Client

Rio Tinto

Location

Pilbara, Western Australia

Industry

Mining

Overview

The Gudai-Darri (originally Koodaideri) project is a greenfield mine development for Rio Tinto Iron Ore, located 35km northwest of the Yandicoogina mine in the East Pilbara mining region. The Gudai-Darri mine will have an annual capacity of 43 million tonnes, underpinning production of the Pilbara Blend, Rio Tinto’s flagship iron ore product.

As Rio Tinto’s most technologically advanced mine, Gudai-Darri is referred to as Rio Tinto’s ‘mine of the future’ with autonomous trucks, trains, drills and the world’s first autonomous water carts. The mine also utilises Rio Tinto’s “digital asset” – a digital replica of the site that combines data from actual processing plants with historical design information to improve how the plants are run.

Scope

Rio Tinto engaged Intellect Systems to supply, manufacture, assemble, and test the following panels for the Gudai-Darri Process Plant Control System (PPCS):

  • Remote I/O Panels (90 units)
  • Remote I/O Extension Panels (23 units)
  • Network Equipment Panels (31 units)
  • Condition Monitoring Panels (3 units)
  • Switchroom Safety PLC Panels (5 units)

Expertise and Intelligence

Rio Tinto required a solution that would be coherent to and enhance the “mine of the future” technology offering at Gudai-Darri.

Intellect Systems’ engineering expertise allowed us to thoroughly understand the client’s engineering requirements and deliver a highly customised and prototyped solution.

The Intellect team fully type-tested the assets’ design in-house to certify that it met the AS/NZS 61439 standard.

Technology at the Forefront

Intellect Systems capitalised on the efficiencies provided by smart manufacturing innovations, such as lean manufacturing, batch sequencing and production automation, to maximise productivity while minimising waste.

Intellect’s manufacturing process steps are mapped to ensure they occur in a tight sequence so the production flows smoothly without delays or bottlenecks.

Our production automation devices, such as wire processing, wire cutting and laser cutting, drive efficiency, reduce costs, and guarantee quality.

By ensuring we are at the forefront of intelligent manufacturing innovations and focusing on process optimisation, the downstream supply chain aligns while the volumes required upstream are delivered – creating both cost and time benefits.

Quality from Start to Finish

In addition to engineering and prototyping, Intellect Systems provided complete, integrated staging and support to the client during factory acceptance testing (FAT).

Intellect Systems are ISO 9001 and 45001 accredited and utilises a proven project delivery framework. Our management systems ensure quality toll gates and reduced risk for our clients.

Intellect System’s engineering innovation, manufacturing intelligence and comprehensive support provide products and solutions that help to unlock additional capacity and enhance the technology offering for our clients.