All posts by Paul Moore

SANY launches SET320S hybrid mining truck in Shenyang

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

With SANY Group Chairman Xiang Wenbo in attendance, the Chinese mining equipment major has celebrated the launch of its largest tonnage hybrid mining truck yet, the SET320S. Featuring a 300-ton loading capacity and electric drive, SANY describes the truck as a game-changer.

The new model, the largest mining truck made yet by SANY, rolled off the production line at SANY Heavy Equipment Industrial Park in Shenyang, China. SANY adds: “Following the success of its predecessors SET150S and SET240S, the SET320S also employs the multi-power coupling hybrid technology but is designed with more power to haul, which is ideal for more efficient open-cast mining operations.”

The technical specifications of the truck have not yet been released but the SET240S uses three smaller 565 kW Weichai WP17 engines plus a 396 kW battery pack for a gross power of 2,091 kW. On these hybrid mining truck models, through electric turbine control technology and energy flow management, SANY says the engines can supply different power levels to work reliably under different working conditions. SANY says this will overcome the pain points of traditional mining trucks, such as high fuel consumption, high noise, and emissions, while greatly improving their energy efficiency and reliability.

The performance of the electric drive system depends on the gross vehicle weight, gradient and length of transport road, rolling resistance, engine power, and other parameters. SANY says the drive system can adjust to the actual working conditions to realise the optimal performance of the mining dump truck.

 

Suncor progresses with AHS at Millennium oil sands mine

Automation, Energy minerals, Equipment maintenance, Mining equipment, Mining safety, Mining services

Suncor has announced that its Base Plant site rolled out 15 Autonomous Haulage Systems (AHS) trucks in May with 20 more trucks deployed in June, completing the first phase of the implementation at Millennium oil sands mine in northern Alberta.

AHS trucks have been tested and used at Suncor’s Base Plant North Steepbank Extension mine since 2018, but this is a first for the much larger Millennium mine.

This deployment is on track with the plan for 91 AHS trucks to be active at Base Plant by year-end. AHS trucks operate using GPS, wireless communication, and perceptive technologies, offering many advantages to operational performance.

Embedding AHS into day-to-day mining operations improves safety, reliability and efficiency, while driving a more competitive mining cost per barrel.

“Technology evolution is not new to Suncor,” says Erika Doka, HR People Readiness lead for AHS. “AHS is another evolution and advancement in terms of the way we work.”

Despite sometimes unpredictable weather conditions that can disrupt road conditions, Millennium Mine AHS provides enhanced safety performance. Due to the operational predictability AHS offers, such as prescribed route mapping and obstacle detection systems, potential injuries and incident rates have decreased at sites with AHS vehicles, ensuring that everyone goes home safely at the end of the day.

“It makes everyone feel safer”, adds Michael Gartenburg, Director Operations – AHS Deployment. “This technology provides for better situational awareness. Every vehicle operating in the autonomous zone has a panel that shows the operator where all the AHS trucks are in the mine, allowing them some control when required and reducing unpredictability.”

The implementation of AHS has also increased fleet productivity and efficiency by reducing equipment stoppages and improving maintenance scheduling. The system’s artificial intelligence allows it to optimise for various driving conditions, reducing the wear and tear on components and allowing the mine sites to reduce maintenance costs.

The introduction of AHS has been a success due to the support from the teams at the mine. The collaboration and efforts that have gone towards AHS, from road maintenance to dispatch, have allowed the fleet to literally roll-out smoothly and safely while increasing productivity on site.

“A lot of work has gone into the success of AHS,” says Gartenburg. “It’s a testament to the capabilities, experience and motivation of those in the mine.”

Suncor adds: “The continuous evolution of AHS deployment has shown that the team at Base Plant’s Millennium mine can adapt and leverage the full value of this innovative technology, solidifying a successful future for Suncor by delivering a more safe, reliable and cost-effective operation.”

The Millennium Mine has installed AHS on both Komatsu 980E and Komatsu 930E trucks. Management of the autonomous projects is mainly done between Suncor and the Komatsu dealer in the oil sands, SMS Equipment, along with Modular Mining Systems and Komatsu Mining input. SMS has a dedicated training facility in Fort McMurray and another in its Acheson headquarters, near Edmonton.

Vale, Komatsu & Cummins announce collaboration to develop dual fuel large trucks

Bulk handling, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Steel and iron ore, Sustainable mining

Vale and Komatsu have signed a pioneering agreement to develop and test, in partnership with Cummins, dual fuel haul trucks, powered by a mixture of ethanol and diesel. They will be the world’s first trucks of their size, with payloads of 230 to 290 tons, to run on ethanol, in a joint investment in research and development that demonstrates the commitment of all three companies to advancing sustainability in the mining industry.

The Dual Fuel Program will contribute to the achievement of Vale’s goals of reducing scope 1 and 2 carbon emissions (direct and indirect) by 33% by 2030 and becoming net-zero by 2050.

The program is a recognition of the necessity to reduce carbon emissions in mining operations. Its goals is to convert existing diesel engines in haul trucks to run on a mix of ethanol and diesel, thus making it considerably more sustainable. The retrofitted trucks will be capable of using up to 70% ethanol and reducing direct CO2 emissions by up to 70%.

“Removing a fossil fuel like diesel from our mine operations is fundamental to achieving our decarbonisation targets,” said José Baltazar, Engineering Director for Mine and Plant Operations at Vale. “Applying the solution to the existing fleet, without the need to immediately purchase new trucks, is an excellent way to move forward with the decarbonisation process, while also maintaining our focus on reliability and production efficiency.”

“We are constantly developing and testing solutions to achieve our carbon reduction targets by 2030. This partnership will go a long way in reaching our collective goals,” said Benjamin Stear, EDT Product Manager at Komatsu. “We look forward to partnering with our customers through the DF change management process while maintaining productive operations to reach our emission reduction goals.”

Over the next two years, the project is anticipated to include the development, testing and implementation of ethanol-diesel engines manufactured by Cummins. Luke Mosier, Mining Product Planning & Strategy Manager at Cummins, highlighted: “Komatsu and Vale are two organisations that share Cummins’ commitment to innovation and accelerating carbon footprint reductions. It will be fantastic to contribute our internal combustion engine expertise on this project that will see further advancement of future ready technology.”

Diesel emissions from mine operations account for 15% of Vale’s direct CO2 emissions. Among mine equipment, the haul truck is the biggest consumer of diesel and therefore the biggest emitter. The decision to develop an ethanol-based solution is driven by its availability within existing supplier networks and high adoption rate in Brazil.

“We have to take advantage of Brazil’s competitive edge in biofuels, since we are one of the world’s largest ethanol producers,” says Ludmila Nascimento, Energy and Decarbonisation Director at Vale. “With this partnership, we can reduce our direct emissions by 2030 with a competitive solution, and also contribute to strengthening this low-emission industry in Brazil.”

Liebherr to present its new mining solutions at MINExpo 2024

Automation, Bulk handling, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software, Power supply for mines, Sustainable mining

Liebherr says it will be sharing its latest news, products, services, and innovations for the mining sector at the world’s largest mining exhibition, MINExpo INTERNATIONAL®, this September, in Las Vegas. Visitors will experience over 2,777 m2 (over 29,000 ft2) of Liebherr exhibits at booth #7832.

Daily masterclasses and live demonstrations will take place at the Liebherr booth each day, showcasing the company’s latest product updates and providing insights into these technologies and services with the latest information from the field. In line with Liebherr’s motto for the event, ‘Your mining partner’, Liebherr will showcase its reliability as a partner for best-in-class equipment, decarbonisation solutions, cutting-edge technology, and service excellence for the mining industry.

Liebherr’s T 264 haul truck will be showcased on the Liebherr booth. The 240-t machine will be equipped with Liebherr’s latest technology, including the Trolley Assist System. Liebherr is also set to reveal the latest technology for the T 264 at an event during the exhibition.

To highlight Liebherr as a reliable partner for decarbonisation solutions, the booth will include the R 9400 E 350 t electric excavator. This machine is not only a testament to Liebherr’s more than 40 years’ experience in the development and manufacture of electric excavators, but also features some of the mining product segment’s latest innovations. This machine will be equipped with various new Liebherr Assistance Systems that will help to optimise day-to-day operations, as well as the company’s brand-new cable reel solution for increased manoeuvrability.

Liebherr’s PR 776 dozer will be a highlight on the booth so visitors can experience Liebherr’s best-in-class equipment. The 70 t dozer boasts the lowest hourly fuel burn – and therefore the lowest greenhouse gas emissions – in its class. Additionally, Liebherr’s Assistance Systems, designed to support operators and increase onsite productivity, will be installed on the PR 776.

Liebherr’s mobile and crawler crane product segment will present the LRT 1100-2.1 rough-terrain crane at this year’s MINExpo. This rough-terrain crane has outrigger monitors as standard that automatically detect the support status of the crane and save it to the crane’s controller. The standard VarioBase® variable support base of the crane further optimises safety by enhancing flexibility on site and increasing the crane’s lifting capacity. The LRT 1100-2.1 has a telescopic boom with Liebherr’s tried-and-tested telematic telescoping system for rough-terrain cranes, on which the various telescoping sections can be extended independently with a single cylinder and then pinned to the telescopic section above.

At Liebherr’s technology showcase, the OEM will share its range of latest innovations. In the decarbonisation space, the company has developed a variety of alternative drives and will showcase some of its brand-new solutions for its range of haul trucks for the first time at MINExpo 2024. Liebherr will also share its new approach and solutions for autonomous haulage and fleet management as well as its new Machine Guidance System.

During the exhibition, Liebherr will present its latest solutions for automating, operating, and maintaining Liebherr equipment. One such solution is LiReCon (Liebherr Remote Control), the teleoperations system for Liebherr dozers. Visitors can see how this remote system helps keep operators safe while increasing equipment uptime and productivity. While on the booth, visitors can also learn about Liebherr’s latest offerings in the digital service space for connecting site technicians to Liebherr experts and minimising equipment downtime in the process.

At this year’s MINExpo, Liebherr will also highlight its capabilities as a partner for service excellence with its range of service products for mining. Visitors will see how the OEM supports customers from initial equipment consultation – with Liebherr’s highly skilled Application Engineering team – right through to machine maintenance, customer support, and equipment upgrades.

Liebherr’s modular design approach to its machines ensures that today’s equipment is future-proofed for the technology of tomorrow. Liebherr’s existing machines can be repowered to run on Liebherr’s D98 series of engines, designed specifically for mining conditions, and can be converted from a diesel to an electric powertrain. This modularity is what enables Liebherr’s modular maintenance program, a service concept that minimises the downtime and risk associated with major component changeouts.

At the Innovation Lab, visitors will see Liebherr’s latest pioneering concepts and technologies for the future of mining. Liebherr’s components product segment will feature innovative technologies as the core of every powerful mining machine. Liebherr’s commitment to excellence and sustainability is demonstrated in every component on display – be it a hydrogen engine, a travel or a wheel drive, a CFRP hybrid hydraulic cylinder, an advanced slewing bearing with bearing clearance monitoring, or the remanufacturing program.

Another highlight in the Innovation Lab is a 55 kW compressor. Backed up by experience gathered during the last two decades and jointly developed by the Liebherr components and aerospace and transportation systems product segments, the high-speed compressor is driven by an electrical motor and features an air bearing. Such technology is an enabler for the deployment of fuel cell propulsion systems with only emissions of water and heat, which aids in the movement for more environmentally friendly transportation.

BQE Water announces first selenium treatment project in Latin America

Base metals, Environmental, Mineral processing, Mining consumables, Mining services, Sustainable mining, Water management

BQE Water Inc., a leader in the treatment and management of mine impacted waters, has announced a contract to perform laboratory testing and conceptual engineering for a non-biological selenium removal water treatment plant using the company’s patented Selen-IX™ technology for a mine in Latin America.

David Kratochvil, CEO of BQE Water, commented: “As the first selenium project with regulatory drivers linked to long-term operation of an existing large scale mine in Latin America, this early-stage technical assessment contract is very significant. First, it allows us to demonstrate the capabilities and quantified benefits of Selen-IX™ in reducing life-cycle costs and risks of selenium management. Second, it helps to increase awareness about non-biological treatment of selenium in Latin America where selenium regulations are in very early stages of adoption and familiarity with commercially proven technological solutions somewhat lags behind North America.”

BQE’s Selen-IX™ technology is a patented and award-winning process of removing selenium from wastewater reaching effluent limits well below 0.002 mg/L, effectively eliminating reliance on dilution, and producing stable non-hazardous solid residue suitable for re-use. Since its first commercial application in 2020, Selen-IX has been successfully implemented at four sites across North America with the fifth installation currently under construction in the US. As the only commercially proven non-biological treatment system, Selen-IX™ offers unique advantages of rapid start-up and ramp-up from minimum to maximum design plant capacity, seasonal or intermittent treatment, zero sensitivity to water temperature, and zero risk of downstream impacts caused by organo-selenium species produced by biological systems.

BQE Water is a service provider specialising in water treatment and management for metals mining, smelting and refining. “We are helping to transform the way the industry thinks about water in the context of natural resource projects by offering services and expertise which enables more sustainable water management practices and improved overall project performance at reduced risks. BQE Water invests in innovation and has developed unique intellectual property through the commercialisation of several new technologies at mine sites around the world for organisations including Glencore, Jiangxi Copper, Freeport-McMoRan and the US EPA.”

Codelco putting climate change action plans in place

Automation, Base metals, Environmental, Equipment maintenance, Mineral project development, Mining consumables, Mining equipment, Mining maintenance, Mining services, Mining techniques, Power supply for mines, Sustainable mining

In June 2024, Chile’s copper mining giant Codelco released its Annual Report for 2023 including its Sustainability Report, in which it laid out its most recent analysis and targets relating to climate change and reducing emissions.

Its medium-term sustainability strategy is driven by six commitments by 2030 – including reduction of emissions by 70%. How is it going to do this? At a high level for Scope 2 emissions, Codelco wants to ensure that 100% of its energy matrix is clean, reducing the carbon footprint through the replacement of all electricity supply contracts towards renewable sources.

IM Editorial Director Paul Moore with Codelco’s Head of Climate Action, Pablo Contreras Silva at Exponor 2024

In January 2024, it renewed a contract with AES Andes for the Ministro Hales and Radomiro Tomic divisions, committing to supply up to 1.6 TWh/year of renewable energy between 2026 and 2040, thus ensuring that 70% of its energy supply will be coming from clean sources by 2026. And in May 2024, Codelco and Engie announced the modification of a electricity purchase and sale contract signed in 2007 between Codelco and Engie’s subsidiary, Central Termoeléctrica Andina SpA (CTA), with which the copper company ensured a 100% clean energy matrix by 2030.

It has also extended its contract with Pampa Elvira Solar which will allow Codelco to maintain the supply of green energy for the operation of its Gabriela Mistral Division for 10 more years.

Moving to electric vehicles, and certainly Codelco has been one of the most progressive large miners globally in converting its worker buses to electric. It recently added 30 Yutong electric buses at its Salvador Division which join another a large number that are already operating across El Teniente (103), Chuquicamata (45) and Andina (7) plus 65 recently added at Radomiro Tomic. To date the largest supplier of electric buses to Codelco has been Chilean company Reborn Electric Motors.

But of course, among the largest emitters are the surface and underground primary mining fleets. Codelco has also committed to achieving 100% electromobility in underground mines, incorporating emission-free technologies for transport vehicles. It has been a pioneer in Chile already in testing machines such as hybrid loaders and battery-powered light vehicles underground.

A 14 t class Epiroc ST14 battery LHD testing program also took place from November 2022 onwards at El Teniente. Codelco says that in one year it has avoided the consumption of 160,000 litres of diesel translates into 433 t less GHG released into the atmosphere. Further tests are planned with other BEVs including a Sandvik machine, with more details set to be released later this year. In utility and ancillary machines, Codelco has already deployed SmartDrive technology from Normet at Chuquicamta Underground including Charmec and Utimec units.

Moving to surface trucks, for the longer term, Codelco is focused on reducing carbon emissions from open pit operations by evaluating technologies, such as a study looking at the potential for a trolley pilot at Radomiro Tomic with at least 1 km of line – if it went ahead this would join the planned AMSA Los Pelambres and Collahuasi trolley lines as one of the first in the country.

To discuss its way forward, at the Exponor 2024 show in early June in Antofagasta IM Editorial Director Paul Moore sat down with Codelco’s Head of Climate Action, Pablo Contreras Silva. In this role he heads the team responsible for implementing the copper mining major’s whole decarbonisation and adaptation to climate change strategy. So this includes Scope 1, Scope 2 but also Scope 3 emissions.

He emphasised that Codelco’s Scope 3, ie indirect emissions, are also a major target currently: “Scope 3 is something not just us but the whole industry faces as it relates to the whole value chain. In Codelco’s case, Scope 3 accounts for 65% of our total emissions so it is something we need to address and we are doing that through various initiatives.”

One of these is that together with the Alta Ley Corporation, the Association of Industrial Mining Suppliers (Aprimin) and the National Mining Society (Sonami), Codelco has developed www.huellaminera.cl, a platform to measure, manage and reduce emissions associated with the inputs and products it receives from suppliers as much as possible.

Looking at Scope 1 and 2, as commercialisation of all battery mining trucks is some way off, what is Codelco looking at in terms of interim emissions wins? “As you know we have set ourselves ambitious targets for 2030 for Scope 1 and 2 and mining trucks account for 70-80% of our Scope 1 emissions. Like everybody else we are looking at the electrification of those trucks – but that is not something we are doing by ourselves. We are working directly with key OEMs – for example we are a member of the GHG Alliance with Komatsu. Plus, we are also working closely with OEMs and others via the ICMM’s Innovation for Cleaner, Safer Vehicles (ICSV) initiative.”

He confirmed that Codelco is looking at the potential for trolley assist, as well as other technologies like battery trucks as well as hybrid retrofits. He added: “It is a complex issue and the technology evolution is taking more time than we would have originally expected – so in the interim we are looking at other options.” He said these include but are not limited to biofuels, synthetic fuels such as e-fuels and other alternatives. And as has been stated by the other mining majors, BHP and Rio Tinto included, it will not be a one size fits all solution.

Chile is also set to host International Mining Events’ Electric Mine 2025 conference, being held May 13-15 at Centro Parque in Las Condes, Santiago.

Epiroc adds to 70 series raiseborers with automation ready Robbins 74 S

Automation, Mine shafts and equipment, Mine ventilation, Mineral project development, Mining consumables, Mining equipment, Mining services

Epiroc’s new Robbins 74 S is the latest machine in its 70 series, which are the most popular models in the OEM’s raiseboring lineup. The Robbins 74 S is a mid-sized raiseboring machine, drilling holes up to 4.5 m in diameter and is reliable in a variety of applications. The machine has enhanced functionality, allowing for safer and more effortless operations while still retaining the same performance as its predecessor.

The Robbins 74 S is automation ready and is designed to minimise manual handling. With the semi-automatic drive head wrench, hydraulic cylinders, and Epiroc Rig Control System (RCS 5) as enablers for automation, users can increase productivity and operator safety. Additionally, thanks to RCS 5, more efficient, reliable, safe, and user-friendly operations can be enabled while reducing overall energy and maintenance costs.

To streamline drilling operations, improve customer service and training techniques, the Robbins 74 S is equipped with digital and automation tools. The Measure While Drilling (MWD) collects drilling data for evaluation and predictive analysis. My Epiroc enhances the customer experience and functionality through a modern interface and comprehensive fleet management, supported by various devices, including smartphones and tablets. Lastly, Virtual Reality technology enables general training and equipment walk-throughs of the raiseboring machine and drill site.

The Robbins 74 S focuses on enhancing the durability of main components and boosting operational efficiency. This raiseboring machine has a new swivel design equipped with wear sleeves to reduce the risk of bailing, wear and tear in high-risk areas and to simplify the assembly. Moreover, the improved drivetrain features a float box positioning indicator that increases control of the threading process through continuous monitoring. Thanks to this, the operator can improve accuracy and proper alignment, resulting in smoother borehole walls and increased durability of the equipment. The drivetrain is also equipped with a protective cover to shield the main machinery from dust, debris, and other physical impact that can cause wear and tear.

With its sturdy and high-quality design, Epiroc adds that the Robbins 74 S facilitates easy operations and maintenance. Standard functions in combination with new machine features, such as the automation ready pipe loader, semi-automatic drive head wrench, and the improved swivel and base plate design, make the machine more efficient. Standard functions include anti-jamming, auto make-up, and the gradual ramp-up of speed and torque.

 

Hexagon, Scania and Fidens successfully debut Brazil’s first teleoperated 8×4 mining truck

Automation, Equipment maintenance, Mining equipment, Mining people, Mining safety, Mining services, Mining software

Hexagon, the global leader in sensor and software technologies, has partnered with Scania and Fidens to successfully debut Brazil’s first ever remotely operated 8×4 mining truck. The collaboration brings together industry knowledge across integrated technology, heavy equipment and situational expertise that Hexagon says will result in significant operational gains for mines in Brazil and worldwide.

The ‘groundbreaking’ initiative combines Hexagon’s sophisticated HARD-LINE TeleOp remote operation technology with Scania’s robust G 500 8×4 XT model mining truck and Fidens’ expertise in mining operations. The result is a remotely operated, super-capacity heavy tipper that prioritises safety while heightening speed and productivity in challenging mining environments.

HARD-LINE TeleOp serves as a virtual command chair for the truck operator, enabling safe navigation of vehicles from kilometres away. Thanks to the solution’s onboard cameras and sensors, operators can perform all normal driving tasks from the chair, positioned in a secure office-like environment, even from a considerable distance. The solution’s faster and more direct communication with the truck’s steering system means that every second that might have been lost to delays in command signals translates directly into increased productivity.

With Brazilian regulators recently mandating the decommissioning of hazardous tailings dams, this teleoperation – which can be adapted to any model Scania truck – Hexagon says is a revolutionary development. The deployment of autonomous solutions can help mine operators safely accelerate work in such high-risk areas while reducing environmental risks and costs.

“This is a watershed moment for Brazilian mines,” says Rodrigo Couto, President, Latin America, Hexagon’s Autonomous Solutions – Mining. “We are shaping a new reality, demonstrating with our partners how technology can help mines be more productive and address the critical need for tailing dam decommissioning. Because TeleOp is adaptable to other truck models, this is just the beginning of what we know will be a highly impactful and positive transformation for the industry.”

Enaex continues to innovate for mining’s bright future

Automation, Bulk handling, Environmental, Explosives and blasting, Mineral processing, Mining consumables, Mining equipment, Mining safety, Mining services, Mining software, Sustainable mining

During the EXPONOR 2024 event in Antofagasta, IM Editorial Director Paul Moore met with Enaex Key Account Manager Sebastian Catron to discuss its latest innovations and offerings to the mining sector. Catron began: “After we win the bidding process to supply explosives and blasting services to a mining customer, whether that is a renewal of an existing contract or a new contract, as part of that commercial relationship, we have KPIs that we must ensure that we meet and hopefully exceed. And one of the best ways of doing that is to introduce new products, technologies and innovations. Our clients’ priorities are topped by productivity, safety and cost reduction – reducing the cost per tonne.”

IM Editorial Director Paul Moore with Sebastian Catron, Enaex Key Account Manager at EXPONOR 2024

Looking at products, two of the Chile-based explosives giant’s latest innovations are in emulsions. “The first one is related to wall control and slope stability – that is being able to more precisely create steeper walls as well as limiting wall damage. This is not a new problem but one that the mining industry is now looking at it with a new perspective particularly as benches in some cases are getting higher and steeper to reduce costs as grades get lower.” Catron said they have developed a lower energy and lower density product called Densiex® that they are testing right now at client sites. “It is an emulsion that stands out for its reduced vibration and VoD, hence it reduces the effect induced by the blast, compared to traditional emulsions. We have already seen a lot of good results and are just adjusting and fine tuning the calibration of the MMUs. It’s a really promising product.”

At the other end of the emulsion scale with high energy products, Enaex is looking the make a positive impact in mine to mill projects, and at expanding the blasting pattern – customers want products that allow to obtain lower powder factors – using less explosives to obtain the same blasted tonnes and maintaining or even improving fragmentation results.

It already has its standard bulk emulsion products Vertex® and Pirex® – Pirex® is a blasting agent that increases safety in mines with more reactive rock with a high pyrite content. Vertex is a versatile blasting agent, specially designed to optimise energy and expand grids. Its new higher energy products are Vertex® S and Pirex® S.

Catron: “Both products are enhanced using proprietary additives including physical sensitisers allowing them to offer high energy and improved power. We are currently penetrating the market with these higher energy products with our larger clients and in the coming years we expect a greater shift away from standard products and towards more engineered products as the focus on cost reduction becomes even greater with lower grades in the copper mining industry. These products bring better fragmentation results; plus a lower overall cost due to a lower powder factor. Plus you are able to expand drilling patterns which comes with savings in the drilling process.”

Innovation also extends to the MMUs themselves. “We are already known for supplying some of the largest MMUs in the industry, our Milodon units which can load 30 tons of explosives, and we continue to work on those in terms of increasing volume and capacity even further. All the Milodon engineering is proprietary to Enaex. And actually, there are a lot of technologies involved in blasting execution that we are able to provide to clients thanks to our MMUs.” A good example is its overhead arm so the truck doesn’t have to relocate every time that it loads a hole.

Enaex RoboPrimer® for robotic and autonomous priming, improving the safety and productivity of the overall process

Work also continues on projects to automate the MMUs and related equipment and also to power them with diesel alternatives. The autonomy work is being done by the Enaex Robotics division. “We are working on three new products – first a semi-autonomous surface Milodon MMU which is already working at an operation near Santiago– it is still trammed manually to the working area but then switches into remote control mode to load the holes with the operator sitting at a control station elsewhere. The semi-autonomous MMU has given us a lot of information and feedback about autonomous operations, that we are pouring into the design and software updates of our fully autonomous MMU: Mine-iTruck®. Then there is RoboPrimer®, our solution for robotic and autonomous priming, which improves the safety and productivity of the overall process. RoboPrimer® has been extensively tested at our testing grounds near Santiago but is not yet being used commercially at client sites. Thirdly we have our UG-iTruck® for underground autonomous loading – this is already running at an underground operation in the north of the country.”

There is also innovation in electronic initiation systems – where there are two new solutions. First is the latest version of its established DaveyTronic programmable electronic detonators called DaveyTronic 5®. “It has a new ASIC meaning increased memory for enhanced data capabilities. It stores blast ID, length, traceability and GPS coordinates. The log files for executed functions ensures better control. Extended delay time provides flexibility for advanced blast designs and optimisation of operations. Enhanced electric protection safeguards against EMP and ESD. Plus a new connector has better mechanical strength and extreme cold resistance.”

Then there is DaveyTronic Edge, where Enaex removed the surface wires, meaning a significant reduction of the operations on the bench (connecting, troubleshooting), while keeping two-way communication. “Bi-directional radio modules are placed on the surface of the open-pit mine. The wireless network communicates with a digital blasting system located a few meters away from the blasting zone and is controlled by a wireless communication protocol specifically developed and optimised to ensure safe, reliable and synchronised operation of hundreds of detonating elements. This is paving the way to teleoperated/ automated priming operations. This has completed testing and is now in a market scaling phase – productivity rates have increased a lot due to the much faster programming and checking of the detonators. For a pattern of 200+ holes this now takes 20 minutes or less – it used to take hours.”

With DaveyTronic Edge, Enaex removed the surface wires, meaning a significant reduction of the operations on the bench while keeping two-way communication

The last area Catron touched on was greater digitalisation of blasting. “We set out to develop a new digital ecosystem to bring increased availability of data and information for closer blasting control. Customers also want better understanding of the next bench in terms of the rock quality and structure. To meet these expectations we developed a solution called Enaex Bright.”

Enaex Bright is a digital platform designed for blasting optimisation and digital integration with mining clients, for the final purpose of enhancing productivity by reducing the variability of the processes. This platform provides the opportunity to learn about the operational process through artificial intelligence tools for the purpose of propose operational optimisations. Moreover, it generates digital information to facilitate integration with clients’ systems and enables traceability of the complete process from design to the blasting result. This makes it much easier to manage KPIs.

Enaex Bright has four main modules – Bright Scan, quality assessment module to control drilling, loading, and blasting execution; Bright Blast to optimise fragmentation and digging results including getting information direct from the blasthole drills as they drill holes using scanners to analyse the rock and predict rock hardness even days or weeks before the pattern is actually blasted and adjust the explosives energy profile for holes based on that. Finally, Bright Fleet to ensure on-time operations and deliveries; and Bright Care to take care of nearby communities and infrastructures.

Chile is also set to host International Mining Events‘ Electric Mine 2025 conference, being held May 13-15 at Centro Parque in Las Condes, Santiago.

Cat MINExpo line-up to include charging systems, autonomous ready 798 AC plus new CAS offering

Automation, Bulk handling, Environmental, Equipment maintenance, Mine shafts and equipment, Mine surveying, Mining consumables, Mining equipment, Mining events, Mining maintenance, Mining safety, Mining services, Mining software, Mining techniques, Power supply for mines

The Caterpillar MINExpo 2024 experience it says will immerse visitors into the mine site of the future; featuring industry leading technologies, groundbreaking advancements in the energy transition and first-of-a-kind customised solutions designed to increase customers’ efficiency, safety and profitability.

The planned 2024 exhibit “reinforces Caterpillar’s position as the global industry leader in mining technology with proven results in autonomy and automation and demonstrated progress in greenhouse gas reduction technologies.”

“Caterpillar’s legacy is to deliver an exceptional experience at every job site through customer focused solutions and services,” says Denise Johnson, Caterpillar Resource Industries’ Group President. “As our exhibit shows, together with our customers, we are mining better, smarter and safer. And this is just the beginning of our closer-than-ever before collaborations with customers.”

The 798 AC is configured for autonomous haulage

The showstopper will be the towering, 372 t (410 ton) Cat® 798 AC diesel-electric drive mining truck which has the highest standard payload in its class. The 798 AC is configured for autonomous haulage with Cat MineStar™ Command for hauling. “We believe systems, such as Command for hauling, are essential to optimise mine site performance, both with our current product line and as we introduce new offerings like our battery electric solutions,” comments Marc Cameron, Senior Vice President, Caterpillar Resource Industries. “Autonomous technology will help monitor and orchestrate the complex balance of onboard energy, available charging assets and production targets to achieve the lowest operating costs.”

Caterpillar’s underground Cat R1700 XE load-haul-dump (LHD) loader features battery-electric propulsion that produces zero exhaust emissions and generates less heat than a reciprocating engine powered model. The Cat R2900 XE LHD provides a high efficiency switch reluctance electric drive system that meets the mining industry’s needs for bigger payloads, faster loading and lower emissions. The 12.2-m-long (40-ft-long) PGS 1260 HD Energy Storage System (ESS) module offers energy storage for charging battery electric machines, and the MEC500 provides mobile equipment charging for the underground mining industry.

“Since MINExpo 2021, our teams have made incredible progress with the development of our electric technology and supporting solutions,” comments Brian Weller, Vice President of Electrification, Caterpillar Resource Industries. “We have been working side-by-side with select customers to accelerate the deployment of Caterpillar’s first battery-electric haul trucks. These machines will soon be operating at our customers’ sites where they will be tested and validated across a variety of applications.”

From fleet management to fully autonomous machine operation, Cat MineStar™ technology it says has transformed the mining industry. Caterpillar provides building block technology packages that are scalable to meet the mining operation’s needs as it moves along the technology integration journey. Visitors will be able to experience interactive engagement with MineStar fleet management solutions for both surface and underground operations at the exhibit’s conversation stations. A third station allows attendees to explore precision mining solutions dedicated to site optimisation.

Every piece of equipment that will be on the show floor is infused with various levels of technology. In addition to the ultra-class 798 AC featuring Command for hauling, the R2900 XE LHD will be equipped with Cat MineStar Command for underground that enables remote machine operation. The diesel-electric LHD will also feature MineStar Detect for underground to safeguard against unintended interactions between personnel and assets and enhance operator alertness, both enhancing operating safety. Optional technologies available for the Cat 995 wheel loader include Payload Overload Prevention, Operator Assist, Operator Coaching and Terrain for loading to further boost operator efficiency and productivity.

Caterpillar is set to launch two new technology offerings to the MineStar ecosystem at the show. Delivering the next layer of safety, its new Collision Awareness System (CAS) is a site-wide solution that uses the latest in technology advancements to enhance situational awareness by warning operators of potential machine interactions before they have a chance to happen. CAS will be highlighted on the 995 and 798. A new office application for Terrain Payload Management expands the payload tracking technology to Cat Electric Rope Shovels and Draglines.

Virtual reality experiences will also allow attendees to ‘get into the cab’ of the Cat 7495 Electric Rope Shovel and 6060 Hydraulic Mining Shovel. Showcasing the capabilities of Cat Command technology, two remote operating stations will give visitors the chance to operate a dozer or rotary blasthole drill located hundreds of miles away from the Caterpillar exhibit. A third station will offer simulations of Cat Command for underground, demonstrating the technology’s versatility and ease of use.

“Customers will experience our latest technology innovations and autonomous developments throughout the Caterpillar show floor at MINExpo,” says Sean McGinnis, Vice President and General Manager of Technology and Global Sales Support for Caterpillar. “Mine site automation makes significant impacts in operations and not just with autonomous haulage. Today, we have customers around the world utilising our autonomous solutions for drilling, loading, dozing, hauling and underground, and we are working with many customers to develop the autonomous sites of tomorrow.”

The in-booth Caterpillar service bay and nearby displays will highlight options available to mining customers for maintaining the machinery and meeting production targets. Track pad displays for rope and hydraulic shovels and dozers will show the latest offerings designed to maximize undercarriage life.

Demonstrating the innovative ways Cat dealers keep machines operating with minimum downtime, attendees will be able to step inside a service van, which makes customized hose and couplings right on site. The van offers the capabilities of quickly returning a machine to service by making the necessary size and length of the hose for repair.

Conversation stations allow team members to engage with customers on a range of topics including, but not limited to: repair options, parts and component remanufacturing, machine rebuilds, various truck body options, and bucket choices. Also, a range of 3D printed parts will be on display along with multiple engine exhibits, including the Cat C32 Reman, C32 core, upgraded 3512 E and C175 cutaway.

Spanning machines to technology to services, Cat Job Site Solutions ties everything together with customized, scalable solutions that are results driven. Team members will meet with attendees to demonstrate how, working with the dealer, Cat Job Site Solutions provides a strategy with intended outcomes and a plan for action that meets the unique challenges of the mine site. Additionally, team members cover how Cat Customer Value Agreements (CVA) provide a custom services package to enable hassle-free ownership of equipment.

From projects in emerging markets to investing in established ones, Cat Financial finances deals globally and understands the mining industry’s cyclical nature and the uniqueness of the customer’s needs. Financial experts at the financing conversation station will be there to explain how Cat Financial is built to deliver customized solutions for the equipment’s lifecycle needs. From initial purchase to maintenance, repairs, rebuilds and technology upgrades, Cat Financial tailors solutions to maximise return on investment of the mining equipment.

The 798 AC features a refreshed cab for operating at high altitudes plus a three-piece window design to improve visibility. Truck messaging will convey the number of ways mines can lower GHG emissions today through alternative fuel options and electric drive systems. Additionally, video stories will show how customer rebuild efforts are driving sustainability at mines, while scale truck bodies will cover the range of options Cat trucks offer for maximising payload and hauling program efficiency.

The latest next generation loader, the recently introduced Cat 995 will anchor the “loading better” display, equipped with a 27.5 m3 (36 yd3) and Cat Advansys™ 230 GET system to move more material with less downtime. Built to the same size as the 994K, the 995 features a higher rated payload and demonstrates 21% higher efficiency and 24% more production than the 994K in equal operating mode.  In Enhance Eco Mode, demonstrates up to a 30% increase in efficiency and 11% reduction in hourly fuel consumption versus the 944K in throttle lock mode.

For the underground space, the displayed diesel electric R2900 XE LHD features optimised lift arm and component geometry plus load-sensing hydraulics to improve breakout force. Compared to its predecessor, the R2900 XE LHD also delivers 52% quicker acceleration; 7% higher speed on grade; and up to a 20% increase in productivity.

Beyond zero-exhaust emissions and fast charging, the battery electric R1700 XE LHD boasts a 15 t (33,069-lb) payload, 18 km/h (11.2 mph) fully loaded top speed and up to 2.5 hours of aggressive run time between charges. Five bucket size options offer capacities ranging from 5.7 to 7.5 m3 (7.5 to 9.8 yd3).

The Cat 24 motor grader will represent the range of haul road maintenance machines that includes the 14, 16 and 18 models. The C24’s High-Performance Circle (HPC) provides a 16,000-hour service life and eliminates frequent inspection, wear strip replacement and circle shoe adjustments. It will be displayed with Caterpillar’s 8.5 m (28-ft) moldboard option – 16% longer than the standard blade – to enhance safety at larger mines by reducing the amount of time spent in the middle lane to clear the windrow.

The largest of the Cat drill rig offering, the exhibited MD6310 rotary drill shares a common platform, parts, components and technologies across the product line. Ideal for high-production drilling on 12 and 15 m (39.4- and 49.2-ft) bench heights, it is capable of drilling up to 311 mm (12.25-in) hole diameters and offers up to 30˚ angle hole drilling for cast blasting. With building-block technologies through semi-autonomous operation, the MD6310 was one key contributing factor to global mining services provider, Thiess, surpassing 1 million metres autonomously drilled milestone using Cat drills.