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Iron Ore
Capability Profile
About DRA
Over more than 30 years, the DRA Group (DRA) has
established itself globally as a first tier supplier of
engineering and project management services. We work
with companies and investors in sectors such as mining
and minerals processing, civil and infrastructure, energy,
water and agriculture.
DRA delivers on time and within budget, every time.
We have a track record of success in challenging
circumstances and we frequently undertake projects that
require innovation in processes and technology. DRA
has the capacity to deliver world class installations in
all terrains from sub-zero climes to jungle environments
and to maintain excellent safety standards under all
conditions.
DRA’s capability includes full-service engineering
solutions from concept to commissioning. We offer
feasibility studies, design, construction, project
management and operations and maintenance services
on an EPC, EPCM, LSKT, BOOM and BOOT basis.
DRA is a private company owned by its employees. It
was founded in 1984 as a service provider to the mining
sector and has developed processing expertise in a
wide range of commodities including gold, platinum,
coal, ferrous metals, diamonds, uranium, base metals,
potash and rare earths. We also offer design and
construction management of both hard and soft rock
surface and underground mining projects.
The DRA infrastructure offering covers a wide range of
solutions from energy, water, transport and ICT to social
and commercial buildings. Our total solutions approach
allows us to design, build and operate infrastructure
projects seamlessly for our clients. Through our
contract operations division, Minopex, our service
offering extends to plant operations, maintenance and
production optimisation.
DRA has offices in nine African countries as well as in
Australia, Canada, China, Europe, India, Oman, Saudi
Arabia and the USA. We have vast experience in Africa
and we offer exceptional expertise to support successful
mining and infrastructure projects across the continent.
At DRA our primary focus areas are our people and
our clients. Thanks to the quality of our people, our
clients benefit from the services of top level engineers,
draughts professionals and project managers – people
who are excited about the opportunities at DRA and
who give priority to understanding our clients’ business
requirements, managing their risk and helping them to
achieve their goals.
At DRA our primary focus areas are
our people and our clients
Khumani Iron Ore Mine, South Africa
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IRON ORE CAPABILITY
DRA’s reputation for successfully delivering large, multifaceted iron ore projects on time and within budget
has made us global leaders in iron ore processing and
beneficiation.
Our services range from large-scale crushing and
screening plants, gravity separation through jigs and
spirals, wet high and low intensity magnetic separation
(WHIMS and LIMS) technology and high density dense
media separation (DMS) processing.
IRON ORE PROJECT EXPERIENCE
We have extensive knowledge in iron ore beneficiation
for hematite and magnetite, from simple crushing and
screening for direct shipping ore (DSO) to more complex
beneficiation, including high-level liberation through AG
milling, magnetic separation, jigging, spirals, up-current
classifiers, flotation and dewatering.
Our in-depth knowledge and experience in iron ore
processing have resulted in our involvement in several
high-calibre projects, as described below.
Project: Khumani Iron Ore Mine,
South Africa
Client: Assmang – African Rainbow
Minerals and Assore JV
In 2004, we were contracted by Assmang, to manage
and design their greenfields Khumani Iron Ore Project
near Kathu in South Africa. This was followed by a
brownfields expansion. The project was delivered ahead
of time and under budget.
It is the largest project DRA has completed, boasting
a total production capacity of 16 Mtpa, with 22 Mtpa
ROM processing capability.
Initially appointed as the study manager, DRA was
subsequently appointed as the main engineering,
procurement, and construction management (EPCM)
contractor for detail design and engineering. DRA was
given overall responsibility as managing contractor for
the end-to-end project management and integration of
the crushing facility, processing plant, stockyards and
infrastructure, which included power, water, roads, rail
sidings and on and off-site accommodation during the
construction phase.
In addition, DRA was commissioned to design and
integrate mine and plant control systems using a
comprehensive management information system
(MIS), which tracks production with accurate, real-time
information.
Our success on these phases of the project resulted
in DRA being appointed for various other phases,
including the EPCM contract for a super fines
beneficiation plant at Khumani in 2011.
This plant uses WHIMS technology to process -1 mm
super fines for the extraction of saleable product.Phase
1 and 1A – also known as the Bruce-King-Mokaning
(BKM) project – of the Khumani Mine project pipeline
involved the construction of a new opencast iron ore
Khumani Iron Ore Mine, South Africa
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Khumani Iron Ore Mine, South Africa
mine and crushing facility on the Bruce farm, adjacent
to the Kumba Sishen mine, and a greenfields 10 Mtpa
ore processing plant on the Parson farm.
Detailed design and engineering of the processing plant
began in 2005 and was completed successfully by the
end of 2008.
The project was delivered on time and within budget,
notwithstanding tight deadlines and highly competitive
market conditions in the construction industry at the
time. The original design of Phase 1 included scope for
the expansion to 16 Mtpa processing capacity.
Results of the Phase 2 feasibility study proved positive,
paving the way for further expansion, known as the
Khumani Expansion Project (KEP). DRA commenced
work on KEP in October 2008 with the construction
of the run-of-mine (ROM) processing facilities and
infrastructure at the King mine.
DRA handed over this section of the project to
operations four months ahead of schedule in
November 2010.
We completed the construction of the additional rail
infrastructure and load-out station in September 2011,
and in October 2011 commissioned a brownfields
expansion of the Parson plant and an extension to the
product yard, four months ahead of schedule.
This project included the expansion of the ROM
blending yard to 1.5 Mtpa capacity and the product
blending and storage yard to 2.5 Mtpa.
In February 2011, a feasibility study was initiated to
investigate the use of magnetic separation technology
by WHIMS with capacity for 1.8 Mtpa and 0.6 Mtpa
product.
The Khumani WHIMS Project (KWP) was approved with
earthworks starting in October 2011 and first material
processed in February 2013, two months ahead of
schedule with handover to operations in May 2013.
IRON ORE PROJECT EXPERIENCE
continued
Project: Labrador Iron Mines, Canada
Client: Labrador Iron Ore
DRA designed, engineered and commissioned Silver
Yards, a 600 tph iron ore beneficiation plant at Labrador
Iron Ore Mines.
throughput by 50% from 400 tph to 600 tph, while the
addition of a WHIMS plant improved the recovery of iron
fines from the rejects stream.
Using a small, highly experienced team, DRA ensured
that the project was delivered ahead of schedule and
below budget.
The plant was initially operated using diesel-powered
generators. Following the commissioning of Phase 3,
the plant was connected to a high-voltage hydro
energy supply.
The project was divided into three phases, all
successfully completed. Phase 3 increased plant
Khumani Iron Ore Mine, South Africa
Project: Sishen Concentrate Project,
South Africa
Project: Palabora Magnetite Project,
South Africa
Client: Kumba Iron Ore
Client: Palabora Mining Company
DRA successfully completed the Pre-feasibility and
Bankable feasibility stage in 2013 for the Sishen
Concentrate project. Kumba Iron Ore’s Sishen Mine
is one of the largest iron ore mining operations in the
world, mining predominately hematite iron ore.
DRA studied and executed a magnetite upgrade project
for Palabora Mining Company in South Africa.
The mine is situated in South Africa’s Northern Cape
Province. Sishen currently produces 41.4 Mtpa ore
product of different sizes using DMS and jig technology.
The ore is mined from existing dump material and
re-pulped prior to pumping into a two stage
LIMS plant. The concentrate is dewatered with belt
filters before product stockpiling.
Both DMS and jig processes produce slimes material
that is stockpiled without any further beneficiation. A
study was initiated in 2005 to investigate beneficiation of
these slimes to saleable products, as they are relatively
rich in Fe content.
The feasibility study included VPHGMS technology,
product dewatering utilising filters, tails deposition
in slurry ponds and materials handling and tie-in to
the existing product stockpiles to increase the overall
production of the Sishen complex.
Project: Labrador Iron Mines, Canada
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what we do
DRA provides a full range of engineering and project services for the iron ore sector. We tailor our services to meet the
needs of our clients, offering both total engineering solutions and customised project solutions.
Our services include:
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Conceptual design and feasibility studies
Detailed design and engineering
Detailed mine design
Customised design of processing plants
Large-scale integrated infrastructure design
Specialised winding systems and shaft
headgear design
Procurement from our international network
of suppliers
Facilitate export credit finance in Africa
Commercial project development
Project and construction management
Commissioning
Contract operations of mineral processing plants
OPERATIONS
expertise
IMPLEMENTATION
Minopex is DRA’s contract operations division that
operates and maintains processing plants on behalf
of clients. These integrated services provide a feedback
loop to our design engineers regarding what works well
and where improvements can be made.
STUDIES
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MINING
MINERAL PROJECTS
MINOPEX
INFRASTRUCTURE
WINDERS
We offer both total engineering solutions
and customised project solutions
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Studies • Implementation • Operations
Complete Solution
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what we do
continued
DRA provides a full range of engineering and project services for the iron ore sector. We tailor our services to meet the
needs of our clients, offering both total engineering solutions and customised project solutions.
CLIENT
PROJECT
DESCRIPTION
COUNTRY
DATE
Assmang
BKM Phase 1
Phase 1 Execution – EPCM 13.2 Mtpa
capacity with 8.4 Mtpa Product
RSA
2006
Assamang
BKM Phase 1a
Expansion
Phase 1a – 16.2 Mtpa capacity with
10 Mtpa Product
RSA
2007
Assmang
Khumani Optimisation
Project
EPCM Modifications to the Khumani
Sampling Plant
RSA
2009
Kumba Iron Ore
Sishen 10 mm Lumpy
Project
LSTK – Materials Handling Study for
New Product Blend
RSA
2011
Labrador Iron Mines Silveryard Phase 1
400 tph DSO Plant
Canada
2011
Assmang
Increase Product Capacity from
10 Mtpa to 16 Mtpa
RSA
2012
Labrador Iron Mines Silveryard Phase 2
Inclusion of TBS to Upgrade Fines
Canada
2012
Assmang
Khumani Optimisation
Project
EPCM 3600 tph Plant – Incorporating
Processes and Infrastructure Optimisation
Projects into Existing Operation
RSA
2013
Kumba
Sishen
DMS Scada Server Room Upgrade
RSA
2013
Assmang
Khumani WHIMS
Super Fines Recovery Plant that
Makes Use of Wet High Intensity
Magnetic Separation
RSA
2013
Labrador Iron Mines Silveryard Phase 3
600 tph Washing, Screening, & Gravity
Beneficiation Plant. Additional TBS
and WHIMS
Canada
2013
Palabora Mining
Company
Phase 1
Belt Filter Plant for Magnetite Product
RSA
2013
Palabora Mining
Company
Phase 2
850 tph Beneficiation Plant with
Magnetic Separation
RSA
2014
Khumani Expansion
Project (KEP)
We tailor our services to
meet the needs of our clients
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DRA PROJECTS (PTY) LTD
Tel: +27 11 202 8600
E-mail: [email protected]
DRA PACIFIC (PTY) LTD
Tel: +61 732 364 157 (Brisbane)
Tel: +61 8 9324 3833 (Perth)
E-mail: [email protected]
DRA TAGGART
Tel: +1 724 754 9800 (USA)
Tel: +1 416 800 8797 (Canada)
E-mail: [email protected]
MINOPEX (PTY) LTD
Tel: +27 11 234 7773
E-mail: [email protected]
Web: www.minopex.co.za
www.DRAglobal.com
DRA Group Holdings (Pty) Ltd