All posts by Paul Moore

Master Drilling & Doppelmayr to cooperate on underground transport technology

Doppelmayr Transport Technology GmbH, based in Wolfurt, Austria has announced a cooperation with raise boring specialist Master Drilling Group Ltd, headquartered in Fochville, South Africa. Doppelmayr did not detail the nature of the tie-up but told IM that the main reason for the cooperation was that both companies “see potential in joining their expertise, in order to contribute to new material transport opportunities for the clients’ benefit.”

One aspect of the cooperation relates to Doppelmayr’s vertical material transport system, Vertical RopeCon®, which the Austrian company says opens up new material transport opportunities for underground mining and which has been referenced in the cooperation announcements.

Doppelmayr says of the technology: “Underground mining makes high demands on material transport, such as limited space as well as the necessity to avoid exhaust emissions and heat development, to name only some. The Doppelmayr Vertical RopeCon® gives the chance to reduce the haul truck fleet and the exhaust emissions.”

The novel concept adapts the proven RopeCon® system to the specific requirements of an underground application. In the loading station, the wheel sets run on guiding rails, which safely guide the belt into the shaft. Ropes in the shaft guide the belt at all times. Doppelmayr says maintenance is simple and cost effective, as all moving parts are mounted to the belt and will pass the terminals at regular intervals. Ropes and shaft can be inspected either using an inspection vehicle or by technical devices. Access to the shaft is not required. In addition, re-use of existing ventilation shafts is possible. As the main drive is installed above ground, underground heat development is reduced.

TOMRA sensor-based sorting and extracting the full value from mined quartz

The global market for quartz has been growing steadily and this trend is set to continue, demanding increasingly high purity levels. This demand comes from different industries, which have varying requirements, so that the most precise mineral sorting is needed. This can be achieved with sensor-based colour and laser sorting technologies – applied individually or in combination – as Jens Michael Bergmann, Global Segment Manager Industrial Minerals and Carolina Vargas Area Sales Manager Europe, India and Rest of the World at TOMRA Mining explained in a recent article.

He pointed out that the quartz market is forecast to continue to grow at an annual rate of around 4% in the next five years driven by a variety of factors. Quartz serves different industries which have a variety of uses for the mineral – and hence varying requirements. One of the main sectors is that of engineered stone for use in the production of kitchen countertops, for example. High-quality white quartz is in very high demand for this application for its extreme resistance to acids, stains and damage, as well as its appealing look. It is also seen as an environmentally sustainable choice because of its abundance in nature and the fact that it can be engineered with minimal waste.

The other key market for quartz is the metallurgical industry, as it is the best source for silicon metal and polysilicon, the semiconductor at the heart of electronics, which is also used for other products, such as photovoltaic cells. The applications in the energy sector, as the world moves toward more sustainable sources such as solar and wind, are driving an increase in the demand for high-purity quartz which is an essential component in solar panels. The technological sector is also expected to be a growing market for high-purity quartz used in electronic devices, whose demand is set to keep rising as the world becomes increasingly connected and more reliant on them. Quartz is also a source of ferrosilicon, which is used in smelters as deoxidiser in the process to produce steel and other alloys – another growing sector. This application doesn´t require the high purity of the previous sectors. Finally, the residue is used in the aggregates industry.

Bergmann says the challenge for mining operations is to meet the very specific requirements of the various sectors. For the metallurgical and engineered stone industries, they need to reliably deliver quartz of consistently high chemical purity – and for silicon production and engineered stone manufacturers, a white product with no impurities of the same colour, such as feldspar, is also essential. Other metallurgical sectors will allow varying levels of impurities, with the darker quartz with lower purity going to ferrosilicon production. In addition to meeting these precise requirements, quartz mining operations need to achieve the capacity to meet the rising demand while ensuring their profitability and reducing their environmental impact.

TOMRA Mining’s tailored solutions combine its Colour and Laser sorters to differentiate the minerals by colour, composition and size in order to meet the specific requirements of the mining operation’s customers. This precise sorting delivers the high quality they need while reducing waste and increasing productivity.

TOMRA Mining says its ‘unique’ Laser sorters “are the perfect solution for mining operations that need high-quality quartz regardless of its colour.” This technology was developed for the TOMRA Food division and has been operating since 1997 in the food industry. Adapting this proven in-house technology for mining applications was a logical development for TOMRA Mining, and the first Laser sorter was purchased by Spanish company Erimsa in 2016 and has been operating successfully since then, delivering consistently high purity quartz for the metallurgical industry.

TOMRA’s Laser sorters use the scattering effect of multiple laser beams to separate a rock containing quartz from a similar-looking rock with none. Quartz returns the laser light in a larger area than other minerals, so that it will appear as a glowing crystal while the others don’t show any scattering effect. Large and pure crystals can be clearly distinguished from other rocks or minerals with a smaller crystal structure, regardless of the colour or chemical composition. This results in consistently higher recovery rates and quality.

This technology proved to be the solution for Spanish quartz producer Ferroglobe, which was facing the challenge of sorting quartz ore from other contaminants with the same colour properties. “Optical sorting was not solving the issue and we needed to consider separation based on other properties,” explains Fernando Alonso, Mine Director. Tests conducted at TOMRA’s Test Center in Wedel, Germany, on samples demonstrated that its laser technology was able to differentiate between high-quality white quartz and other contaminants, while colour sorting would be unable to separate it. The tests revealed that with the Laser sorter, Ferroglobe would be able to deliver consistently high quality quartz.

Thierry Alary, VP Purchasing & Supply Chain at Ferroglobe highlighted: “Operations will definitely improve. By solving that specific problem, sorting becomes more accurate impacting on recovery rate, avoiding contamination and reducing further processing. Additionally, we detected potential for development in other products and sites.”

To achieve the highest purity levels, TOMRA’s Laser sorters can be combined with Colour sorting technology. Once the non-contaminated quartz rock is detected by the Laser sorter, the product is exposed to the Colour sorter, which uses a high-resolution camera to recognise materials based on their color and shape.

Turkish mining company Mikroman is successfully using this combination of TOMRA Laser and Colour sorters to differentiate products to meet the different needs of the four industries it serves: white and light grey quartz with low iron oxide content for engineered stones; grey and yellow for the glass industry; colored for the ferrosilicon and metallurgical sectors; and colored gravel for aggregates. As a representative of Mikroman said: “Before having TOMRA sorters, we were worried about quality and low capacity, but now we have achieved the desired quality standard and we have seen a decrease in waste, which means productivity has increased.”

TOMRA’s Laser sorters can also be equipped with red, green and blue lasers to fulfil simple colour sorting tasks, giving mining operations the flexibility to adjust according to changes in the demand switching from one sorting program to the other as needed.

TOMRA says its sorting solutions efficiently remove more waste in the early stages, significantly reducing the material fed into the processing plant and consequently increasing the mine’s capacity. Less material going through the crushing process also delivers significant cost and energy savings. “Considering that 3% of the world’s energy is used to crush rocks, the early ejection of waste can give an important contribution to the industry’s sustainability. In addition, if the material is sorted at the mine, far less material will be transported to the processing plant, further reducing costs and the environmental impact of the operation.”

A further benefit of the precise sorting of TOMRA’s Laser technology is the competitive advantage it provides for the mining operation which can guarantee a high-quality, homogeneous quartz for its customers.

TOMRA says it draws on its in-house know-how and field experience in helping quartz mining operations maximise the value of their resource to provide tailor-made solutions that precisely match the specific situation and requirements of the individual customer. Its Test Centre plays an important role in identifying the most suitable technology and validate the proposed solution. It adds: “TOMRA’s support extends beyond commissioning, as its team remains at the customer’s side to ensure the equipment continues to operate at its best and provide fast and effective support as required.”

Thiess partners with Augment Technologies on blast movement solutions

Thiess has announced that it has partnered with Augment Technologies, saying it marks a significant step forward in its commitment to innovation and excellence in the mining industry. Through this partnership, it will be leveraging Augment Technologies’ ‘groundbreaking’ AI-driven 3D blast movement software to create a Muckpile Block Model™.

The global mining services provider adds: “With the Muckpile Block Model™ we are set to revolutionise our operations in providing accurate understanding of ore loss and dilution after a blast, enabling operations upstream and downstream to make better decisions. At Thiess, we believe in harnessing the power of people and technology to drive sustainable change and improve outcomes for our clients and stakeholders. This collaboration with Augment Technologies aligns perfectly with our vision of integrating cutting-edge solutions to stay ahead in the industry.”

Augment Technologies says that its cornerstone Ore Movement Policy (OMP) “is the first and only blast movement solution that makes use of a physics engine and machine learning to transform the ore control block model into an accurate Muckpile Block Model™ within minutes after a blast. For the first time high resolution and high fidelity information flows through the mine value chain to minimise ore loss and dilution, optimise ore control and improve metal recovery.”

Metso Truck Body deployed on Volvo A60H ADT for Volvo Days 2024

At the recent Volvo Days 2024 event that ran from late May at its Eskilstuna, Sweden Customer Center, Volvo CE demonstrated its ambition to lead in sustainability and productivity by presenting pioneering launches and a fresh solutions-based approach – enabling sustainable change for customers in both regulated and less regulated markets.

One of the interesting technology developments on display was a 55 t class Volvo A60H articulated dump truck (ADT) fitted with a Metso Truck Body (MTB). The Metso MTB is a lightweight truck body that combines the best qualities of high-strength steel and rubber. Designed to be lighter yet tougher, it is optimal for hard rock and heavy-duty applications. To date it has been installed on rigid dump trucks so its use for an ADT was a major step for the solution into the smaller mining, quarrying and mining contractor market.

Metso told IM that the objective when developing the A60H for Volvo was to produce a heavy-duty truck body with a dual focus: maximum payload and safety while ensuring sustainability and longevity. The result is a lightweight body with rounded corners and rubber lining.

Key features of the MTB include an increased payload. Carrying additional volume per haul, the Metso Truck Body enhances efficiency by reducing the total number of rounds required, reducing the carbon footprint.​ The rubber lining also provides a significantly longer lifetime, ensuring prolonged performance and durability even in the most demanding environments.

Metso adds that the innovative design also makes the body lighter than traditional ones, leading to reduced energy consumption per haul and a corresponding decrease in greenhouse gas emissions.​ Its rubber lining is designed to last up to 20,000 hours, significantly lowering the frequency of maintenance needed, reducing environmental impact from repair operations and spare parts manufacturing.​ In terms of risk, Metso also argues that the use of rubber lining minimises hot work and significantly reduces the risk to staff, resulting in an 88.67% reduction in exposure.

Finally, the rounded corners and rubber lining drastically diminish material carryback, ensuring a higher payload per haul. Plus a possible decrease in noise pollution by up to 25 dBA contributes to a healthier work environment and lessens the impact on local wildlife.​ Notably, the human ear perceives a 10 dBA reduction as effectively halving the noise level.

Metso adds that the Volvo A60H can be customised with Metso’s specially designed accessories and configurations, optimising efficiency. This includes choices in from rubber linings, each meticulously engineered to address specific wear and impact conditions unique to the operation. The ‘eyebrows’ and side rock protections shield against the challenges posed by loading and hauling operations.

Modular panels, designed for resilience and convenience, facilitate easy maintenance and allow for swift replacement. Durable mud flaps keep dirt away, safeguarding the truck and reducing the need for cleaning. A robust tailgate, specifically designed for the Metso haul truck body and Volvo A60H, improves material retention and minimises spillage.

BHP starts operating Komatsu 4800XPC electric cable shovel at Escondida

BHP has announced the start of operations at Escondida copper mine of the first 4800XPC electric cable shovel in Chile and Latin America and the third in the world, designed and manufactured by Komatsu.

With a weight of approximately 1,750 tons in operation, it is the shovel with the highest capacity worldwide, loading 400-ton mining trucks in just three passes, one less than other equipment currently on the market. This allows increasing efficiency during the truck loading process and generating a significant improvement in costs per ton, as well as increasing the safety and comfort of those who operate it.

Alejandro Tapia, President of BHP Escondida noted: “Having the 4800XPC shovel in our fleet of equipment is a great contribution to advancing the operational challenges we have in Escondida. We are very happy that the shovel with the greatest capacity has arrived at the main copper producer in the world. I want to congratulate all the teams involved in the assembly and delivery of this shovel, which was achieved without safety incidents and in less time compared to the other two teams on the market.”

“For Komatsu, the start of operations of the 4800XPC shovel strengthens a relationship that we have had with BHP for decades. In this sense, being able to introduce this model in the industry serves to continue promoting mining in Chile. With this, our intention is to create value together so that both companies continue to position themselves as a reference in mining innovations worldwide,” commented Carlos Soto, Executive Vice President of Komatsu Cummins Chile.

Among its main features, the incorporation of new technologies that allow greater excavation power without reducing the useful life of the equipment, lower loads due to impact or improper operation, improved payload and excavation performance through control and application stand out as does its ‘intelligent’ power usage and in addition less operator fatigue due to the reduction of swinging movements (boom jacking).

The delivery of this new shovel is a significant advance in the national industry, since it is the first time that a copper mine in the world will use equipment of these characteristics. South Africa received the second 4800XPC shovel from Komatsu, where it went into operation in demanding conditions, high hardness and abrasiveness in Anglo American’s Mogalakewna platinum mine earlier this year. The first unit was put into operation at Fording River coal mine in 2019.

Australia’s Gears Mining launches ‘world’s largest’ mill liner handler machine

With projects on every continent, Toowoomba, Queensland-based organisation Gears Mining, has announced the launch of what it says is the world’s largest liner handler machine. This new machine, with a record-breaking weighted capacity of 8,100 kg, it says is a significant advancement and positions Gears Mining at the forefront of the mining equipment industry.

Gears Mining added that the introduction of this innovative Liner Handler is expected to have a substantial impact on the Australian economy. This technology has provided over 100 jobs to the Toowoomba region and is projected to provide more into the future. “Our new Liner Handler is not just a step forward in technology; it’s a leap towards ensuring that our clients can achieve maximum productivity with minimal interruption,” said Ben Dunlop, Co-Director of Gears Mining.

As Gears Mining continues to grow and expand its services internationally, it says the launch of the world’s largest mill relining machine is just the beginning. “We are proud to contribute to the international mining industry, setting new benchmarks and helping to create jobs,” said Damon Frizzell, Co-Director of Gears Mining.

The design of the new Liner Handler Gears Mining it says reflects its commitment to reliability, ease of maintenance, and operator safety. With capacities ranging from 500 kg to an impressive 9,100 kg, Gears Mining says it ensures that its equipment meets the diverse needs of the mining industry. The new 8,100 kg model it adds is specifically optimised for high performance and efficiency, which is crucial for large-scale mining operations.

Gears Mining specialises in Liner Handler solutions and a wide range of mining equipment and services. “From rock breakers and liner handlers to comprehensive maintenance and training, Gears Mining ensures optimal plant efficiency and safety across Australian and international mining regions.”

Safety features of its Liner Handlers include Auto Setup Mode which allows the Liner Handler to automatically configure itself for installation in to the mill with the press of a button. This eliminates the risk to an operator from potential falling at heights hazard; plus it removes operator error and reduces the potential for machine damage as well as eliminates the use of potentially faulty pendants, other inefficient or unsafe methods of boom positioning.

Operator Seat Install Mode allows the Liner Handler to position itself to allow for safe installation of the operator seat. This minimises falling from heights risks associated with fatigue, poor lighting and poor judgement by MRM operators; and it removes manual handling issues associated with seat installation.

A CANBus system manages machine health, ensuring an optimal safe operating environment. It maximises the safety of the environment for operator by constantly monitoring all systems on the Liner Handler. It also reduces relining downtime with dual operator screens instantly showing fault codes. Gears Mining systems use rugged mobile fleet style IP68 rated electrical connectors throughout the electrical system to reduce potential failure points.

Finally, Pack up Mode is a quick and simple method of returning the machine to its parked/storage position. It reduces the requirement for the operator to climb over the machine to return the liner handler to its parked position and it eliminates the potential hazard of falling from heights. It also reduces the risk of operator error and the potential for machine damage.

China’s Fambition reveals its BEV loader ambitions

IM recently sat down with Ning Xiaofeng, President of Qingdao Fambition Heavy Machinery Co. Ltd, at the Exponor 2024 mining event in Antofagasta, Chile. As one of the leading Chinese manufacturers of underground mining equipment, Fambition considers Chile an important market. The company delivered four 10 t LHDs to Codelco in late 2019 and maintains a warehouse and support team in Rancagua.

Xiaofeng shared updates on the company’s fleet electrification plans. Fambition already offers electric versions of its LHDs – the FL07E, FL10E, and FL14E in the 7, 10, and 14 t classes. These models feature an electro-hydraulic controlled variable flow system, a constant tension induction automatic control cable-reel system, and an on-board display that provides real-time operating parameters and self-diagnosis capabilities. Standard features include a visible remote control system, with options for an automatic centralised lubrication system and an Ansul centralised fire protection system.

Fambition already has a well established range of cable tethered electric models like the LF14E

Xiaofeng revealed that Fambition has now developed a battery-electric FL07B LHD, which will debut at the Bauma China show from November 26-29 in Shanghai. Discussing the transition to electric equipment, Xiaofeng said: “This battery loader improves three aspects: air quality by eliminating diesel particulates, reduced noise, and better working conditions for the operator, including ergonomic enhancements.”

The company already has a significant number of cable-tethered loaders operating in China, with the 10 t FL10E being the most popular model, primarily used in iron ore and copper mines.

What’s driving the shift from cable to full BEV? “Our customers are asking for a full battery model,” Xiaofeng explained. “We are also solving a transportation problem, as machine fleets in China often move to new operations within the same mining complex. With cable machines, you need to set up the cable infrastructure, whereas battery machines can be more easily moved between mines.”

Fambition started with the 7 t model because it is a commonly used size in China. Additionally, China leads the world in battery technology and production. Xiaofeng noted that China’s strict battery safety regulations and procedures made the 7 t model the best initial option, as the battery pack size is more mature and meets all necessary safety regulations for underground mining.

While there is no launch customer yet, a letter of intent has been signed with a mine operator to conduct an initial trial with the machine in a currently non-working mine to carry out safety tests in real mine conditions.

The first model will feature a plug-in charging system, with plans for future models to include a battery swap option. Xiaofeng also mentioned that the goal is to market the FL07B globally, not just in China. In the long run, although batteries are more environmentally friendly than diesel, especially when powered by renewable energy, he believes technologies like hydrogen combustion engines will likely replace current battery-driven technologies in the near future.

Carola-Coemin grows Sandvik TH663i fleet in Chile

Sandvik Mining & Rock Solutions has announced the delivery of the latest 63 t class TH663i truck as part of an order for six units that was awarded last year by customer Grupo Minero Carola-Coemin in Chile.

The OEM says this truck stands out for its ability to raise sustainability, safety and technology indexes. “The award represents a growth in the fleet and confirms the commitment to our customer Grupo Minero Carola-Coemin. We look forward to further consolidating this relationship, which has been growing steadily in recent years.”

The Carola-Coemin Group is made up of 100% Chilean capital, and is dedicated to the extraction of minerals and production of copper, gold and silver concentrates. The ore is extracted from the Carola mine and subsequently processed at the Cerrillos plant, where the concentrate is produced which is then processed at the Hernán Videla L Smelter.

Carola is an underground deposit from which ore is extracted through sub level stoping with production carried out up to 50 m above sea level. All of the ore is processed at the Cerrillos plant, 11 km away from the main adit.

The Cerrillos plant is owned by Compañía Exploradora y Explotadora Minera Chileno Rumana and is located 30 km south of the city of Copiapó. It produces copper concentrates through a conventional flotation process. The ore comes from Carola mine and is mainly composed of chalcopyrite and other copper mineralisation. Within the production process, the operation of a state-of-the-art tailings thickener allows deposition of paste tailings instead of conventional tailings, recovering and reusing over 85% of the process water, in addition to providing greater physical and chemical stability to the mining process.

Underground mining will form one of two streams at the forthcoming Electric Mine 2025 conference being held May 13-15 at Centro Parque in Santiago, Chile. For more information see www.theelectricmine.com

 

Gekko highlights ILR and Carbon Scout successes plus gravity box potential

In its latest newsletter update, Gekko has provided updates on some of its key technologies. It says its InLine Leach Reactor (ILR) has achieved notable success at Barrick Gold Corporation’s Bulyanhulu Gold Mine in Tanzania, achieving exceptional recovery rates of 99%+.

Before acquiring the ILR, the Bulyanhulu metallurgical staff realised that they were not treating a large fine gold component. This led them to Gekko’s ILR which can handle all the size ranges from very fine to very coarse. After starting up the ILR, they were achieving 99%+ recovery treating all the gold, including the fine component that was previously removed in the desliming step.

Gekko says the ILR’s efficient design and mineral leaching chemistry have led to high gold recovery rates, offering a significant boost to production efficiency. “With its ability to be easily retrofitted into existing gravity circuits, the ILR presents a promising opportunity for enhanced production and profitability in the gold mining industry, especially amidst the backdrop of strong gold prices. The success of the ILR at Bulyanhulu highlights the importance of continuous improvement in the mining industry.

The Gekko Carbon Scout, which Gekko describes as a ground-breaking innovation in real-time gold processing technology, it adds is experiencing increased interest, highlighted by recent purchases from Ravenswood Gold and Oceana Gold (Macreas operation). The Carbon Scout is a self-contained sampling system that revolutionises gold processing by providing real-time measurements of crucial parameters such as pH, dissolved oxygen, and gold concentration in carbon-in-leach (CIL) and carbon-in-pulp (CIP) circuits.

“A standout feature of the Carbon Scout is its ability to accurately measure carbon density within the pulp, with an impressive precision of ±0.5 grams per litre. This data enables operators to automate carbon movement, optimising distribution and enhancing gold recovery processes. The device’s adoption by major players underscores the importance of real-time data analysis and quick decision making to ensure sites are not losing any gold to the tailings dam. Contact Gekko and start prioritising circuit optimisation with the Carbon Scout.”

Finally by leveraging separation techniques and implementing pre-concentration measures to reduce initial mass, Gekko says its streamlined gravity-based processes not only boost the grade for downstream intensive processing but also maximise the recovery of precious minerals like gold.

“Recovering minerals as they liberate or removing gangue as it liberates is a key strategy in increasing recovery, increasing pre-concentration and reducing energy consumption in mills. Traditionally, grinding ore to fine particles has been considered essential for optimal recovery rates. However, Gekko’s game-changing continuous gravity recovery device – the continuous InLine Pressure Jig (IPJ) has changed this thinking. The IPJ efficiently separates coarse mineral-bearing particles and gangue from the feed material without the need for extensive grinding, consistently delivering exceptional recovery rates.”

Gekko adds: “Determining the mineralogy of an ore material is critical for optimising the operation of a gravity circuit. Whether the mineral is free or occluded with other sulphides, or whether multiple liberating particle sizes exist, will help determine the optimal gravity flowsheet design for the best recovery of mineral. Gekko’s Gravity Box installations have achieved success globally, showcasing the versatility and efficacy of this gravity-based solutions. Both continuous gravity and batch gravity ‘gravity box’ designs are available.”

Epiroc USA’s first Boltec M10 Battery launches operations at Nevada Gold Mines

Epiroc, the global mining equipment leader, has successfully introduced the first Boltec M10 Battery rig in the US at Nevada Gold Mines. It says this marks a significant step toward greener practices in the mining industry. Russ Osborne, Key Account Manager at Epiroc USA, shared his excitement, saying: “We’re thrilled to help our customers lead the charge in electrifying the US mining sector with the Boltec M10 Battery.”

The Boltec M10 SG rock bolting rig for ground support Epiroc says brings multiple enhancements to underground operations, including an improved operator work environment, reduced noise, and a smaller environmental footprint. The rig features an onboard charger for convenient battery charging during downtime, ensuring uninterrupted drilling operations.

Epiroc’s Competency Center for Underground Mining, headquartered in Elko, Nevada, offers advanced technical support in the region, as well as specialised electrification, and battery-electric vehicle (BEV) expertise, including diesel-to-battery conversions. The centre is equipped to service and support BEV transition.

“Nevada Gold Mines embraces shifting to a more decarbonised method of mining and is looking forward to the benefits of the BEV Boltec M10 and seeing its success. The Boltec M10 has proven to be a valuable asset in the industry, providing environmental benefits and optimising operational efficiency,” said David Byrnes, Mine Manager, NGM Leeville Underground Complex.

This successful deployment of the first BEV Boltec in the US Epiroc says underscores its dedication to advanced mining practices, aligning with the industry’s shift towards cleaner and more efficient technologies.