All posts by Paul Moore

Hitachi Energy on mine electrification – start small and think big

Automation, Base metals, Bulk handling, Environmental, Equipment maintenance, IoT, Mineral processing, Mining consumables, Mining equipment, Mining maintenance, Mining people, Mining services, Mining software, Power supply for mines, Precious metals, Sustainable mining

Just prior to the recent Electric Mine 2024 conference in Perth, Western Australia, we caught up with Arnaldo Bertazzi, VP Industry Network Leader – Industries, at Hitachi Energy. He says that the key to electrification in mining is to start small and think big. Electricity will be the backbone of the entire mine energy system, and digitalisation is one of the fundamental technology areas this is enabling the energy transition in mining.  

Arnaldo Bertazzi, VP Industry Network Leader – Industries, at Hitachi Energy

Q One of your most anticipated solutions in mining electrification is a high-voltage fast charger – can you provide an update on this? 

We remain committed to supporting the electrification of mining and developing the right charging solutions for our customers’ fleet electrification. Two key focus areas of Hitachi Energy are standards and interoperability. We have been focused on CharIN standards to extend MCS for mining, especially X-MCS to extend the power, voltage, and ruggedised MCS for the mining environment, and have been working with miners and other industry partners to get this right. Our investigations have shown there is no one-size-fits-all solution, so we support using high power static charging and dynamic charging. These solutions will find applications beyond mining, in marine and rail environments. Safety and reliability are critical to the success of heavy haul flash charge solutions and we are utilising our bus charging solution and scaling it up for mining. The recent acquisition of eks Energy is a strategic investment in the charging solutions space (such as the Waratah 840 MW/1680 MWh super battery) and forms part of our portfolio of technologies that can scale up to the largest capacities. 

Q How will digitalisation help achieve the all-electric mine and can you give some examples of how Hitachi Energy is delivering in this space? 

Hitachi Energy identifies digitalisation as being a key component to the overall success of decarbonising mining activities, however we also see it as an enabler and accelerator towards achieving an all-electric mine. Digitalisation is not only functional to electrification – it also potentially enables higher flexibility and efficiency across all mining processes, as well as improving safety. In fact, it permits the optimisation of logistical and relevant transactions, optimisation of demand/production balance, and minimisation of operational costs, eg demurrage cost. Furthermore, when applied to asset management, it can easily support prognostic maintenance of assets based on the online knowledge of the status and call to service of any specific asset. Additionally, improved and greater safety is achievable through autonomous vehicle control and ‘digital fencing’ obtained through wearable sensors. Just one example, the electrification of underground equipment reduces the need for ventilation, while also generating economic advantage when associated with a smart control of the ventilation. Finally, if at least part of the electricity is produced by the mine with solar and/or wind, digital control and supervision will unleash the whole economic potential of the associated µ-Grids. The transition to an all-electric mine will involve major capital

Hitachi Energy is a global leader in transformers, offering liquid-filled and dry-type transformers, as well as services for complete life-cycle support

investments, and those investments will typically take multiple years to realise. Investments in grid infrastructure, electric mining vehicles, charging infrastructure, and renewable energy projects are complex and can have interdependencies on each other.  As such, it is critical to understand how to transition from today’s operating scenario to the future scenarios that will play out over time. The ability to understand and digitally replicate today’s mining operations, processes, and efficiencies – a so-called “baseline” mining scenario – can be a huge advantage in planning the electrification transition.  With such a replica, the production targets, operational processes, energy demand landscape, and carbon position can be studied, optimised or constrained according to business objectives. Recent advancements in AI and ML can also rapidly speed up the process of achieving a digital replica. Electrification and digitalisation work together to achieve a mine with lower carbon footprint and higher economic efficiency. Energy management systems, energy trading software, and certification of renewable energy use, will become mandatory for an electrified mine. The company’s energy and digitalisation experts support customers with digital landscapes and the supporting solutions that will be deployed within the investment and energy transition strategies defined for our customers. Solutions spanning the all-electric mine digital landscape include network management systems and solutions facilitating grid scale monitoring, control and automation of generation, transmission, distribution, and renewable energy assets. Energy portfolio management offers an end-to-end solution for mission-critical investment, regulatory, operating and trading decisions, and asset and work management solutions support the optimisation of portfolio resources to balance performance, risk, and cost. 

Q In some regions, mines are already highly electric. Are there lessons to be learned from these operations when mine operators are transitioning to electric? 

The first lesson we can learn is that one size does not fit all. Each mine, region, and type of mineralisation has its own unique challenges. Flexibility is key, and different miners have different reasons for electrifying. Cost and energy security have been at the forefront in driving these highly electric mines, and this will continue as renewables drive down the price of energy. A second lesson from this is the importance of renewables integration and power quality. As we see more reliance on electricity for energy, we need more technology to ensure the mine has the resilience to maintain operations during complex failures. The amount of electricity required will be enormous. Many mines will see their demand soar and will need to plan accordingly. We must also recognise the role of diesel-elimination in improving the air quality in underground mines. In that regard, not all fossil fuels are equal – eliminating diesel from underground mines has real, additional health benefits for mine workers besides the obvious sustainability considerations. 

Q How can mine sites effectively leverage electrification to enhance smart operations, incorporating data analytics and improving performance? 

Mine operations can strategically harness electrification to enhance smart operations, integrating data analytics, and driving performance improvements. Initially, electrification emerged as a pathway to enhance health, safety, and environmental (HSE) conditions in underground mining, while simultaneously allowing for cost savings in expensive ventilation systems and (CE) equipment maintenance. Beyond these initial benefits, building synergies between electrification and digitalisation can transform into a comprehensive solution that enables dynamic monitoring, control, and optimisation of mining operations. This integration has the potential to significantly influence the cost structure of an operation and reinforce sustainable practices within the industry. At Hitachi Energy, our unwavering focus lies in the seamless integration of electrification and digitalisation for decarbonisation. Through our product portfolio of electrical equipment and systems complemented by innovative digital solutions, we strive to lead the charge toward a more sustainable and efficient mining landscape.

Q What are key considerations for an electric mine and ensuring sustainable operations?   

Definitely power quality and matching supply with demand. The cost of variable renewable energy is already lower than fossil fuels. Electrification is inevitable. However, the key challenge is matching renewable power to the reality of continuous mining. I must also add – emissions tracking, proper management, and settlement of PPAs, carbon credits trading, proper monitoring and control of all electrical equipment and systems through our innovative IoT and communication technologies, asset performance management systems, network control, etc. 

Q What are the main drivers of electrification? 

There are many drivers, but we see the main ones being cost, energy security, energy diversity, the elimination of diesel particulates in underground mines, shortening the energy supply chain, social licence, improved reliability, and reduced maintenance. Reducing carbon emissions is often the main driver, accelerated by the decreasing cost of energy. This will enable a switch to electric mines, with the need to comply with new laws and regulations related to HSE and emissions. 

Q Will electric fleets require mines to have more power, more power reliability, plus more power redundancy and storage? How is Hitachi Energy helping mining clients deliver on these? 

Absolutely. This will be a big factor especially for directly shipping ores like iron and aluminium, where haul fleets use much more energy than the mine plant. Hitachi Group and Hitachi Energy have a wide range of solutions that have been proven to help our mining clients navigate the energy transition. For instance, Hitachi Energy is promoting high-power static charging which allows the utilisation of haul trucks to be very high, while offering flexibility and costs similar to diesel. Additionally Hitachi Energy and BluVein, an innovator in dynamic charging technology, have signed a Memorandum of Understanding (MoU) to accelerate the electrification of heavy haul mining fleets and solve one of the biggest challenges in decarbonising mine operations. Hitachi Energy’s advanced power electronics and digital charging technologies allow BluVein’s e-rail charging technology to deliver electricity safely and reliably to haul trucks of up to 400 metric tons while transporting materials. The collaboration will fast-track the development of a high-powered, fast, and flexible dynamic charging solution for surface and underground mines and quarries in Australia and across the globe. BluVein will focus on its leading-edge e-rail and truck connections, which Hitachi Energy will further complement with advanced power electronics and digital solutions to power and monitor the whole system. 

The Hitachi Energy collaboration with BluVein combines solutions to deliver electricity safely to battery-electric trucks of up to 400 t 

Q As mine operators are adopting digital transformation, what are the first steps toward change? 

As mentioned earlier, understanding the “as is” state of the mining operation, energy demand, and carbon position is an excellent first step. These steps need not be all-encompassing; they can be segmented to deal with specific issues and aligned with the overarching corporate objectives of the customer.  Digital transformation will include managing a “system of systems” to fully leverage the benefits and ensure the multiple constraints of the evolving mine will continue to deliver production targets and return on investment.   

Murray & Roberts Cementation’s full mining services package

Bulk handling, Equipment maintenance, Mine shafts and equipment, Mineral project development, Mining consumables, Mining services, Sustainable mining, Water management

A household name for shaft sinking in Africa’s mining sector, Murray & Roberts Cementation has over the decades developed a wide portfolio of mining services – some better known than others. “Through our constant innovation across a range of fields, built on the expertise of our highly experienced staff, we keep developing very interesting responses to customer’s challenges,” says Pieter Oosthuysen, Senior Project Manager at Murray & Roberts Cementation.

Among the sector’s growing challenges has been the criminality associated with illegal mining activities. The company has developed solutions to prevent cable theft – including the encasing of cables in grout-filled pipes – and to seal off old areas using grout packs that create permanent barriers.

“Water management has also become a key issue for mines, especially in the mature deep-level gold mining sector,” says Oosthuysen. “Here, their issues are about ensuring responsible water management as well as reducing pumping costs from dormant or mined-out mining areas. This often requires that old underground areas be sealed off to contain the massive water pressures at depth.”

This is by no means a new issue, of course, but Murray & Roberts Cementation has been in this field for so long that they literally ‘wrote the book,’ he notes. The company was part of the team that developed the Code of Practice for designing and constructing high pressure bulkhead plugs, and has a track record dating back decades with plugs and water doors.

“Our team collaborates with plug designers to guarantee that the plug’s design and placement are constructable,” he explains. “The successful construction and pumping of these plugs relies on the use of our mobile grout plants to overcome logistical obstacles.”

It demonstrated this capacity many years ago, when the company’s intervention saved the West Driefontein gold mine from flooding back in 1968. Since then, it has pushed the boundaries of technology to achieve a successful plug at over 2,800 m deep at ERPM’s 68 Level – where it also placed its longest plug segment at an impressive 24 m.

Managing water in the underground environment is not the only place where the company has excelled. As the public spotlight has focused on the safety of tailings dams, Murray & Roberts Cementation helps mines with the crucial task of draining water from these facilities.

“If drainage pipes from the penstocks are damaged over time, these need to be replaced to ensure proper drainage to support the stability of the dam,” he says. “While the mine installs new penstocks and drainage, we wash out these old pipes, install intrusion pipes and seal them off to ensure no leakage.”

Behind these achievements is Murray & Roberts Cementation’s pioneering role in the field of grout plants. It was the first to design and implement a high pressure pumping system that could convey grout from a surface plant to workings underground; the distances regularly covered by these systems have been between three and seven kilometres.

With further capability in aspects including raise drilling, silo and settler construction, blind hole boring, vent passes and ore and shaft rehabilitation, the company presents an unmatched portfolio, according to Dirk Visser, who is also a Senior Project Manager at Murray & Roberts Cementation.

“It is these additional support services that make us really unique in the market,” argues Visser. “Most other players will specialise in one or other aspect of this work, but we give customers the advantage of an integrated solution – allowing us to assume more project risk and relieving customers of significant coordination responsibility.”

For this reason, the company can manage projects that demand drilling and cementation, for instance, while also providing the raiseboring and remote shotcreting functions. The capacity to deliver these offerings, he emphasises, demands skills and experience which requires considerable investment.

“The core talent in our division has an average length of service between 12 and 18 years – with many employees reaching 30 to 40 years within the business,” he says. “We also continuously replenish our skills pipeline with up-to-date, relevant training which includes state-of-the-art training facilities including mock-ups for a grout plant, drop raise and raise drilling.”

The necessary hardware is also an important part of any successful project, and the investment by Murray & Roberts Cementation has also been significant. There is an extensive fleet of machines for the raiseboring part of the business, with more than 8 km of drill pipe available.

“All that we do is underpinned by our comprehensive Murray & Roberts Cementation safety system, which has been developed by taking best practice and enhancing our own CRM systems,” he concludes. “The effectiveness is our safety commitment is demonstrated by our track record – with over seven million fatality-free shifts.”

Manage geoscientific data more efficiently with the latest GIM Suite 5.3 release

IoT, Mine surveying, Mineral exploration, Mining services, Mining software

Global information management software company, acQuire Technology Solutions says it is enabling geologists to manage their geoscientific data more efficiently with the latest GIM Suite 5.3 software release.

GIM Suite has been built for the future of data management, with the aim to improve the way geologists and miners manage their data. The latest GIM Suite 5.3 release introduces a secure REST API for seamless, third-party system-to-system integration and builds on existing features to improve logging methods for diverse data capture scenarios in mining and exploration, as part of the collection of new features available.

Charl Retief, acQuire’s Mining Value Stream Leader, says acQuire is continually evolving GIM Suite to ensure customers are working with the leading software for geoscientific information management. “The new REST API provides a secure and seamless way to access and transfer your geoscientific information across your mining software eco-system. For GIM Suite customers and third-party vendors, you can utilise the REST API when developing integrations to query, create and update data stored in GIM Suite. This eliminates the need for manual import and export data routines, or writing SQL scripts, all while adhering to your business rules on site.”

In addition to the REST API, GIM Suite 5.3 also empowers customers to log data in their preferred way using GIM Suite’s graphical logging interface or a grid-based view. “Geologists can create and group multiple samples and log intervals more efficiently now, while adhering to any company validation rules set,” explains Retief.

“Rapidly capturing data and validating records on entry is now simpler. With GIM Suite 5.3, you can use grid-style logging with a keyboard and use keyboard shortcuts to navigate and easily enter your data.”

Additional enhancements to despatch tasks and GIM Suite’s web-based task menu and properties have also been included in GIM Suite 5.3 to allow for greater user flexibility and an enhanced user experience. acQuire’s GIM Suite it says is designed to support users in making confident decisions using their geoscientific information.

Tailings 2024 – greater collaboration and evolution driving progress

Base metals, Bulk handling, Environmental, Mine surveying, Mineral processing, Mining consumables, Mining safety, Mining services, Precious metals, Steel and iron ore, Sustainable mining, Water management

The Tailings 2024 conference is being organised by Gecamin, the Universidad Tecnica Federico Santa Maria, Universidade Federal de Ouro Preto and The TAilings and IndustriaL waste ENGineering (TAILENG) Center, and will be held June 12-14 in the Sheraton Santiago in Chile. Ahead of the event, we spoke to Geraldo Paes, Corporate Geotechnical Director at global mining company Vale, who is also the Chair of the event this year. The wide ranging discussion covered trends in tailings management, water as a resource, tailings disposal innovation and tailings monitoring.

Geraldo Paes, Corporate Geotechnical Director, Vale and Tailings 2024 Chair

Q This is Gecamin’s 10th Tailings event – how have you seen the industry, by which I mean the consultants, engineers, regulators, miners and solution providers, evolve in that time in its approach to tailings management?

Reflecting especially on the past five years, I’ve witnessed significant evolution within the industry in tailings management. Stakeholders, including consultants, engineers, regulators, miners, and solution providers, have become more proactive in applying technology, improving processes and practices and emphasising ESG in tailings management. This shift towards greater collaboration has been notable, aligning with values such as ethics, safety, and integrity, which are transforming the industry’s culture. As a big advocate for safe and responsible mining, I’ve seen how these values drive industry-wide progress.

Q Water is increasingly seen as a valuable resource – is water would you say among the most important or the most important factor driving tailings technology today?

Water conservation has indeed emerged as a critical factor driving tailings technology today. Throughout my career, I’ve come to understand the vital importance of water as a precious resource, not just for our operations but for the communities and ecosystems we serve. This awareness has fuelled my commitment to developing solutions that not only optimise water usage but also prioritise safety, efficiency, and environmental stewardship.

Q Do you see a future where conventional tailings, thickened/paste tailings and filtered tailings will all continue to play their part based on the particular aspects of the project concerned, or that the industry will move towards a more standardised method of dealing with tailings?

The future of tailings management most likely involves a combination of all these methods, each tailored to the specific requirements of individual projects. While standardisation may offer certain benefits, the diversity of geological, hydrological and operational contexts suggests that a flexible, case-by-case approach will remain prevalent. In my point of view, the most important change is not in the method of disposal itself, but in the fact that safety and environmental responsibility are driving factors in choosing those methods and in operating TSFs across the world.

Q Is there still room for innovation in tailings management in your view? Will different approaches to processing such as the greater use of dry grinding and coarse particle flotation also help to change the tailings status quo in mining?

Absolutely, there’s a lot of room for innovation in tailings management. Innovations such as dry grinding and coarse particle flotation present promising avenues for improving efficiency and reducing environmental impact. I would add to this list the many possibilities for reusing, reducing and reimagining tailings – these will be amongst the greatest challenges for the mining industry in the coming years. At Vale, we continually seek new technologies and approaches to drive sustainable change. I am positive that at the Tailings 2024 conference we will see many innovative solutions which have the potential to challenge the status quo and push the boundaries of what’s possible in our industry.

Q Tailings monitoring via satellites and using the latest sensors is another important topic – the tools that help mining operations manage their tailings operations. Again, is technology advancement aiding industry in this regard and is this an important topic within the event agenda?

Definitely. Technology advancements, including satellite monitoring and sensor integration, have revolutionised tailings management, providing real-time data and insights for effective decision-making. This goes to show how much we, as an industry, have progressed over the last few years and how much technology we now have applied to our TSFs. At Vale, we recognise the importance of leveraging these tools to enhance safety, performance monitoring, and operational efficiency. This focus on technological innovation is a priority on the Tailings 2024 agenda, reflecting our commitment to continuous improvement in tailings management practices.

Brazil’s U&M making progress on hybrid trucks

Automation, Bulk handling, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining services, Sustainable mining

Brazil’s largest mining contractor is confident it can be scaling up a new battery-electric hybrid truck platform and retrofitting the country’s second biggest surface mine diesel vehicle fleet in the next two years, The Electric Mine 2024 heard. “We really want to get into a future where mining becomes safe, intelligent and sustainable,” U&M Mineração e Construção Project Coordinator Lucca Machado said at the event in Perth, Western Australia.

“We see that our initiatives, along with other projects around the world, are going to help us get there. And hopefully sooner than later.”

U&M has been working for about seven years on heavy vehicle automation and in 2020 it initiated a hybrid diesel-electric truck program focused, initially, on getting a suitable power-to-weight balance on a Komatsu 730 186 t truck using LFP lithium-ion battery cells made in China and hybrid platform system components developed with partners in Brazil.

The latter included Semikron Danfoss on the truck’s DC-to-DC converter; transformer and reactor specialist AQ Trafotek; and local electromobility hardware and software start-ups MVP e-solutions and EVPV Power.

U&M has two autonomous trucks running at a gold-mining client’s site in Brazil.

Lucca Machado, part of the third generation of the Machado family that owns U&M, said the company was also “trying to explore as much as possible the synergy” between autonomous and hybrid-power vehicle systems.

He said U&M was moving towards validation of its hybrid platform system at a client site by the end of 2024.

“We are hopeful that we can get in the next couple of months this [test 730] truck running at our proving ground. After that focus will shift to stress-testing the truck at one of our mine sites in Brazil. That’s where we see whether the technology is working or not. That’s where we see the performance of the new components. Next year is where we really focus on system optimisation. And there is quite a bit to be done.”

Machado said downsizing the truck’s diesel engine – perhaps by as much as 50% to circa-1,000 horsepower – would be part of the project’s ongoing optimisation focus. As would exploring the impact and timing of different battery charging options, including regenerative braking, on the energy profile of a truck in a production cycle.

“Our focus is to get that done at the beginning of 2025 and after that moving into scale,” he said. “We know that [scaling] is tough. We have quite a lot of experience with our autonomous project. But we are confident that, working with the partners that we have, we can bring this to our clients at the end of next year.”

U&M has more than 90 Komatsu 730 trucks in a total fleet of about 800 heavy and support vehicles.

It wants to develop a commercial 730 truck retrofit kit costing under US$200,000, sans the battery pack. “Then the battery will change depending on the chemistry we use and we know that within a couple of years it’s going to be a different one,” Machado said. “We have a bit over 250 trucks that have 10-20 years of life ahead of them and really running into the risk of being technologically obsolete [in future]. So that’s a very big motivation for us, along with increased performance [of the trucks]. We’re aware there are quite a few challenges with these new technologies.”

He adds: “And we see really that the biggest one of them is trying to fit with the current day operational profile of the trucks. These trucks are running 24-7. They are very reliable and very flexible. If we’re going to help our clients get to their 2030 [decarbonisation] goals we need to have different strategies. There isn’t going to be one solution that fits everything. As a mining contractor charging infrastructure is a challenge. We have quite a few short-term contracts. So we have to go to one place and next year we will be somewhere else. So the hybrid retrofit we’ve been working on … is a really natural first step for decarbonisation because it’s a simple solution and we can make preparations now.”

This story was written by Richard Roberts of InvestMETS, one of The Electric Mine 2024 Supporting Partners

Zero Nexus secures funding to lead collaborative education on BEV fleet adoption in mining

Automation, Base metals, Equipment maintenance, Mine shafts and equipment, Mine ventilation, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining techniques, Precious metals, Sustainable mining

Zero Nexus Inc, a research company in sustainable mining solutions, has announced the launch of the ‘Electric Vehicles in Mining Operations (EVMO)’ project, another step towards the electrification of the mining industry. This initiative is funded by Natural Resources Canada (NRCan) through the education and awareness project funding – clean transportation and clean fuels call for proposals, with additional investment from the Mining Innovation Commercialisation Accelerator (MICA) and collaboration from leading mining entities.

The EVMO project is designed to understand and provide awareness around the challenges that may hinder the widespread adoption of fleets of Battery Electric Vehicles (BEVs) in mining operations. To accomplish this, Zero Nexus and the project partners aim to foster a deeper understanding of challenges and solutions to facilitate the transition to BEV fleets within the sector through a comprehensive approach that includes stakeholder engagement, research, and on-site evaluations.

Zero Nexus Inc adds that it is proud to have industry leaders from New Gold Inc, Agnico Eagle Mines, Sudbury Integrated Nickel Operations (a Glencore company), and NRCan-CanmetMINING, along with a representative from MICA, forming the project’s steering committee. This committee will guide the initiative towards comprehensive and relevant outcomes to address the industry’s needs as mine operators prepare to transition to BEV fleets.

MICA’s involvement includes enhancing the project’s visibility, networking within the mining sector, and facilitating early access to findings and best practices. MICA Network Director Chamirai Charles Nyabeze believes that “the future of underground mining is electric and that this project will accelerate the BEV transition.” This collaboration underscores the commitment of all parties to drive innovation and sustainability in mining through the adoption of clean technologies.

The EVMO project represents an opportunity to accelerate the journey towards sustainable mining operations. By addressing the technical, organisational, and knowledge barriers to BEV adoption at the fleet scale, Zero Nexus Inc says it and its partners are laying the groundwork for a cleaner, more efficient future in mining.

“We appreciate the support and openness of our project partners, who are providing valuable access to their operations.” said Edward Fagan, Associate Partner at Zero Nexus. “We’re at a significant juncture for underground Battery Electric Vehicles (BEVs), with some of the first global mining operations transitioning to full electric, many of which are in Canada and participating in this project. By conducting this project across multiple organisations at the same time, we aim to gather and disseminate key insights on adopting a BEV fleet effectively. These insights, meant to assist not just the participating companies but the broader mining community, will be made available through the support of NRCan. This collaborative effort and the willingness to share knowledge and experience among the steering committee members are crucial for our collective success.” 

Open autonomy a miner’s best friend: Wenco

Automation, IoT, Mining equipment, Mining services, Mining software

Open autonomy and increased competition in the mining equipment and fleet management space are going to be key levers for resource developers looking to turn economically marginal ore deposits into dollars, The Electric Mine 2024 heard.

Mining heavyweights such as Rio Tinto, Hancock Prospecting and others are currently working closely with traditional mining and non-mining technology companies to advance development of smaller autonomous and electric vehicles, fleet management and potential swarm robotic mining applications.

Successful commercialisation is likely to open the door for many others sitting on resources that historically wouldn’t have interested the majors.

VP Commercial at Wenco International Mining Systems, Glen Trainor said at The Electric Mine 2024 in Perth, Western Australia, the mining industry’s increasing challenges with falling ore grades, deeper operations, longer ore and waste haulage routes and rising – not decreasing – energy consumption, were well documented.

Haul truck and drill rig autonomy had been shown to improve productivity at a limited number of sites so far. Electrification was the major test in front of the industry – to move away from its reliance on high-density and highly flexible diesel and gas at a time when energy use was growing – and autonomy loomed as an even bigger part of the economic equation in a new era, Trainor said.

Specifically, open autonomy. “Open autonomy will allow the mining companies to maintain mixed fleets [of equipment],” Trainor said. “Open, published standards that allow any vehicle autonomous system to talk to any fleet management system will invite competition. And competition is healthy for the industry. It will invite competition for autonomous systems from other industries into our industry; [competition] from other autonomous technology providers who may not own trucks, or who may not own fleet management systems [FMS]. They can now come into the mining industry and help the autonomy program.”

He added: “Enter smaller electric trucks into this scenario and now you have some innovation in the industry in terms of the potential for swarm mining. Smaller digger units to load smaller trucks – that allows more selective mining. All of this makes these satellite deposits easier to access. And what it will eventually do is allow us that potential to access these previously uneconomic deposits.”

Trainor said 35-year-old Wenco, owned by Japan’s Hitachi Construction Machinery, led a move from proprietary to open FMS databases two decades ago. It wasn’t a popular move among FMS suppliers then and that “parallels the situation with OEM autonomous solutions today.”

“The mining industry has been moving more towards open standards and published standards,” he said. “But unfortunately the OEM autonomy systems are moving away from integration standards. You are required to purchase that OEM truck, then you’re required to purchase that OEM’s autonomy system, then you’re required to purchase that OEM’s fleet management system. That eliminates the ability for the mining company to select best of breed. They can’t select the FMS system they want. They can’t keep their mixed fleets. We term this the closed stack.”

“We are part of Hitachi Construction Machinery. And we’re proud to be part of that autonomous solution. It’s a good solution. I’m not saying that OEM autonomous solutions are bad. They’ve proven themselves. They’re effective. They work. But what I’m saying is that they may not meet all of the challenges within the industry today.

Trainor continued: “HCM is very customer-centric. They are backing Wenco in this open autonomous program. They recognise as well that the open autonomy initiative will be better for the industry.”

Trainor said Wenco also recognised the business risk attached to ‘closed stack’ technologies. “If our customers wanted open autonomy they had to rip our systems out. So about eight years ago we started devising the plan for the open autonomous system to save that. These systems are not easy to replace. There is [embedded] integration with a lot of data sources out there. ERP systems, human resources, finance, engineering, mining, etc … To go in and redevelop all of those interfaces is a lot of work.”

Trainor said the ISO 23725 autonomous system and fleet management system interoperability standard opened the way for seamless integration of existing and new technologies, and for new players to come in and innovate in the mining arena. A long list of technology firms were developing autonomous systems for on and offroad vehicles. Not all would come into mining, but a number of new brands were already active in the market.

“On our side we’re working with the dispatch algorithms to ensure that the FMS can handle hundreds upon hundreds of trucks in a swarm,” Trainor said. “We heard from Freeport McMoRan [at the conference] that they already have 140 large trucks out there. With these smaller trucks we’re going to get to 200 or 300 vehicles.”

Asked if mining customers were actively looking to transition to autonomy and BE simultaneously, Trainor said: “I think what we’re seeing now is the preparation for it. They don’t want to commit to anything right now that’s going to lock them into a certain path. Having open autonomy available now means they have pieces in place that are dynamic and that can evolve. I think that’s where the open standard gives that flexibility and comfort; where you are not being locked into a solution at the moment.”

This story was written by Richard Roberts of InvestMETS, one of The Electric Mine 2024 Supporting Partners

Sandvik, Byrnecut collaborate for a diesel-electric future

Bulk handling, Environmental, Equipment maintenance, Mine ventilation, Mining consumables, Mining equipment, Mining maintenance, Mining services, Sustainable mining

Leading contract miner Byrnecut will collaborate with Sandvik to develop new diesel-electric mining equipment with the aim to boost sustainability, efficiency and productivity underground. Under an agreement signed at The Electric Mine 2024 conference in Perth, Australia last week, the companies will work together to develop underground loaders and trucks featuring electric drivetrains. The overall goal is to create equipment that matches Byrnecut’s specific capability requirements and helps optimise operations.

Pat Boniwell, Managing Director at Byrnecut Australia, welcomed the collaboration. “Diesel-electric equipment has a proven ability to combine the low-maintenance benefits of electric machines with the flexibility of diesel,” Boniwell said. “We have a long association with Sandvik and we’re pleased to be providing input and feedback that will help shape the new Sandvik diesel-electric range. We’re also looking forward to passing benefits of this collaboration on to our customers.”

Mats Eriksson, President of Sandvik Mining and Rock Solutions, said the future of mining is likely to include a combination of multiple coexisting technologies. “An immediate switch to full battery-electric isn’t feasible for every operation,” Eriksson said. “We have extensive expertise in both battery-electric and conventional diesel technology within Sandvik, and we believe combining this expertise will lead to new productive solutions for our customers. We’re delighted that Byrnecut is sharing its knowledge of underground and will provide feedback to help us develop the best diesel-electric loaders and trucks.”

Diesel-electric machines typically have a diesel engine that drives a generator which, in turn, provides electricity to motors responsible for movement and operating equipment. Unlike conventional diesel, diesel-electric machines generally have no torque converter and fewer rotating components, allowing for a more flexible design, requiring less maintenance and enabling lower operating costs while maintaining high availability.

Sandvik announced last year that it was moving ahead with developing a diesel-electric range of underground loaders and trucks to complement its leading battery-electric offering. The decision followed the showcasing of Sandvik’s Toro™ diesel-electric truck demonstrator to customers at a technology workshop in Turku, Finland in 2022.

The collaboration between Sandvik and Byrnecut will initially involve establishing a common vision for optimizing Sandvik diesel-electric machines for Byrnecut’s needs. Byrnecut will then work together with Sandvik on the design of the machines and provide feedback at various testing stages, including pre-factory testing, operational testing and trial testing.

Boniwell said Byrnecut is exploring a wide range of different technologies and is eager to embrace innovations that reduce costs, improve safety and increase productivity and sustainability. “It’s likely the transition to battery-electric will be a gradual process with both electric, diesel and potentially diesel-electric machines operating side by side in the meantime,” he said.

Engineering and procurement win for Worley at South32’s Hermosa

Base metals, Bulk handling, Mine ventilation, Mineral project development, Mining services, Power supply for mines, Precious metals

Worley has been awarded a contract to provide detailed engineering and procurement services for the underground infrastructure and the surface non-process facilities of the zinc-lead-silver Taylor deposit at South32’s Hermosa project in Arizona.

Under this contract, Worley will support the design and procurement of underground mechanical and electrical infrastructure for excavation, power distribution, and dewatering, along with maintenance and ore handling systems.

It will also integrate ventilation, shaft transport, and communication infrastructure for the underground operations, as well as the design for the surface non-process facilities.

The project team will be based in Phoenix, Arizona but Worley says it will also draw on other mining experts from around the world to help South32 and its other partners to ensure safety in design and timely execution of the project.

The Hermosa project targets 75% less water usage compared to other mines in the region. It will also incorporate automation and advanced technologies to further reduce CO2 emissions associated with the mine.

“This is our first project with South32 in North America, underlining our dedication to the US mining sector while helping provide minerals that are essential for the energy transition,” said Tom Foster, President US Operations and Worley Consulting.

“Collaborating with South32, we’ll work to enable a data-centric, ‘digital asset’ approach, ensuring seamless updates, operations, maintenance, and future expansions throughout the mine’s lifecycle. This innovative approach will be underpinned by our expertise in project delivery, both underground and at the surface. We look forward to working alongside South32 and other project partners to deliver this critical project.”

 

WEG delivers operational efficiency at a Canadian gold mine

Mine shafts and equipment, Mining consumables, Mining services, Power supply for mines, Precious metals

WEG, through its commercial branch in the USA, says it recently closed a comprehensive order with a major player in the mining sector in Canada for the supply of two synchronous condenser systems. These systems will be installed in a gold mine located in the gold belt region in northeastern Ontario, Canada.

WEG’s synchronous condensers, which enhance stability and availability in electrical grids, will be installed in the mine’s substation where 230 kV transmission lines are stepped down to 13.8 kV bus bars that power various electrical loads of the gold mine. WEG’s scope includes the synchronous condensers, specifically designed for the application; auxiliary motor starting systems; the complete capacitor protection, control, and excitation system; and the oil lubrication systems for bearings.

The commercial branch has been supporting clients in North America in synchronous condenser systems since 2015, with a turnkey system already operational in the USA since 2018 and multiple systems currently in operation. With this experience, WEC says it has developed robust local supply partners that expand local capabilities and add value to integrated project offerings. It adds: “Through this supply, we demonstrate our expertise in bringing simplicity to a complex need. By collaborating and building trust in this way, we make WEG the natural choice.”