All posts by Paul Moore

Molycop opens new SAG Ball line in Cilegon, Indonesia

Comminution of minerals, Mineral processing, Mining consumables, Mining people, Mining services

Molycop has opened a new SAG Ball line in Cilegon, Indonesia, that will double its SAG Ball production capacity from 50,000 t to 100,000 t. The new line positions Molycop to meet the region’s increasing demand with greater efficiency and reliability.

In a significant achievement, the production line also achieves a local content certification of above 50% and is operated by a fully local workforce. This reflects Molycop’s commitment to local sourcing and its dedication to fostering talent and opportunities within the community.

Jim Anderson, Molycop CEO, announced the opening of the new production line in front of the Australian Ambassador to Indonesia and other distinguished guests.

He said the occasion marked a significant milestone for Molycop in Indonesia, its customers and the broader local community. “Cilegon has been home to Molycop’s operations for over 25 years. This facility is one of 14 strategically located plants in some of the world’s most important mining regions. Initially established to service the local Indonesian mining industry, our Cilegon plant now proudly supports operations across Southeast Asia.”

He added that Molycop had invested more than US$100 million in the region in the last 25 years. “This commitment underscores our belief in Indonesia’s industrial landscape’s potential and resilience. Today’s inauguration of the new SAG ball production line is a testament to this enduring investment.”

In addition to investing in Cilegon, Molycop has acquired the Cikande Plant, the first High-Chrome grinding media plant to be 100% Molycop-owned. The acquisition brings 75 new employees into the Molycop Indonesia team. It also diversifies its product mix and market reach, further strengthening its position in the industry.

Molycop adds: “The success and growth of Molycop in Indonesia are deeply rooted in our partnership with the local community and our dedicated workforce. We are committed to continuing this journey of growth and collaboration, ensuring that the benefits of our investments are felt throughout the region.”

Anderson told the assembled guests that their support and collaboration made the opening of the production line possible. He also gave his special thanks to the Molycop team in Indonesia and the dignitaries and representatives from Freeport who attended. He concluded: “I want to thank everyone – our employees, partners, customers, and the community – for their unwavering support and commitment. We are building a stronger, more resilient future for the mining industry and beyond.”

 

ERG signs MoU with Hitachi & Eurasian Machinery to convert trucks for trolley assist

Bulk handling, Environmental, Equipment maintenance, Mine operation news, Mining consumables, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Steel and iron ore, Sustainable mining

During a recent business forum at the ‘Central Asia plus Japan Dialogue,’ Eurasian Resources Group (ERG), the diversified natural resources group headquartered in Luxembourg, signed a memorandum of understanding (MoUs) with Japan’s Hitachi Construction Machinery (HCM), the global producer of construction and mining equipment, and its official distributor in Central Asia, Eurasian Machinery LLP.

Hitachi Construction Machinery will supply ERG with modified diesel-electric drive EH4000 mining dump trucks to operate at the Kacharsky iron ore mine in Kazakhstan. which will help enable ERG to achieve its environmental management goals. The MoU will enable Hitachi’s EH4000 mining dump trucks to run on electricity via trolley assist.

The electrification of ERG’s truck fleet will substantially reduce local carbon emissions at the Kacharsky mine site. The company will also undertake a long-term contract for a full range of services, including the development of servicing infrastructure, and the supply of spare parts and large components.

ERG told IM: “We have analysed the conversion of 42 Hitachi EH4000 dump trucks into trolley trucks and the creation of a trolley infrastructure in the Kacharsky mine. We are currently evaluating in detail the economic feasibility. The total length of the trolley lines should be 9.9 km. Factory-built 220 t Hitachi EH4000 dump trucks can be converted into trolley trucks. So it creates an opportunity to operate in two modes: diesel mode and trolley line mode. When the trolley line mode is activated, the power transmission from the diesel engine is switched off, the pantograph is lifted and connected to the trolley line as a power source, and the power is supplied to the hub motors.”

The MoU will be facilitated by Hitachi’s regional distribution partner, Eurasian Machinery, and it will support the development of ESG-focused construction practices across ERG’s global operations. The MoU was signed by the Chairman of ERG’s Board of Directors, Shukhrat Ibragimov, the CEO of Eurasian Machinery, Mehmet Kemal Cetinelli, and the President of Hitachi Construction Machinery Co, Masafumi Senzaki.

To further improve economic and environmental performance, the partners have outlined plans to conduct joint feasibility studies, to support the full electrification of ERG’s mining fleet.

In addition, a second MoU has been announced between ERG and Japan’s Mitsui & Co. ERG intends to upgrade up to 30% of its truck fleet by purchasing Komatsu equipment through KOMEK Machinery Kazakhstan LLP. The MoU also envisages collaboration to achieve ‘green’ ferrochrome production targets. Mitsui plans to conduct a feasibility study for a potential wind power development project for ERG.

Commenting on the signed MoUs, Chairman of ERG’s Board of Directors, Shukhrat Ibragimov, said: “International cooperation on this scale will give new impetus to the development of our company in line with the ESG agenda. We aim to not only improve our business practices, but to ensure that our businesses are in line with the highest global standards. The priority is to ensure smooth operations and achieve production targets while complying fully with safety rules and operating in a responsible manner. We are convinced that this will be reflected in the quality of our products while contributing to the development of Kazakhstan’s economy.”

Arch Resources & CONSOL Energy to merge into coal giant Core Natural Resources

Coal technology, Mine shafts and equipment, Mineral commodities, Mineral processing, Mining mergers and acquisitions

Arch Resources, Inc and CONSOL Energy Inc have announced that they have entered into a definitive agreement to combine in an all-stock merger of equals to create Core Natural Resources, a premier North American natural resource company focused on global markets.

Core Natural Resources will be a leading producer and exporter of high-quality, low-cost coals with offerings ranging from metallurgical to high calorific value thermal coals. With mining operations and terminal facilities across six states, the combined company will own 11 mines, including one of the largest, lowest cost, and highest calorific value thermal coal mining complexes in North America and one of the largest, lowest cost, and highest quality metallurgical coal mine portfolios in the US.

In addition, the combined company will have access to global markets via ownership interests in two export terminals on the US Eastern seaboard, along with strategic connectivity to ports on the West Coast and Gulf of Mexico. Arch and CONSOL sold an aggregate of approximately 101 million tons of coal in 2023 to steelmaking, industrial, and power-generation customers.

Pro forma, Core Natural Resources would have a market capitalization of approximately $5.2 billion as of August 19, 2024, and on a pro forma basis for 2023, revenues were approximately $5.7 billion and adjusted EBITDA was approximately $1.8 billion, excluding expected synergies.

Jimmy Brock, Chairman and Chief Executive Officer of CONSOL, said: “We are excited to bring our companies together to create a new industry leader that is ideally positioned to meet the rising demand for critical resources and energy around the world. Our assets are highly complementary, resulting in increased diversification across coal types, end uses, and geographies. In addition, Core Natural Resources is expected to have a strong balance sheet, ample liquidity, and robust free cash flow to deliver industry-leading capital returns. We look forward to working closely together to continue meeting the world’s steel, infrastructure, and energy needs that are so critical to our everyday lives and to capture the significant benefits and long-term value we believe this merger will create for our stockholders, employees, customers, and the communities in which we live and operate.”

Paul Lang, Chief Executive Officer of Arch, said: “This merger will join two proven leadership teams and best-in-sector operating platforms to establish a premier North American coal producer with worldwide reach and world-class mining and logistics capabilities. Core Natural Resources will enjoy the benefits of CONSOL’s growing seaborne thermal business focused on industrial applications coupled with Arch’s significant exposure to attractive global metallurgical coal markets. Together, we expect to realise meaningful operating synergies through the optimisation of support functions, greatly enhanced marketing opportunities, and a significantly expanded logistics network, which will enhance our ability to deliver coal reliably and efficiently to our global customers. Importantly, both companies are driven by a deep commitment to safety, environmental and social stewardship and operating excellence, and we will continue to build around these commitments as we work to deliver superior value to stockholders.”

The merger will create a diversified coal producer with a broad portfolio of high-quality metallurgical and thermal coals focused on seaborne markets where the business is highly contracted. More than 35 Mt/y of this coal will be produced by a best-in-sector portfolio of longwall operations at CONSOL’s Pennsylvania Mining Complex and Arch’s Leer, Leer South and West Elk mines.

Greater diversification across multiple growth markets and geographies with little, if any, overlap. The ability of Core Natural Resources to provide a range of coal qualities and blends will enable it to serve a more diverse customer base across multiple growth markets and geographies. For example, metallurgical coal produced by the combined company is a key input in the production of new steel from blast furnaces. Blast furnace steel constitutes 70% of the world’s steel output.

Metallurgical coal is expected to remain in strong demand for decades to come, as new steel will be essential in supporting the world’s growing population, ongoing economic development, continued urbanisation, and the build-out of a low-carbon economy. Furthermore, the high calorific value thermal coal mined by the combined company is increasingly sought after in industrial markets. On a pro forma basis in 2023, Core Natural Resources would have delivered more than 25 Mt/y to support key end-use applications, including cement production and other industrial uses, as well as to serve resurgent power generation demand driven by AI, data centres, and EV expansion. In addition, CONSOL Innovations provides the ability to focus on developing and commercialising cutting edge technologies in carbon products and carbon management.

Core Natural Resources will have an ownership interest in approximately 25 Mt/y of export coal capacity across two marine export terminals on the US Eastern seaboard and have strategic connectivity to ports on the West Coast and Gulf of Mexico. The potential to optimise this expanded export capacity and logistics capabilities is expected to enhance reliable, efficient coal delivery to global customers.

The transaction is expected to be accretive to free cash flow for both Arch and CONSOL in the first full year following close. The combination is expected to generate $110 million to $140 million of annual cost and operational synergies within six to 18 months following the close of the transaction, primarily from logistics optimisation, coal blending and related opportunities, as well as procurement and SG&A efficiencies. Core Natural Resources will be headquartered in Canonsburg, Pennsylvania, leveraging its close proximity to the majority of its mining and export operations, and will maintain a presence in St. Louis.

BHP deploys electric Liebherr R 9400 E excavator at Yandi

Bulk handling, Mining consumables, Mining equipment, Power supply for mines, Steel and iron ore, Sustainable mining

BHP has taken another important step on its operational decarbonisation journey with the first electric excavator in BHP’s fleet now operational at its Yandi iron ore mine in the Pilbara, Western Australia. Instead of a diesel engine, the R 9400 E Liebherr electric excavator has an electric motor, with power fed to the machine by a trailing cable.

Equipped with Liebherr’s autonomous cable reeler for optimal on-site mobility, this innovation boosts productivity and operator safety. Western Australia Iron Ore (WAIO) Asset President Tim Day said reducing diesel in the business was key to helping achieve BHP’s medium-term target to reduce operational greenhouse gas (GHG) emissions (Scopes 1 and 2 from its operated assets) by at least 30% by FY2030 (from adjusted FY2020 levels) – and ultimately its long-term goal of net zero operational GHG emissions by CY2050.

“Electrification of our fleet is our preferred solution to displace greenhouse gas emissions from using diesel – from trucks to trains to excavators – we’re working hard to electrify our equipment,” Day said. “Collaborations with partners like Liebherr are critical to accelerate development of the technology required to reduce diesel emissions, while ensuring we continue to improve the safety and productivity of our operations.”

Brian Boitano, Executive General Manager, Sales and Marketing, Liebherr-Australia said: “The R 9400 E is a testament to Liebherr’s dedication to providing innovative and efficient zero emission solutions for the mining sector. We are thrilled to partner with BHP, a forward-thinking industry leader, to introduce our proven electric excavators into their operations and to help them move forward in their decarbonisation journey.”

This milestone BHP said not only underscores its commitment to adopting cutting-edge technologies but also highlights Liebherr’s role as a trusted partner and solutions provider within the mining sector.

BHP added: “Our strategy aims to decarbonise our mining equipment by switching from diesel to renewable electricity or other low to zero GHG emissions power. Renewable electricity is not purchased through the market as WAIO is not connected to an existing grid, so we are working through the best way to introduce the large volumes of renewable or other low to zero emissions power that we will need.”

It continued: “This includes a number of actions to decarbonise our sites, with a focus on maximising renewable electricity and other sources of low to zero GHG emissions power, diesel displacement through electrification, and working to manage fugitive methane emissions.”

FLSmidth to deliver concentrate and tailings filters to South32’s Hermosa

Base metals, Bulk handling, Mineral processing, Mining consumables, Mining services, Sustainable mining

FLSmidth says it is to deliver concentrate and tailings filters to South32’s Hermosa critical minerals project in the US. This new FLSmidth order will contribute to an increased supply of critical minerals such as zinc and manganese supporting the continued electrification of society.

The mine operation is designed to minimise its environmental impact, and the equipment that FLSmidth will deliver plays a critical role in supporting this. FLSmidth has received an order to deliver five AFP2500 concentrate and tailings filters to Hermosa which is located in the Patagonia Mountains of southern Arizona, US.

A key requirement for South32 is to utilise the most efficient process technologies with the lowest environmental impact. The project’s design is expected to result in ~75% less water consumption compared to other mines in the region, and FLSmidth’s filter tailings technology will be a key enabler of this.

“A key element in enabling sustainable mining is among other to reduce water consumption. Consequently, South32’s ambition of developing a mine operation with a low environmental impact, including a significantly reduced water consumption, is fully aligned with our MissionZero ambitions. Tailings filtration is one of the core competencies of FLSmidth, and therefore we are obviously pleased to support the development of this important project,” comments Chris Reinbold, Products Business Line President at FLSmidth. The value of the order has not been disclosed.

St Barbara invests in semi-mobile skid-mounted MMD Sizer at Simberi in PNG

Comminution of minerals, Equipment maintenance, Mineral processing, Mining consumables, Mining equipment, Mining maintenance, Mining services, Precious metals

St Barbara Ltd says that results of the current testwork program have allowed the early selection of the Saleable Concentrate Flowsheet option for the Simberi Sulphides Expansion, three months ahead of schedule. The expansion project has the potential to extend the life of mine by at least 10 years. The Simberi Operations consist of an open pit gold mine and processing plant on the northernmost island in the Tabar group of islands in the province of New Ireland in Papua New Guinea.

The testwork program has also confirmed that the Sorowar ore has significantly lower competency than previous test results, reducing the average life of mine (LOM) ore competency by 20% thereby reducing the crushing and grinding energy requirements.

Managing Director and CEO Andrew Strelein said: “We are excited by the improvements in the recoveries-to- concentrate and overall recovery being achieved in the flotation testwork we have completed to date. The results have allowed us to take an early decision in favour of the Saleable Concentrate Flowsheet, three months earlier than anticipated.”

He adds: “The confirmation of our expectations of the consistency and competency of the Sorowar ore’s crushing and grinding characteristics with those of Simberi’s other ore zones is a breakthrough. The simplification of the ROM pad and crushing circuit was just the first ‘value-unlock’ that we anticipate from this important clarification of the Sorowar ore properties. The testwork program is revealing enormous potential for flexibility in the sequencing of the open pits, pit backfill strategies to reduce waste dump construction and potential savings in waste haulage costs as well as dramatically simplifying mine closure and reclamation planning.”

Strelein continues: “The demonstrated benefit of the flotation circuit design optimisation and the value we have unlocked from confirming Sorowar’s ore properties have already delivered a return on our investment in FY24’s comprehensive metallurgical drilling and testwork campaign.”

The company says it is well funded to complete the next phases of work and beyond, including the investment in Pre- Expansion Growth Capital. This sets it up to deliver the clearest possible scope of work for the final investment decision anticipated in Q2 December FY26.

With comminution testwork now complete, preliminary comminution modelling of the LOM ore blend has confirmed the crushing and grinding circuit configuration and major equipment sizing. Crushing will be via a new MMD 625 Series Sizer. This has recently been purchased.

The existing 2.6 MW SAG mill is being retained and will be coupled with a new 5 MW ball mill. The ball mill size is based on a preliminary grind size selection of 106 μm as it showed an improved recovery, grade and concentrate mass pull over the previously selected grind size of 150 μm. Further grind size versus recovery testwork is planned and an economic assessment of the final optimum grind size will be made when testwork is complete.

The circuit design that includes retention of the existing SAG mill will minimise downtime related to tie-in of the new circuit. The current Carbon-in-Leach plant has parallel, rather than sequential, SAG and ball milling circuits allowing the SAG mill to continue operating while the new ball mill is installed. The circuit design will also be configured to allow rapid changeover between oxide/transitional ore processing (direct leach) and sulphide ores (flotation and leach).

Cyclone overflow from the new ball mill circuit will be pumped to a new flotation circuit. Flotation circuit configuration and equipment selection will reflect the testwork objectives of maximising flotation gold recovery as the tailings leach recoveries are relatively low (<50%); and producing a concentrate with a gold grade suitable for sale.

Flotation tails streams will be combined and leached in the existing leach/Carbon-in-Leach circuit. Testwork to date suggests that the leach stage will add approximately 6% to the overall recovery, which justifies its continuing operation for the treatment of the flotation tails. The gold recovered in the leach circuit is much lower than for the current operation and therefore the existing gold recovery circuit will not require upgrading.

As previously outlined in its 10 Year Plus Outlook for Simberi, St Barbara has committed to funding some of the Sulphide Expansion activities ahead of the formal investment decision. These investments support the improved performance/reliability of the current operations and/or removes the complexity and improves the timing of the future construction timeline (eg camp upgrades and process plant structural refurbishment).

Two low hour Volvo A60H trucks were purchased for trialling to confirm performance and cost parameters following the Mine Fleet Selection trade-off study that was conducted late last year. These trucks were identified in the study as being one of the preferred options as they provide a combination of higher capacity than the current small articulated trucks (CAT 740 / 745, Terex TA400 and Rokbak RA40s), whilst maintaining a narrower width and better manoeuvrability than larger rigid body alternatives such as the CAT 777, which is well suited to narrower cutbacks on the smaller pits. These trucks are now in service and are contributing to the current mining operations.

The semi-mobile Sizer unit has been ordered from MMD to replace the current feeder-breaker that feeds the Aerial Rope Conveyor (RopeCon). The Sizer will be utilised over the next few years, in a skid-mounted configuration, to provide greater crushing capacity and improved product size on the more competent ore that is being exposed in the deeper parts of the Sorowar orebody. This will improve the RopeCon availability and present a finer feed size to the milling circuit. The Sizer has been selected to meet the Sulphides Expansion duty specification and will be relocated to its permanent installation at the process plant when the RopeCon is decommissioned. The RopeCon will be replaced by a shorter dedicated haul road to a new run-of-mine (ROM) pad at the Process Plant as part of the Sulphides Expansion.

For FY25 the mine plan has been adjusted to deliver a softer blend to the existing feeder-breaker before commissioning the new Sizer in Q3 March FY25. This will minimise the impact of harder ores on the availability of the RopeCon until the Sizer is commissioned. The RopeCon belt is also being replaced in September 2024, which will also provide additional service life and reliability for the remaining years of oxide processing.

 

Macmahon invests in hydraulic excavators at Matarbe after successful study

Bulk handling, Environmental, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Precious metals, Sustainable mining

In its just released 2024 Sustainability Report, mining contracting major Macmahon laid out its commitment to minimising its impacts on the environment by collaborating with clients to reduce, recycle, and rehabilitate, as well as promoting environmental and sustainability awareness and identifying energy efficient and carbon reduction opportunities.

In FY24, Macmahon established its first three- year ESG roadmap based on its FY23 strategy and sustainability framework, establishing strong foundations for its ESG strategy. It is already progressing, with Scope 1 and 2 emissions dropping from 2,004 tonnes CO2-e in FY23 to 1,871 tonnes CO2-e in FY24. A Climate Transition Plan will be developed in FY25 to demonstrate how Macmahon will transition to a low carbon future, outlining its pathway to achieve interim and long-term carbon targets, decarbonisation goals and drive positive outcomes.

At the Martabe Gold Mine in Indonesia, Macmahon partnered with the Indonesian Komatsu dealer United Tractors to conduct a comprehensive fuel usage study evaluating the performance of hybrid excavators. The study aimed to compare the efficiency and environmental impacts of a Komatsu HB365-1 hybrid hydraulic excavator against a Komatsu PC300-8MO excavator. The study involved collecting and analysing three months of machine data, followed by comparing the results through a controlled comparison test.

To ensure accurate and reliable results, the following conditions were maintained throughout the controlled comparison test:

  • Same Operator: Both excavators were operated by the same individual to eliminate variations in operator performance.
  • Good Condition: Both machines were maintained in optimal condition, ready for testing.
  • Same Material: The excavators worked with identical materials to ensure consistency.
  • Method: The application and time distribution were kept the same for both excavators.

The study produced the following notable outcomes. Machine data showed the Komatsu HB365-1 hybrid hydraulic excavator demonstrated a 9.6% per hour reduction in fuel consumption compared to the Komatsu PC300-8MO. The actual comparison test confirmed the Komatsu HB365-1 hybrid hydraulic excavator demonstrated a 9.27% per hour reduction in fuel consumption compared to the Komatsu PC300-8MO in high swing time activities in a loading cycle. The potential carbon savings achieved with the HB365-1 hybrid excavator equate to 6 kg per hour.

Macmahon adds: “The fuel usage study highlights the significant advantages of using hybrid excavators in mining and civil infrastructure operations. The Komatsu HB365-1 hybrid hydraulic excavator not only cut fuel consumption but also significantly boosted efficiency, allowing more work to be done with the same fuel while offering potential carbon savings. As a result, Macmahon now operates seven hybrid excavators at the Martabe mine site across various mining and civil works. These findings underscore Macmahon’s commitment to working with OEM partners to ensure we are working to sustainable practices and innovation in mining and civil infrastructure operations, paving the way for more environmentally friendly and cost-effective solutions in the industry.”

Improved Cat® 6020 shovel delivers high uptime & efficiency plus extra durability

Bulk handling, Mining equipment, Mining services, Sustainable mining

Powering through the toughest materials, the Cat® 6020 Hydraulic Mining Shovel meets the mining industry’s need for durable, reliable and highly efficient digging performance. To align with the rest of the Cat hydraulic mining shovel lineup, the model nomenclature has been updated from the Cat 6020B to the 6020.

Today’s 6020 shovel Caterpillar says offers the same features, fast cycle times and high reliability as its predecessor. “Offering powerful performance, the next generation of engine powering the machine delivers improved reliability. Plus, the 6020’s hydraulic optimisation dynamically assigns individual pumps or groups of pumps to deliver the exact flow pressure that each hydraulic function requires. This reduces waste and heat, prolongs component lives, and improves fuel consumption.”

The new Cat C32B replaces the previous Cat 32 engine to offer more reliable and durable operation. With designs certified to meet a range of emissions standards worldwide, the new C32B engine is a direct replacement for the C32. No additional hardware is required for engine replacement to upgrade existing machines in the field. The C32B offers the same 776 kW (1,040 hp) rated power as its predecessor.

Higher flow oil and baffles in the oil cooler keep the engine core cooled and lubricated, while the engine’s new cylinder head with optimised water jacket maximises heat transfer. The C32B’s ability to deliver higher power in certain applications comes from increased piston compression height.

An updated crankshaft and connecting rods with larger journals increase durability by reducing contact pressure and optimising bearing performance, while a new cylinder block helps increase structural capability. All valves are equipped with oil metering stem seals and reduced contact pressure geometry for maximum life.

Increasing reliability, a thicker shim gasket reduces the risk of head-to-block oil leaks. More durable exhaust valves, especially when operating at high power, reduce the chance of exhaust valve failures. Dual sensor coolant protection detects potential coolant leaks sooner than the previous capabilities to avoid costly downtime.

Hydraulic optimisation for the 6020 shovel dynamically assigns individual pumps or groups of pumps to deliver the exact flow and pressure required by each hydraulic function. Reducing waste and excess heat buildup, hydraulic optimisation provides efficient use of the engine for greater productivity, less energy and fuel consumption, and reduced component wear. With its 22 t (24-ton) payload, the 6020 efficiently loads the Cat 775 truck in three passes, 777 in four passes, 785 in six passes and 789 in eight passes.

Designed for operator comfort, the next generation cab on the 6020 offers class-leading visibility for operating productively, safely and efficiently. Electronic-hydraulic servo joystick control delivers fast and precise machine movements with less operator fatigue, while five-circuit hydraulics allow for simultaneous control of two cylinder motions, two travel motions and swing. The large 254 mm (10 in) high-definition colour touchscreen puts all vital machine and diagnostic data at the operators’ fingertips. A safer training environment is facilitated by unobstructed views of the digging environment and emergency stop button easily accessible from both training seats.

A range of onboard and optional technology offerings boosts productivity, efficiency and health of the 6020 shovel. The machine’s board control system employs multiple sensors to monitor operating data, record faults, and notify the operator audibly and visually for early detection of faults. Factory-ready for Cat MineStar™ Solutions, MineStar Health is fully integrated as an option to deliver critical event-based and operating data. Also available are MineStar Fleet for real-time machine tracking, assignment and productivity management; Terrain that enables guidance technology and high-precision management of shovel operators; and Detect to increase operator awareness and enhance safety.

Moving fast vital in mining’s open era: Hexagon leaders

Automation, IoT, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software, Sustainable mining

Richard Roberts, Editorial Director at Beacon Events, recently interviewed some key figures at Hexagon ahead of its participation at the IMARC event in Sydney in October 2024.

Wendy Hodgetts, Safety Manager at the Rosebery zinc-copper mine in western Tasmania, gave a warts-and-all deep dive on the historic mine’s introduction of a state-of-the-art operator alertness system (OAS). Senior Gold Fields operations leader, Michael Place, provided equally eye-opening insights into the gold major’s digital and automation journey in Australia.

Hexagon’s Mining division Asia Pacific Vice President Ben Rogers says the openness of the industry’s leaders today – on display at the technology company’s recent regional mining forum in Perth, Western Australia – is worth savouring.

“The willingness of our customers to talk openly and to share information and provide feedback in these forums, exactly as you saw in Perth, and as we saw later in Almaty [Kazakhstan], is not something I’ve been used to in my career,” says Rogers, who spent more than a decade in senior technology management roles at Rio Tinto.

“Where mining houses wouldn’t previously want to talk about this technology, be it productivity or safety, we’re seeing organisations share more and more in order to learn and grow. It is a lot more accepted now. I think the other takeaway for me from these forums is that the technology vendors – and I joined Hexagon because it has technology that spans the whole mining and metals value chain – are less about product focus and more about delivering a value proposition. How can technology be applied to drive business value?”

Mining’s need to accelerate learning and solve material problems – many with the aid of software, automation and possibly artificial intelligence – is no doubt a key factor in the industry’s surging connectivity.

Dave Goddard, Acting President of Hexagon’s Mining division, sees generally higher levels of technological literacy as another factor. “There’s familiarity with the various technologies that perhaps wasn’t there in the past,” he says. “There’s a lot of mobility in the mining industry. People are moving around from company to company and getting experience with different solutions and there is probably more general agreement on the value of the solutions. I think that migrates more readily into an open forum.”

Rogers and US-based Goddard, who will share their experiences and insights at IMARC in Sydney in October, have had different vantage points but have both watched the mining technology landscape change significantly in the past decade.

Major international mining equipment manufacturers have been big buyers of niche mining tech firms. Hexagon and Canada’s Constellation Software have built large mining tech stacks. The likes of Australia’s Imdex and Orica have also been prominent players in the M&A arena.

There is a race among the leading mining tech players to integrate products and position themselves for a long-term uptick in digital and automation technology adoption.

“The vision we have is a relentless focus on value for the customer,” Goddard says. “How can we help our customers operate in the most productive and most safe manner? “Fundamentally, mining hasn’t changed. It’s making the big rock smaller. You have larger machines so that you can lower your labour cost per tonne and you can increase your throughput in order to meet the commodity demands of a growing world. But fundamentally, the process hasn’t changed. The cost drivers have evolved with the advent of technology. You have to be more efficient. The way you do that is by adding technology to eliminate the waste – both the wasted movement and the wasted process – and do so in a manner that provides a safe environment.”

He added: “One of the advantages of being a technology company and not an iron manufacturer is that we’re a lot more agile. We’re able to provide solutions that have value to the customer in a shorter period of time.”

Rogers said: “That agility extends to Hexagon AB, the broader parent company. Hexagon is a technology company in multiple sectors and industries, with the ability to bring to bear other technologies that may sit in other industries in an agile format, to mining. I think that gives us a tremendous advantage as we work to deliver value across mining and metals supply chains.”

As Australia’s largest and most significant mining event, IMARC attracts over 9,000 decision-makers, industry leaders, policymakers, investors, commodity buyers, technical experts, innovators, and educators from more than 120 countries. For three action-packed days, attendees will engage in cutting-edge learning, forge valuable deals, and experience unparalleled networking opportunities.

Reko Diq orders continue with fine grinding, separation & tailings solutions from Weir

Base metals, Bulk handling, Comminution of minerals, Environmental, Mineral processing, Mining consumables, Mining maintenance, Mining services, Precious metals, Sustainable mining

Weir Group PLC has been awarded a contract to provide industry-leading energy efficient, sustainable solutions to the Reko Diq copper-gold project, the 50% owned greenfield development by Barrick Gold Corporation.

The Tier 1 copper project is located in the Chagai district of Balochistan in Pakistan and is targeting first production in 2028 with an estimated mine life of 40+ years. During the first phase of the project, Weir will provide fine grinding, separation and tailings solutions.

Featured equipment includes Weir’s market leading ENDURON® HPGRs, ENDURON® Elite wet and dry vibrating screens, WARMAN® slurry pumps, and CAVEX® hydrocyclones. Among the equipment to be provided are Weir’s large format HPGRs – the highest capacity design in the market.

The initial £53 million contract award will be recognised in the order book in accordance with a phased call-off aligned with manufacturing lead times, with £26 million recognised immediately and the remaining orders to be booked in Q4 2024 and Q1 2025.

After commissioning of the equipment, aftermarket support will be provided via an on-site purpose-built service centre staffed with Weir technical personnel. The receipt of orders associated with the contract award during 2024 does not result in a change to Weir’s full year 2024 financial guidance as of 30 July 2024.

Commenting on the contract award, Jon Stanton, Chief Executive Officer of Weir said: “We are delighted to have secured this significant contract which represents further industry acceptance of Weir’s differentiated sustainable and cost-effective redefined flowsheet solution, with our market leading HPGR technology particularly suited for the water-scarce climate and geology of the Reko Diq copper-gold project. Our engineers have designed an innovative solution that comprehensively addresses the particular challenges of this project and is a great example of working in close partnership with an ambitious customer who shares in our purpose to sustainably and efficiently deliver the natural resources essential to create a better future for our world.”

“Barrick is pleased to be partnering with Weir in delivering sustainable mining and processing in the new mining frontier of Balochistan. The Reko Diq project will grow Barrick’s strategically significant copper and gold portfolios, benefiting all its Pakistan and Balochistan stakeholders,” said Mark Bristow, Barrick President and CEO.