All posts by Daniel Gleeson

Pronto and Komatsu to demo autonomous haulage tech at Heidelberg’s Lake Bridgeport quarry

Automation, Mine operation news, Mining services, , , , ,

Pronto’s Autonomous Haulage System (AHS) is set to be deployed at Heidelberg Materials North America’s Lake Bridgeport quarry in Texas, USA, following a successful pilot of the technology with Heidelberg in 2023.

The pilot in question was conducted in partnership with Komatsu North America, with the next phase also set to be on a Komatsu platform to include the integration of Komatsu Smart Quarry technologies. The latter technologies will enable enhanced data collection and analysis, as well as improved safety and productivity, according to Pronto.

A Silicon Valley-based autonomy pioneer, Pronto has designed its AHS to be the simplest, fastest to deploy, easiest to use, and most cost-effective solution in the market. It has been deployed in multiple sites across the world. It leverages advanced sensors, cameras and artificial intelligence to autonomously operate haul trucks in complex and dynamic environments.

Last year, Pronto announced a partnership with RAICO SA, a leading mining and forestry equipment sales and rental services provider in Chile, to scale mining and forestry autonomy in the country, while the company has also worked extensively with Bell on integrating the technology into its trucks.

Pronto said: “Pronto’s AHS is the industry’s most cost-effective solution to addressing the challenge of recruiting skilled operatives, while also increasing the utilisation of haul truck assets.”

DDD Group expands screening capacity with Sovatec buy

Comminution of minerals, Mineral processing, Mining equipment, Mining mergers and acquisitions, , ,

DDD Group, based in North Rhine-Westphalia, Germany, has taken over the business activities of the Italian company Sovatec s.r.l, expanding its wire and polyurethane screens capacity.

The new DDD subsidiary, headquartered in Stazzano (Piedmont), has been producing high-quality wire and polyurethane screens for various industries and applications, particularly for the separation of mining and quarrying products, since it was founded in 1973.

In addition to the significant increase in capacity in the production of wire screens, DDD Group is expecting to leverage synergies and expand its own product range through the integration of polyurethane screens.

The “Sovatec” name will be retained, as will the current 50 employees, all of whom will continue to be employed under the new management. Within the group, Sovatec will act as a “Center of Excellence” for heavy-duty screens in the future.

Paul Tüshaus, Managing Director of Dorstener Drahtwerke, sees the acquisition of Sovatec as an investment in the future of all the companies in the group: “With the subsidiaries MSD, CES, MDC and Sovatec, DDD Group is advancing to become one of the most important global suppliers for the screening industry. In the future, we will be able to supply our customers even faster and more comprehensively. At the same time, the expansion of our portfolio will make us more resistant and increase our technical expertise, which we want to bring to the market in the form of technical innovations.”

Rio Tinto and Aymium to investigate renewable metallurgical biocarbon production

Energy minerals, Sustainable mining, , , , , , , , , , , ,

Rio Tinto and Aymium have formed a new joint venture named Évolys Québec Inc to, they say, manufacture a renewable metallurgical biocarbon product to reduce carbon emissions in large scale industrial processes.

This biocarbon, sourced from biomass residues, offers an alternative for anthracite currently used in ilmenite smelting processes at Rio Tinto’s metallurgical complex in Sorel-Tracy, Canada.

The joint venture will be established on the site of a former pulp and paper mill in Thurso, Québec. The Government of Québec selected Rio Tinto and Aymium to jointly revitalise these assets.

The proposed facility will use Aymium’s proprietary technology to locally produce high-quality biocarbon – a raw material in high demand, essential to fulfilling Rio Tinto’s commitments to decarbonisation. Rio Tinto has already observed promising results with this technology through the use of materials produced by Aymium at its metallurgical complex in Sorel-Tracy.

Rio Tinto Iron and Titanium (RTIT) and Diamonds Managing Director, Sophie Bergeron, said: “Decarbonisation is at the core of Rio Tinto’s strategy, and the Évolys joint venture provides us with a unique opportunity to produce local biocarbon, thereby reducing the carbon footprint of our Québec operations.

“We are pleased to be working with the Government of Québec to give a second life to the former Fortress site in Thurso and look forward to collaborating with local communities and our partner, Aymium, to develop a project that will not only benefit the environment but also reinvigorate the regional economy.”

Aymium CEO, James Mennell, added: “It is a fantastic opportunity for Aymium to expand our partnership with Rio Tinto through Évolys and develop this new project in Québec in addition to our current developments in the United States. Aymium is actively offering their products to several customers in Canada, and we see a great potential to expand the usage of biocarbon across many industries.”

Québec Minister of Economy, Innovation and Energy; Minister for Regional Economic Development; and Minister for the Metropolis and the Montreal Region, Pierre Fitzgibbon, said: “The Évolys Québec project will enable a sustainable revival of the former Fortress site. It’s a new beginning with a technology that both decarbonizes our economy and adds value to the region’s forest residues.

Évolys will lease the portion of the pulp and paper mill that will be revitalised. Both partners are committed to advancing products and technologies that go beyond the conventional use of biocarbon as a substitute for fossil fuels, Rio says.

In 2022, Rio Tinto formed a strategic partnership with Aymium. In 2023, Rio Tinto further bolstered its collaboration with Aymium through an additional investment. This funding followed a thorough trial of Aymium’s biocarbon as a potential alternative energy source at Rio Tinto’s metallurgical complex in Sorel-Tracy.

The pulp and paper mill, formerly owned by Fortress, is located in the municipalities of Thurso and Lochaber-Partie-Ouest and closed in 2019. The Government of Québec appointed Deloitte to manage the takeover file and to evaluate the proposals received from candidates interested in taking over the facilities, including biomass already available.

Major Drilling eyes unique AI-powered offering with DGI/KORE partnership

Mineral exploration, Mining mergers and acquisitions, Mining services, Mining software, , , , , , , , , ,

Major Drilling Group International Inc has announced a new partnership with downhole technology company DGI Geoscience Inc (DGI) and its affiliate company, artificial intelligence (AI)-powered core logging tech innovator, KORE GeoSystems Inc, that, it says, positions Major Drilling at the forefront of AI advancements in the drilling industry.

The combination of Major Drilling’s fleet, skilled drilling teams and its TrailBlazer Rock5 technology, with KORE’s digital rock analysis platform, provides the opportunity to deliver valuable data to customers, Major Drilling says. This is complemented by the borehole data acquisition services offered by DGI to provide a unique service offering in the industry today, it added.

Denis Larocque, President and CEO of Major Drilling, said: “This alliance is a continuation of Major Drilling’s progression in drilling innovation, and also part of our growth strategy as we invest in the future of mining.”

Marc Landry, newly appointed Chief Technology Officer, added: “As our traditional drilling services evolve, the full complement of DGI/KORE products and services alongside Major Drilling’s developing technologies will see our service offering transform and help our customers during this mining upcycle. For example, KORE uses AI to automate processing of core logging, greatly reducing time and improving consistency, enabling our customers to get real-time, remote access to results across the globe.”

Under the agreement, Major Drilling will acquire an approximate 40% interest in DGI/KORE for a C$15 million ($10.8 million) cash consideration. As part of this investment, Canadian Shield Capital, a Toronto-based growth equity firm, is selling its interest in DGI/KORE.

The value of this transaction for Major Drilling resides in adding geological solutions to its specialised drilling, providing a unique service offering that encompasses the latest advanced technology, it says. This investment supports the company’s efforts to position itself as the contractor of choice to the drilling industry by providing solutions to help accelerate customers’ projects with timely and quality data contributing to their geological model.

Vince Gerrie, President and CEO of KORE, said: “We are thrilled to support Major Drilling with KORE’s cutting-edge SPECTOR integrated technology suite. Our transformative AI powered digital core logging platform significantly increases productivity, consistency and enhances data insights for our customers.”

Chris Drielsma, President and CEO of DGI, said: “Through our powerful new partnership with Major Drilling, the mining sector can access turnkey geological, geophysical and geotechnical drillside orebody intelligence solutions. We are very excited to be part of this evolution of drill performance, helping maximise the value from drilling through our geoscience solutions.”

ABB identifies mine hoist maintenance strategy to boost annual production

Mine shafts and equipment, Mining equipment, Mining services, ,

ABB has completed a study to benchmark current hoisting maintenance strategies, reporting that, on average, mining companies have the potential to achieve more than a month of additional production time annually by following recommended predictive maintenance strategies.

The benchmark report includes inputs from mining companies across six regions and eight different industry sectors including diamonds, gold, copper and potash, to better understand the state of hoist maintenance strategies around the world. Collaborating with customers, ABB reviewed every key aspect of the hoist system. The results highlighted that mining companies using reactive maintenance could make up a gap of around 15% in availability compared with those already following more proactive approaches.

As ore grades in established sites become depleted while demand for resources grows, the industry is shifting to deeper mining to reach these critical resources. Mine hoists offer the most efficient way to transport heavy loads of ore from the depths, and therefore must operate at the highest possible levels of reliability and productivity, ABB says. The company identified a need for greater standardisation and insight regarding optimal maintenance strategies to help its customers keep mine hoists running.

The value of predictive maintenance was reinforced through this project. Those faced with the highest levels of availability loss had, on average, dedicated less of their maintenance strategy to proactive approach versus reactive (75% and 25%, retrospectively). While periodic maintenance has been implemented across hoist systems, continuous monitoring and assessment were much further behind. Of those surveyed, only 16% had applied continuous predictive monitoring to their mechanical systems, ABB says.

Using these insights, ABB devised its ‘World Class Maintenance Standard’ for hoists. While every mine hoist maintenance system should be designed for the specific requirements of individual hoists, the standard aims to provide mining companies with a baseline for devising the optimal solution for hoist longevity, ABB says. The standard recommends that 90% of maintenance strategy be focused on predictive maintenance to achieve the highest availability levels.

John Manuell, Global Service Manager for Hoisting, ABB Process Industries, says: “Hoists are one of the most expensive and vital assets within a mining operation, so keeping them running optimally is crucial for an effective mining operation. Without a thorough maintenance program, replacing these systems can be costly, risky and time-consuming. We designed the World Class Maintenance Standard to give users a benchmark to design the right program for their assets and reinforce the value, which, when fully utilised, can keep hoists running for several decades. From here, we are devising a framework to simplify maintenance services, which will be available to customers later this year.”

Epiroc Scooptrams to receive the Wearpact GET treatment

Equipment maintenance, Mining equipment, , , , , ,

Epiroc Scooptram underground loaders can now be equipped with CR Powered by Epiroc Wearpact ground engagement tools (GET) option as factory-fit, the OEM says, offering extended wear life.

Wearpact GET is a premium edge lip built feature on the bucket, suitable for any material and loading conditions, according to the company. This integration follows CR, an Australian provider of advanced GET and digital solutions, joining Epiroc in February 2023.

Epiroc says its high performance underground loaders are designed with safety, reliability, serviceability, productivity and operator comfort in mind. Customers can augment these benefits by adding the Wearpact feature to the Scooptram loader for hard-rock underground mining applications.

The Wearpact GET is a safe, high-quality, bolt-on GET system. The low profile, self-sharpening edge ensures optimal penetration and clean engagement at every pass, ensuring up to 40% longer wear life, according to the company.

Erik Gert, Global Product Manager – Large Loaders, Underground division, Epiroc, said: “The Scooptram underground loaders are productive machines and one of the most important parts that keeps productivity ongoing is a well functioning bucket. By adding the Wearpact GET option on a standard machine, customers will enhance their loader bucket with a longer life. This means less time spent in the repair shop and less downtime for the Scooptram loader, leading to a continuous productivity cycle.”

Hannah Sabih, CR Powered by Epiroc GM Underground, added: “Epiroc’s loaders are already market-leading, and now buckets will come with our Wearpact GET for the best possible performance. The retainer is engaged from the top of the lip, enabling safer installation and change out, as well as reliable retention. The low profile ensures maximum wear life of the GET, reducing maintenance downtime and improving machine availability.”

The GET is already available for Scooptram ST18 and Scooptram ST14 loaders in the Smart and Green series, with Scooptram ST7 and Scooptram ST1030 options available in 2025, the company says.

TAKRAF India wins bucketwheel excavator maintenance work from India’s NLCIL

Bulk handling, Equipment maintenance, Mining equipment, Mining services,

TAKRAF India says NLC India Limited (NLCIL) recently awarded the company with four new orders for the revamping and maintenance of various bucketwheel excavators (BWEs).

NLCIL, incorporated in 1956, is a public sector company of the Government of India and one of the country’s largest lignite and power producers. As a Navratna entity, NLCIL has also been bestowed a prestigious status given to only a few select Indian Public Sector Undertakings, and as such has enhanced financial autonomy.

NLCIL operates three open-pit mines with a total installed capacity of 28.5 Mt/y at Neyveli, Tamilnadu, India.

Two of the orders awarded to TAKRAF India concern the major revamping of both mechanical and electrical portions of one 1,400 litre (1.4 cu.m) BWE and two 700 litre (0.7 cu.m) BWEs for other OEM supplied equipment in NLCIL’s mines.

The principal purpose of the revamping orders is to extend the operational life of the equipment.

The remaining two orders concern two maintenance contracts (mechanical and electrical respectively) with the equipment details as follows:

  • Two 1,400 litre BWEs originally supplied by TAKRAF; and
  • Three 1,400 litre BWEs originally supplied by another OEM.

The main purpose of the maintenance order is to reduce downtime and ensure equipment availability.

Gopal Kalyanakrishnan, Managing Director of TAKRAF India, said: “Our collaboration with NLCIL dates back more than 30 years and the newly awarded contracts are indicative of the trusting relationship between NLCIL and TAKRAF India. I sincerely thank all colleagues for their hard work and efforts. We look forward to commissioning the orders and continuing to work together to best support the needs of NLCIL in the future.”

The successful and ongoing collaboration between NLCIL and TAKRAF India dates back to the 1980s. Since then, several orders have been successfully commissioned. The orders range from the supply of various 700 and 1,400 litre BWEs, spreaders (capacity ranging from 11,000 t/h to 20,000 t/h), a mobile transfer conveyor, various stockyard equipment to similar revamping orders that TAKRAF India commissioned in 2018 and 2021.

Kovatera to launch new BEV model line at MINExpo 2024

Environmental, Mining equipment, Mining events, Mining services, Sustainable mining

Kovatera Inc is to launch the Battery Electric Vehicle (BEV) model line at MINExpo 2024 in a move that, it says, will revolutionise the mining industry with its advanced technology and commitment to sustainability.

The Canada-based company specialises in designing and manufacturing versatile mining utility vehicles for the underground mining sector. It also prides itself on comprehensive after-sales service and customer support.

Established in 1999, Kovatera has expanded significantly and relocated to a state-of-the-art 35,000 sq.ft (3,252 sq.m) manufacturing facility in 2012. It currently offers two main product lines: the KT Series line of heavy-duty underground trucks on a 13,000 lb (5,897 kg) platform and the KM Series of utility vehicles (a KM200 pictured) resembling heavy-duty tractors, which serve as Kovatera’s flagship product.

The BEVs to be showcased at MINExpo offer superior performance, efficiency and environmental benefits, according to Kovatera, setting a new standard for mining equipment globally.

“BEVs provide several advantages over traditional diesel equipment, including zero emissions, significantly improving air quality and safety in confined spaces,” Kovatera says. “They operate quietly and with reduced heat generation, creating a more conducive and productive work environment.”

It added: “This initiative underscores Kovatera’s dedication to sustainable practices and responsible resource extraction. It aims to establish new benchmarks in eco-friendly mining solutions. Each BEV model can be customised to match its diesel counterparts’ functionality, ensuring seamless integration into existing mining operations.”

Kovatera says the company will showcase its KT300e battery-electric utility vehicle and its BEV lineup in Las Vegas, September 24-26.

Zenith Energy to help Lynas move to gas-firmed hybrid renewable power station at Mt Weld

Energy minerals, Environmental, Mining services, Power supply for mines, Sustainable mining, , , ,

Zenith Energy says it has signed contracts with Lynas Rare Earths Ltd to design, build, own, operate and maintain a hybrid power station at Lynas’ Mt Weld mine, 35 km southeast of Laverton, Western Australia.

The Mt Weld hybrid power station will include a 24 MW Wind Farm, 7 MW solar PV farm and a 12 MW/12 MWh battery energy storage system (BESS). This renewable facility will be supported by a 17 MW high efficiency gas fired power station, with 5 MW of standby diesel generation, Zenith explained. The total installed capacity of the Mt Weld Power Station upon completion will be approximately 65 MW.

The term of the PPA is 15 years, commencing from commercial operation of the wind farm, which is scheduled to occur in 2026. The diesel and gas facilities are scheduled to be completed in the first half of 2025, with solar and BESS to be installed progressively, and full operation expected in 2026.

The Mt Weld hybrid power station has been designed to run “engine-off” during periods of high renewable energy production and achieve an average annual renewable energy percentage of up to approximately 70%.

Zenith calls itself a leading independent power provider at the forefront of the transition to renewable energy in the mining sector. It is currently contracted to operate 15 separate remote generation power facilities, with a capacity of more than 650 MW across Western Australia and the Northern Territory.

Zenith has already commenced early construction works at the Mt Weld site, having entered into Preliminary and Early Works Agreements with Lynas in 2023.

Zenith CEO and Managing Director, Hamish Moffat, said: “As a leading provider of sustainable energy solutions to the Australian resources market, Zenith is pleased to be working with Lynas, the world’s only significant producer of separated rare earth materials outside of China, on the high renewable energy fraction hybrid power solution to their Mt Weld operations. The signing of the Mt Weld hybrid power station PPA represents a significant milestone for Zenith Energy, with our contracted wind capacity now exceeding 100 MW. Zenith look forward to enabling Lynas to deliver on their productivity and decarbonisation objectives.”.

Lynas CEO and Managing Director, Amanda Lacaze, added: “Lynas produces materials used in the manufacture of 21st Century technologies and we look forward to working with Zenith Energy as it delivers a 21st Century power solution for Mt Weld. As part of our commitment to reducing GHG emissions and progressively transitioning to cleaner energy sources, the existing Mt Weld diesel power plant will be decommissioned as soon as the thermal (gas) power station is completed. Moving away from the legacy diesel power plant to a gas-firmed hybrid renewable power station is a significant step in our GHG emissions reduction plan. Pleasingly, our commitment to renewable energy sources also offers a lower unit cost of power compared to a thermal-only power solution.”

Bortana-South32

The EMC ready to hand over the baton in mining’s decarbonisation race

Environmental, Mining equipment, Mining services, Power supply for mines, Sustainable mining, , , , , , , , ,

The Electric Mine Consortium is not Graeme Stanway’s first innovation rodeo. As the founder of State of Play, a global research platform in natural resources, energy and infrastructure, which also publishes the largest survey on strategy and innovation in mining, he has engaged with many individual and groups of companies looking to spur on mining innovation.

State of Play is the custodian of the EMC and is responsible for bringing almost 20 companies all focused on accelerating progress towards the fully electrified zero CO2 and zero particulates mine together.

Stanway, as Chair of the EMC, has had a front row seat for this journey over the last four years, and was aware the time would come to ‘wrap up’ the consortium’s proceedings – expected on September 30.

“We always knew it was a fixed term,” he told IM. “To be honest, I thought it would be sooner. When we first started, a three-year engagement period sounded about right if things worked well. There is only so long you can keep a core group of companies and people on such an intense innovation journey.”

Four years might sound short – according to Stanway and State of Play’s data it’s the average period that business’ plan their innovation journeys for – but the electrification landscape has changed substantially in that period.

“When we started there was no significant electrification simulation capability, not really any specialised consulting, limited engineering services,” he said. “Now, you can go out and get a study and people are already building mines that are 90% powered off renewables. We also have metrics being introduced that could have a noticeable impact on the way projects go through FIDs.

“The large production equipment is the one thing that is left, but people now know the pathways they need to follow. They would acquire this electric equipment tomorrow if the incentives were there. This would accelerate equipment supply and bring capital costs down, creating a virtuous cycle of adoption.”

He can reference a white paper released by EMC members Perenti and IGO, along with ABB, in May, as an example of how an all-electric mine is possible. It can also be argued that the Australian underground mining sector has caught up and, in some respects, overtaken its rivals in Canada when it comes to electrification. This includes its leading status as an off-grid renewable energy pioneer, as well as hosting the first trial of the world’s biggest underground battery-electric truck at Sunrise Dam in Western Australia’s Goldfields region.

The numbers also back this up, with the EMC starting with five mining companies and getting to 13 in the end. The EMC has also overseen more than 15 non-commercial engagement forums with OEMs and CEOs.

Graeme Stanway (left) moderating a panel session at The Electric Mine 2024, in Perth, in May

Yet, the EMC’s influence goes beyond this, according to Stanway.

Major and mid-tier Canadian gold miners – Agnico Eagle Mines and New Gold, for example – have generously provided valuable input to specific EMC teams, while a significant amount of suppliers engaged with and learnt from that core group of 13 mining companies.

“Many of the small suppliers used this experience as a product and business development opportunity,” Stanway says. “This also benefitted the mining companies that were able to realise new solutions or services in the marketplace.”

One area that Stanway reflects on as lagging his initial expectations was getting trials off the ground.

The EMC has seen over 70 equipment trials across all fleet types, supplemented by an industry first data sharing platform. This has led to accelerated equipment adoption, but Stanway still thinks there could have been more, particularly with larger production equipment.

“I underestimated how quickly trials would get off the ground,” he said. “Even after everyone’s aspirations were laid out and there was a broad understanding of the technology at hand and the opportunities to be had with these, the momentum slowed in terms of moving to trial and adoption stages.”

He also laments that the initial push to accelerate progress towards the fully electrified zero CO2 and zero particulates mine did not result in an overarching commitment to fully remove diesel particulate matter (DPM) from the underground mining sector.

At The Electric Mine 2024 in May, Chris Carr, Acting COO of IGO, said stricter standards for airborne DPM emissions in Australia and elsewhere would “push electrification a lot harder”.

MasterMined Innovation CEO, Tony Sprague, added to this, telling The Electric Mine 2024 that DPM, and specifically nano-DPM, was “the elephant in the room” and the “real driver of getting diesel out of the underground mine and to achieve the electric mine”. He explained: “There is a new [emission] target that is coming from Safe Work Australia that is not far away. When it’s going to land we’re not too sure, but if it does land it’s going to be very problematic for the industry.”

Stanway said some of this reticence could be tied to the “portfolio mentality” of some of the larger mining companies with legacy assets, and a lack of acknowledgement from leaders on the health and safety risks that come with going underground at existing operations.

“The one thing that hasn’t happened with electrification is the wholesale change in leadership intent to shift as fast as possible,” Stanway says. “A lot of these targets, particularly production equipment conversion, are set to beyond 2030 which is outside of the purview of what gets the attention of the current crop of CEOs.

“I think it is the leadership intent that is needed as much as the technology development in this space. Once the leadership intent ‘flips’, the momentum will step up another gear.”

Progress towards the fully electrified zero CO2 and zero particulates mine has still been vast, he acknowledged, saying that the investment climate and mentality has shifted to help fund new technology adoption.

“People are now open to spending more money in areas that come with uncertain outcomes,” he says, referencing investments in artificial intelligence (AI). “In that regard, it’s not just the quantum of money that has increased, it’s also the willingness to spend money in areas that they wouldn’t have before.”

This shift will benefit other complementary areas of mine electrification and decarbonisation – such as automation, AI and energy sourcing.

Yet, there is no obvious next consortium opportunity on the horizon, according to Stanway.

“Electrification was that rare beast in that it was decarbonisation driven so wasn’t competitive at the time we started,” he said. “These types of opportunities only come around once in a while. In that regard, I’m glad we were able to make such an impact in a short space of time, and we’re able to hand the baton onto the consortium members and the broader industry to advance these areas further.”