Conference Proceedings
Iron Ore and Open Pit Operators Conference Proceeding 2026
Conference Proceedings
Iron Ore and Open Pit Operators Conference Proceeding 2026
Driving excellence in surface mining operations – a case study on Nutrien’s Aurora phosphate mine
Operational‑excellence initiatives in mining seek to increase production and reduce operating costs through low‑capital, high‑impact improvements that can be rapidly deployed across the value chain. These initiatives typically focus on bottleneck elimination, improved equipment performance, and stronger operational decision‑making. This paper presents a case study of an operational transformation at Nutrien’s Aurora phosphate mine, demonstrating how efficiency gains were achieved across key surface‑mining domains, including ore handling, equipment reliability, mine planning, and digital automation. The engagement aimed to strengthen Nutrien’s operational capabilities by identifying performance gaps and implementing targeted improvements. A two‑month diagnostic phase identified 23 improvement opportunities across the mines, beneficiation plant, and site‑wide asset management, of which ten were prioritised for implementation. Beginning in March 2025, a series of quick‑win initiatives were launched to deliver rapid impact and support Nutrien’s broader operational excellence journey. Key improvements focused on reducing non‑productive time and stabilising ore flow. Measures included implementing hot‑seating during shift changeovers, optimising refuelling practices, repositioning excavators to minimise swing times, and improving coordination between mobile equipment. Reliability of critical ore‑handling infrastructure was enhanced through improved spare‑equipment strategies, real‑time slurry‑density monitoring, and process simplification. Slurry handling was further stabilised by consolidating feed tanks and optimising pumping systems to increase slurry density, reduce water usage, and improve downstream performance. Digital tools were deployed to improve downtime tracking, data integrity, and real‑time operational visibility, enabling proactive stockpile management and maintenance planning while sustaining production targets. Overall, the case study demonstrates that sustained performance improvement is driven by accurate root‑cause identification, integration of real‑time insights into daily operations, and strong workforce ownership aligned with technical and digital solutions.
Contributor(s):
N Smit, J Pierce, R Jahan and A Premachandra
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- Published: 2026
- Pages: 10
- PDF Size: 1.245 Mb.
- Unique ID: P-05438-T4S2J8