All posts by Paul Moore

Holcim deploys battery-electric wide body mining trucks in Argentina and Colombia

Holcim has been pioneering the introduction of battery electric mining trucks at its South American operations, introducing the technology in the cement industry limestone quarrying sector in Argentina and Colombia for the first time via BEV trucks from China’s XCMG and SANY respectively.

Firstly, Holcim Argentina has announces the addition of an electric truck to its fleet, contributing to reducing carbon emissions and in line with its sustainability strategy. In addition, it is the first electric truck to be used in quarries in the country, a step forward that it says represents a clear transformation of the construction industry towards a future with more innovation and sustainability.

With the entry into operation of the XGMG XDR80TE, Holcim Argentina will avoid the emission of more than 225 tons of CO2 per year, which is equivalent to removing 53.6 cars from circulation or the same CO2 absorbed by a forest with a surface area of ​​more than 7.5 times the surface area of ​​the Central Park of Mendoza. In addition, a significant reduction in operating costs and an improvement in the homogeneity of raw materials are expected, crucial aspects to optimise quarry operations.

This project, led by the Holcim Argentina’s Decarbonisation team, required a total investment of more than US$300,000 for the acquisition of the truck, the installation of a charging station and the adaptation of the existing infrastructure. Currently, the truck will be incorporated into the limestone quarries at the Capdeville plant, in the province of Mendoza.

“Sustainability is at the heart of our strategy, and as part of this path we have the objective of reducing our impact on the planet. This means transforming each of our processes throughout the company’s value chain. The electrification of our internal fleet is one of the key objectives on our path towards the decarbonisation of our quarries, an area in which progress is being made throughout the world and in Argentina we lead the sector,” said Marilina Moro, Head of Decarbonisation at Holcim Argentina.

With a capacity of 45 m³, the truck can transport up to 72 t, establishing itself as a key player in Holcim Argentina’s quarry operations. Weighing 43 t kg, this truck is both robust and innovative in terms of energy efficiency and operational safety. It features an energy recovery braking system, which allows the battery to be charged during braking, reducing energy consumption and improving operational efficiency. In addition, the truck incorporates an automatic gearbox and a panoramic video system for assistance in reversing manoeuvres, ensuring safer and more precise handling in daily operations.

This initiative reinforces Holcim’s position as a pioneer in the adoption of sustainable technologies and lays the foundation for future innovations in the local market. It comes after a similar move by Holcim over in Colombia, where earlier this year Holcim Colombia deployed battery electric wide body mining trucks – four units of the SANY SKT105E. They are already operating in its limestone quarries at the cement plant in Nobsa, Boyacá and are supplied with 100% renewable electricity, from hydraulic and solar generation, completely eliminating the consumption of fossil fuels.

SANY all electric SKT105E trucks at Holcim Colombia’s operations

The 70 t class mining trucks are equipped to address logistical challenges with efficiency and sustainability, because they have innovative technology in vehicles of that size, in which energy is generated to recharge its battery, while descending a slope with a load.

This allows the equipment to deliver excellent results in mine operations such as Nobsa, where most of the hauling is done downhill, with lower energy consumption in recharging the trucks at the station and completely replacing fossil fuel consumption, which contributes significantly to reducing CO2 emissions. The new fleet is supplied with energy from 100% renewable sources from a main station with an individual charger for each piece of equipment.

Martín Costanian, Executive President of Holcim Colombia, stated: “We are proud to be the first company in the sector to bring this equipment to Colombia, marking a milestone for the market, thus demonstrating that it is possible to decarbonise the construction sector. We aim to become a net-zero company by 2050 and are committed to meeting this goal while continuing to build progress for people and the planet.”

Its incorporation into the operation will represent a saving in fossil fuel consumption of approximately 100,000 gallons per year, which translates into avoiding more than 1,900 tons of CO2 from diesel combustion, which will allow the company to deliver increasingly sustainable products to its customers.

In addition to a lower-emission operation, the new electric trucks have a load capacity of 15 additional tons compared to the current ones, which implies efficiency in the transport of material.

With sustainability at the heart of its strategy, the company says it made this investment in order to contribute to the creation of a more sustainable construction sector and to continue offering its clients a portfolio of comprehensive solutions that aim to decarbonise construction “and build a world that works for everyone.”

Cummins highlights bridge technologies at MINExpo 2024

Cummins has announced it will outline its new bridge technology strategy and display advanced internal combustion products for mining applications at MINExpo 2024. Taking place September 24-26 in Las Vegas, USA, Cummins will be discussing the role of bridge technologies, such as hybrid solutions, in reducing mining emissions and Total Cost of Ownership (TCO) for miners. Displayed on stand, Cummins will also be showcasing its latest generation QSK60 and QSK95 engines.

An overview of PrevenTech® digital solutions and a virtual tour of Cummins’ Master Rebuild Centre (MRC) will also be available to visitors at the MINExpo 2024 Cummins stand.

Molly Puga, Executive Director of Strategy, Product Planning & Digital at Cummins, said: “MINExpo 2024 is a great opportunity for us to discuss our strategy for helping miners achieve their carbon reduction goals – both in the short- and long-term. We’re keen to communicate the role emerging bridge technologies can play today alongside internal combustion engines in a diverse portfolio of power solutions for mining. We look forward to talking to customers about how we intend to achieve carbon neutrality in a way that supports TCO and the rigorous day-to-day demands of mining, highlighting how we can make immediate impacts, whilst progressing towards a zero emissions future.”

Cummins hybrid capabilities will be discussed on booth at MINExpo as an example of Cummins’ bridge technology strategy launch for the sector. Cummins will highlight its core, modular hybrid architecture alongside plans for both first-fit and retrofit applications for miners. Cummins believes hybrid solutions offer an affordable way to reduce emissions compared to alternatives like trolley assist and can be used in cohesion with HVO-ready internal combustion engines to generate additional emissions benefits.

Leading the showcase of internal combustion engine technology will be the Tier 4 Final/Stage V compliant Cummins QSK60, which delivers a maximum of 2,850 hp (2,125 kW) and a maximum torque of 8,274 lb-ft (11,218 Nm). Equipped with advanced diagnostics and serviced by Cummins global distribution network, the QSK60 provides over 20,000 hours of operation before requiring an engine overhaul. This engine can then be rebuilt over three times throughout its lifetime, significantly reducing the potential total cost of ownership (TCO) for miners.

In addition, Cummins will be displaying its QSK95 on-stand. This EPA Tier 2 emissions equivalent is the most powerful mining engine available and features an output of over 4,400 hp (3,281 kW) and a peak torque of 17,802 lb-ft (24,136 Nm). The 16-cylinder QSK95 is a clean sheet engine platform, designed with optimum power-to-weight ratio for 400T haul trucks, with engine ratings to maximise fuel efficiency and productivity. The engine also utilises four single-stage turbos, alongside external oil and lube coolers, to improve engine serviceability.

Visitors to the Cummins booth at MINExpo will also see the company’s latest developments in advanced diagnostics and prognostics with PrevenTech®. The technology detects potential equipment health issues before they occur, informing operators of potential performance issues and recommended service ahead of failure and subsequent downtime. Cummins PrevenTech® is a system that can be installed on Cummins engines to reduce TCO from unexpected servicing for miners.

At MINExpo Cummins will be discussing how choosing its engines leads to low cost of production thanks to its extensive aftermarket service and support. At the stand Cummins ambassadors will be on hand to talk through a range of offerings, such as its PowerCare™ service contracts, genuine parts and more.

A virtual tour will also be available on stand of the recently opened Cummins Master Rebuild Centre (MRC) in Krakow, Poland, the first of its kind in Europe. This tour will provide insight into how employees at the 4,600 m2 MRC in Krakow rebuild Cummins high horsepower engines with displacements of 19 to 78 litres, and in the 450 hp to 3,500 hp range, including renowned Cummins engines such as the QSK19, QSK38 and QSK60.

Cummins engine rebuilds go through a six-stage remanufacturing process that sees the engine disassembled, cleaned, inspected, re-machined, reassembled with Genuine Cummins parts and tested. As a result, the engine’s life is extended, its performance is enhanced and TCO is reduced due to greater engine uptime.

Epiroc unveils the diesel-electric Minetruck MT66 S eDrive

The new Minetruck MT66 S eDrive is the first of Epiroc’s large-capacity mine trucks to feature the latest generation electric drivetrain. Along with an upgraded and powerful diesel-engine, the hauler combines the cost-effectiveness of a traditional mine truck with the productivity of an electric one – without requiring change to a mine’s infrastructure.

The Minetruck MT66 S eDrive has been completely redesigned to feature an electric drivetrain, powered by the strongest engine yet in Epiroc’s line-up of underground mine trucks. With several other upgrades, such as weight reduction and better utilisation of the engine’s sweet spot, the truck can reach up to 11% higher ramp speed compared to current models.

“Minetruck MT66 S eDrive has been built from scratch with room for an additional tonne in the box, making it the largest capacity underground mine truck on the market. By combining power with innovation, it really is the best of two worlds,” says Wayne Symes, President at Epiroc’s Underground division.

Epiroc adds that while the Minetruck MT66 S eDrive enables both higher maximum payload and increased speed compared to other high-capacity mine trucks, it also reduces fuel consumption by up to 7% thanks to the electric drivetrain. The removal of mechanical parts also lowers maintenance costs, promising reduced total cost of ownership. All in all, with all these improvements on board, it says the Minetruck MT66 S eDrive offers an easy step to improve productivity quickly.

“In a typical mining application, the increased payload capacity means that the Minetruck MT66 S eDrive can add an additional cycle each day compared to a 65 t mine truck. That means well over 23,000 additional tonnes annually for our customers’ productivity,” says Martin Wallman, Global Portfolio Manager Underground Trucks at Epiroc’s Underground division.

The Minetruck MT66 S eDrive is being displayed at MINExpo International in Las Vegas, September 24-26. After the show, field trials will be conducted together with Gold Fields Australia, starting in Q2 2025.

Metso expands flotation mixing offering with innovative FloatForce®+ mechanism

Metso is expanding its flotation portfolio with a new innovative solution, the FloatForce®+ mixing mechanism. With FloatForce®+, part of Metso’s Planet Positive offering, Metso introduces a plug-and-play solution that it says maximises metallurgical recovery, boosts pumping efficiency, and reduces energy consumption, helping customers recover valuable materials and increase revenue.

Launched in 2006, Metso adds that FloatForce® has already set the standard for efficient flotation mixing mechanisms in the industry, but recent R&D breakthroughs have unveiled new ways to further enhance performance and sustainability.

“The FloatForce+ is designed for seamless plug-and-play installation with existing FloatForce configurations. It’s also compatible with other mixing mechanisms, needing only minimal modifications for integration,” says Christian Cardoso, Product Manager, Mechanical Flotation Services at Metso.

Flotation technology has played a pivotal role in Metso’s history for over five decades. Through subsequent advancements in the company’s evolution, Metso has significantly influenced the trajectory of mechanical flotation technology and helped to propel the industry forward.

“Metso’s new flotation mixing mechanism marks the latest advancement in our ongoing journey of flotation innovation and represents a major milestone in our Planet Positive initiatives,” says Antti Rinne, VP, Flotation at Metso.

Metso’s developments in flotation cell technology enable upgrading and retrofitting of older flotation equipment for enhanced performance. It adds: “This upgrade aligns with our sustainability goals by optimising manufacturing materials and integrates seamlessly with digital solutions, enabling customers to track energy consumption, recoveries, and maintenance planning.”

Metso’s Floatforce®+ solution will be featured next week at MINExpo 2024, in Las Vegas, USA from September 24-26.

Bell and MacLean announce tech collaboration including 5G/LTE network in Sudbury

Telecomms major Bell and MacLean, the world’s largest Canadian-based manufacturer of underground mining equipment, today announced a technology collaboration to better support the evolving needs of mining customers. The innovations being introduced will improve equipment interoperability – the way in which machines exchange and make use of information – enhancing safety for workers and driving sustainable practices and reduced vehicle emissions.

The installation of a Bell Private Mobile Network (PMN) at the MacLean Research & Training Facility in Sudbury, Ontario, provides a communications infrastructure perfectly suited for mining vehicle innovation. Bell’s PMN will transform the test facility into a Centre of Excellence, leveraging Bell’s secure 5G/LTE network that delivers persistent, dedicated bandwidth and signal stability from the surface shop to the underground environment.

This Centre of Excellence serves as the foundation for MacLean’s mobile equipment research and development. It enables the company’s mining vehicles to be more dependably controlled remotely, with real-time monitoring data to support rapid decision-making. Remote operations allow machines to work together better, maximising the potential for the deployment of semi or fully autonomous mining, where underground excavations can be done safely by operators above ground. Remote operators can also monitor vehicles from a distance without lag, powered by Bell’s low-latency PMN.

The collaboration between Bell and MacLean exemplifies a commitment to sustainable mining practices as Bell has also installed PMN coverage at MacLean’s Electric Vehicle refurbishment plant located in the same facility. Replicating the operating environment in the manufacturing facility optimises quality assurance and manufacturing efficiencies. Accelerating the transformation of mining companies’ digital services enables the deployment of electric vehicles underground using sophisticated battery technologies that leverage real-time monitoring, with reductions in fuel use and CO2 emissions.

David Jacques, VP Engineering, MacLean: “What we’re doing here at our research and training facility is quite literally building the mine of the future, now, leveraging Bell’s leading-edge mobile network technology, so that we can accelerate the industry transition to mining in a way that maximises the benefits from emerging automation and digitalisation technologies. This new private mobile network technology will help us pursue our core work of driving safety and productivity improvements in mining, here in Canada and around the globe. I’m delighted with the results of this collaboration and know that it will open new possibilities for our Advanced Vehicles and Technology team at our test facility to pursue their important innovation work.”

Costa Pantazopoulos, VP Product, Bell: “Bell’s private mobile network will allow MacLean to drive the modernisation of mining operations in Canada supporting the interoperability of equipment, safer environments for all workers, and fostering a more sustainable future through the enablement of battery electric mining vehicles. Our collaboration will support the opportunity for innovative Canadian Internet of Things solutions providers to test and modify their solutions to perform at the exacting standards required in rugged, real-world mining conditions in MacLean’s Centre of Excellence.”

Cat introduces Dynamic Energy Transfer for battery & diesel-electric mining trucks

Today, Caterpillar Inc has unveiled an innovative OEM-designed solution to help solve one of the most complex aspects of the mining industry’s energy transition – energy management.

Cat® Dynamic Energy Transfer (DET) is described as a fully Caterpillar-developed system that can transfer energy to both diesel-electric and battery-electric large mining trucks while they are working around a mine site. It can also charge a machine’s batteries while operating with increased speed on grade, improving operational efficiency and machine uptime. The innovative Cat DET system provides the industry with options to support both near-term and long-term sustainability strategies.

“We believe Cat DET provides a technological leap for the mining industry. Our team of innovators designed this system to provide immediate benefit to miners who want to lower their operating costs and greenhouse gas emissions today while also creating flexibility for the future,” said Denise Johnson, Caterpillar’s Resource Industries Group President. “We know customers need choices to fit their unique site objectives. We are proud to deliver an innovative, integrated solution that can support their needs of today and those of the future.”

Cat DET is comprised of a series of integrated elements, including a power module that converts energy from a mine site’s power source, an electrified rail system to transmit the energy and a machine system to transfer the energy to the truck’s powertrain.

It says the rail system is a highly deployable, mobile solution that can be customised to customers’ specific site layouts, including high-speed and curved haul roads, enabling higher productivity. The connecting arm can be installed on either side of a truck and on multiple truck models, providing options to fit customers’ specific operations. It can also be used on mature or developing sites, and it can be easily moved or expanded to allow maximum mine site coverage.

Cat DET will integrate with the Cat MineStar™ Command for hauling solution, merging autonomy and electrification technologies to provide a holistic site solution.

Caterpillar Senior Vice President Marc Cameron explained: “We believe mine sites will benefit from enhanced efficiency with the integration of electrification and automation. When combined, these technologies will help miners achieve production targets while simultaneously managing energy demands.” The Cat DET system will be on display as part of Caterpillar’s MINExpo 2024 exhibit.

Kal Tire to offer KalPRO tools globally via partnership with distributor Haltec

Kal Tire’s Innovation Centre in western Canada has been designing and producing proprietary tooling for nearly 10 years to help improve safety and efficiency for its mining tyre technicians. From tools that reduce fatigue and strain to ones that eliminate high risk, KalPRO tools enable technicians to perform work with greater ease, efficiency and safety.

Now, some KalPRO tools will be available to technicians globally through Haltec/AME International, a leading manufacturer and worldwide distributor of tyre service tools.

Kal Tire says it has a longstanding commitment to innovation and continuous improvement, driven by its team members who identify challenges and opportunities in the field. Until now, these tools were exclusively used by Kal Tire teams on the sites where they work. As they have proven to make a difference, interest in using them outside of Kal Tire has been building.

“We believe it’s our responsibility to make our work around the wheel as safe as possible, so we’ve focused on reinvesting in our teams, the tools they use and the way they work,” says Dan Allan, Senior Vice President, Kal Tire’s Mining Tire Group. “Our KalPRO tools go such a long way in protecting technicians and we saw this partnership with Haltec and AME as a valuable way to bring those benefits to the entire industry.”

The first tool to be widely available through Haltec’s AME International catalogue will be the KalPRO ValveShield, a heavy-duty magnetic valve housing that prevents rocks and debris from displacing valve stems and causing tire failure. This device has proven to provide substantial productivity savings on mine sites across numerous regions.

The KalPRO ValveShield will be on display and available for order taking at the upcoming MINExpo 2024 in Las Vegas, September 24-26, at both Kal Tire’s booth, Haltec’s, and AME International’s.

“This represents an ideal partnership. Some of the best ideas come from people looking for a better way to achieve a result. Kal Tire changes nearly every sized tyre that is made and can field test in several environments,” says Keith Jarman, President of AME International. “Haltec and AME’s global distribution network can help deliver these innovations to the industry effectively, improving efficiencies and safety.”

Also on display at Kal Tire’s MINExpo booth, will be another highly anticipated KalPRO tool, WheelJaws, which uses remote-controlled clamps that take technicians out of harm’s way during the final and most dangerous step of tyre and wheel assembly removal.

Other KalPRO tools that have been developed and deployed in Kal Tire operations include the GATR or Gravity Assist Tooling Rig for weightless operation of heavy tools like 36 kg torque guns; RamDrive, securing rams for safer bead breaking; and SpringLock, for safer lock ring installation and removal “Our relationship with Haltec spans decades of collaboration and mutual trust,” says Allan. “We look forward to adding more of our KalPRO tools to the Haltec and AME catalogue in months to come.”

Sandvik opens new BC facility to support customers in Western Canada

Sandvik Mining and Rock Solutions has officially opened its newest facility, in the Campbell Heights business park area of Surrey, British Columbia. This strategic addition to Sandvik’s Canadian network comes as part of the company’s commitment to enhance customer service and support amid evolving industry demands.

The Surrey facility, spanning nearly 40,000 square feet, will enable the company to provide comprehensive support to its customers in Western Canada. It is strategically positioned near the Vancouver International Airport, port and major highways, facilitating seamless logistics operations. The facility primarily comprises a state-of-the-art distribution centre serving as a local hub for Sandvik’s aftermarket logistics group. Additionally, it houses a dedicated component workshop, office space, meeting facilities, customer service centre and a training facility.

Jandre Visser, Logistics Manager for Sandvik Parts and Services, emphasised the timely nature of the expansion. “With supply chain constraints affecting industries worldwide, we recognise the importance of ensuring shorter and more predictable lead times for our customers,” Visser said. “By investing in inventory closer to operations and expanding our network, we aim to mitigate risks and enhance service reliability.”

Peter Corcoran, Vice President, Sales Area Canada, Sandvik Mining and Rock Solutions, highlighted the facility’s role in Sandvik’s broader strategy. “The opening of the Surrey facility marks the initial step in our comprehensive evaluation of Sandvik’s network across Canada,” Corcoran said. “As the industry undergoes transformative changes, including electrification, automation and data-driven optimisation, we are committed to being at the forefront of innovation and customer support.”

Huge feeders made at VIVA Engineering for Virta’s Centinela project up for award

The Southern African Institute of Steel Construction (SAISC) has announced that its member company, structural steel fabrication contractor VIVA Engineering, based in Kempton Park, Gauteng, has been nominated  in the Mining/Industrial category for the SAISC Steel Awards 2024 – for its role as the constructor of 11 extra heavy duty belt feeders for client Virta Inc.

The feeders form part of the bulk materials handling scope of the huge $4.4 billion Nueva Centinela project that was given the green light by Antofagasta Minerals (AMSA) in December 2023, with Virta having been awarded contracts for both feeders and conveyors. The Centinela Second Concentrator Project will produce an additional 170,000 copper equivalent tonnes per annum, comprising 144,000 t of copper production, 130,000 oz of gold production and 3,500 t of molybdenum production, with a 36-year mine life based on Centinela’s substantial ore reserve of two billion tonnes. The new project will have lower net cash costs through an increased focus on concentrator capacity that incorporates modern technologies, increased by-products and greater economies of scale.

The 1,829 mm x 17 m long belt feeders were designed by Virta Inc and constructed at VIVA Engineering then shipped to Chile, where they will be used by Centinela to handle extraction of copper ore underneath the main ROM stockpiles.

The VIVA scope included feed chutes, skirts, discharge chutes, and the mainframe. The feeders use an all welded construction for maximum strength. VIVA started the 600 km, oversize transport of the 50 t-plus feeder units on July 29, with three units delivered to Durban on July 31 following by the remaining eight units with the last five units delivered by mid-August to the port from where they were shipped onward to Chile.

Virta states: “A project like this – from detailing and fabrication through pre-assembly, belt splicing and modular transport – was initially envisioned to require up to nine months, yet with world-class team dedication, collaboration and VIRTA’s partnerships with VIVA, Lorbrand, and Semperit, we completed the full scope in about six months.”

Each feeder was structurally engineered not only for its operating application but also for strength and rigidity under unitised lifting, as each unit makes its way by truck, then ship, then truck to the site in Chile. The feeders were loaded onto the trucks in the VIVA yard with a 220 t crane.

Virta was awarded the design, supply, pre-assembly and delivery of three types of feeders (11 total) for handling of coarse, intermediate and fine ore. The scope included all mechanical and structural engineering, DEM chute design, steel fabrication (frames, hoppers, chutes, spile bars) and supply of all idlers, pulleys, belt and hydraulic drives. Structural engineering included strict adherence to Chilean design codes for operation in one of the most seismically active areas in the world.

Major equipment includes Lorbrand pulleys and idlers, Hagglunds hydraulic drives ranging from 400 to 550 kNm torque, and Semperit ST4000 and ST4500 steel-cord conveyor belt imported into South Africa from Poland.

Virta says it partnered with the VIVA team to perform steel detailing, 3D modelling, fabrication, pre-assembly, rigging and logistics coordination. The VIVA logistics team managed all necessary local logistics, assembly crews and oversize-load transport permitting. The pre-assembly at VIVA included idlers, pulleys and steelcord belt splicing. With the installation and alignment of large components and splicing of the steelcord belt in a controlled, efficient shop environment, Virta says this innovative and optimised pre-assembly strategy significantly reduces site installation time, schedule and risk.

Tribe Technology’s first autonomous RC rig arrives at AARP in Australia

Tribe Technology PLC, the disruptive technology-first developer and manufacturer of world-class autonomous mining equipment, has announced the arrival of its first autonomous reverse circulation (RC) TTDS GC 700 drill rig from the manufacturing site in Belfast, Northern Ireland, to the Australian Automation & Robotics Precinct (AARP) in Neerabup, Western Australia.

This is a major milestone for the company and is the culmination of significant engineering hours over the last four years, pioneering design and innovation along with extensive collaboration with its first customer, McKay Drilling, a subsidiary of Major Drilling Group International Inc.

This first drill rig has been manufactured and sold to industry leading drilling contractor, Major Drilling, for use at a Tier 1 iron ore mining asset in Australia. In line with the company’s announcement on 30 July 2024, the Drill Rig arrived on schedule in Perth, Australia.

The company will now undertake, in collaboration with the customer, additional system testing, integration with the Tribe Tech autonomous sample system, development of the software remote control systems and test drilling of holes at a depth of up to 60 m at the AARP, located in Perth. In line with the company’s contract with the customer, a stage payment invoice has been issued and paid at this milestone.

Derek Loughlin Chief Technology Officer at Tribe Tech, commented: “Our first Drill Rig has travelled by sea freight and successfully disembarked from the Fremantle port and arrived today at the AARP facility in Perth. We are extremely excited to carry out the next stage of integration testing including the first operation of the Drill Rig with our autonomous sample system and performing drilling operations for the first time within the AARP environment.”