Roy Hill – ROM4 Mine Expansion
Roy Hill is a world-class iron ore operation located in Western Australia’s Pilbara region that delivers around 60 million tonnes per annum of iron ore. As part of their ROM4 mine expansion, Roy Hill constructed a new overland conveyor system totaling over 8km in length. PROK was selected to manufacture and supply the idlers for the new system. PROK was awarded the contract for the conveyor idlers off the back of a long history of success with various overland conveyor systems across the globe. Roy Hill required the new overland conveyor to connect a new crusher to the existing mine infrastructure. The system comprises 2 overland conveyor systems approximately 8km in length. The entire project scope for the conveyor components included the manufacture and supply of 23,500 rollers and 6,500 idler frames. The majority of the rollers will be PROK HDPE, our market-leading, lightweight composite roller. PROK HDPE was chosen due to its lightweight construction and exceptional reliability. The rollers include dual-layer wear indicator technology which facilitates smarter roller maintenance. Over 17,000 rollers are PROK HDPE, our market-leading, lightweight composite roller with dual layer wear indicator technology.
Mach Energy – TLO Upgrade
The Mt Pleasant coal operation is located in the Hunter Valley and is planned to produce 10.5 million tonnes of thermal coal per annum. PROK designed, manufactured and supplied 2km of overland conveyor structure, 1900 idler frames, 8000 steel rollers and 14 engineered pulleys as part of the MACH Energy Mt Pleasant TLO upgrade.
FMG – Iron Bridge
Fortescue is one of the world’s largest producers of iron ore. Their new mining hub - Iron Bridge produces magnetite. Global conveyor components manufacturer PROK has been awarded a major contract for the design, manufacture and supply of conveyor pulleys at the Iron Bridge Magnetite Project, a joint venture between Fortescue Metals Group subsidiary FMG Iron Bridge and Formosa Steel IB Pty. Ltd, near Port Hedland in Western Australia. PROK will design, manufacture and supply around 170 complete pulleys from their Bayswater production facility in Perth, Western Australia. The pulleys will be installed across 25 new conveyors at the Iron Bridge site.
Hay Point Coal Terminal _ CV11P & CV21P
Hay Point is located 40 km south of Mackay and is the coal-loading terminal for the Bowen Basin mines in Queensland, Australia. PROK designed, manufactured and supplied 2,000 galvanised and painted idler frames and 8,500 low noise aluminium rollers as part of the Hay Point CV11P and CV21P conveyor upgrades.
Teck Resources – QB2
Teck’s Quebrada Blanca Phase 2 (QB2) project will be one of the largest copper operations in the world and will be developed under the current Quebrada Blanca operation deposit. PROK Chile was engaged for the manufacture and supply of 57 engineered pulleys for the project. The dimensions range from 450mm to 2000mm in diameter. PROK pulleys are Designed with years of industry advancement and infinite fatigue life criteria. These pulleys delivered to QB2 will assist with maximising uptime and reducing their total cost of ownership.
Rio Tinto – Kennecott Copper
PROK was contracted for the manufacture and supply of PROK heavy duty engineered pulleys and over 13,000 PROK Flow Formed rollers. The 4 non-drive pulleys weighed approximately 25 tonnes each, with a diameter of 1800mm. The dual drive pulleys weighed around 36 tonnes each, with a diameter of 2000m. Rio Tinto Kennecott is a copper mine located just outside Salt Lake City, Utah, US and wholly owned by Rio Tinto. The Kennecott site has been operational for more than 100 years, mining and processing minerals from the rich orebody of the Bingham Canyon Mine. In 2020, the site undertook significant upgrades and expansion to its minerals processing infrastructure which included moving an existing crusher which meant there was a requirement for a new overland conveyor.
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