All posts by Paul Moore

SANY India starts production of SKT105E battery mining truck in Bharat

Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Sustainable mining

SANY India, part of China’s SANY Group, the global manufacturer of construction and mining equipment, has unveiled the SKT105E Electric Dump Truck, the first of its kind to be locally manufactured in India. It said “this groundbreaking addition to SANY’s portfolio marks a significant milestone in the nation’s mining industry.” The unveiling ceremony, held at SANY India’s state of the art factory in Bharat, was attended by Deepak Garg, Vice Chairman & Managing Director of SANY India & South Asia, along with guests and industry professionals.

The SKT105E electric dump truck SANY India represents a new era in mining technology, combining local expertise with global innovation. “Designed to meet the rigorous demands of open-cast mining operations, this fully electric off-highway dump truck boasts exceptional energy efficiency and cost-effectiveness. With an impressive payload capacity of 70 tonnes, it stands as a powerhouse asset for mining enterprises across the nation.”

The SKT105E has a high density lithium iron phosphate battery pack with battery capacity of 396 kWh and a charging time of about 1 hour (25% to 95% SOC). The battery pack is made of a customised extruded aluminium casing, which SANY says greatly improves the vibration-proof performance.

Garg, in his address at the launch event, emphasised the significance of the SKT105E in driving sustainable mining practices in India. He stated, “The SKT105E marks a historic moment for Sany India and the Indian mining industry. By localising production and introducing cutting-edge electric technology, we are not only enhancing operational efficiency but also contributing to the nation’s vision of sustainable development.”

SANY India says the SKT105E’s innovative design, coupled with its zero-emission operation, makes it an environmentally friendly solution for mining sites. Its advanced electric propulsion system ensures optimal performance while reducing carbon footprint, thereby aligning with India’s commitment to combat climate change.

Furthermore, Garg highlighted SANY India’s dedication to fostering local manufacturing capabilities and empowering the nation’s economy. He stated: “The SKT105E is a testament to Sany India’s commitment to ‘Make in India’ initiative. By manufacturing locally, we not only create job opportunities but also strengthen the indigenous manufacturing ecosystem.”

The launch event was attended by SANY India’s senior management, staff, and workers, alongside esteemed guests and industry leaders. Key figures were there such as Sauro Ray, Head of the Mining Business Unit; Sanjay Saxena, COO of SANY India; Daryl Lean, VP of SANY Group; Sunil More, Director of Factory Operations; and Sandeep Laroiya, Senior VP of Customer Support & R&D.

Vertex Minerals to expedite gold production with acquisition of Gekko plant

Mineral processing, Mining services, Precious metals

Vertex Minerals Ltd has finalised its acquisition of a Gekko gold gravity processing plant in a strategic move aimed at expediting gold production and optimising operational efficiency. The plant, originally located at the Morningstar Gold Mine in Victoria, will now be relocated to Vertex’s Hill End Gold Project.

Renowned for its modular design and high throughput capacity, the Gekko plant presents an attractive proposition for Vertex to strengthen its gold processing capabilities. With features such as PLC-operated sequenced stop/start capability, remote monitoring, and full spare parts support, the plant is set to enhance operational efficiency while keeping operating costs in check.

Key benefits of the Gekko processing plant include a substantially higher throughput and potential for further upgrades; streamlined operation requiring only two operators; and comprehensive monitoring capabilities covering density, mass flows, and sampling. It has enhanced security measures for gold processing plus full support from Gekko Systems. Plus it features an ergonomic design and state-of-the-art safety systems, with lower power usage contributing to sustainability goals. Gekko says its team will collaborate with Vertex Minerals to help make the project a success.

Macmahon agrees mobile equipment sale at Dawson South

Bulk handling, Coal technology, Equipment maintenance, Mining consumables, Mining equipment

Macmahon has executed an equipment sale agreement pursuant to which Macmahon has agreed to sell a substantial portion of its mobile equipment fleet at the Dawson South project. The Dawson South project is located in Queensland and forms part of the Dawson Mine, being an open cut steel making coal mine.

The mobile equipment was sold at market rates which were at or above book value, for cash consideration, and is expected to result in net cash inflows of approximately A$44 million to be collected during FY24 and FY25.

Macmahon is currently the mining contractor at the Dawson South project with the existing contract due to end on June 30,  2024. The parties are in negotiations on the terms of the new contract, which is expected to commence on or before July 1, 2024. Macmahon expects to retain its incumbent workforce of approximately 210 employees.

No new capital expenditure is expected over the new term due to the divestment of a large portion of the Dawson South equipment fleet, which will be utilised on the project. Macmahon says it “is focussed on its strategy of improving the cash-backed return on average capital employed in the business and is pleased to deliver a solution that meets the client’s needs, is in line with the company’s strategy, and improves sustainable free cash flow generation.”

Macmahon reaffirms that it expects to deliver FY24 revenue of between A$1.8 billion to A$1.9 billion and underlying EBIT(A) of A$130 million to A$140 million. Managing Director and Chief Executive Officer Michael Finnegan said: “I’m pleased we have been able to sell a substantial portion of the Dawson South fleet and progress Macmahon’s capital light strategy to improve ROACE performance – where our target was recently increased from 15% to 20%. I would like to thank the Macmahon team who have worked closely with our client to deliver this solution.”

New equipment additions and mining progress at key MinRes operations

Bulk handling, High tech minerals, Mineral commodities, Mineral project development, Mining equipment, Mining services, Steel and iron ore, Sustainable mining

Mineral Resources Ltd has been making progress on a number of fronts across its operations and projects. At its Ken’s Bore surface iron ore minesite, part of its Onslow Iron project, MinRes has welcomed a new Komatsu hybrid electric wheel loader to its growing fleet – the first delivered in Western Australia. It says this electric loader comes with host of benefits – including substantially less carbon emissions compared to mechanical drives – and features a fully regenerative SR hybrid drive system.

It has also commenced preliminary development works to support underground future mining at the Mt Marion lithium operation, it says signalling an exciting new chapter for the world-class mine. Mt Marion is located approximately 40 km southwest of Kalgoorlie in the Goldfields region of Western Australia.

The operation is jointly owned by MinRes (50%) and one of the world’s largest lithium hydroxide producers, Jiangxi Ganfeng Lithium Co Ltd (50%). During Q2 FY24, a diamond drilling program significantly increased confidence in the underground resource in the mine’s upper North Pit. Drilling confirmed the North Pit underground ore body is vertically dipping with a strike length of 500 m and a thickness of 30 to 60 m. Pegmatites were intercepted around 1.2 km below surface.

MinRes also recently announced the underground Mineral Resource at Mt Marion had doubled to 19.3 Mt, with a full underground study targeted for completion by mid-2024. A development contract has already been awarded to locally based specialist underground development contractor, Develop Global, for the establishment of an exploration decline at Mt Marion.

Works include establishment of surface facilities supporting underground mining activity, installation of underground mine infrastructure, excavating underground capital development and exploration drill platforms, and obtaining geological and operational data to support future mining activities.

A key project milestone was recently achieved through the successful first blast fired for the decline box-cut, with significant earthworks now under way to support a target depth of 350 m within the next 18 months. During this time, MinRes aims to complete an additional 80,000 m of reverse circulation and diamond drilling targeting the underground resource below the mine’s Central and C2 pits to further map and define the underground potential.

Chief Executive Lithium Joshua Thurlow said the start of preliminary underground works marked an exciting new phase for one of the world’s few operating hard rock lithium mines. “MinRes has been managing all open pit mining operations at Mt Marion since 2016 and this site is a key asset in our growing world-class lithium portfolio,” Thurlow said. “Recent underground exploration success has confirmed that we’ve barely scratched the surface of this mine’s potential. Having now doubled the underground Mineral Resource, we’re pushing ahead with building the necessary infrastructure and technical expertise to transition Mt Marion into an open pit and underground mining operation.”

MinRes also owns and operates the Bald Hill mine in the Goldfields and operates the Wodgina lithium operation in the Pilbara region under a 50/50 joint venture with Albemarle Corporation.

 

 

Thiess gets six year contract extension at BHP’s Mount Arthur South Operations

Bulk handling, Coal technology, Equipment maintenance, Mineral project development, Mining consumables, Mining equipment, Mining maintenance, Mining safety

Contract mining and mining services leader Thiess has been awarded a six-year contract extension with BHP for the Mount Arthur South Operations coal mine in New South Wales, Australia. With revenue of A$1.9 billion, this contract sees Thiess continuing to provide mining services at the Mount Arthur South mine, operating and maintaining mining equipment to support BHP’s production requirements, and working with BHP and the local community towards the planned mine closure.

Thiess Group Executive Chair and CEO Michael Wright said: “This contract extension acknowledges Thiess’ strong safety record and ongoing operational performance, and builds on the longstanding relationship between Thiess and BHP that started more than 30 years ago. We are strongly aligned with BHP in our commitment to diversity in our workforce, as demonstrated by our award winning MASITE program, which has resulted in significant increases in the number of our local Indigenous and female employees.”

Thiess Group Executive Australia East Rae O’Brien said: “Thiess has played a key part in supporting the local economy and community of the Hunter Valley region, dating back 80 years, and we are proud to be given the opportunity to continue our presence in the region alongside BHP.”

Suncor says Fort Hills to get new super size Komatsu PC9000 excavator

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

As the market stands today, the largest available big surface mining hydraulic excavators are generally in the 800 t class – the Komatsu PC8000 (shown in the attached photo), Hitachi EX8000 and Liebherr R 9800. Caterpillar still in theory has the 1,000 t 6090 FS face shovel machine – whose design dates from O&K days in Dortmund (which became Terex O&K then briefly was part of Bucyrus) before its  acquisition by Caterpillar in 2011. But this unit (then it was the RH400) has not been built in some years and the 6090 is no longer listed on the Caterpillar website as it is undergoing numerous upgrades to bring it into line with Cat’s next generation of shovels which has already been done with the 6060 FS and BH (backhoe) models. Back in 2012 Cat also built a 1,270 t model, the 6120B H FS, with hybrid technology, but this project was shelved.

Now it seems there is a new super sized excavator in the market – the Komatsu PC9000. In a recent news story, oil sands miner Suncor stated via Jason Wyman, General Manager for the Mine and Tailings team at Fort Hills, that the mine’s fleet of trucks and shovels that moves approximately 300 Mt of material every year is growing including through this new shovel model.

“The decision to invest in new equipment, specifically 23 Komatsu 980 haul trucks and one hydraulic shovel, was introduced from the annual mine plan,” explains Wyman. “The mine plan outlines production targets and operational strategies, ultimately determining the required equipment. As Fort Hills grew, trucks and shovels were initially purchased in 2014; however, as volumes increased and haul distances grew, rental equipment was secured to meet business plan commitments. This rental equipment comes at a significant premium, affecting the mine’s overall cost structure.”

He adds: “Overall, we have purchased 55 new trucks for the region, with 23 allocated to our Fort Hills site, and 32 to Base Plant. The purchases of the haul trucks and shovels will reduce the mine’s operating cost.”

At Fort Hills, the new trucks and hydraulic shovel he says will be gradually rolled out throughout 2024, including the mentioned Komatsu PC9000, which he describes as the largest hydraulic shovel in the world, arriving towards the end of the year.

”The new equipment will reinforce a commitment to Fort Hills’ competitiveness,” says Wyman. Along with the new fleet come ambitious goals for Fort Hills like driving down the cost per tonne, he adds.

”Given the substantial volume of material moved annually, the new equipment will position Fort Hills as a best-in-class operator, surpassing the limitations of the previous rental strategy. The ownership of equipment allows for more control over maintenance programs, increasing equipment availability and overall efficiency”

Fort Hills’ investment in trucks and shovels he says will help Suncor achieve its goal of being Canada’s leading energy provider by enhancing operational efficiency and reducing costs. “As the new equipment is gradually integrated into the mine’s operations, the team remains optimistic about the positive impact it will have on Fort Hills’ long-term success.”

Komatsu would not comment officially to IM but by its existing nomenclature a PC9000 would be a 900 t machine; and with the 6090 no longer listed, that would indeed make it the world’s largest available hydraulic shovel today. As all of Komatsu’s other shovels are available  in both backhoe and face shovel as well as diesel or AC electric cable power, this is likely to be the case with the PC9000 as well. As the diesel PC8000 has two Cummins QSK60 engines the diesel model is likely to be equipped with dual QSK78 engines.

First Mode to accelerate mining truck decarbonisation retrofit adoption with Mitsui collaboration

Bulk handling, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Sustainable mining

First Mode, the pioneering developer and manufacturer of decarbonisation products for heavy industry, has announced a strategic alliance with Mitsui & Co Ltd, the international trading company and investment group with extensive interests in the mining industry, to accelerate heavy industry’s adoption of low-carbon and zero-emissions product solutions at scale.

First Mode says its considerable expertise in powertrain systems electrification and hydrogen technologies, coupled with Mitsui’s global business network, will uniquely equip the alliance to explore new business opportunities that catalyse the integration of First Mode’s Path to Zero™ product line into previously hard-to-abate sectors like mining.

“We are honoured to enter into a strategic alliance with Mitsui to support and help scale our solutions that are proven to reduce heavy industry’s polluting outputs. The collaboration underscores our shared commitment to sustainability and the critical role of partnerships when addressing complex global challenges through innovation,” said Julian Soles, CEO of First Mode.

In mining, a typical heavy-haul truck burns about 1 million litres of diesel fuel per year and remains in continuous operation for 10-15 years. Across First Mode’s customer market, over 13,000 of these trucks are in global operation, releasing 35 million metric tons of carbon dioxide annually – the equivalent emissions of 8 million passenger cars per year.

To help the sector achieve its goal of 85-100% emissions reduction by 2050, First Mode’s Path to Zero™ product line begins with a low-risk hybrid electric vehicle (HEV) retrofit that requires no infrastructure changes and uses regenerative braking to decrease truck fuel use and carbon emissions by up to 25%. From there, the HEV’s interoperable ‘feed forward’ design enables mining companies to complete their fleet conversion to zero-emissions using First Mode’s full battery or next-generation hydrogen fuel cell EV drivetrains at a pace and timeline that they control.

“Mitsui recognises First Mode as a pioneer in decarbonisation solutions for the mining sector, particularly in the replacement of diesel fuel. Our relationship with them dates back to 2020, when we first explored the possibility of testing their early-stage fuel cell innovation at one of our mine sites. As such, we are eager to support their growth by leveraging our presence in the mining, mobility, and other heavy industries. Moreover, we will utilise our capabilities in renewable energy, green hydrogen, and hydrogen-derived synthetic fuels, along with our extensive network and investments in the clean energy sector, which includes batteries and hydrogen-related solutions like storage tanks. These efforts align with our commitment to a sustainable future,” said Ken Ito, General Manager of Mitsui’s Coal & Carbon Solution Division.

First Mode has been working in the mining sector since 2018, with successes that include developing the world’s first and largest hydrogen fuel cell electric truck in partnership with Anglo American’s nuGen™ zero emissions technology program. In 2023, following a capital investment and supply agreement with Anglo American that made Anglo American not only the majority shareholder but also a key customer, First Mode launched its Path to Zero™ product line of diesel hybrid, battery electric, and next-generation hydrogen fuel cell drivetrains.

First Mode says nothing like its Path to Zero™ product line exists in the market today because its sequential retrofit approach to decarbonisation “helps mining, rail, and other heavy industry companies safeguard their original haulage investments while also starting, progressing, and succeeding on their path to zero emissions.”

 

Bunting sells 120 ElectroMax Overband Magnets in only five years

Bulk handling, Mineral commodities, Mineral processing, Mining services

April 2024 marks five years since the launch of the ElectroMax Overband Magnet and, in that period, Bunting has built and shipped 120 units for a value exceeding £3 million. The ElectroMax Overband Magnets successfully separate ferrous metal from conveyed material in recycling plants, mines, and quarries, bulk handling terminals, and power stations.

Bunting is one of the world’s leading designers and manufacturers of magnetic separators, eddy current separators, metal detectors and electrostatic separators. The Bunting European manufacturing facilities are in Redditch, just outside Birmingham, and Berkhamsted, both in the United Kingdom.

The ElectroMax Overband Magnet uses a strong and deep electromagnetic field to lift and separate ferrous metal out of conveyed materials such as waste, mined ore, and quarried rock. Unlike other designs of electro overband magnet, the electromagnet is cooled with air rather than oil. This significantly reduces the weight and size, whilst being environmentally friendly by not using oil.

The ElectroMax Overband Magnet is 185% stronger than equivalent Permanent Overband Magnets and 25% lighter. Bunting states: “The development was in response to customers’ requests for smaller, lighter, and more compact Electro Overband Magnets without compromising separation performance. The ElectroMax is ideal for applications where space is limited or when extra separation power is required.”

In November 2020, Bunting expanded the range with the introduction of the ElectroMax-Plus Overband Magnet. This Overband operates up to 600 mm suspension height (the distance between the conveyor belt and the face of the magnet), up from 450 mm on a standard ElectroMax. At a suspension height of 500 mm, the ElectroMax-Plus is over 105% stronger (in terms of Force Index) than the equivalent ElectroMax. This incredible additional magnetic force removes small tramp ferrous metal commonly missed by permanent Overband Magnets.

Since the launch of the ElectroMax Overband Magnet in April 2019, Bunting has designed and built 120 units of varying sizes and for a diverse range of applications. Destinations include across Europe, North America, Africa, and Australasia.

The smallest ElectroMax Overband Magnet is the model EMAX 100, weighing just over 2,000 kg and suitable for conveyors with 1,000 mm wide belts. Bunting has sold multiple units for different applications including the removal of tramp ferrous metal from 400 t/h of gypsum rock at a quarry in Leicestershire, UK. At the site, the EMAX 100 was 400mm above a conveyor with a 900 mm belt width running at 2.14 m/sec.

In contrast, the EMAX-Plus 180 is the largest ElectroMax designed and built by the Redditch team. Despite the intense magnetic power, the EMAX-Plus 180 only weighs 4,900 kg, with an 1,800 mm long electromagnet mounted inside a 3,350 mm long by 1,400 mm wide frame.

Bunting has built three EMAX-Plus 180 units, with two installed at a coal terminal in Virginia, USA. The installation has the EMAX-Plus 180 magnets mounted 450 mm above a conveyor with an 1800mm wide belt travelling at the high speed of 5 m/sec. The two EMAX-Plus 180 Overbands remove tramp ferrous metal from 5,000 t/h of coal.

The third EMAX-Plus 180 is installed in an Indonesia limestone quarry. A conveyor with an 1,800 mm wide belt is transporting 200 t/h of limestone, with tramp ferrous metal being removed by the EMAX-Plus 180 suspended at 400 mm.

“Listening to our customers led to our development of the ElectroMax Overband Magnet, which has become one of our most popular magnetic separators,” explained Bunting’s European Technical Director, Adrian Coleman. “We continued developing the technology with the ElectroMax-Plus, further enhancing the magnetic power to weight and size ratio. As the demand for enhanced metal separation requirements become more widespread, an increasing number of customers are turning to the ElectroMax.”

Schlam marks milestone with delivery of 2,000th Hercules dump truck body

Bulk handling, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Sustainable mining

Western Australian mining product and services supplier Schlam has announced the commemoration of the delivery of its 2,000th Hercules dump truck body. This significant achievement it says underscores Schlam’s commitment to excellence and innovation, and to making mining equipment more productive the world over.

Last week, the company reached this milestone with the completion of ‘Hercules A2000’, marking a momentous occasion for the entire team. Staff from across the company gathered to celebrate this historic milestone and to reflect on the company’s successful journey. “It was great to see our extended team converging to celebrate an important milestone in our company history, one that they all played a part in,” said Hendrik Mueller, Managing Director of Schlam Payload Asia-Pacific. “It was also a testament to our principle of working ‘stronger together.”

The Schlam Hercules dump truck body Schlam says is renowned for its proven performance, quality and reliability, trusted by Tier 1 mining companies, mining contractors, and OEM truck suppliers worldwide. The first Hercules was manufactured in Australia in 2003. It took 17 years to reach the 1,000th milestone, with the 2,000th body being built four years later.

In that short time, Schlam has grown its global footprint, with the Hercules now operating on mine sites across six continents. “In a relatively short time we’ve developed into a truly global company,” said Mueller. “We’ve celebrated many milestones along the way, including the recent establishment of a dedicated Americas office situated in Tucson, Arizona, to better serve our customers within the region.”

With its unique curved design and innovative use of materials, the Hercules dump truck body “is lighter yet stronger, offering miners numerous advantages, including a demonstrated payload increase above 10% and a significant service life extension.” Schlam attributes its success to its focus on innovation, advanced engineering design and delivering on the individual needs of customers.

“Hercules is built for miners, with miners,” said Mueller. “Our sales and technical support teams work closely with our customers to ensure that every Hercules is uniquely designed and built to meet the specific site requirements of the site it will operate on.” Schlam has also implemented manufacturing efficiencies through the introduction of robotics, automation, and LEAN manufacturing principles, ensuring high-quality production while meeting growing demand. As Schlam celebrates the delivery of its 2,000th Hercules dump truck body, the company says it remains steadfast in its mission to provide innovative solutions that drive efficiency and productivity in the mining industry.

Glencore’s Lomas Lab continues to progress in Chile

Automation, Base metals, Equipment maintenance, Mineral commodities, Mining equipment, Sustainable mining

Glencore says its Lomas Lab initiative at its Lomas Bayas copper mine in Chile continues to progress. The miner states: “We’re taking innovation and operational efficiency to a new level with our digitalisation and automation technology initiatives.” This project is also playing an important role in proving out new technologies that can then be applied to other Glencore operations around the world.

In the first quarter of 2024, Lomas Bayas completed the conversion of four Komatsu 930E-5 trucks to autonomy using Komatsu’s Frontrunner technology, and it expects to conclude the piloting stage in May 2024. The company has stated that should this be successful, the project will see a gradual increase the number of autonomous trucks until the entire fleet of 27 units goes autonomous by 2025.

In addition, Lomas Bayas has successfully integrated two autonomous drilling rigs, marking another milestone in our journey towards Mining 4.0. These are both Caterpillar drills converted to autonomy using FLANDERS’ ARDVARC technology. It is the first operation to adopt intelligent drill technology globally in Glencore mining operations.

Finally, the mining group says that commitment to ongoing training has been instrumental in the process. As an example, more than 600 mobile team drivers have been trained on the mine’s collision avoidance system (CAS), prioritising safety. The mine has also held workshops to certify more than 40 people in the operation of the autonomous trucks.