ONE FAMILY'S DESTINY - THE ROY HILL IRON ORE PROJECT - WESTBUSINESS Wednesday, May 21, 2014
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WESTBUSINESS • Wednesday, May 21, 2014
ONE FAMILY'S
DESTINY
THE ROY HILL IRON ORE PROJECT
PROUDLY SUPPORTING THE
Roy Hill Iron Ore Project
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4 The Roy Hill Project Wednesday, May 21, 2014
A message from the Premier
he Roy Hill iron ore project is one of the most that well-planned projects are able to weather
T significant projects to be undertaken in
Western Australia in recent years.
At an estimated cost of $10 billion, the Roy Hill
changing economic climates.
The iron ore industry is already a major pillar
of the WA economy, employing thousands of
project is the largest iron ore project under workers and contributing around $4.3 billion in
construction this year globally, with a capacity of royalties in 2013.
55 million tonnes at full production. By 2020, WA could be exporting 850 to 950
Construction of this massive project, which million tonnes of iron ore, some 50 per cent more
includes new railway and port facilities, will than current output levels.
create around 3600 jobs, and ongoing operations First shipments from Roy Hill are expected by
will require 2000 workers. the end of 2015, further cementing the State’s
Recently, Roy Hill reached a significant position as a global leader in the iron ore market.
milestone with the completion of a On behalf of the State Government, I would like
US$7.2billion funding package to deliver to congratulate all those who have been involved
the project, involving five international in this project’s progress so far, including Roy
export credit agencies and commercial Hill’s parent company Hancock Prospecting, and
banks from across the world. joint venture partners Marubeni, Posco, and
The finalisation of this funding package China Steel Corporation.
represents a vote of confidence in the ongoing I would also like to congratulate those within
performance of West Australia’s resources Government who have worked to facilitate the
industry from the international finance sector. development of this major project, including
At a time when some onlookers are sceptical through the negotiation and implementation of a
about future growth in the West Australian State Agreement, and in progressing native title,
resources sector, the Roy Hill project is proof that environmental and other approvals.
significant projects are still on the horizon, and Colin Barnett
INSIDE From Roy Hill’s chief executive
T
he company we build today will
determine how successful we
are moving forward.
To drive and maximise
efficiencies across the business, we
have integrated our corporate,
marketing and operations functions
through our new corporate head
office and remote operations centre.
THE ROAD TO ROY HILL P6-8 THE HOUSE OF HANCOCK P10-11 Because we are constrained at
Getting the $7 billion needed to pay A chance sighting over the Pilbara in Port Hedland in regard to how much
for everything was just the start. the 1950s changed history. we can export, we must do things
differently.
It is a business imperative our
people know how to work smarter,
apply fit for purpose thinking and
focus on value to ensure a
maximum return to our
shareholders.
A key driver of success is the
foundation that is set in regards to
how the company operates and the
behaviours people bring to the
HOW IT WORKS P12-16 THE NERVE CENTRE P22-23
workplace.
Inside the Roy Hill operation — from The ore body may be in the Pilbara
One of the unique challenges of
mine to port. but Roy Hill’s brain is in Perth.
being a greenfields project is
embedding a culture that aligns
employees to our vision and
empowers them to achieve our goals.
Our vision and values of lead,
care, think and perform go to the
heart of who we are, what we stand
for and what each and every one of
us needs to do to achieve success.
Roy Hill is a landmark mining
project which will deliver enormous
benefits to the broader community.
A RICH BENEFACTOR P26-28 THE END GAME P30-31
These are exciting times as we
How wealth created in the Pilbara Inside the Chinese steel mills which
continue to build one of the world’s
pays for the great Aussie lifestyle. drive the iron ore industry.
major resource-based projects.
Barry Fitzgerald
6 The Roy Hill Project Wednesday, May 21, 2014 For
A new kid
on the red
dusty block
Roy Hill is a project 22 years in the making.
STEPHEN BELL charts its history
n a balmy March evening Gina Rinehart
O and a host of international financiers
signed a thick sheaf of documents in a
Singapore business room.
The Hancock Prospecting chairwoman had just
made history by inking a US$7.2 billion loan
agreement for her Roy Hill iron ore development
— the biggest project financing ever completed for
a mining venture. Groundbreakers: Hancock Prospecting’s John Klepec, Tad Watroba, Gina Rinehart and Roy Hill chief executive
The backing of the five export credit agencies Barry Fitzgerald start work at Roy Hill’s corporate headquarters and remote operations centre in June, 2012. Gr
and 19 banks was sweet vindication for Australia’s
richest woman. recent Singapore function to celebrate the debt The forecast sailing of Roy Hill’s first cargo from rel
She’d endured years of speculation that her $10 milestone. Port Hedland late next year will represent the A
billion mine, rail and port project would struggle “So we set up a beautiful sit-down luncheon at high water mark of a remarkable 23-year journey Ri
to secure debt funding as other Pilbara miners the side of the Fortescue River and I had the that began in March 1992 with the death of Mr ge
slashed expenditure after a fall in iron ore prices pleasure of being able to personally meet every Hancock — the man credited with uncovering dr
and rising Australian costs. participant and discuss the importance of their much of the Pilbara’s vast iron ore riches in the scr
Credit was a scarce commodity and the cautious support.” 1950s.
bankers eked out their painstaking due diligence The debt deal ensured the chairwoman would Pi
for 15 months, including site visits to Roy Hill — achieve a long ambition of owning and running a oy Hill wasn’t among the deposits identified wi
about 270km south of Port Hedland near the
Chichester Ranges.
“When the commercial banks came to visit, we
Pilbara iron ore mine unrelated to the legacy of
her famous father, Lang Hancock. So confident
was she of wooing the bankers that Roy Hill was
R by Mrs Rinehart’s father. It is a separate
area to the north of Newman once held by
competitor BHP Billiton.
Ch
ar
M
were determined to give them an experience that nearly one-third built by the time the bank deal “Fortunately our competitors’ drill holes were of
they would never forget,” Mrs Rinehart said at a was finalised. not in the best locations and they had T
P
w
PM
thewest.com.au
014 For all the latest news The Roy Hill Project 7
Road to Roy Hill
MARCH 1992 Gina Rinehart assumes chairmanship
of Hancock Prospecting after the
death of Lang Hancock
MID 1992 Gina Rinehart and Richard Paquay,
Hancock Prospecting’s chief
geologist, conduct their initial
prospecting trip to Roy Hill
JAN 13, 1993 Hancock Prospecting granted Roy Hill
exploration licences
JANUARY, 2010 Korean groups POSCO and STX Corp.
make initial $332 million investment
in Roy Hill
JUNE 2, 2011 Dredging operations begin at Port
Hedland’s inner harbour
MARCH 30, 2012 Asian consortium led by Korea’s
POSCO and Japan’s Marubeni pays
$3.2 billion to complete 30 per cent
purchase of Roy Hill
JUNE, 2012 Construction starts on $47 million
headquarters and remote operations
centre at Perth airport
MAY 25, 2012 Approval to hire up to 1715 foreign
e workers under Labor government’s
Grand scale: An aerial view of the Roy Hill mine site in April. Roy Hill is destined to be the biggest single-pit mine in the Pilbara. first Enterprise Migration Agreement
generates media storm
om relinquished the tenements,” Mrs Rinehart said. for the area to be pegged and exploration licences
MARCH, 2013 Signs a $5.6 billion fixed price
A few months after her father’s death, Mrs were granted to Hancock Prospecting in 1993.
construction contract with South
y Rinehart and Hancock Prospecting’s chief However, in those pre-boom days iron ore was an
Korea’s Samsung Group
geologist Richard Paquay flew to Newman and unloved commodity and Hancock was under
drove 120km to Roy Hill, an unremarkable patch of financial stress, according to Mrs Rinehart. NOVEMBER, 2013 Workers move into ROC at Perth
scrub named after one of the early settlers. “We could not afford to maintain all the rental Airport
“It was different from the normal sites in the and exploration requirements and lost about half MARCH 20, 2014 Receives US$7.2bn in debt from five
Pilbara in that it was a very extensive flat plain the area we had originally pegged,” she said. export credit agencies and a
d with just a few small rises,” Mrs Rinehart said. “Despite this we still managed to implement an consortium of 19 commercial banks
Mainly hidden under soil and scree near the exploration drilling program to help prove up the to complete funding of the $10
Chichester Ranges, many people drove across the resource that we knew was there. billion project
area without suspecting it hosted a treasure trove “In fact, this drilling program never really
of iron ore. APRIL 30, 2014 Roy Hill mines first ore from Kulbee
......................................................................................................................
The ground surveys proved encouraging enough ៑ CONTINUED P8 Creek location
Proud to be associated with the Roy Hill Project.
www.plantman.com.au y s!USTRALIA7IDEs
PM 16641
1300 857 820
8 The Roy Hill Project Wednesday, May 21, 2014
Many people drove across
the area without suspecting
it hosted a treasure trove of
iron ore.
....................................................................................................................
្ FROM P7
stopped as we did more drilling over the years, to
the extent that we had completed 13,000 holes by
the time we had secured the finance.”
A shortage of ready cash wasn’t the only reason
that Roy Hill stayed in the ground for so long.
In the 1990s Hancock Prospecting was pouring
millions of dollars into the Hope Downs project, Early days: Gina Rinehart and chief geologist Richard Ceremonial: Representatives of commercial banks on
one of Lang’s original Pilbara discoveries. Paquay before the start of Roy Hill in 1992. the edge of the Fortescue River in June.
Then, in the 2000s, Hancock Prospecting ran
into political roadblocks when land it assumed Rinehart said. By late 2009, Hancock Prospecting acquired 30 per cent of the project at a projected
was earmarked for Roy Hill’s port space was had spent more than $100 million and undertaken cost of $3.2 billion.
allocated to other companies. 431,147 metres of drilling. The project ownership now stands at Hancock
It eventually “re-secured” two berths at Port This, alongside a partly completed feasibility Prospecting 70 per cent, with Marubeni, POSCO,
Hedland at the cost of extra dredging study, was enough to lure South Korea’s POSCO, and China Steel Corp holding the balance.
commitments. which had been looking to secure more iron ore With debt and equity funds secured, the race
for its Asian steel mills. was on for Roy Hill to finish construction and
eanwhile, drilling continued to turn up Alongside STX Corp, POSCO invested an initial meet its 2015 shipping target.
M more premium-grade ore.
“Roy Hill is an outstanding iron ore
project as the last billion-tonne, high grade, low
$332 million to help complete a bankable
feasibility study and bankroll the Port Hedland
dredging.
Key to that task was South Korean conglomerate
Samsung C&T winning the lead construction role
in March last year under a $5.6 billion contract.
phosphorus, open cut deposit outside of the Two years later, in March 2012, it became clear The fixed-price deal helped Hancock and its
majors in the Pilbara, in the world’s best address how much offshore investors valued Roy Hill’s partners bank the project, because the contractor
for iron ore — near our Asian friends,” Mrs high-grade ore when an Asian consortium carries the risk of any cost blow-outs and delays.
GUMA ICRG
PROUD TO BE INVOLVED IN THE ROY HILL PROJECT
Guma ICRG is a mining services company owned and operated by Nyiyaparli
Traditional Owners, servicing the East Pilbara region of Western Australia.
We provide well-trained and managed onsite teams, supported by our parent
company ICRG’s experienced management group. Our people are the cornerstone of
our business and we invest heavily in their development, safety and well-being.
Guma ICRG has a site services contract at the Roy Hill Project, supporting civil
maintenance, installations and other ad hoc works across the port landside
facilities, rail camps, mine site and village.
This involves earthworks, roadworks, logistics and landscaping, the
construction of light steel structures, buildings, culverts, drains and fencing,
as well as electrical, mechanical and concrete works.
In partnership with NRW, Guma ICRG is also providing plant and labour hire
across the Roy Hill Project.
We are proud to be part of the Roy Hill Project, working to achieve objectives
in a safe, sustainable and cost effective manner, while ensuring
Aboriginal communities benefit and contribute to the
success of the mining sector.
www.guma.com.au (08) 6188 7300
www.pbworld.com
10 The Roy Hill Project Wednesday, May 21, 2014 For
The sight-seeing trip that f
Lang Hancock’s vision for the After taking ore samples over 100km in the Lang and his long-time business partner Peter pa
Hamersley gorges, the self-described “boy from Wright also wooed the Melbourne office of Rio Ri
Pilbara has become part of folklore, the bush” was surprised to learn they assayed 2 Tinto. After initial scepticism, the British miner th
STEPHEN BELL writes per cent higher in iron than the standard blast signed a deal with the Hancock-Wright in
furnace feed used in the US at the time. partnership to form Hamersley Iron. Ri
t was a chance few minutes of Pilbara In essence, he had discovered one of the world’s In 1966, Hamersley commissioned the Tom “h
I sight-seeing that changed the course of
Australian history.
On a late November day in 1952, Lang Hancock,
richest deposits overlooked by previous
surveyors, possibly because the high iron content
had bamboozled remote sensing instruments.
Price mine and established Dampier — a key
Pilbara port which today exports 150 million
tonnes of iron ore each year. The Hancock family
co
on
navigating his light plane through the Hamersley It is a remarkable prospecting tale now firmly and the descendants of Peter Wright still receive de
Ranges alongside wife Hope, spotted rusty red entrenched in mining folklore, but the obstinate royalties from each tonne shipped.
rocks in a gorge cut by the Turner River. visionary still had mountains to climb in order to Later in life Lang was a dividing figure because Pr
Then a 43-year-old pastoralist and part-time profit from his find. The deposits were essentially of his outspoken brand of conservatism. But few La
prospector, Lang only flew the unusual route worthless in the 1950s because Australian exports dispute his leading role as an iron ore trail-blazer am
when heavy storm clouds forced him to drop of iron ore were banned (a legacy of World War 2 alongside less lauded figures such as prospector an
altitude and change direction at the start of a when, ironically, the commodity was considered Stan Hilditch who, in 1957, discovered the huge be
long trip back to Perth. scarce), and the WA Government wouldn’t allow Mount Whaleback deposit near Newman that’s
Flying low, he noticed the gorge walls looked pegging of tenements. now mined by BHP Billiton. Ha
like “solid iron” coloured deep ochre red. Lacking tenure and battling disbelief in The ensuing five decades have he
Lang’s keen eye had picked out what many Canberra, Lang lobbied relentlessly over several been equally colourful, if not Au
scientific instruments had missed — huge years, finally bulldozing his way to a partial more so, for the House of
deposits of iron ore that would stoke the fortunes lifting of the embargo in late 1960. It took another Hancock. After Lang died in
of a famous family empire and eventually become year for the pegging ban to be removed and March 1992, chairmanship
Australia’s most valuable export commodity. Hancock finally had its foot on the rich ore. of the family company
In
ov
ir
Pioneer: Lang Hancock at
Mt Nicholas.thewest.com.au
014 For all the latest news The Roy Hill Project 11
for ever changed Australia
passed to his then 38-year old daughter, Gina richest and most powerful women in the world. JUNE 10, 1909 Lang Hancock born in Perth
Rinehart, who immediately set about rebuilding Similar to her father, Mrs Rinehart has become
the brand. While acknowledging her father’s key a contentious national figure because of her NOVEMBER 22, Lang’s iron ore discovery flight with
influence in Hancock Prospecting’s fortunes, Mrs forthright views on topics such as the cost of 1952 wife, Hope
Rinehart dislikes being referred to as an labour, the mining tax and the development of the FEBRUARY 9, Gina born to Hope and Lang
“heiress”, pointing out the perilous state of the North. 1954
company’s finances upon Lang’s death. She also faced court battles against several
And the value of the Hamersley royalty really antagonists over the years. 1955 Lang establishes family company
only took off in the mid-2000s as China’s iron ore Amid the legal stoushes Hancock has Hancock Prospecting Pty. Ltd.
demand ballooned. diversified from its original reliance on 1960 Australian export embargo on iron
It was in that boom phase that Hancock Hamersley royalties, reaping billions of dollars ore lifted
Prospecting sold half of Hope Downs — one of from thermal coal assets in Queensland, mining
1960-61 Pegging of areas discovered by
Lang’s key legacy assets — to Rio Tinto, enabling manganese in the Pilbara and investing in media
Lang after WA lifts ban
a multi-billion dollar development and forging assets Ten Network and Fairfax.
another link in the long chain of association And in 2011 Mrs Rinehart took a definitive step 1961-62 Hamersley Iron formed after
between the two groups. towards her long-cherished ambition of becoming development agreements
When Hope Downs started production, an iron ore producer in her own right with the negotiated between Lang, Peter
Hancock’s direct share of the iron ore profits effective start of Roy Hill’s development in the Wright and Rio Tinto
helped propel Mrs Rinehart to the title of Pilbara. 1966 Hamersley’s Tom Price mine
Australia’s wealthiest person, and one of the But that’s another story. commissioned, and port and town
of Dampier established
MARCH 27, 1992 Death of Lang Hancock; Gina
In essence, he had discovered one of the world’s richest deposits Rinehart assumes chairmanship of
Hancock Prospecting
overlooked by previous surveyors, possibly because the high DECEMBER 1992 Hancock Prospecting pegs Roy Hill
iron content had bamboozled remote sensing instruments. iron ore tenements
JULY 2005 Hancock Prospecting sells half of
Hope Downs project to Rio Tinto
NOVEMBER 2007 Hope Downs mine begins
production
MARCH 2014 Roy Hill completes funding with
US$7.2bn project debt12 The Roy Hill Project Wednesday, May 21, 2014 Fo
ANATOMY OF ROY HILL
In the Pilbara, most things mining-related are
bigger than Texas, whether it’s massive pits,
monster haul trucks, or 2.5km-long ore trains
snaking their way to the coast.
The mine
oy Hill will not be reinventing the wheel to
Yet Roy Hill will still stand proud in this land of
the giants. The $10 billion development is set to
become one of the world’s biggest mines,
R extract its multi-billion tonne deposit over
the next two decades, according the mine’s
general manager, Bill Lamb.
It will rely on tried and tested open cut mining
contained in a mineral tenement that stretches technology, operated by an on-site workforce of
1,000.
for 34km. “Waste, low grade and ore material will be
It will also boast the Pilbara’s single biggest ore blasted prior to excavation, allowing it to be dug at
processing facility. Starting from September a higher rate,” Mr Lamb explained.
“It will then be loaded into dump trucks and
2015, Roy Hill plans to ramp up its iron ore hauled to various destinations depending on its
production to 55 million tonnes a year, dwarfing physical and chemical properties.
“On average, the mining team will have to
most Pilbara mine sites. remove four tonnes of waste and low-grade
Nearly all of the other big WA iron ore mines material for every one tonne of ore mined.
“At steady state, this equates to over 300 million
have been developed in stages. Rio Tinto’s tonnes of total primary material mined each year,
Yandicoogina mine has roughly the same which in anyone’s terms is a very large amount.”
As a result of the large total volume mined, Roy An aerial shot of the Roy Hill mine taken in April.
capacity as Roy Hill. But Rio grew its mine in Hill’s method of mining will allow for the bulk of
stages spread over 16 years, expanding output the waste material to be backfilled into depleted which sit on the surface in the hills, to a
to satisfy rising Chinese demand. Roy Hill, in pits, therefore minimising the final disturbance maximum of 110m depth in the southern extents
footprint at the same time as offering countless of the deposit,” he said.
contrast, is developing its giant-sized capacity short haul opportunities for the mining trucks, “Mined ore will be trucked to remote crushing
from day one to make full use of port space. Mr Lamb said. stations, then conveyed to a central processing
“The depth of the ore body varies from outcrops, facility.” Gthewest.com.au
014 For all the latest news The Roy Hill Project 13
ANATOMY OF ROY HILL
Processing
esigned to produce premium-grade lump
D and fines products, the processing plant
incorporates low-risk, proved Pilbara iron
ore processing technology.
The processing plant will treat ore from both
above and below the water table.
The amenability of the ore has been extensively
tested with a wet scrubbing, screening and
desanding process selected as a result.
Earthmoving The majority of impurities in the ore body are
equipment tied up in clay-rich shale bands which can easily
preparing the pad be removed by gravity separation.
for the mine The modular facility consists of multiple
processing plant in components including three remote crushing
August. stations; overland conveying; a crushed ore
stockpile; multiple wet scrubbing, classification
and dewatering circuits; several stackers and a
reclaimer.
After final processing, the mine’s lump ore
product will range in size from 8mm to 40mm,
while fines will be less than 8mm.
From the product stockpiles, a reclaimer
loads the product on to waiting train cars via a
train load-out facility.
The processing plant is one of the most
technically challenging parts of Roy Hill’s supply
Grade control drilling at the Roy Hill mine in February. Processing plant bulk earthworks. chain.
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A
T
W
20
de
Piling construction for
for East Turner River re
rail bridge in po
February.
ph
se
va
Mr
Stacked, welded ANATOMY OF ROY HILL cars with a total payload of 32,062 tonnes, will
rail steel at the operate each day. ma
flash butt welding
yard in February.
Rail Due to the rugged, undulating terrain to the
north of the mine, each train will be assisted by
rear-located, manned banker locomotives for the
first 30km of the journey.
wh
ar
ar
in
oy Hill is building (and will own and Roy Hill will employ a state-of-the-art automatic
R operate) a 344km heavy-haul railway to
transport processed iron ore from the mine
to a dedicated port stockyard located south-west of
train protection and signalling system to improve
safety and efficiency. It will also prepare the
network for future autonomous rail operations.
ex
iro
ca
Port Hedland. This system will use “full vehicle tracking”,
At full production, five ore trains, each which will be the first of its kind to be used in Rail construction locomotives ready to commence ra
consisting of three locomotives hauling 232 ore Australia, Roy Hill says. track laying for the 344km railway in April. ca014
thewest.com.au
For all the latest news The Roy Hill Project 15
ANATOMY OF ROY HILL
The port
hile Hancock Prospecting had run
W exploration camps over many years, it
was dredging at Port Hedland in June,
2011, that marked the unofficial start of Roy Hill’s
development
The $230 million of dredging, to clear a channel
for big iron ore ships, was a State Government
requirement in granting the two-berth lease at the
port.
“It was a major risk when we undertook
physical works of this magnitude without having
secured the required equity or finance, and with The enormous scale of the port construction project is becoming clear.
various government approvals still to finalise,”
Mrs Rinehart recalled.
Some of the 5.6 million cubic metres of dredged
material was dumped in approved locations at sea,
while the remainder was pumped to a holding
area above land — Area G. After construction this
area will be handed to the port authority for
industrial usage. First piles in place for the Point Stanley Wharf.
Roy Hill’s port will receive, stockpile, screen and
export 55 million tonnes a year of direct shipped After reclaiming, ore is conveyed to an
iron ore as lump and fines. The stockyard will be 800m-long wharf and a 12,700 tonnes per hour
capable of storing over 5Mt of ore. ship-loader, which moves the finished product
Port facilities include an 11,250 tonnes per hour onto giant ore carriers bound for Asia — the final
rail car dumper, which removes ore from each rail link in a long chain that stretches back to the
car ready for conveying to stockpiles. excavators at Roy Hill. Bulldozers move dredged spoil material in 2012.
We Deliver in the Pilbara.
Brookfield Multiplex has established a strong What sets us apart is our unique combination
presence in the Pilbara having completed the of contracting expertise, financial strength and
Roy Hill Mine Accommodation Village in 2013. long term collaborative relationships, meaning
clients and partners trust us to deliver safely
We were also awarded the contract for and efficiently - on time and on budget.
the Roy Hill Non Processing Infrastructure
Image: Roy Hill Mine Accommodation Village, Western Australia
project, demonstrating our ability to remain
competitive on small as well as large projects.
CONSTRUCTION DEVELOPMENT ENGINEERING INFRASTRUCTURE
brookfieldmultiplex.com
SYDNEY PERTH MELBOURNE ADELAIDE BRISBANE
For Perth enquiries please call 08 9483 089916 The Roy Hill Project Wednesday, May 21, 2014
Hungry work: Roy Hill’s dining hall, one WA’s biggest. Picture: Bill Hatto
ANATOMY OF ROY HILL Home away from home: Roy Hill’s main accomodation camp in December, 2013.
Housing 10km from the mine’s airport, is arguably WA’s
most luxurious resources camp.
Each air-conditioned room is 4.2m wide —
bigger than the standard 3.5m room — and is
uilding a town nearly the size of Kalbarri in furnished with a king-sized single bed and
B the middle of the Pilbara — from scratch —
is a daunting task. Building one that is an
attractive place to live is even tougher.
ensuite. Each unit has internet, a phone and a TV
which has its own Roy Hill information service.
Employees have access to a tavern, gym, tennis
The Roy Hill accommodation village currently courts, putting green, volleyball and basketball
has about 900 residents and at its peak it will have courts and an indoor cricket facility.
2000 people living in it. Each week tonnes of supplies are trucked to the
The yet-to-be formally named complex, about village from Perth and Port Hedland. Amenities: The village’s tavern.We’re excited to be an integral
Working together part of the Roy Hill Project,
partnering with Roy Hill to deliver early
mining services at the mine, including load
to deliver value and haul, drill and blast, and mine-related
infrastructure.
In operation for over 90 years, we are a leading
industry supplier of open cut mining services in
Western Australia.
We’re looking forward to working safely and
innovatively with Roy Hill, and bringing
employment and local business
opportunities to the West
Australian economy.
Ph: (08) 6212 9500
www.downergroup.com/mining18 The Roy Hill Project Wednesday, May 21, 2014
THE FACES OF ROY HILL
Ian Crawford
Chief operating officer
an Crawford is the man who has to link
I seamlessly the mine, processing, rail and port
operations so that the Roy Hill project is
ultimately capable of shifting 340 million tonnes of
material every year.
That’s 340 million tonnes which need to be
blasted with explosives, lifted onto trucks,
processed and separated into lump and
fines-grade ore, transported by locomotive for
hundreds of kilometres and finally dumped into
waiting cargo ships at Port Hedland.
It is an enormous task but one which the
53-year-old father of two relishes.
Mr Crawford has had to work to link the various
arms of the business in the full glare of the public
spotlight — as well as under the watchful eyes of
the project’s financial backers.
“It’s a once-in-a-lifetime experience being
funded from export credit agencies,” he said. “We
have had to prove ourselves to the lenders as well
as prove the quality of the project.”
Mr Crawford has been with Roy Hill for less
than three years but mining is in his blood — he
was born in Edinburgh and worked in the British Picture: Iain Gillespie
coal industry before moving overseas 20 years ago.
A big vision needs the
right partners.
Securing US$7.2 billion of finance is never easy. As a leading natural resources bank in
Which is why the partners in Roy Hill, one of Australia we are proud to have supported
Australia’s highest quality iron ore projects, the Roy Hill project.
had confidence in ANZ’s support.
anz.com
Australia and New Zealand Banking Group Limited (ANZ) ABN 11 005 357 522. ANZ’s colour blue is a trade mark of ANZ. 05/14 16671-2Alinta Energy powering the Pilbara and Roy Hill • Alinta Energy owns and operates the Newman Power Station. • Alinta Energy will construct a new high-voltage transmission line from its Newman Power Station to supply the full power requirements of the Roy Hill Mine. • Construction of the 123km 220kV transmission line has begun. The completed line will have capacity to supply additional potential customers. • Alinta Energy will also construct a 33kV distribution system and a 6MW diesel-fuelled power station located at the Roy Hill Mine. • Roy Hill and Alinta Energy have worked closely to take an initial supply concept through to a fully-developed solution that ensures the long-term power needs of the Roy Hill Mine are secure. • Alinta Energy’s construction project, which will employ up to 150 people through WA-based suppliers at its peak, is scheduled to be operational in early in 2015. • The recent termination of a State Agreement now allows Alinta Energy to continue to expand its footprint in the Pilbara through development of additional generation capacity and competitive power solutions.
20 The Roy Hill Project Wednesday, May 21, 2014
THE FACES OF ROY HILL
Sanjiv
Manchanda
Project director
roject director Sanjiv Manchanda’s tongue is
P firmly in his cheek when he talks about his
role.
“I have a simple job. I just have to build it.”
The 50-year-old electrical engineer has a
daunting job.
He is responsible for overseeing contracts for
the engineering, construction and commissioning
of the mine, processing, rail and port
infrastructure that gets ore to market.
It is a role which sees him “live and breathe”
Samsung C&T — the company tasked with Picture: Lincoln Baker
delivering much of Roy Hill’s infrastructure,
which is now more than one-third complete.
Samsung C&T was “critical to the project”, Mr procurement and construction contractor Australia, Africa, India, Malaysia and Indonesia.
Manchanda said, for delivering construction of certainly helped to give a level of confidence to the He played a considerable role in delivering the
the project on time and budget to the required export credit agencies when they were conducting infrastructure required such as the
quality. their due diligence on the project,” Mr accommodation camps, internal mine roads and
Samsung C&T’s reputation also gave “comfort Manchanda said. the Ginbata Airport at the mine, which has
and certainty” to Roy Hill’s bankers. Mr Manchanda brings significant experience to ensured that the Roy Hill project can keep ticking
“The appointment of a company of the size and the project in the design and construction of big off the milestone’s now the debt finance has been
stature of Samsung C&T as our engineering, mining and minerals processing projects in secured.// U N R I VA L L E D PA R T N E R S H I P
The Hitachi EH5000AC-3 mining truck and EX8000-6 backhoe excavator.
From the factory to the pit, Hitachi’s ultra-class hydraulic excavators and electric drive mining
trucks are engineered to maximise the productivity of mining operations. Our flagship machines
deliver unmatched performance and reliability when it comes to loading and haulage.
The most powerful and productive combination yet.22 The Roy Hill Project Wednesday, May 21, 2014 Fo
Inside Roy Hill’s Perth nerve centre
The ore body may be in the Pilbara but, as STEPHEN BELL explains, Roy Hill’s brain is in the city
echnology and automation are mining buzz It also means that Roy Hill hits the ground architect and I had hoped to include. Maybe later
T words and Roy Hill believes it has caught the
vibe well before shipping a tonne of iron ore.
In November, hundreds of Roy Hill employees
running thanks to a quick turnaround on
planning and construction for the new HQ.
Gina Rinehart joined other key Roy Hill and
some can be incorporated, after Roy Hill achieves
shipments and revenue.”
Mrs Rinehart’s influence is apparent in the
started moving into the project’s new Hancock executives in turning the first sods of soil sleek, three-storey edifice of stonework, stainless
headquarters and remote operations centre, a hub at the site in June, 2012, nearly two years before steel and glass, which overlooks a commercial
that amalgamates operations, marketing and the Pilbara mine-rail-port development was precinct just a few minutes drive from the
corporate services near Perth Airport. ensured by a US$7.2 billion bank funding deal. international terminal.
Illuminating: A “It allows us to manage the operations in an Construction of the building took 16 months. Roy Hill’s new hub aims to bring high-tech
night-time view integrated way — identifying challenges, “I’m pleased to say it was built on time and savvy to the dusty business of mining but doesn’t
of the operations solutions and new productivity improvements,” within budget,” Mrs Rinehart told Roy Hill’s lack in aesthetics.
centre near Perth Roy Hill’s general manager demand chain Mike financiers at a recent Singapore function. Inside reception visitors are confronted by the
Airport. Lomman said. “Yes, it meant trimming a few things the gorge wall — a collection of 137cm Samsung Re
screens adorning a wall like a giant puzzle.
Alongside a countdown clock for milestones, vid
such as the date of first exports in late 2015, it the
displays a “virtual” waterfall, though screens can life
be individually tuned to all manner of visual R
popcorn such as Pilbara beauty spots. be
The building’s interior is punctuated by vie
sandstone features sourced from the Kimberley: wh
the carpet design recalls the red rocky ground of an
the Pilbara and the reception desks and internal rea
elevator bring to mind rusty iron ore. T
A boardroom with all the latest mi
Iron awe
Something important is happening in the Pilbara region in West Australia, the
world’s premier iron ore province: the $10 billion Roy Hill Iron Ore project. One
The Roy Hill project is
changing the face of Australia.
Local, regional and indigenous employment and contracting opportunities
Roy Hill will have around 4,000 construction workers at its peak and 2,000
of Australia’s largest independent integrated mining, rail and port projects, operational staff once the mine is operational.
and the largest mining project finance deal of its kind in the world, Roy Hill is
significantly contributing to the Australian economy. Expanding our trade credentials
The project will add even more weight to our exceptional export flow. Roy Hill
We’re backing Roy Hill because we’re passionate about projects that will deliver export volume greater than our national wheat exports; or double
have such vast potential for Australia. the nation’s annual wine exports; or greater than the total of Australia’s
combined wool, seafood and lamb exports.
Owned by Hancock Prospecting Pty Ltd (70%), Marubeni Corporation of Japan
Creating innovation
(15%), POSCO of South Korea (12.5%) and China Steel Corporation (2.5%), the
project will also create change across the region, providing a high quality and Roy Hill is a powerhouse of innovation, using state-of-the-art, high-technology
reliable iron ore supply, especially to Asia. systems, automation and processes to deliver reliable, sustained and low cost
production of iron ore that’s known for its quality and grade.
We’re backing Roy Hill – providing the structuring, expertise and finance that
will bring the project to life – because we’re passionate about projects that have Only the best could make a deal of this scope work – that’s why we invested
such vast potential for Australia. the very best of NAB into the Roy Hill project. As joint debt adviser, mandated
lead arranger for the project financing and transactional bank to Roy Hill, we’re
Here’s a snapshot of what the project will bring to our economy: proud to be involved in this significant project.
To find out more call Brad Calleja, Global Head of Resources +61 3 8641 4596
© 2014 National Australia Bank Limited ABN 12 004 044 937 AFSL and Australian Credit Licence 230686 A108315-0514 SBPJ759WA014
thewest.com.au
For all the latest news The Roy Hill Project 23
‘The port limit means that we always
have to maintain a disciplined focus
on cost minimisation; it also
encourages innovation to introduce
r
s new efficiencies.’
Mike Lomman, general manager demand chain
s
chain, consisting of one mine, one rail line and
one port, as opposed to the multiple sites operated
by Rio Tinto, BHP and Fortescue.
Roy Hill, however, insists the new ROC is vital.
t “Because Roy Hill has a 55mtpa throughput
limit, set by its port capacity, the onus is on
achieving absolute end-to-end integration and
Remote control: The centre is designed to achieve ’absolute end-to-end integration’. Picture: Simon Santi efficiency to support the business model,” Mr
Lomman said.
videoconferencing gadgets is overseen by one of flat screens. It is impressive, and Roy Hill has the “The port limit means that we always have to
the chairwoman’s favourite oil paintings of her advantage of using proved technology. maintain a disciplined focus on cost
n life in the Pilbara. Rio Tinto launched its remote operations centre minimisation; it also encourages innovation to
Roy Hill won’t confirm this but Mrs Rinehart is near Perth’s Domestic Airport in 2010, and is in introduce new efficiencies.
believed to have a dedicated office near the the process of automating some of its Pilbara “It is already the thought-centre of the project
viewing area for the remote operations centre, operations, including driverless trucks. with weekly planning sessions to ensure
where up to 70 Roy Hill personnel will monitor BHP Billiton Iron Ore opened its integrated operational readiness for each of the milestones
and control the giant mine, rail and port project in remote operations centre, located inside its new ahead — in doing so, nothing is left to chance.”
real time. office tower at Brookfield Plaza, mid last year. When construction winds down next year, the
The myriad data include 3-D animations of Some have queried why Roy Hill requires an ......................................................................................................................
mining and construction displayed on super-sized ROC, given that it involves a simpler logistical ៑ CONTINUED P2424 The Roy Hill Project Wednesday, May 21, 2014 For
TH
S
En
S
div
an
en
de
sh
zo
Team effort: Staff from the remote operations centre at their new office in December.
de
...................................................................................................... pr
្ FROM P23 attempts to “industrialise” the mining, ac
processing and transport of iron ore. ‘It is already the thought- leg
ROC will be front and centre as Roy Hill’s As at other mine sites, the holy grail of co
demand chain team — responsible for the automation is to deliver safer workplaces
centre of the project stu
planning, scheduling and execution of re
production activities — kicks into top
for employees, while making production
activities cheaper and more reliable.
with weekly planning sig
gear.
The technology will be used to ensure
Roy Hill also believes it has the jump on
competitors by embedding the potential for
sessions to ensure wi
activities conform to the mine plan, while
instigating continuous improvement to
later automation into the design of its
operations from day one.
operational readiness.’ rig
de
“optimise” production. This should minimise “retrofitting” po
After start-up, automation of some issues encountered by some other Mike Lomman, general manager so
activities will be an objective, as Roy Hill organisations, Mr Lomman said. demand chain ma
SUPPORTING ROY HILL
FOR THE LONG TERM
J000178A
SKILLED is proud to be supporting the Roy Hill project from our position as Australia’s
leading provider of workforce solutions to the mining industry. With experience and
expertise across mining, rail and port we look forward to working with Roy Hill
throughout construction and operations.
Our industry leading safety systems, local presence and market leading training,
apprenticeship and Indigenous employment programs make SKILLED a partner
of choice for Australia’s mining leaders.
FOR MORE DETAILS CALL 1300 361 582 OR VISIT WWW.SKILLED.COM.AU
243014
thewest.com.au
For all the latest news The Roy Hill Project 25
THE FACES OF ROY HILL Innovative
healthcare
Susanna Beech solutions for the
Mining sector
Environment and approvals manager
usanna Beech, manager environment
S and approvals, joined Roy Hill three
years ago.
“Roy Hill is being constructed across a
• Tailored and Flexible
Healthcare Solutions
• Environmental and
diverse range of environmental landscapes
Public Health
and within areas containing significant
environmental values, such as the • Aero-Medical
Evacuation (AME)
development of a port ore-handling and
ship-loading facility within the intertidal • Occupational Health
zone of the Port Hedland Port,” she said. • Training and Consultancy
“Our success so far has been the early
development of business systems to identify,
prioritise, implement and track
achievement of approval requirements and
legal obligations. Furthermore,
comprehensive baseline environmental
studies along with solid stakeholder ISO
9001
ISO
14001
ISO
18001
relationships enabled us to achieve a
Quality Environmental Occupational
Management Management Health & Safety
Management
significant number of project approvals
within short timeframes.
“We have undertaken a three-year
rigorous debt-financing process involving
detailed assessments of the project risks,
potential impacts to environmental and
social values and the development of
management practices to reduce risk.”
WE CONNECT BUSINESS, IDEAS, LIFE.
J000178A
Ansaldo STS is proud to be delivering a signalling and communications solution for
the Roy Hill Iron Ore Project that sets a new benchmark in operational flexibility and
efficiency for heavy haulage mining railways. www.ansaldo-sts.com
2436504πHSRM21051426 The Roy Hill Project Wednesday, May 21, 2014 For
Bankrolling the A pl
Mining in the Pilbara is fundamental to the national accounts — and
our way of life. Economics editor SHANE WRIGHT reports —
ro
he WA Budget lives or dies by how much iron of recent years — but the WA Government has m
T ore is shipped out of the State.
And it’s almost as important to the Federal
Budget, as the long-awaited surge in exports
benefited also.
The WA Government is the ultimate owner of
the iron ore. And it’s the Government that has
G
pumps cash back into the barren coffers of grown ever more dependent on the royalties on lik
Canberra. that iron ore for its day-to-day operation. Au
Iron ore now accounts for almost one in every The State Treasury lives and breathes on the fin
three export dollars raised by Australian iron ore spot price.
businesses. Royalties from miners account for 20 per cent of co
Most of those dollars are funnelled through Port the revenue that helps pay for the State’s teachers,
Hedland — the world’s biggest iron ore port. police officers and nurses. pe
Over the past year, exports through Port A fifth of the State’s teachers, a fifth of the police
Hedland to China have climbed by 50 per cent. force and a fifth of the State’s roads are paid for tr
They were up by 7 per cent in April alone. from the red earth being shipped out to Asia. gr
While this growth is being pursued by The surplus in State Treasurer Mike Nahan’s
companies such as Rio Tinto, BHP Billiton and first Budget came in no small part from activities
Fortescue, many of the benefits flow back to in the Pilbara. Of
taxpayers at the State and Federal level. As that dependence has grown, so to the se
The communities of the Pilbara and the fragility of the State budget.
employees, managers and shareholders of the big The rule of thumb for the State Budget is that a co
Prime Minister mining companies are the biggest direct $US1 dollar movement either way in the price of a th
Tony Abbott beneficiaries of the mining and construction boom tonne of iron ore changes WA’s royalties take by suthewest.com.au
014 For all the latest news The Roy Hill Project 27
e Aussie lifestyle
plus or minus $45 million. It is a volatile game. When things go awry for miners, so to for the
d Mining royalty income has one perverse effect Federal Budget.
— for every $100 million increase in iron ore The most obvious impact occurred in 2009-10.
royalty revenue, the State will lose about $90 Company tax to Canberra fell by 10 per cent.
million (over a period of time) through reduced The tax collected from the mining sector dropped
GST. by 50 per cent.
It’s not just the State that depends on iron ore. It was a decline that added many billions of
At a macroeconomic level, iron ore exports are dollars to that year’s $55 billion Budget deficit.
likely to add about 0.3 percentage points to Deloitte Access Economics, in its most recent
Australia’s total increase in national income this analysis of the state of the Federal Budget, noted
financial year. the best proxy for understanding the nation’s
That would be a threefold increase of the finances used to be the unemployment rate.
of contribution made the previous year. No longer. The best proxy is now coal and iron
s, In terms of GDP, iron ore will add about 0.8 ore prices.
percentage points to growth. According to these respected forecasters, if the
ce Given the way the rest of the economy is price for both commodities follows the trajectory
tracking, that will amount to a third of total GDP of past commodity booms and busts, then the hole
growth. in the Budget would be $36 billion. That’s just shy
All this feeds into the Federal Budget. of the annual cost of the age pension.
s Recent figures from the Australian Taxation Both thermal and coking coal prices have
Office highlighted the importance of the mining slipped by more than 50 per cent since their high
sector, and particularly iron ore producers. point in 2010. Iron ore has fallen, but not by quite
Miners paid $15 billion of the $64 billion in as much, while it has been more than offset by an
a company tax receipts collected in 2011-12. Much of increase in sales.
a that $15 billion came from big iron ore miners ...................................................................................................................... Premier
such as Rio, BHP and Fortescue. ៑ CONTINUED P28 Colin Barnett
Laing O’Rourke
Engineering the future
Working in partnership to deliver
Western Australia’s infrastructure
needs for more than 30 years laingorourke.com28 The Roy Hill Project Wednesday, May 21, 2014 Fo
CONGRATULATIONS SPOT IRON ORE PRICE
ROY HILL
$US/t
200
140
2430642πBLRM210514
80
20
2002-03 2013-14
Source: World Bank
...............................................................................................
្ FROM P27 “Second, Australia is the lowest cost
producer of iron ore, so that even if
However, there is some good news for overall demand for iron ore slows, other
the Budget (both Federal and State) even producers are likely to see cuts before
if iron ore prices slip a little further. there is a reduction in demand for
HSBC chief economist Paul Bloxham Australian iron ore.”
argues that though there has been a All of which is positive for both Dr
RED is proud to be slowdown in the overall Chinese
economy, the bit that keeps buying
Nahan, Federal Treasurer Joe Hockey
and their respective budgets.
delivering construction Australian iron ore is still strong. And it has been good for the nation’s
“While China’s growth has weakened, standard of living: Australia has moved
services to the world class much of the slowdown has been in from the 13th richest nation in the world
manufacturing, while growth in (as measured by exchange rate adjusted
Roy Hill iron ore project. infrastructure investment — which is per capita GDP) to about 6th.
the key driver of demand for steel — has Once Australia rode the sheep’s back.
remained strong and is expected to Now we’re all passengers on a bulk
www.redengineers.com.au continue,” he said. carrier headed to Asia.thewest.com.au
014 For all the latest news The Roy Hill Project 29
THE FACES OF ROY HILL
WORKFORCE SNAPSHOT
Colyn Louw ᔡ Peak construction workforce:
3800
ᔡ Operations phase: approximately
1800 employees at full
Human resources general manager production, consisting of 1500
FIFO employees and a number of
olyn Louw, general manager for human
C resources, says Roy Hill is a chance to work
on a tier-one project and be part of
something special.
employees living in Port Hedland.
The balance is based at the
corporate head office and remote
operations centre in Perth.
“We are building a major mining project that ᔡ Operational employee numbers
4
will be a market differentiator,” he said. “Roy Hill will increase by 320 in 2014, 530
is a truly WA-based company, with 95 per cent of in 2015, 250 in 2016 and the
our operations workforce to date hired from remainder over the period 2017 to
within the State. We want people who are skilled 2020.
and business savvy, think and act like business
r owners, understand and apply effective use of cost
drivers and embrace productivity as a way of
doing business. It is these qualities which will
deliver sustainable value to all our stakeholders.”
According to Mr Louw, innovation lays the
foundation for long-term business growth and
positions companies for future success.
“We aim to evolve our business by adopting the
d processes, technologies, and mindsets necessary
ld to strengthen our long-term operation,” he said.
d “We want to be a high-performing business
where people realise their potential. Our values,
k. supported by defined capabilities and behaviours,
are a constant reminder of what we are working Picture: Iain Gillespie
towards and forms the basis of our culture.”30 The Roy Hill Project Wednesday, May 21, 2014 Fo
Iron ore end game: Inside the m
hina’s premier steel factory, Baosteel, is the been because it is a dangerous part of the facility.
China’s Baosteel complex is
one-third bigger than Rottnest.
KIM MACDONALD describes life
C quintessential expression of Chinese toil.
It is a groaning, steaming behemoth that
produces 43 million tonnes of steel a year in a
Just over a year ago two people were killed and
13 injured, one with third-degree burns to 99 per
cent of his body, when molten steel spilled from a
fr
in
relentless, round-the-clock operation. refining furnace. th
inside the final destination for The West Australian gained an insight into the
30sq km area of land in Shanghai to which WA
The workers had been cleaning molten slag from
the furnace when a hook lifting the furnace failed,
co
much of WA’s iron ore owes much of its current standard of living during toppling the 270-tonne structure. m
a guided tour organised by the Australian As we passed we saw sparks fire out of the top in al
Institute of Management WA. a reminder of its ferocious force. al
Baosteel, China’s biggest listed steelmaker, is The scene soon disappeared from sight when the an
one of WA iron ore’s biggest customers, and its tour bus veered back into tree-lined streets.
orders not only create mining jobs but help Baosteel’s green belt sprawls for more than 40 50
finance the schools, hospitals and infrastructure per cent of the facility, which is the size of Macau sl
that rely on mining royalties. and a third bigger than Rottnest Island.
That thought was top of mind on that drizzly Baosteel’s official website claims its air quality th
winter’s morning in February as we watched is on par with a State-level scenic spot and it is the
ships come into the Yangtze River and deliver the first metallurgical company to meet new tr
rocks all the way from the dust bowl of the environmental standards. an
Pilbara. Visitors tend to walk away impressed by its
The ships were unloaded at Baosteel’s port and greenery, even though the heart of the operation — w
the ore taken directly to the blast furnace a few the heat strip mill — looks like a post-apocalyptic —
kilometres away within the same facility. scene. do
Our tour bus did not stop at the blast furnace, The cavernous mill is dark and loud — you have
much to our disappointment. to shout to be heard above the clanging sounds of ap
End product: Workers walk past rolls of steel at a Baosteel production line. No explanation was given, though it could have industry. w
Leading
The Way.
Centrals are proud of our ongoing contribution to the
Roy Hill Iron Ore Project. Our involvement includes the
construction of eleven Rail Bridges, civil and in-ground services
for the Mine Non Process Infrastructure Buildings and provision of
civil resources for the construction of the Main Processing Plant.
Successfully delivering multi-disciplined construction services for the
Mining, Oil & Gas and Infrastructure sectors across Australia.
www.centralsystems.com.au
Preserving Today. Constructing Tomorrow.
Perth | Port Hedland | Newman | Brisbane | Townsville
46 Edward Street, Osborne Park, WA 6017 t: 08 9443 2928 e: info@centralsystems.com.auYou can also read
