BHP South Flank Iron Ore Project

Client: BHP

Location: Pilbara Region, WA, Australia

Business Segment: Urban Solutions

Industry: Mining & Metals

Map showing the location of BHP South Flank Iron Ore Project

Executive Summary

Fluor was selected by BHP to provide engineering, procurement and construction management services for its South Flank iron ore project in the Pilbara region, Western Australia. South Flank is the largest iron ore processing facility ever built in Western Australia.

The project included an 80-million-ton-per-year crushing and screening plant, an overland conveyor system and rail-loading facilities.

Client's Challenge

The South Flank project fully replaced production from the 80-million-tons-per-annum (100% basis) Yandi mine, which was nearing the end of its economic life. South Flank was a capital-efficient project offering attractive returns. The project enhanced the average quality of BHP's Western Australia Iron Ore (WAIO) production and allowed BHP to benefit from price premiums for higher-quality lump and fines products.

Fluor's Solution

Offering more than 50 years of iron ore experience, Fluor had worked with BHP on numerous prior iron ore projects in the Pilbara region. We joined BHP at the later stages of the definition phase study of the project when we were awarded the follow-on project and construction management scope.

The work was performed from BHP's office in Perth, with Fluor and BHP managing the project together as an integrated project team.

After construction started in July 2018, the project achieved 50% completion in October 2019. The project team reached a construction milestone in November 2019, erecting the first 1,500 tons of modules in the ore-handling plant. Construction began on the Primary Crusher 2 facility in February 2020.