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World’s largest iron ore mine to go truckless with ABB automation project

ABB has won orders totaling US$140 million from Vale S.A. to supply automation and electrical equipment for the world's largest iron ore project investment, which comprises in the development of a mine and a processing plant located in Brazil. 

Located in the Amazon region in northern Brazil, the Carajas Serra Sul S11D project, comprising the mine and processing plant, represents a US$8 billion investment. The project is expected to be delivered in the second half of 2016 and Vale is expecting the issuance of the project's implementation license in the first half of 2013.

The project will use shiftable conveyor belts instead of off-highway trucks to transport the iron ore from the mine to the processing plant. This is the first time a truckless solution will be used on a large scale at an iron ore mine.

Truckless systems significantly reduce operating costs and produce lower carbon emissions. If the S11D mine were to be operated using trucks, it would need around 100 off-highway trucks and consume 77 percent more diesel per year.

For comparison, Vale's Northern system, located in Carajas, produced 110 million tons in 2011; S11D will have an estimated nominal capacity of 90 million tons per year after the ramp up phase is concluded.

The project will allow Vale to increase production by approximately 90 million tons, while substantially reducing emissions and improving operational efficiency and process safety.

ABB will provide the automation and electrification to transport the ore into the processing plant, and will completely automate all plant processes. The order includes a centralised 800xA control system for processing operations, so that personnel can be located away from the site, for improved safety and continued production.

ABB wins $140 million order in Brazil to automate world?s largest iron ore mine investmentABB's solution also enables the automatic recovery and piling of iron ore by controlling and positioning equipment through satellite signal and via GPS, and by using 3D scanning for field screening.

ABB will also provide electrical infrastructure for the new processing plant, related energy distribution equipment for reliable and consistent power supply, and engineering and installation services.

The delivery includes medium and low voltage motors for use with frequency converters, the primary power transmission stations, duplication of the telecom system for the railroad and 37 secondary substations in self-contained E-Houses (electrical houses).

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