All posts by Paul Moore

Rio Tinto approves new solar plant to power Kennecott

Rio Tinto has approved construction of a new 25MW solar plant at its Kennecott copper operation in Utah, bringing the mine’s total solar capacity to 30MW.

The new solar plant will be located next to Kennecott’s existing 5MW solar plant, which was completed in 2023. Together, the two solar plants will reduce Kennecott’s Scope 2 emissions by approximately 6%, or 21,000 tons of carbon dioxide equivalent per year. This is equivalent to removing around 5,000 petroleum-powered passenger cars from the road.

Construction of the 25MW solar plant is expected to be completed next year and create short-term employment opportunities for up to 100 labourers, as well as a small number of long-term operations and maintenance roles. Bechtel Corporation will design and manage construction of the plant.

Kennecott, which already has one of the lowest carbon footprints of any copper producer in the US, has reduced its carbon footprint more than 80% since 2018 through initiatives such as closing its coal-powered power plant, building a 5MW solar farm, transitioning the mining fleet to renewable diesel, and using battery electric vehicles in underground mining.

Rio Tinto Kennecott Managing Director Nate Foster said: “Expanding our solar farm is the latest step in our journey to reduce our carbon footprint. Together with other measures we’ve taken, such as closing a coal-fired power plant, deploying battery electric vehicles underground, and our recent transition to renewable diesel, we have reduced our emissions by millions of tons over the past few years.”

He adds: “We’re demonstrating every day that sustainable practices and resource production can go hand-in-hand to benefit our company as well as our community.” The 210-acre solar array will include more than 71,000 panels, which contain tellurium produced by Kennecott, a byproduct of mining and refining copper. In 2022, Kennecott became one of only two US producers of this critical mineral. Both copper and tellurium are vital components of photovoltaic solar panels.

Komatsu introduces new WA700-8 wheel loader

Komatsu has announced the new WA700-8, a powerful and efficient addition to its range of wheel loaders designed for quarry operations and aggregate producers. This wheel loader is an ideal four-pass match with 70-ton trucks such as Komatsu’s new HD605-10 haul truck. The WA700-8 also offers substantial improvements in performance, efficiency and operator comfort compared to its predecessor, the WA700-3.

Compared to the previous model, the WA700-8 delivers up to 8% more gross power and 15% more torque, making it a robust choice for demanding work environments; plus a 6% increase in lifting force and rated load, allowing operators to handle larger volumes of material with greater ease. It also offers up to 8% more fuel efficiency, helping reduce operating costs while maintaining high productivity.

The WA700-8 features a comfortable cabin with technology designed to help reduce operator fatigue on long shifts, including a new advanced joystick steering system and electronic pilot control levers for precision and ease of operation. Automation features such as an automatic digging system, semi-automatic approach, and semi-auto dump systems simplify repetitive tasks, helping operators optimise load cycles. These systems are particularly beneficial for less experienced operators, helping to close skills gaps and enhance overall operational efficiency.

On challenging terrain, the variable traction control system helps prevent tyre slippage, prolonging tyre life and improving safety in wet or slippery conditions. The loader’s modulated clutch system offers precise control for smooth transitions between forward and reverse, which is critical during truck-loading operations. An available KomVision camera system provides operators with a comprehensive view of the machine’s surroundings, and Komtrax Plus offers remote monitoring and data-driven insights that can help reduce unplanned downtime.

“The new WA700-8 can help quarry operations hit that sweet spot for 70-ton truck loading, making every pass count,” said Sebastian Witkowski, Product Manager. “With a heavier operating weight, greater static tipping load and larger breakout force than the previous model, the WA700-8 is a productive and efficient wheel loader that is ideal for quarry operations.”

ABB launches SIL 3 certified ABB Ability™ Safety Plus Hoist Protector Version 3.0

ABB is launching the latest technology development in its portfolio of mine hoist safety products by introducing the fully SIL 3 certified ABB Ability™ Safety Plus Hoist Protector Version 3.0. This solution is part of the ABB Ability™ Safety Plus for hoists suite, the first fully SIL 3 certified mine hoist solutions with highest level of safety on the market​.

With this release, independently certified according to IEC 62061 Ed. 2.0, ABB has increased the number of safety functions to include many that are applicable to smaller hoists and Blair multi-rope hoists, as well as functions based on the continuous monitoring of the rope load.

It is now also applicable to the full hoist lifecycle. The life of a hoist normally starts with sinking the shaft. Digging and creating the shaft carry different risks to operating the completed hoist. Previously, operators needed separate safety products to deal with these two life stages of underground hoisting equipment, but the latest version of ABB Ability™ Safety Plus Hoist Protector can handle the full lifecycle of the hoist, from shaft sinking all the way to the end of life.

The 3.0 version also means a step change in the productisation of hoist safety technology, which has two major benefits. Compared with designing a bespoke safety solution for every hoist and its site and having to perform the complete functional safety verification and validation on each project, Safety Plus Hoist Protector V 3.0 is already validated and third-party certified for 25 different safety functions, off the shelf, at a significantly lower cost to customers. If other custom safety functions are required for a particular site, the product is already prepared for a simple integration of these functions into its ecosystem.

Having products that handle the whole mine hoist safety across an ever-expanding number of customer sites allows ABB to receive feedback from a global user base, and redeploy improvements made based on the learnings to all sites.

ABB states: “Whether you are required to comply with local regulations or simply want to improve your standards, we have designed ABB Ability™ Safety Plus for hoists. It is the first fully SIL 3 (Safety Integrity Level) certified suite of solutions for hoists, rigorously examined and certified by an independent functional safety certifying body, and strictly developed in accordance with the International ‘Safety of Machinery’ standard IEC 62061.”

It is composed of three solutions offering the highest level of safety available on the market: Safety Plus Hoist Monitor, Safety Plus Brake System, and Safety Plus Hoist Protector.

Gradiant’s alkaLi it says sets new standards in Direct Lithium Extraction

Gradiant’s spin-out, alkaLi, it says is leading the direct lithium extraction (DLE) and production market with its EC2 technology, which has demonstrated a ‘groundbreaking’ 97% lithium recovery rate from salar brines in North America. The new technology is guaranteed by Gradiant to deliver at least 95% lithium recovery at customer sites. It says this empowers industries to produce battery-grade lithium carbonate faster, cheaper, and more sustainably than ever.

alkaLi’s EC2 technology it says is the first and only all-in-one solution engineered to extract, concentrate, and convert battery-grade lithium to meet the accelerating demand from EVs, energy storage, and electronics. It says producers now benefit from reduced costs with 50% lower OPEX and CAPEX costs; industry-leading sustainability with minimised carbon and water footprints; accelerated Production now measured in hours, not months;  compact footprint in the form of rapidly deployable mobile 20 ft or 40 ft containers; and expedited permitting with product water in discharge compliance and ready for re-injection.

alkaLi has already proven EC2’s concentrate process for a leading US energy company at a commercial site in Clayton Valley, Nevada, to demonstrate the effectiveness of the foundational CFRO technology to concentrate lithium to battery-grade quality.

Demonstration testing of EC2’s three stages using salar brine feedwater confirms extraction of over 95% DLE efficiency, even with high COD content; plus CFRO technology concentrates lithium to battery-grade levels above 200,000 mg/L. It precipitates highly concentrated lithium into a solid to produce battery-grade lithium carbonate or lithium hydroxide. alkaLi’s Elemental Technology approach adapts the EC2 technology stack to recover a wide range of other critical minerals, including copper, nickel, cobalt, manganese, magnesium, and iron.

Later this month, alkaLi says it will commission a custom solution with a global mining leader in Western Australia, focusing on nickel and cobalt recovery from mine wastewater. Enhanced with Gradiant’s Selective Chemical Extraction technology, the solution purifies feedwater, readying it for CFRO – “a breakthrough system that outperforms any commercially available RO processes, delivering a concentrated 300,000 mg/L product with minimal energy use.”

Once deployed, alkaLi will transform tailing ponds from environmental liabilities into valuable mineral sources, offering a sustainable path to meet global mineral demand. At another site in Southeast Asia, the EC2 technology is already converting mine wastewater into high-value industrial-grade magnesium sulphate.

“alkaLi’s modular approach to engineering the EC2 technology stack continues a Gradiant philosophy of maximising the impact of our cutting-edge innovation across industries and regions,” said Prakash Govindan, COO of Gradiant. “The minerals we target are essential to accelerating the electrification of society, and I am thrilled that alkaLi will play such an important role in availing these raw materials to the world’s pioneers.”

Gekko Systems Wolff Concentrator enhances gold recovery and water stewardship

Gekko Systems has announced the launch of the Wolff Batch Centrifugal Concentrator, described as a groundbreaking technology designed to transform gold processing by utilising ‘dirty’ water. The ‘first of its kind’ innovation Gekko Systems says enables mining companies to recycle water efficiently, addressing water stewardship and enhancing sustainability, while reducing maintenance costs and requirements.

The mining industry is committed to enhancing water management practices while also improving efficiency, safety, and productivity. In some locations, mines face the challenge of having no or very limited access to fresh water. The Wolff gravity-based, batch centrifugal concentration (BCC) system helps meet these challenges by enabling mines to operate using non-potable water, including both recycled and contaminated sources.

“Water is a scarce commodity in mining and mining operations are now looking for ways to reduce fresh water consumption,” said Sandy Gray, Co-Founder and lead inventor at Gekko Systems. “The Wolff enables mines worldwide to improve resource availability and recovery while enhancing sustainability through the use of recycled water.”

Traditionally, maintaining batch centrifugal concentrators (BCC) involves complex and costly procedures, characterised by significant downtime and safety risks associated with crane operations. The Wolff transforms this process with its unique patented bowl design, reducing maintenance time and eliminating the need for cranes during bowl changes, resulting in a significantly safer working environment for mine personnel.

Kaiser Reef has partnered with Gekko Systems in a pilot project using the Wolff at their processing plant in Maldon, Victoria. The collaboration Gekko says is yielding exceptional results, including improved gold recovery, a decrease in the stripping requirements of carbon, as well as a reduction in reagents consumption within the CIL circuit.

Kaiser Reef is entering into new high grade ore body that responds very well to gravity recovery. “However, we have a small throughput, so it was difficult to use traditional gravity concentrators due to the volume of water required. Using Gekko’s new Wolff BCC technology we have been able to install the unit using process water enabling us to improve recovery and reduce operating costs,” said Dylan Morgan, Processing Manager, Kaiser Reef.

Sandy Gray is appreciative of the support of Kaiser Reef: “It has been fantastic that Kaiser Reef’s vision and management focus has allowed us to install new technology into their circuit. We appreciate the support that Kaiser Reef has shown Gekko that has allowed us to take the new Wolff technology to a new level so that it is now market ready. We’re looking forward to witnessing its impact in the mining industry.”

The cited Gekko Wolff Concentrator operational benefits are that it is tailored for dirty water usage with anti-plugging design features and segmented bowl; plus it enables water recycling in processing gold, reducing the need for fresh water. It also reduces maintenance time and improves safety by eliminating the need for cranes to manage bowl changes plus meets low head height requirements for installation.

EACON Mining wins two more AHS projects utilising new autonomous electric trucks

EACON Mining has announced two new autonomous haulage projects in the aggregate mining sector, both utilising the all electric mining truck model EY70E. A total of 29 units of the EY70E will be deployed at the Pingyin Quarry and the Shuichang Quarry.

The company stated: “Both projects mark EACON’s expanded presence in the quarry sector, driven by strong customer trust in our AHS solutions. The use of fully electric vehicles in these operations supports sustainable mining development, contributing to more environmentally friendly practices.”

The Pingyin Quarry, operated by contractor China National Building Material Group (CNBM), has an annual production capacity of 8 Mt, supported by three production lines. Each cycle for the 19 EY70E trucks at this site spans up to 6 km. On the other project, Shuichang Quarry, 10 EY70E trucks will be deployed for a newly established aggregate production line. Owned by Shougang Group, Shuichang Quarry is an iron ore site that plans to repurpose waste dump material for aggregate production after mining completion.

The EY70E deployed in these projects is the latest model from the collaboration between EACON and Yutong. This fully electric truck has a payload capacity of 70 t and is equipped with EACON’s advanced autonomous haulage system, ORCASTRA®, and drive-by-wire steering system, built on Yutong’s base truck platform. The base truck for the EY70E has been well received globally, and since its launch in August 2021, the base model for the EY70E has sold over 600 units across three countries. This electric truck supports zero carbon emissions while offering reduced maintenance and repair costs. The EY70E’s regenerative braking technology recovers energy during downhill trips, enabling extended travel distances in operations with loaded downhill haulage.

Yutong is a key OEM partner of EACON. Another jointly developed, battery-powered autonomous model, the EY60E, has been operating in a fleet of 20 at the Fushan Quarry – which is also managed by contractor CNBM – since May 2023. This fleet has collectively traveled over 470,000 km, reducing emissions by more than 3,000 t.

EACON says it is leading the mining industry’s shift to electrification, pioneering fully electric autonomous vehicles. “Our commitment to innovation and sustainability defines our mission to reshape mining – enhancing safety, cutting emissions, and setting new standards for a cleaner, more sustainable future.”

 

SLR Consulting acquires Robertson GeoConsultants Inc

SLR Consulting (Canada) Ltd recently announced the acquisition of Robertson GeoConsultants Inc (RGC) as of November 1, 2024. RGC is a global consulting firm that specialises in mine water characterisation, geochemistry and acid rock drainage/metal leaching, hydrology, hydrogeology and groundwater modelling for the mining industry. The move comes just after SLR Consulting announced the acquisition of Wardell Armstrong in the UK in October.

Based in Vancouver, British Columbia, Canada, RGC has completed over 150 projects in 16 countries at some of the largest and most remote mines in the world. The statement said: “RGC brings a highly skilled team of engineers and scientists known for their technical excellence and a commitment to delivering innovative, practical solutions for clients. The addition of RGC to the SLR team represents another step forward for SLR in the building of our capability and industry profile, significantly strengthening our integrated mine water services capabilities in Canada and globally.”

It added that RGC’s focus on advancing leading environmental approaches and technologies aligns with SLR values and mission of Making Sustainability Happen. Craig Johnston, SLR Canada’s Managing Director, said, “We share common visions and values with RGC, and I am thrilled to welcome them to our team. As SLR continues to grow and build out our services, RGC is a strategic addition in a highly specialized technical area related to mine water management. We look forward to leveraging their expertise to continue delivering value-driven solutions and build trusted partnerships with our clients.”

Christoph Wels, RGC’s President and Senior Hydrogeologist, added: “We are excited to join the SLR team. At RGC, we prioritise technical excellence, innovation, client relationships, and fostering a strong team culture – ideals that we also see reflected at SLR. This alignment makes it a great partnership. We look forward to contributing our experience and skills to SLR while expanding our team and client base, across Canada and the world.”

Mining truck automation tech company CiDi files for IPO in Hong Kong

Demand for autonomous mining truck technology industry in China is growing rapidly, driven by the ageing workforce in mining, increased labour costs, a desire to boost efficiency as well as regulatory safety mandates. Therefore the competitive landscape also continues to heat up.

Along with TAGE Idriver, Waytous and EACON Mining, which have been widely covered in IM in recent years is CiDi Inc, which on November 7 filed an IPO application to the Hong Kong Stock Exchange (HKEX), with China International Capital Corporation, China Securities International, and Ping An of China Asset Management (Hong Kong) as joint sponsors. If approved, CiDi will become the first publicly listed autonomous mining truck company in China. Its backers include the venture capital unit of Baidu, Sequoia China and Legend Holdings.

In the filing, CiDi states: “Our pioneering full-stack autonomous mining solution, METAMINE, automates labor-intensive mining operations by integrating our proprietary algorithms with widely-used autonomous driving hardware for commercial vehicles, enabling autonomous operation and remote monitoring of driverless mining trucks. A challenging but critical process in autonomous mining is deploying driverless mining trucks alongside existing human-driven vehicles at mining sites, as it is costly and often impractical to transition to fully autonomous mining operations within a short timeframe.”

It claims to have delivered the world’s largest driverless mining fleet operating with manned vehicles, it says according to data from China Insights Industry Consultancy Ltd (CIC), a market research consultant. CiDi adds: “Our autonomous mining trucks also significantly boosted mining efficiency to 104% of that of human-driven mining trucks, as certified by the National Institute of Metrology of China (NIM) in 2022.” It additionally claims that this makes CiDi “the first and only autonomous driving company in China to achieve such efficiency as of the Latest Practicable Date,” again citing CIC. The efficiency test compared nine of CiDi’s driverless mining trucks to nine human-driven trucks (with drivers working 8-hour shifts), all operating for 16 hours daily under otherwise the same conditions.

CiDi says it served 31, 44, 85 and 100 customers as of December 31, 2021, 2022 and 2023 and June 30, 2024, respectively. As of September 30, 2024, it says it had delivered 123 autonomous mining trucks and received indicative orders for 320 autonomous mining trucks and 206 sets of standalone autonomous truck systems. Key clients include the Taiwan Cement Corporation (TCC) Cement Mine in Jurong, Jiangsu Province, where it says a fleet of autonomous EV mining trucks equipped with its technology had successfully operated for a total of 765,800 kilometres up to May 10 2024, having commercially run for over 500 days, hauling a total of 8.9 Mt of material, resulting in 4,489 t of carbon emissions savings. These are 60 t class SKT90E trucks supplied by SANY.

Internationally, it is liasing closely with the Kingdom of Saudi Arabia for potential deployment of autonomous haulage technology for the huge NEOM urban development project. On the R&D side CiDi has hubs in Changsha, Chongqing and Chengdu with projects including developing an all battery, cabless autonomous prototype truck.

It adds: “Our revenue increased from RMB77.4 million in 2021 to RMB132.6 million in 2023 with a CAGR of 30.9%, and increased significantly by 472.6% from RMB45.1 million in the six months ended June 30, 2023 to RMB258.5 million in the six months ended June 30, 2024. Our gross profit increased from RMB6.8 million in the six months ended June 30, 2023 to RMB44.4 million in the six months ended June 30, 2024.”

The company then includes some information about the autonomous mining truck industry in China. “In 2023, the total shipment of autonomous mining trucks in China was approximately 800 units. This is projected to increase to approximately 3,800 units in 2026 and further to over 13,000 units in 2030. Globally, the total shipment of autonomous mining trucks was approximately 1,200 units in 2023, and is expected to increase to approximately 6,000 units in 2026 and exceed 20,000 units in 2030. In 2023, the average price of autonomous mining trucks in China was approximately RMB2.5 million per unit, compared to over RMB5.0 million per unit in the international market.”

Again attributing figures to CIC, CiDi says China’s autonomous mining market is highly concentrated, with the top four players accounting for a total market share of 89.9% in terms of revenues from autonomous mining in the six months ended June 30, 2024, while the market share of each remaining player is below 5%.

CiDi adds: “China’s autonomous mining industry is rapidly expanding, with market size reaching RMB0.4 billion in 2023, representing approximately 35.4% of the autonomous driving market within closed environments. By 2030, the market is expected to grow significantly to RMB24.8 billion, at a CAGR of 78.4% from 2023 to 2030. The total addressable market size of China’s autonomous mining industry in 2023 was approximately RMB550 billion.”

XCMG marks a decade of UzXCMG joint venture operations in Uzbekistan

Marking its 10th anniversary, the UzXCMG joint venture has successfully manufactured its 3,000th piece of equipment plus has announced significant expansions including a new customs warehouse to boost logistics efficiency. The milestone was celebrated on October 21, 2024 with multiple agreements signed to enhance local industry and talent development.

Since its establishment in 2014 as XCMG’s first manufacturing base in Central Asia, UzXCMG says it has rooted itself deeply into the local market. Over the past decade, it has delivered thousands of machines widely used in mining, municipal engineering, and agricultural irrigation projects across Uzbekistan. This contribution has significantly propelled economic growth within the region. The company is a joint venture between XCMG and Joint Stock Company Uzbekistan Railways.

The anniversary event was highlighted by a series of celebratory activities including the signing of a major contract for one hundred wheel excavators. These machines are set to support various large-scale projects in urban construction and mining sectors locally. Additionally, UzXCMG inaugurated its customs warehouse, which is expected to greatly enhance clearance and logistics operations facilitating quicker customer responses.

In an effort to foster local talent development, Xuzhou Construction Machinery Technician College along with UzXCMG signed cooperation agreements with representatives from the Khwarezm regional government. These agreements aim at establishing the XCMG Modern Construction Equipment Industrial Academy, which will integrate educational resources from government, enterprises, and schools creating a leading example for industry education while training skilled local personnel.

Yang Dongsheng, Chairman of XCMG Machinery, expressed confidence in deepening cooperation within Uzbekistan under the company’s localised strategy ‘In Uzbekistan, For Uzbekistan.’ He emphasized this approach as foundational for transforming UzXCMG into Central Asia’s production hub over the next decade, injecting new vitality into regional development.

Murodjon Achilov Azamatovich, First Deputy Governor of Khorezm region praised UzXCMG’s contributions saying: “Not only does UzXCMG provide us with advanced engineering machinery, but also plays a crucial role in our economic growth through job creation and skill training programs.”

With these developments, UzXCMG not only commemorates ten years of successful operations, but also sets a robust foundation for future growth ensuring continued support towards Uzbekistan’s developmental goals. UzXCMG XCMG says represents an essential production base aimed at serving not just Uzbekistan but also broader Central Asian markets through innovative construction solutions tailored to local needs.

Caterpillar successfully demonstrates fully autonomous 777 truck with Luck Stone

Caterpillar Inc says it has successfully demonstrated the fully autonomous operation of its Cat® 777 off-highway truck. The debut of this latest model of Cat® MineStar™ Command for hauling at Luck Stone’s Bull Run plant in Chantilly, Virginia, it says marks a significant milestone in Caterpillar’s objective to deliver an autonomous hauling solution for the quarry and aggregates sector.

This successful deployment of machinery and technology highlights the progress being made between Caterpillar and Luck Stone, the largest family-owned and operated producer of crushed stone, sand, and gravel in the United States. In December 2022, Luck Stone and Caterpillar announced an agreement to accelerate the development of Caterpillar’s autonomous solutions for quarry and aggregate applications.

This marks Caterpillar’s first deployment of autonomous technology in the aggregates industry and will expand the company’s autonomous truck fleet to include the 100-ton-class (90 t class) Cat® 777.

Caterpillar has long been recognised as an industry leader in autonomy, with autonomous trucks on three continents having travelled more than 325 million kilometres and autonomously moving more than 8.62 billion tonnes. The current fleet of Caterpillar’s autonomous trucks with Command for hauling moves more tons per year worldwide than the total annual US crushed stone production.

Some of the world’s largest mines are using Cat Command technology to achieve performance improvements. For two years, Caterpillar has been embedded with Luck Stone to build expertise in quarry operations, aiming to develop a system that is scalable and economically viable for customers across the quarry industry while also helping them to achieve a step change in safety and productivity.

“Congratulations to both the Luck Stone and Caterpillar teams for this outstanding achievement. It’s meaningful not just for Bull Run operations, but for our customers of all sizes as we develop new technologies to serve the quarry and aggregates as well as construction industries,” said Denise Johnson, Group President of Caterpillar’s Resource Industries. “This hands-on collaboration has accelerated our ability to scale our proven mining solution for this sector.”

The success of autonomous hauling at Bull Run plant marks the initial milestone in the collaboration between Caterpillar and Luck Stone. This achievement lays the foundation for ongoing testing and validation of assumptions and technology before making autonomous technology commercially available in the aggregates industry.

“The successful implementation of an autonomous hauling solution at our Bull Run Plant is a major accomplishment for Luck Stone associates, for Caterpillar, and for our industry. Our mission is to ignite human potential and positively impact the lives of others, and this project does just that by providing opportunities and experiences for our associates to grow and learn. Caterpillar’s innovative technology will also improve safety and be a tool for attracting the next generation of mining professionals. We’re excited for the future and what’s next for autonomy, and thankful for our continued, collaborative relationship with Caterpillar,” said Charlie Luck, Chairman and CEO, Luck Companies.