All posts by Paul Moore

Flender One – writing the next chapter in industrial gearboxes

Automation, Bulk handling, Comminution of minerals, Equipment maintenance, Mineral processing, Mining consumables, Mining maintenance, Mining services, Power supply for mines

Flender CEO Andreas Evertz said “we are reinventing the standard” when the company introduced the Flender One single stage version to the market last year. Now, this reinvention has entered its next chapter with Flender announcing the global launch of the next extension of Flender One gearboxes. After the models for pumps and paper applications, Flender One expands its reach, offering versatile solutions for over one hundred different applications.

The new gear units are designed to meet a wide range of application needs, many of which are relevant to mining including bucket elevators, belt conveyors, and hoisting applications. With a broad spectrum of power classes, sizes, and designs, these gear units it says ensure optimal coverage of various industrial requirements.

Flender states: “Flender One stands out with its tailored solutions. Customers only purchase what they need, eliminating unnecessary components and maximising efficiency. This customisation reduces operating expenses and enhances performance, providing a perfect fit for each specific application. Additionally, the gearboxes offer a wide range of add-on parts and customisable output shafts.”

It says the Flender One design saves both time and money in planning and plant operations. “The new configuration process can be completed in minutes with just three parameters. Combined with instantly accessible 3-D data, prompt quotations, and shorter delivery times due to automated manufacturing processes, project timelines are accelerated from the planning phase.” Flender added that plant operators can achieve up to 25% time savings in planning through simplified processes.

In operation, the Flender One platform reduces operating expenses. All gearboxes are equipped with performance-optimised Metaperform® gearing, reducing power dissipation by up to 20% compared to previous models and a 30% higher thermal capacity. Also, the bearing lifetime increases by 80%. “This results in faster cost amortisation for industrial gearboxes from Flender than ever before.”

Flender One offers built-in gear unit intelligence straight from the factory. Each unit comes with an integrated AIQ Core sensor, providing digital monitoring and intelligent onboard analytical functions. This allows for increased plant availability and process optimisation, reducing unplanned downtime by up to 70%. Data- and need-based maintenance intervals can decrease service costs by up to 40% and service-related downtime by up to 50%. The optional torque measurement function allows for process and operating point optimisation. The AIQ Core torque can be easily selected via the configurator.

Rouven Daniel, President Industrial Gear Units at Flender, also once again stresses the fact that with the help of collected data and AI models, Flender is now able to size the gearboxes only as large as needed for the respective application. “Most industrial gearboxes from all manufacturers in the field, including Flender, are oversized by up to 50%. With Flender One and AIQ, we have the right tools to continuously eliminate this oversizing together with our customers. As a result, we will realise massive savings in raw materials, energy consumption, delivery times and installation space. Any waste is eliminated in terms of the environment and costs.”

In the future, further expansions of the Flender One platform will make it possible to configure gearboxes tailored to the respective application and the associated requirements. Despite maximum individuality, customers will benefit from the advantages of series production – process efficiency in production and thus fast delivery times and low costs. “This is made possible by a real milestone in transmission manufacturing: the complete digitisation of the engineering process. It triggers the design exactly according to customer requirements and translates it into a fully automated manufacturing and delivery process.”

Evertz comments: “Flender One represents a significant shift in how we think about gearboxes. It is not just a mechanical iteration of its predecessor FSG but an entirely new solution from the first customer inquiry to operation in the plant.”

Daniel adds: “Flender One stands for being more individual, efficient, and smarter. With an easy-to-understand configuration process, automated manufacturing, and comprehensive 3-D data and documentation in the cloud, it saves our customers valuable time. In operation, Flender One excels with improved power dissipation and AIQ optimisation, making it the most efficient Flender gearbox solution we have ever introduced.”

Flender One succeeds the renowned standard industrial gearbox range, FSG, with over 500,000 units in the field. As the most successful standard industrial gearbox range to date, FSG sets a high bar, but Flender says Flender One is ready to surpass it with its innovative features and superior performance.

Almina selects Sandvik to provide 32-unit fleet in Portugal

Automation, Base metals, Equipment maintenance, Mine shafts and equipment, Mineral project development, Mining equipment, Mining services

Sandvik Mining and Rock Solutions will deliver a 32-unit fleet of loaders, autonomous trucks and underground drills to Almina Minas do Alentejo SA through an order from Portuguese distributor Cimertex. The order includes 20 Toro™ TH663i trucks, five Toro™ LH621i loaders, four Sandvik DS411 rock bolters and three Sandvik DL421 longhole production drills. Deliveries will begin during Q3 2024 and continue through 2025.

The equipment order will help Almina double its current production capacity in Portugal’s Iberian pyrite belt to 6 Mt/y.  The agreement follows a 2023 order from Cimertex for 18 Toro™ TH663i trucks, all of which have been delivered.

“Almina will soon operate one of the largest Sandvik fleets in all of Europe,” said Álvaro Bastos, Executive Director at Cimertex. “Almina is seeking higher productivity and lower costs, and Sandvik’s autonomous loaders and longhole drills have already proven to deliver higher utilisation operating during shift change.”

Twelve of the 20 Toro™ TH663i trucks in the latest order will be equipped with AutoMine® Fleet, a highly advanced automation system for a fleet of Sandvik underground loaders and trucks sharing the same production area. The scalable system offers automatic control of traffic management, allowing operators to monitor the process remotely and simultaneously control and monitor multiple operations from a remote control room.

Established in 1964, Cimertex is the exclusive representative in Portugal of several leading equipment brands. In addition to decades of equipment provision, Cimertex has a specialised aftersales service team capable of supporting equipment throughout the Portuguese territory. The Sandvik order includes a seven-year full aftermarket service contract for Almina.

“This cooperation represents a strong mutual trust among Almina, Cimertex and Sandvik, and strengthens more than 20 years of collaboration with our strategic partner and Portuguese distributor Cimertex,” said Enrique Mota, Territory Manager for Iberia at Sandvik Mining and Rock Solutions.

NHL driving forward new technology mining trucks in China with global market potential

Automation, Base metals, Bulk handling, Environmental, Equipment maintenance, Industrial minerals, Mining consumables, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Steel and iron ore, Sustainable mining

At The Electric Mine 2024, Inner Mongolia North Hauler Joint Stock Co Ltd (NHL)’s Guojun Dong, its VP of Finance & Head of International Division, gave a deep dive into the Baotou-based mining truck major’s progress with new energy hauler solutions. He co-presented with Roy Zou, Group Vice President – International Division at partner Alta Technology, which manufactures traction control systems and provides electrical control systems and infrastructure for many of these new mining truck solutions; building on its wide experience in the high speed rail industry.

Dong went into some detail on NHL’s quite remarkable progress so far in supplying battery electric, hybrid and hydrogen mining trucks in China – arguably in terms of what it has actually achieved it is further ahead than any other OEM in these future technology rollouts. That this is happening in China is perhaps understandable given the vast market size – over 1,200 open pit mines in China alone. Plus it is also being driven by the ever greater government focus on greener mining.

Guojun Dong, NHL VP of Finance & Head of International Division speaking at The Electric Mine 2024

“Here is what we have done and what we have planned for the new energy. You can see up to now we already have the 50 ton, 65 ton, 100 ton and 130 ton electric trucks that have already been delivered to customers.” These are the TR50E, TR56E, TR100E and TR130E. He added that NHL sees the market as having a requirement for the TR200E and TR240E trucks and that these projects are under consideration. Today NHL works mainly with CATL for battery supply, using lithium iron phosphate chemistry, plus works primarily with Cummins on engines and Wabtec with electric wheel motors.

Looking back on its electric mining truck experience from a timeline point of view, this dates all the way back to 2013 and its delivery of six NTE330T trolley assist diesel trucks to Swakop Uranium’s Husab mine in Namibia, which are still running today. Its TR50E battery truck was developed back in 2015 and today around 100 of these are working with customer Conch Cement at its limestone mining operations with another 50 at other customer sites. NHL also built a TR65E battery truck in 2022 and the TR100E in 2023 of which 50 have now been supplied including many units to Conch Cement. The NTH35 hybrid truck was built in 2018. More than 15 NTE130E battery trucks have now also been supplied to the market and it will produce the NTE150E by end-2024. Battery trolley options are also under development.

The experience in the cement industry with the TR100E in recent years has been very positive – achieving over 110,000 t/y of production with each truck running over 16 hours operation per day and doing over 55 trips per day. Static charging takes less than 50 minutes.

Then he moved on to hybrid trucks. Interestingly it started with a very small model, the NTH35, in 2018 to prove out the technology but has followed this up with the ultraclass NTH260 which was developed in close partnership with Cummins and was recently delivered to the customer Baogang Group’s Baiyun iron mine, for trial operation. The partners are also well advanced with an NTH100E model.

He said the NTH260 (payload 236 t) with its ‘battery assist drive’ brings fuel savings of up to 20% so lowers fuel cost by over US$210,000 per year. Plus it means reduced maintenance costs, extended overhaul cycle and improved operational efficiency. Carbon reduction is up to 20% so a cut of over 540 t per year.

Next up hydrogen trucks – FCEVs. Last year a 136 t class (150 ton) NTH150 was delivered to Huolinhe coal mine. IM understands that it has been performing well – though operating hours are less than 1,000 – the issue with hydrogen trucks is the same as elsewhere in the world – related to infrastructure. There’s no cheap solution of compressed hydrogen storage at site and delivery for now, the cost of a local solution is high, so more progress will be made when the cost of compressed hydrogen is low enough for the operation. It is also not yet certain whether the Chinese market will shift towards just battery electric or also hydrogen and as such the OEMs – like NHL but also number two XCMG – are hedging their bets and offering both options.

Dong emphasised that customers in the Chinese market want a fully green ‘package’ solution and showed an interesting ecosystem graphic showing green power generation then power supplied to charging stations and onto battery trucks then an alternative of green power to hydrogen production by electrolysis of water, hydrogenation and then supply to hydrogen trucks.

On the topic of autonomy, NHL together with partners like TAGE Idriver has delivered more than 260 autonomous trucks to more than 20 open pit mining sites with a 100% repurchase rate. This includes Julong Copper, part of Zijin Mining, at over 5,455 m altitude.

A final note on the future – by the end of 2024 NHL is looking to have ready an autonomous, 136 t (150 ton) class cabless truck – the AT150 Smart Battery Truck. It will have four wheel steering, double A-arm nitrogen suspension, V2V communication, and will have dual powertrain options – a battery pack or a diesel engine. Customers in China are keen to trial the latest technologies and options so there is no shortage of mines wanting to trial the new prototype.

XCMG’s 240 ton hydrogen mining truck set to deploy in Baorixile mine by end 2024

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

China’s XCMG is advancing its hydrogen plans in mining trucks – on April 24, 2024, coal mining giant CHN Energy, XCMG and THIKO New Energy held a signing ceremony for “the world’s first” 240 ton class hydrogen mining truck in Hulunbuir, Inner Mongolia.

According to the agreement, the three parties have formed a consortium which will rely on the broad mining application scenarios of CHN Energy, and relying on the technology of XCMG in the field of mining trucks, and the advantages of THIKO New Energy in the development of high-powered hydrogen fuel cells and hydrogen resource integration.

The aim is to deliver the jointly developed truck in the fourth quarter of 2024 for deployment at the huge Baorixile coal mine of CHN Energy. The truck will be a Fuel Cell Electric Vehicle (FCEV) equipped with a battery pack as well as the fuel cell power.

The statement said: “Among the many application scenarios of hydrogen fuel cell vehicles, the mining industry is extremely optimistic about their use, and hydrogen mining trucks are also quietly being developed. Mining enterprises are an important subject of global mining governance, and the carbon reduction of mining enterprises will become an important indicator of global mining governance and an important indicator of the sustainable development of these enterprises.”

Baorixile coal mine has a production capacity of 35 Mt/y, making it one of the largest open-pit coal mines in China. At present, 80 kW, 110 kW and 130 kW fuel cell designs have been developed and 180 kW, 220 kW and 300 kW hydrogen fuel cell systems are being developed for high-power applications such as mines. THIKO New Energy states: “The products have obvious advantages in key technical indicators such as rated power, power density, life, and cold start temperature. With the acceleration of the localisation and production of fuel cell core materials and the expansion of the scale of fuel cell application, the price of fuel cell systems continues to decline, so the price of hydrogen-powered fuel trucks will also come down.”

THIKO New Energy also has plans to  construct new green hydrogen generation in the Hulunbuir region as part of a closed-loop business model. “The development and application of a 240 ton of hydrogen mining truck marks a key step in the development strategy of high power hydrogen fuel cell systems…hydrogen energy is ushering in unprecedented strategic development opportunities…the commercial era of hydrogen mining trucks will also be getting closer and closer.”

Signing ceremony between XCMG, CHN Energy and THIKO New Energy

Separately, XCMG has already unveil a new smaller class hydrogen fuel cell dump truck model, the EHSL552F, equipped with a 120 kW hydrogen fuel cell and high-power battery system. It says this launch marks a significant step in reducing greenhouse gas emissions by 99.3 kg on a daily basis for large-scale transportation projects such as mining operations.

To meet the demand for long-distance operational capabilities, XCMG’s latest hydrogen-powered vehicle it says integrates advanced technology with robust performance features. The EHSL552F model includes a fast 6-speed gearbox and boasts substantial chassis clearance, enabling it to easily navigate steep slopes.

The vehicle’s design incorporates computer-aided topology optimisation, along with new materials and processes that reduce the vehicle weight by 200 kg without compromising structural strength or reliability. Additionally, the EHSL552F is designed for reduced maintenance costs within its lifespan of over 1.5 million kilometres.

Since 2021, XCMG has been researching and manufacturing hydrogen energy equipment, culminating in the creation of the Shanghai Hydrogen Energy Technology Research Institute in April 2022. The company has unveiled 16 different hydrogen energy equipment models, covering various sectors, including mining trucks. June 2023 saw the global debut of the XC968-FCEV, a small hydrogen-powered electric loader developed in collaboration with a coal mining customer in China, marking its official operation.

Codelco’s Salvador Division bus fleet goes electric plus first primary crusher starts up at Rajo Inca

Base metals, Comminution of minerals, Environmental, Mineral processing, Mining equipment, Mining people, Mining services, Sustainable mining

In the presence of the Undersecretary of Mining, Suina Chahuán, and Codelco Executive President, Rubén Alvarado, Codelco recently launched its ‘Electromobility for El Salvador’ program, through which its Salvador Division in the Atacama Region converted 100% of its bus fleet to electric. This project was implemented by Enel X and Tandem Industrial and executed under a new investment vehicle for electromobility led by BTG Pactual.

The program also included the inauguration of smart bus stops, located in various parts of the city, which were built – both their structure and their seats – with recycled materials and are supplied with solar energy. They are equipped with security cameras and have two information screens that broadcast news from the camp and live information on the bus route.

Likewise, users of these buses can access a mobile application to find out the schedule of the routes and see online the place where their transport is located. This project has also considered the integration of people in its design, since the buses will transport both Codelco workers and workers from contractor companies.

The El Salvador program is part of Codelco’s commitment to achieve carbon neutrality by 2050, a goal that has led the company to form the largest mining fleet of electric buses in national mining. The 30 buses in this fleet join the 155 that operate distributed in El Teniente, Chuquicamata and Andina. To date the largest supplier of electric buses to Codelco has been Chilean company Reborn Electric. 

Alvarado, said that “milestones like this manage to reconcile fundamental values: we lower emissions, we develop smart bus stops with a circular economy, we integrate Codelco and contractor personnel; all based on collaboration with the companies we work with.”

These new buses for Salvador have a 350 km range and were manufactured by the Chinese company Yutong and have wide spaces between seats, belts with alarms, three TV screens and several internal cameras, which allow better visualisation for the drivers. The project has been implemented under the Charging as a Service (CaaS) model, which offers a comprehensive solution for infrastructure, maintenance, and energy management of the charging stations through the construction of electro-terminals.

To charge the bus fleet, Enel X has set up two charging terminals in the mining city (North Terminal and South Terminal), each equipped with 8 charging stations totalling 150 kW of power to allow for an agile, dynamic, and flexible operation. Tandem is the company responsible for operating the new electric buses.

Chahuán pointed out that “this allows us to advance in a more sustainable mining future with higher quality for the transfer of workers. In addition, it is an important step towards meeting Codelco’s carbon neutrality goals, for which we congratulate the company.”

Christian Toutin, General Manager of Codelco Salvador, highlighted that “this project seeks to highlight the new mining that we want to develop, taking care of the environment and transforming our entire fleet to electric buses, with smart bus stops, mobile applications, but most importantly, integrating our own workers and those of collaborating companies, since we all seek the goal of more humane and efficient mining.”

The launch ceremony of the ‘Electromobility for El Salvador’ program was attended by various regional authorities, along with representatives of workers, neighbourhood associations and representatives of companies that worked on this project, such as Yutong, Tandem, Enel X and PSINet.

The main focus of the Salvador Division today is the new Rajo Inca project, for which Codelco in May began testing some of the equipment that will process the copper ore extracted from the new pit. Rajo Inca will enable larger scale open pit mining and processing at Salvador Division’s facilities, which are being optimised to increase capacity and prolong the useful mine life by 47 years. It is extracting the remaining ore resources of the Indio Muerto deposit which have previously been mined using underground methods. Salvador Division has also carried out surface mining from the Campamento Antiguo and Quebrada M open pit mines.

Primary crushers at Rajo Inca project, Salvador Division

Capacity of the expanded concentrator plant will gradually increase to 37,000 t/d.  Specifically, the first of two new primary crushers, which will crush the mined rock in the dry processing stage, began operation. This first step is part of the start-up of the project, and marks the beginning of the progressive implementation of a series of new equipment and facilities, which will enable the entry into operation of the project at the end of H2 2024. After the start of the tests in the first crusher, a second is being added, and followed by the grinding and flotation processes in the concentrator plant.

“This implementation progressively activates more than 700 pieces of equipment and over 16 thousand signals in the control system, which implies a great deal of coordination and logistics work. Compliance with this phase is part of the process of moving Rajo Inca forward and commits us even more to our country and the Atacama Region,” said Toutin.

Harmony Gold standardises on Nerospec neroHUB Vehicle Intervention Control System

Mine shafts and equipment, Mining equipment, Mining safety, Mining services, Precious metals, Sustainable mining

Nerospec OSCON says that it has achieved group-wide standardisation with Harmony Gold. Its solutions will now be implemented across all Harmony Gold mines, enhancing safety and efficiency. It added: “This partnership is a significant step in our mission to create safer mining environments. By integrating NEROSPEC OSCON’s innovative technologies, Harmony Gold is setting a new benchmark for safety and operational excellence.”

Specifically, it covers deployment of the neroHUB Vehicle Intervention Control System which helps to enable Level 9 collision avoidance. South Africa’s Department of Mineral Resources and Energy (DMRE) brought into law in December 2022 the Chapter 8 clauses of the Mine Health and Safety Act Regulations relating to Level 9 vehicle intervention for collision avoidance in trackless mobile machinery, both surface and underground.

The neroHUB provides a universal interface for Trackless Mining Machines (TMM) and Collision Warning Systems (CWS). It increases productivity and improves mine safety with the intelligent use of CRAWL and STOP processes as well as providing uniform and secure records to promote operational efficiency.

Harmony operates eight underground gold mines in the Witwatersrand Basin – Moab Khotsong, Mponeng, Tshepong North and South, Doornkop, Joel, Target 1, Kusasalethu and Masimong. It also operates the Kalgold open pit. Outside of South Africa it operates the Hidden Valley open pit gold and silver mine in PNG, where it also has 50% of the Wafi-Golpu underground project. In Australia it has the Eva copper project.

In its 2023 ESG report, Harmony states: “Harmony aims to comply with legislation because we care about employees’ safety, not just compliance. We began our proactive journey towards better safety requirements well before it became legislation on 22 December 2022 when the South African government legislated that trackless mobile machinery must be retrofitted with a Level 9 collision avoidance system…our implementation plan is specific and measurable, considering cost, maintenance and productivity implications. Based on site risk assessments, we conduct ongoing data management and reporting as well as employee awareness campaigns.”

BHP outlines mining fleet decarbonisation opportunities but also the realities

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

BHP recently gave additional insight into its progress and plans related to emissions reduction in a special Decarbonisation Roundtable for investors held on June 26. Dr Graham Winkelman, BHP Vice President Climate said the global miner is on track to deliver its FY2030 target of at least a 30% reduction in operational GHG emissions in FY2030 against a FY2020 baseline adding that its medium-term target and long-term goal of net zero by 2050 are both related to Scopes 1 and 2 emissions from its operated assets, or ‘operational’ GHG emissions.

Winkelman continued: “As we grow to meet increasing demand for our commodities, the pathway to net zero for our operational emissions will not be a straight line. Our pathway reflects the dynamic nature of the assets we operate and the availability and readiness of decarbonisation solutions.”

Then it was over to Daniel Heal, Vice President Operational Decarbonisation, BHP Minerals Australia to talk about on the ground mining fleets. As might be expected, re: Scope 1 emissions, globally mining trucks represent BHP’s largest diesel usage. Each year, BHP’s global operations use roughly 1,850 megalitres of diesel in over 1,500 pieces of equipment – of which over half – 800+ are mining trucks.

Heal commented that BHP continues to believe that an electrified mining fleet will be more economic than hydrogen. “This is primarily driven by the overall efficiency of an electrified pathway, compared to other fuels…some of our core mining equipment is already available in an electrical configuration. For example, both BMA and Escondida operate electric shovels, and Escondida has had electric drills for many years. Electrification can also lead to improved maintenance performance, the elimination of diesel particulate matter, and reduction in noise and vibrations.”

He adds: “We consider alternative fuels such as biofuels as a backup option if electrification is delayed or unsuccessful, and we continue to monitor developments in this area. This is informed by a trial that concluded last year that provided us valuable insights into using hydro-treated vegetable oil in multiple types of mining equipment. The trial also identified some of the challenging commercial and social concerns associated with these fuels. Replacing diesel will require us to develop a whole new operational ecosystem to surround the fleet and every part of the mine will be touched by this change.”

Then Heal took its operations in Chile and Australia in turn. For its operated assets in Chile, BHP continues to study trolley assisted haul trucks at Escondida and Spence, to reduce diesel consumption but also as a key enabler for future rollout battery electric haul trucks. It will approach trolley assist in three stages. “Firstly, over the coming years we will be progressively replacing our current mechanical drive haul trucks with electric drive ones. Then, we will implement trolley assist. This electrical infrastructure works like an electric tram or train network. Trucks connect to it while moving and receive electricity directly to power their electric drives, reducing diesel use. We will soon begin testing diesel-electric trolley assist at Escondida, followed by Spence, with implementation of the first stage expected to start in FY2028 and FY2029, respectively.”

And finally, next decade, BHP will expand the trolley infrastructure to assist a transition from diesel-electric to battery electric haul trucks. This will allow the energy to go straight to charging the truck’s batteries while operating, reducing the time that the truck would need to stop to be charged. And once trolley and battery electric trucks are proven, it is planning a widespread adoption across its operated assets in Chile.

For diesel displacement in Australia, Heal said BHP is working through key areas including “the way we plan and operate our mines; how and when we charge our equipment; how we manage power supply and demand; the skills and people we will need; and, critically, the additional safety considerations these changes will bring.”

BHP is collaborating with equipment manufacturers and others across the industry to accelerate development of the technology required. It has a comprehensive program of trials underway or set to start in the coming years. He added that some of these dates have shifted a little since it presented a similar table last year, but added that this is not surprising given the complexity of developing new technology at this scale. “Despite this, we still anticipate our first battery-electric truck sites and locomotives to be in operation from late this decade – assuming our trials are successful.”

BHP currently has the first Caterpillar battery electric haul truck enroute to its WAIO Jimblebar mine, and in June Heal and the decarbonisation team from BHP visited Caterpillar’s Proving Ground in Tucson Arizona to witness the very first Caterpillar 793 battery electric truck in action. He states: “In terms of performance, we are expecting it to be on par or even superior to an equivalent diesel truck. Fully loaded to its rated capacity, the Caterpillar battery electric truck achieved the same top speed as a diesel equivalent truck and travelled 1 kilometre up a 10% grade at the same pace as a diesel truck. A battery electric truck will need to be charged more often than a diesel truck is currently refuelled, but we expect to be able to counter that in some places using dynamic energy transfer, such as trolley systems.”

Furthermore, when receiving electricity directly through a dynamic energy transfer system, BHP expects a battery truck could outperform a current diesel truck uphill and, on a downhill grade, the truck captures the energy that would normally be lost to heat and returns it to the battery. “Our planned site trials will gather real data to help firm up modelling assumptions, inform the investment business cases and provide greater certainty to our plans.”

The presentation stated that BHP expects operational deployment of both the Caterpillar Early Learner battery truck and Komatsu’s battery truck (the Power Agnostic battery truck) from 2028 (the Komatsu trucks are set to be delivered to the Pilbara in 2026), should successful trials be completed – to speed up learnings BHP is trialling the Caterpillar BEV truck and Rio Tinto the Komatsu BEV truck.

Another example of trial progress is BHP’s deployment of a Liebherr 9400E electric excavator, which is one of the first in Australia, which has been operating in a trial since early 2024 at its Yandi operations, part of West Australia Iron Ore. It says these electric excavators are set for deployment from 2027.

Hitachi Construction Machinery begins technological trial of battery trolley mining truck at Kansanshi

Base metals, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Precious metals, Sustainable mining

Hitachi Construction Machinery Co Ltd has announced the commencement of the world’s first technological feasibility trial of an ultra-large full battery rigid frame dump truck by an OEM operating at First Quantum Minerals Ltd’s Kansanshi copper and gold mine in the Republic of Zambia.

The technological feasibility trial, which began in June 2024, is being conducted at First Quantum’s Kansanshi deep open-pit copper-gold mine, one of the company’s largest mines, in Zambia. The technological feasibility trial aims to verify the basic performance of operations required of a battery-powered dump truck – such as travelling, turning, and stopping – under actual operating loads, as well as the verification of battery charging and discharging cycles.

First Quantum are leaders in trolley system operations with in-house technology development and deployment, and at their Kansanshi copper and gold mine can provide Hitachi Construction Machinery with the infrastructure and facilities that are needed to test a full battery dump truck, such as proven overhead dynamic charging solutions and variety of haul circuits in an actual operational mining environment. The use of Kansanshi infrastructure and the collaboration with First Quantum are the key differentiators, to fast tracking this evolving technology design which makes it the ideal practical and commercially viable solution.

Further to this, renewable energy accounts for 92% of Zambia’s energy, and in addition to hydroelectric power generation, solar, wind, biogas, and other power sources from First Quantum are expected to be scaled up in the future. The challenge of achieving true decarbonisation is underway in Zambia, a country with abundant renewable energy requirements and will help Hitachi Construction Machinery to leverage this technology trial to further product development and broader applicational studies with customers around the world, thereby helping them to achieve their zero emissions goals.

Hitachi Construction Machinery’s Vice President and Executive Officer, President of Mining Business Unit, Eiji Fukunishi, stated: “Mining companies around the world are working to reduce emissions. As an Original Equipment Manufacturer, it is our vision to provide solutions that can reduce our customers’ environmental footprint. The battery dump truck represents the future, not only for the Hitachi Construction Machinery Group but for the mining industry as a whole, and we are pleased to establish this proving ground on an active mine site and work with First Quantum on advancing this zero emission solution.”

First Quantum’s Director Mining, John Gregory, stated: “Battery zero emissions development with little to no impact on payload, production and fleet size is achievable with trolley assist and First Quantum have mastered this technology by working with 2,600V systems of Hitachi Construction Machinery to provide stable platforms with multiple trucks on the overhead line at the same time. This system is operational, practical and economical feasible solution that will reduce emissions in mining for many years to come.”

The full battery dump truck was jointly developed with ABB Ltd, a technology leader in electrification and automation. Based on Hitachi Construction Machinery’s extensive experience with dump trucks equipped with trolley dynamic charging systems, the full battery dump truck is able to continuously operate practically in sites, by directly charging from the overhead lines and regenerative braking system without needing to stop and charging through the adoption of the battery system developed by ABB. In addition, limiting the battery volume reduces the battery weight as a percentage of the overall vehicle weight and helps maximise the load capacity to display a high level of cost performance.

With environmental awareness on the rise in the mining industry, there is growing interest in the electrification of mining machinery as part of efforts to reduce greenhouse gas emissions. To meet the high customer demand for the electrification of dump trucks in particular, which are operated in large numbers at mining sites, Hitachi Construction Machinery began collaborating with ABB in June 2021 to develop the full battery dump truck. On March 1, 2023, Hitachi Construction Machinery signed a letter of intent (LOI) with First Quantum to establish a zero emission partnership. Hitachi Construction Machinery completed the test machine version of a full battery dump truck, and on January 20, 2024, this test machine was shipped to First Quantum. The assembly of the test unit was recently completed in Zambia, and the technological feasibility trial began now that the basic operation has been confirmed.

The Hitachi Construction Machinery Group says it will accelerate its efforts to put the full battery dump truck into practical use while engaging in co-creation with our customers to help achieve net zero greenhouse gas emissions from mining machinery.

By drawing the electrical power from the dynamic charging system required during operation will limit the volume of batteries on the trucks, providing a sustainable solution. In addition, the system aims to reduce the lifecycle costs and environmental impact through life cycle assessment by drawing electrical power from the overhead system while connected, simultaneously charging the battery in an appropriate manner to reduce the load and depth of discharge, maximising battery life. Limiting the battery volume lessens the weight of the battery solution on the vehicle, maximizing the battery dump truck’s payload capacity. The solution draws electrical power from the dynamic charging system during operation while simultaneously charging the battery, removing the need to stop the vehicle for recharging. Therefore, achieving a higher rate of continuous operation to maintain productivity at site.

Sandvik delivers fifth DR412i rotary blasthole rig to Glencore’s Hail Creek

Bulk handling, Coal technology, Equipment maintenance, Explosives and blasting, Mining consumables, Mining equipment, Mining maintenance, Mining services, Mining software

Sandvik recently delivered a fifth DR412i rotary blasthole drilling rig to Glencore Australia’s Hail Creek coal mine, with another DR412i scheduled for future delivery which would bring the fleet size to six. Sandvik stated: “The DR412i blasthole drill is designed to deliver dependable penetration and greater return on investment, and we are excited to see the results this fleet of DR412i’s provides Glencore.”

The 18 m mast on this rig model delivers a total depth capacity of 33.1 m, removing the need to add pipe, which improves productivity and reduces costs. It is standard equipped for rotary with optional down-the-hole (DTH) hammer drilling power.

A single centralised service centre shortens the time for fluid fills, improves utilisation and reduces the risk of fluid spills and harmful environmental impact. The Sandvik Intelligent Control System Architecture (SICA) gives the operator real-time feedback about DR412i’s performance and health, along with tools for drill planning, reporting and analysis, improving availability and productivity. It uses a CAN bus controlled hydraulic system to monitor the machine, allowing for timely preventative maintenance and delivering higher availability.

It can drill holes of 203-311 mm with a single pass hole depth of up to 17.8 m. Pipes can be handled from within the cab using the Sandvik carousel and breakout system, with optional hands free bits changing capability. A new-generation ergonomically-designed cab includes controls on the armrests, touchscreens, angled windows to reduce glare and a safari-style roof to keep the cab cooler. Wider, 360-degree walkways enable superior drill access for routine maintenance. An optional hydraulic main-access stairway can be mounted to provide a parallel step onto and off of the drill.

Advanced compressor management reduces the compressor load allowing the operator to manage air volumes and pressures to maximise efficiency and reduce fuel burn reducing CO₂ footprint and extending engine and compressor life.

 

 

Barminco awarded three-year contract extension at AngloGold Ashanti’s Sunrise Dam

Bulk handling, Equipment maintenance, Mineral project development, Mining consumables, Mining equipment, Mining maintenance, Mining services, Precious metals

Perenti Ltd has announced that its underground mining business, Barminco, has been awarded a three-year extension of its mining services contract at AngloGold Ashanti’s Sunrise Dam underground gold mine in the Goldfields of Western Australia. The A$450 million contract is for three years commencing October 1, 2024 and includes underground development, production and mining support services. No new growth capital expenditure is required.

Mark Norwell, Managing Director & Chief Executive Officer of Perenti said: “AngloGold Ashanti is one of our largest clients, and we are proud to have worked with them for the past 20 years. Perenti has an excellent track record at extending existing contracts which we attribute to our collaborative relationship with our clients. Successful maintenance of our long-term relationships ultimately supports our business, as continuation of contracts does not require the upfront capital expenditure of new contracts. Ultimately this supports generation of free cash flow which continues to be a key focus of our strategy.”

Gabrielle Iwanow, President of Contract Mining at Perenti said: “Our people are at the heart of our success and their dedication, innovative thinking and highly skilled efforts have again resulted in the award of a significant contract for a long-standing client within a great mine in Western Australia. We are proud to have partnered with AngloGold Ashanti for over two decades, delivering on our purpose of creating enduring value and certainty.”