The QMM ilmenite project comprises the mining and processing operations of a minerals sands deposit at Fort Dauphin (Tolagnaro) in the southeastern region of Madagascar.

The project aims to dredge mine the deposit at Mandena, north of Fort Dauphin, using a conventional cutter suction dredge, gravity separate the HMC (heavy minerals concentrate) on a floating concentrator in the dredging pond, further separate the HMC into various products and tailings in the land-based minerals separation plant, before transporting the product to a new port facility to be built at Ehoala, to the south of Fort Dauphin.  Products delivered to the port are shipped for further processing by offshore QMM/Rio Tinto facilities.

The project also includes all associated infrastructure, including power generation and distribution, township development, water supply, sewerage collection and treatment, haul and access roads. 

Scope of Services
Hatch completed a feasibility study for a mineral sands mining and processing facility, including related infrastructure.  Subsequent continuing work included detailed engineering and procurement activities, and early works/pioneering contracts site activities. 

The project took three years to complete, and comprises a dredge mining plant, a concentrator, a minerals separation plant, a power station, more than 20 km of roads, 300-plus housing estate, a quarry, and an export port facility.  The storage, shiploading and buildings at the port fall under the scope of work of the JV.

Hatch, as part of the Mandena JV, provided engineering, procurement and construction management services for this project. In this partnership Hatch was responsible for the engineering, procurement and commissioning of the project, while the other JV partner was responsible for the logistics, contract and construction management aspects.

In particular, the Mandena JV provided the following services:

• Engineering in the process, civil, architectural, structural, mechanical, piping, electrical, and process control and automation engineering disciplines
• Procurement management and purchasing
• Contract administration
• Logistics management, including transport logistics, materials management and warehousing
• Project services management including administration of the project planning, estimating, cost control, accounts administration, document control, and information technology functions
• Construction management, including site safety management
• Commissioning management to the end of the cold commissioning phaseProject closeout within defined parameters

Project Highlights

• The project is the largest in Madagascar’s history
• The remoteness of the site together with a lack of infrastructure required thorough planning be done on logistical issues, and a substantial portion of the project costs related to infrastructure – this includes the new port, roads, power supply, water supply, and housing
• A quarry was developed to supply rock and aggregate for the port and various civil works
• Part of the financing for the port facility came from the World Bank

Project Safety

• Five million workhours completed without a Lost Time Injury

Awards & Special Client Recognition

• Rio Tinto 2009 Chief Executive's Safety Award
• Technical auditors for QIT Madagascar Minerals (QMM) and Rio Tinto have told the QMM team that the optimal use of space, ergonomic layout and general quality of engineering provided by Hatch for the QMM ilmenite project in Madagascar have resulted in the best designed mineral mining and separation plant the auditors have ever seen