Jimblebar: star of the WAIO constellation

Jimblebar is a key component of BHP’s (ASX: BHP) WA iron ore (WAIO) operations, an integrated system of four processing hubs and five open-cut mines in the Pilbara region connected by more than 1,000km of rail infrastructure and port facilities.

The operation iron ore mine located 40km east of Newman is part of an 85:15 joint venture between BHP and Mitsui and ITOCHU. The operation is regarded as reliable and dependable by BHP, as it continues to demonstrate its strengths across performance, productivity and innovation.

In FY24, WAIO posted record production of 255mt (BHP share) with Jimblebar contributing a whopping 73,111t, up from 66,801t the year prior. In addition to posting large numbers, Jimblebar also delivered a favourable product mix, driving an increase in ore demand leading to increased portside sales to China.

BHP expects FY25 production to be in the range of 255mt to 265.5mt, with Jimblebar contributing heavily to this goal.

But there’s much more to Jimblebar than just ore, it’s also a shining example of how the WAIO system can advance into the future through strategic partnerships and a dedication to progressive success.

Jimblebar expansion

Jimblebar currently employs about 800 permanent workers, but a planned expansion for the mine will likely need an increased workforce over the development period.

The Jimblebar optimisation project is currently being assessed by the EPA. The proposed project concerns the expansion and amalgamation of existing operations at Jimblebar iron ore revised proposal, orebody 18, and orebody 31.

The works would include new above and below water table mining, overburden storage areas, beneficiation plant, overland conveyor, creek diversions, haul and access roads, pipelines and associated infrastructure. A

ll mines and associated elements are proposed to be consolidated into the Jimblebar Hub Combined Proposal.

Mining of iron ore deposits will be undertaken above and below the water table. Mining operations will include open pits, overburden storage areas and the construction and operation of associated mine, processing and rail infrastructure.

Beneficiation project

The Jimblebar beneficiation project is currently in the works. First initiated in CY21, the main construction and commissioning works are planned to begin in Q3 CY25 through to Q3 CY27.

The mission for the beneficiation project is dual-pronged — to lift ore quality while reducing carbon emissions to maximise asset value.

BHP intends to achieve this by integrating a deslime plant into the existing mine hub.

The project will deliver the first major wet processing facility for WAIO in four decades. Modification and construction of associated processing infrastructure will be undertaken, including transfer station modifications, conveyor systems, wet screens, desliming cyclones, belt filtration, tailings thickening and disposal, sample station, stockyard drainage, plant services, electrical and control services and non-process infrastructure.

Calibre, a member of WSP, was awarded the engineering, procurement and construction management (EPCM) services contract for the design phase study.

The project, valued at about $1b, is in line with BHP’s commitment to supporting its communities, as requirements relating to the engagement of local and Indigenous vendors will be included in the selection criteria.

Electrification trials with Cat

According to BHP, data and technology, including automation and artificial intelligence, are further unlocking growth opportunities and enhancing the company’s operating performance, enabling it to be safer, more efficient and more sustainable.

The rollout of BHP’s first fully autonomous haul truck fleet at Jimblebar was completed in 2017, resulting in reduced risk exposure to driving-related hazards, improved productivity and an opportunity for our workforce to gain new skills.

BHP is driving forward with this momentum. In September 2024, BHP was the first customer to announce plans to trial Caterpillar’s Cat® Dynamic Energy Transfer (DET) system on battery electric and diesel electric mining trucks at its sites.

The trials include validating the solution in the company’s iron ore and copper businesses, including CAT 793 fleet at Jimblebar and CAT 798 fleet at Escondida. The planned trials are the result of over two years of close collaboration between BHP and Caterpillar to find sustainable and viable energy transfer solutions.

The new technology from Caterpillar can transfer energy to both diesel electric and battery electric large mining trucks while they are working around a mine site. It can also charge an electric haul truck’s battery while the machine is on the move, and the system’s infrastructure is flexible, which allows it to be easily relocated when compared to current commercialised offerings, including large, fixed overhead trolleys.

The electrification of Jimblebar will help propel the company towards its vision of enabling zero-emissions mining truck deployment. According to BHP, the company’s biggest remaining source of operational GHG emissions is diesel.

Projects like this will continue to play an essential part of BHP’s goal of net-zero operational emissions by 2050. At Jimblebar and Newman, truck automation has resulted in a 90 per cent reduction in heavy vehicle safety risks.

NRW contract

In another powerful partnership NRW Civil & Mining was awarded a development contract for the Jimblebar mine.

The scope of the contract includes various civil, building, mechanical and electrical works to support sustainable production at Jimblebar.

The project will include bulk earthworks and covers the construction of several permanent facilities.

The contract also includes the construction of a new floodway and an LV access road

complete with heavy and light vehicle standpipes and washdown facility. Additionally,

the contract requires a HDPE pipeline re-alignment and installation of a 33kV

overhead powerline.

The contract is valued at approximately $109m and was set to commence in November 2024. The project is scheduled for completion in Q2 2026 and will employ a team of up to 120 personnel and 55 items of plant and equipment.