal, Liberia Nimba Western Range DSO, 4 Mtpa Ongoing EPCM
African Minerals, Sierra Leone Tonkolili, 20 Mtpa Ongoing PMC
Baobab Resources, Mozambique Tete Iron Ore Project Ongoing PFS
Sesa Goa (Vedanta), Liberia Western Cluster Iron Ore Project, 30 Mtpa Ongoing SS
ArcelorMittal, Liberia Nimba Western Range Iron Ore, 4 Mtpa 2011 EPCM
Rio Tinto, Guinea Simandou, 70 Mtpa 2010 PFS
GUELB II, MAURITANIASociété Nationale Industrielle et Minière (SNIM)
Project Status: Under constructionExpected completion date 2013
4.5 Mtpa concentrator including some local infrastructure
Open pit minePrimary crusher and stockpileDry SAG milling and screening at 1.6 mmDry magnetic separation to make BF grade concentrateHPGRs added as pebble crushersSpirals plant added to recover hematiteWet magnetic separation plant added to process fines
GUELB II, MAURITANIA –THE ORE
Banded Iron Formation - Magnetite + QuartzCoarse grained – liberation size > 400 micronsFine grained – liberation at < 400 micronsProject feed = 50/50 blend36% Fe, 96% as magnetiteProduct specification < 4.7% SiO2Limited amount of hematite – mined separately
GUELB II, MAURITANIA
CLOSING COMMENTS•Increasingly high CAPEX, OPEX•High output required to compensate low grades and p rice of commodity•‘Superproducts’ input for steelmaking•Succession Source for Iron Ore
THANK YOU FOR ATTENDING!