Nestled in the rugged fjords of Western Norway, the Engebø rutile and garnet mine will be the first greenfield mining project in the Scandinavian country in almost 40 years. Nordic Mining is carving out a state-of-the-art hard rock mining and processing operation to extract some of the world’s highest-grade rutile (TiO2) and garnet. This project promises to set new benchmarks for environmental stewardship and engineering innovation, heralding in the future of resource extraction.

The operations at Engebø will process 1.5 million tonnes of ore annually. With an expected mine life of 40 years, operations will begin in the fourth quarter of 2024, eventually transitioning to underground mining.

The project scope in the execution phase includes a dedicated mine access and service road, state-of-the-art process plant facilities, tailings disposal systems, export infrastructure tailored for ocean-going vessels, and on-site utilities, including desalinated water and access roads. The site will be powered by renewable hydroelectric energy, ensuring a minimal carbon footprint, a key sustainability goal of the project.

Getting here has been no easy feat. Norway has some of the most stringent environmental protection permitting and processing requirements, and as the country’s first greenfield mine in decades, stakeholder management, environmental compliance, and community consultation have been paramount.

Our history with the project began in 2017 when Nordic Mining first engaged Hatch to complete feasibility studies and foundational project planning. The study results were not what Nordic Mining had hoped for; the originally proposed process was deemed financially not viable at the release of the definitive feasibility study in March 2020.

Some may have walked away, but we shared Nordic Mining’s vision and knew that we could do what we do best—reimagine that vision into reality. We were challenged by Nordic Mining to think outside of the box and revisit some of the earliest design concepts from the concept study and prefeasibility study as the resource knowledge and processing testwork experience had significantly increased from the start of the project. The result? A unique process based on a gravity-fed system that will turn the mine into a leading producer of high-grade rutile and garnet, securing long-term operations and market competitiveness.

Our proposed solution has ore mined in the pit being fed into a shaft through the center of the ore body. At the bottom, the ore is mechanically fed to the primary crusher via apron feeder, and then transported by overland conveyors into the comminution plant for secondary and tertiary crushing. The innovative gravity-fed design minimizes materials handling and with an automated crushing and conveying system, no workers are required within the mountain during operation, thereby reducing health and safety risks and minimizing operating costs.

Following the crushing and comminution circuits, crushed ore is slurried using process water prepared by the on-site desalination plant. Slurry is introduced to the mineral processing plants through the primary mill followed by a series of gravity and magnetic separation processes. The resultant products are dried, impurities are extracted, and the high-grade mineral concentrate is transported to the final product silos where they are ready for ship loading onto international ocean-going vessels.

The revised solution includes cost savings achieved by moving to an EPC execution model and modifying the process plant design from 17 modularized units to three main process buildings, significantly compressing the overall plant footprint and reducing the total project cost by 30% without compromising on processing capabilities.

With a workable design and plan in hand, Nordic Mining was positioned to make their dream a reality. In 2021, they asked us to serve as their project management consultant. Our role is to integrate into the owner’s team and encompasses construction management, engineering coordination, and integration of the EPC partnership, ensuring continued expert management and engineering support, along with detailed process engineering and plant layout designs.

As the project moved into execution, ensuring a smooth transition from blueprint to reality has included oversight of the construction process, adherence to rigorous design specifications and international standards, and management of many project aspects, guaranteeing timely and budget-compliant completion. With four local EPC contractors responsible for execution of different aspects of the project, on-site support to Nordic Mining is necessary to address real-time challenges and ensure quality of all deliverables.

Revised approach leads to 30% cost reduction

Our commissioning experts have been involved in the project throughout, providing testing and components for operational readiness and preparing the site for seamless operation post-construction with no interruptions in service.

The Engebø rutile and garnet project faced extraordinary challenges due to its location and environmental sensitivities. The site, set within a fjord region, required careful planning to reduce environmental effects and guarantee safe procedures.

Nordic Mining’s approach included creation of a complete Environmental and Social Management System (ESMS) and adoption of mining methods to address the geotechnical conditions and achieve effective ore extraction. These strategies were successful, minimizing environmental impact.

The project addresses environmental sustainability through several key initiatives. The use of regional hydroelectric power for the process plant energy requirements reduces carbon emissions, contributing to a low-carbon footprint. The project implements sustainable materials and systems, including advanced waste management practices. Incredibly, the production process has a 99% reduction in chemical usage for mineral separation and has 80% less CO₂ emissions when compared to the original proposed process design.

Independent studies indicate that the Engebø project will have the lowest greenhouse gas emissions among all producers of titanium feedstock globally, achieved through efficient resource utilization and the minimal physical footprint.

Nordic Mining wanted to create an eco-friendly and economically feasible mining project. We engineered a solution that was both efficient and compliant with global standards, keeping the venture within budget and on schedule—a forward-thinking strategy that promotes enduring financial stability and rewarding outcomes for stakeholders.

By combining strategic foresight with precision in execution, Nordic Mining and Hatch are advancing the mining industry and setting a new standard for sustainability and social responsibility. Nordic Mining’s commitment to environmental stewardship and community engagement demonstrates that progress in mining can go hand-in-hand with a greener, more equitable future.