Background
Gudai-Darri, Rio Tinto’s most technologically advanced iron ore mine, represents a step-change in mining automation and efficiency. With cutting-edge autonomous haul trucks, robotic ore sampling, and a digital twin processing plant, the site is built for high productivity and safety. However, like any major mining operation, effective dust control is crucial to maintaining operational integrity and worker safety.

The Challenge
The Dust Collector in the laboratory area required critical upgrades to improve dust containment during lab operations. Additionally, rocks entering the bucket cleaner were causing significant damage to the ducting, leading to inefficiencies in air pollution control and increased maintenance needs. To ensure compliance with safety and operational standards, Rio Tinto engaged Aerison as a primary contractor to assess and enhance the site’s dust extraction and air pollution control systems.

Key Learnings & Scope of Work
Aerison’s scope at Gudai-Darri focused on a comprehensive assessment and upgrade of the site’s air pollution control assets, ensuring enhanced dust management and system performance. Through this process, key insights emerged:

• The Importance of Proactive Maintenance: Addressing wear and tear before failure occurs can prevent costly shutdowns.
• Custom Solutions for Unique Challenges: Standard dust control measures aren’t always enough – tailored solutions like reinforced ducting and upgraded extraction hoods significantly improve system longevity.
• Balancing Efficiency with Safety: Modifying the system for improved performance must be done with strict adherence to structural integrity and compliance standards.

Key activities included:

• Design Check & Structural Integrity Assessment: Evaluating the existing system design using OEM information to identify improvement opportunities and ensure compliance with industry standards.
• Supply and Installation of New Extraction Hoods: Implementing new hoods as required to optimise dust capture efficiency.
• Detailed Design of Support Systems: Engineering robust support structures to reinforce the integrity of dust extraction components.
• Duct Cleaning and System Balancing: Removing built-up dust and debris within ducting to restore optimal airflow and functionality.
• Re-commissioning of the Dust Extraction, Vacuum, and Waste Transfer System: Ensuring seamless integration of upgraded components for improved performance and reliability.

The Approach
Aerison’s expertise in air pollution control enabled a structured approach to diagnosing and addressing the site’s dust management challenges. A combination of site inspections, engineering assessments, and precision installations ensured that the upgrades were executed with minimal disruption to ongoing operations. By leveraging advanced design principles and high-quality materials, Aerison’s team worked to fortify the dust control infrastructure against wear and tear while improving containment efficiency.

Project Status
The maintenance and upgrade work is ongoing, with Aerison continuing to support Rio Tinto in achieving a safer and more efficient dust management system. By proactively addressing dust containment issues, Aerison is helping Gudai-Darri maintain its status as an industry-leading, technologically advanced mining operation.

Why Aerison?
With decades of expertise in air pollution control, Aerison is uniquely positioned to deliver tailored dust management solutions for complex mining environments. Our deep understanding of mining infrastructure, coupled with our commitment to innovation and safety, ensures that our clients receive high-performance solutions that align with their operational goals.

For more information on how Aerison can assist with dust control and air pollution management solutions, contact us at sales@aerison.com.