Aerial view of a Pilbara iron ore mine, processing plant, railway, stockyard and export terminal

Pit to Port

Pilbara iron ore.
From pit to port.

Follow the connected mines, processing plants, heavy-haul rail, stockyards and port equipment behind Australia's iron ore exports.

Follow the handovers Open the machine index

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Four resources. Four different operating chains.

Iron ore is the original pit-to-port system. Coal, lithium and gold follow different processing, transport and customer pathways.

One operating system

The supply chain is only as strong as the handover between stages.

Pit to port is a practical way to understand iron ore operations. Instead of viewing a mine, train or shiploader in isolation, it shows how material, information, maintenance and people move through the complete chain.

A delay at one asset can change the work required many kilometres away. Reliability is a system outcome.

Animated system map

One parcel of ore. Seven handovers.

Ore moving

01PitDrill, blast, dig and haul
02ProcessFeed, crush, screen and blend
03Load-outMeter ore into rail wagons
04RailHeavy-haul movement to port
05StockyardDump, convey and stack
06ReclaimRecover and transfer to wharf
07ShipLoad nominated vessel holds

Conceptual flow only. The exact process, plant arrangement and handover points differ by operation, ore type, product specification and port.

Labelled aerial schematic showing an Australian iron ore system from open-pit mining and processing through rail, stockyards and port operations — **Whole-system view:** follow the material path from the drill and blast area through crushing, rail transport, stockyard blending and shiploading. Conceptual learning visual—not a site flowsheet or operating instruction.

The operating journey

What happens at each handover.

Follow a representative Pilbara iron ore flow. Every operation is configured differently, but the system logic is broadly recognisable.

Labelled schematic of iron ore drills, loading units and haul trucks with key wear and inspection areas

Open full size ↗01

Create and move run-of-mine ore

Pit

Geology and mine planning identify the ore. Drill and blast crews fragment the rock, then excavators or shovels load haul trucks for the run to the crusher or run-of-mine stockpile.

Key handover: Fragmented ore reaches the ROM pad or crusher feed in the planned material stream.
System dependency: Mine plan, blast result, loading-tool match, haul roads, dispatch and crusher availability.

Labelled schematic of iron ore feeders, crushers, screens, conveyors and dust control systems

Open full size ↗02

Prepare a consistent saleable product

Processing

Feeders regulate the flow into crushers. Screens separate material by size, while site-specific circuits may wash, beneficiate or blend ore before it reaches product stockpiles or train load-out.

Key handover: The plant delivers a controlled product stream with the size and quality required by the downstream route.
System dependency: Feed condition, crusher and screen circuit, chute flow, conveyor availability and product-quality decisions.

ROM bin & feeders Primary crushers Screens Plant conveyors

Labelled schematic of an iron ore train load-out system and its major wear areas

Open full size ↗03

Transfer product into the rail system

Rail load-out

Load-out bins, gates and weighing or control systems place ore into each wagon. Consistent loading matters because train performance, axle loads and the next port handling stage all depend on it.

Key handover: Each wagon leaves with a controlled load profile and the product information required by the rail and port systems.
System dependency: Bin level, gate timing, weighing, sampling, train speed or indexing and wagon-load limits.

Product bins Apron or belt feeders Load-out gates Sampling & controls

Long iron ore train travelling through the Pilbara toward the coast

Move bulk tonnes over distance

Heavy-haul rail

Locomotives, ore cars, track, signalling, train control and maintenance facilities operate as one logistics system. The railway is the moving link between inland mines and coastal export terminals.

Key handover: The loaded consist arrives at port in the sequence required by the receival and stockyard plan.
System dependency: Locomotive and wagon condition, braking, track, signalling, network control and dumper availability.

Locomotives Ore cars Track & points Signalling & train control

Aerial view of iron ore stockyards, berths and shiploading facilities at Port Hedland

Receive trains and build stockpiles

Unload and stack

At port, wagons are unloaded through a railcar dumper or another terminal-specific arrangement. Conveyors transfer the ore to stackers, which build planned stockpiles for storage, blending and vessel schedules.

Key handover: Ore is unloaded, transferred and placed into a defined stockpile that remains traceable to the product plan.
System dependency: Train positioning, dumper sequence, hopper and feeder flow, conveyor route, yard space and stacking strategy.

Railcar dumper Car positioner Transfer conveyors Stackers

Bucket wheel reclaimer recovering iron ore from a stockpile

Recover the product and fill the vessel

Reclaim and shipload

Bucket wheel reclaimers recover ore from nominated stockpiles. Yard and wharf conveyors deliver it to travelling shiploaders, which distribute the cargo across nominated holds under terminal and marine controls.

Key handover: The nominated product reaches the correct vessel hold at a rate controlled by the full stockyard-to-berth system.
System dependency: Stockpile access, reclaim sequence, conveyor route, berth readiness, vessel plan, marine limits and shiploader availability.

Bucket wheel reclaimers Yard & wharf conveyors Transfer stations Shiploaders

Images: conceptual editorial and representative visuals from The FIFO Hub media library. Schematics support learning and are not OEM drawings, site flowsheets or operating instructions.

Pit-to-port machine index

Nine equipment families. One connected material path.

Use the summary for context, open The FIFO Hub's full guide for assemblies and maintenance disciplines, then follow the OEM or operator link for authoritative product information.

01Pit

Drills, shovels and haul trucks

Create blast holes, load fragmented material and move ore or waste to the planned destination.

Major assemblies: Drill mast and rotary system; shovel or excavator digging system; truck powertrain, retarding, brakes, steering, tyres and body.
Material handover: Run-of-mine ore at the crusher or ROM pad.

Detailed FIFO Hub guide Komatsu surface mining equipment

02Processing

Feeders, crushers and screens

Meter incoming ore, reduce top size and classify material into the streams required by the plant and product plan.

Major assemblies: ROM receival, feeder drive and pans or belt, crusher chamber and lubrication, screen decks, exciters, chutes and controls.
Material handover: Controlled size fractions for conveying, recirculation or product storage.

Detailed FIFO Hub guide Metso feeders and processing equipment

03Rail load-out

Train load-out systems

Place a controlled mass and profile of product into each moving or indexed ore car.

Major assemblies: Load-out bin, liners, feeders, gates, chutes, weighing, train detection, sampling, PLC logic and communications.
Material handover: A loaded, measured and documented ore train.

Detailed FIFO Hub guide TAKRAF wagon and truck loading

04Heavy-haul rail

Locomotives, ore cars and rail

Move bulk tonnes between inland mining hubs and coastal terminals as one controlled railway system.

Major assemblies: Traction and energy systems, braking, wheelsets, bearings, couplers, track, points, signalling, wayside detection and network control.
Material handover: The planned train arrives at the nominated port receival stream.

Detailed FIFO Hub guide Wabtec Pilbara locomotive technology

05Port receival

Railcar dumpers and positioners

Index and secure wagons, unload ore into a hopper and release the empty consist through a controlled sequence.

Major assemblies: Indexer or positioner, clamps, dumper barrel or tippler, support rollers, drives, hopper, feeders, dust control and interlocks.
Material handover: Ore at a controlled rate on the port receival conveyor.

Detailed FIFO Hub guide TAKRAF wagon unloading systems

06Stockyard

Stackers and stockpiles

Place incoming product into defined stockpiles for storage, sequencing, blending and later reclaim.

Major assemblies: Tripper, boom conveyor, long travel, slew, luff, brakes, restraints, cable management, positioning and pile-profile controls.
Material handover: A planned stockpile available to the reclaim and shipping schedule.

Detailed FIFO Hub guide TAKRAF stackers and handling equipment

07Reclaim

Bucket wheel reclaimers

Cut controlled slices from a nominated stockpile and feed the recovered product onto the outbound yard conveyor.

Major assemblies: Bucket wheel, buckets and drive, discharge chute, boom conveyor, slew, luff, long travel, machine structure and automation.
Material handover: A controlled reclaim stream matched to the outbound route.

Detailed FIFO Hub guide TAKRAF bucket-wheel reclaimers

08Transfer

Conveyors and transfer stations

Carry ore continuously between machines while controlling belt tension, alignment, loading, discharge and route selection.

Major assemblies: Belt, pulleys, idlers, drives, take-up, cleaners, skirts, chutes, structure, protection, instruments and route controls.
Material handover: A stable material stream at the correct downstream machine or berth route.

Detailed FIFO Hub guide Continental conveying solutions

09Berth

Shiploaders and berth systems

Receive ore from the wharf conveyor and place it into nominated vessel holds under the loading and marine plan.

Major assemblies: Approach conveyor, tripper or transfer, boom and shuttle conveyor, long travel, slew or luff, telescopic chute, spoon and controls.
Material handover: Export product placed into the vessel in the planned hold sequence.

Detailed FIFO Hub guide Pilbara Ports facility information

Technical boundary: Machine capacity, configuration, control philosophy, operating limits, inspection criteria and isolation requirements are site- and asset-specific. Use current OEM manuals, drawings and approved site procedures for work decisions.

Worked example: BHP

Newman to Nelson Point.

BHP's Western Australia Iron Ore network is a useful real-world example of the connected system. Ore from Newman Operations joins the heavy-haul rail network to Port Hedland, where port plant receives, stores, reclaims and loads it for export.

This is an editorial overview, not a route diagram or operating instruction. Individual products may be blended, redirected or handled differently according to the production and shipping plan.

Open the equipment library

2.5+ kmBHP's published train length

264ore cars in BHP's published example

12,500 t/hlisted load rate for certain BHP Port Hedland shiploaders

Published operator and port figures. Equipment arrangements and achievable rates remain site- and berth-specific.

People behind the system

Operations depend on more than operators.

ElectriciansMechanical fittersBoilermakersRiggersOperatorsMaintainersPlannersEngineersSupervisorsRail crewsMarine teamsInspectorsSchedulersSupport teams

Sources and further reading

Go to the operator, port and OEM.

Checked 28 August 2026. External links open the primary source.

BHP — Western Australia Iron Ore

BHP describes WAIO as an integrated system of mines, rail and port operations in the Pilbara.

BHP — Newman Operations

BHP confirms that ore from Newman is transported by rail to Port Hedland.

BHP — Port Hedland Ports

Operator overview of BHP's Port Hedland system, including its 2.5 km, 264-car iron ore trains.

Pilbara Ports — Port of Port Hedland

Official port context and operating information for the world's largest bulk export port.

Pilbara Ports — Port facilities

Official berth and shiploader information; figures are berth- and facility-specific.

TAKRAF — Materials handling equipment

OEM library covering wagon unloading, stackers, bucket-wheel reclaimers and shiploaders.

Komatsu — Surface mining equipment

OEM overview of mining trucks, rope shovels, excavators, blasthole drills, dozers and related systems.

Metso — Feeders

OEM explanation of apron, belt, grizzly, pan and other feeders used to regulate material transfer.

Technical note: Capacities, train consists, stockyard layouts and machine arrangements vary. Use current OEM manuals, engineering drawings, approved procedures and site requirements for operational or maintenance decisions.

Pilbara iron ore.From pit to port.