All posts by Paul Moore

CIMIC’s Sedgman & CPB selected by BHP to undertake Western Ridge Crusher Project

Bulk handling, Comminution of minerals, Environmental, Mineral processing, Mineral project development, Mining services, Steel and iron ore

CIMIC Group companies Sedgman and CPB Contractors, in joint venture, have been selected by BHP to undertake the Western Ridge Crusher Project in Western Australia. The project, which will generate revenue to CIMIC of A$757 million, involves an end-to-end solution for design and construction of a new 30 Mt/y primary crusher (separately procured by BHP) and a 12 km overland conveyor, radial stacker and associated stockpiling systems, with a capacity of 30 Mt/y.

Sedgman and CPB Contractors have worked with BHP during the past 12 months to progress engineering, design and long-lead procurement for the project. The team will now commence construction at the end of May 2024.

CIMIC Group Executive Chairman Juan Santamaria said: “The unique combination of Sedgman’s mineral processing experience and CPB Contractors’ construction expertise provides our clients with the certainty of a proven track record in the delivery of major process infrastructure in the mining industry.”

Sedgman Managing Director Grant Fraser said: “We are pleased to continue our longstanding relationship with BHP and extensive work with CPB Contractors to deliver value for the Western Ridge Crusher Project. It is an exciting, long-term development in Western Australia.”

CPB Contractors Managing Director Jason Spears said: “CPB Contractors has a legacy delivering major projects for BHP in Western Australia and a current workforce based in the Pilbara region. We will continue to work closely with the local community to leverage employment, business and social opportunities with a focus on skills, training and diversity.”

Construction is expected to be completed ready for production to commence in the first quarter of FY27. The Western Ridge Crusher site is on Nyiyaparli Country in the Pilbara region, approximately 21 km southwest of Newman.

Liebherr – moving more tonnes Down Under

Automation, Bulk handling, Mineral commodities, Mining consumables, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Steel and iron ore, Sustainable mining

Liebherr is growing in the Australian market and has been making some really significant investments to reflect that. This includes expanding its Perth mining facility, adding 47,000 m2 of workshop, office and build space to the complex. Perth is Liebherr-Australia’s second largest branch after the company’s head office in Adelaide, South Australia. Ahead of The Electric Mine 2024 event May 21-23 in Crown Perth, IM Editorial Director Paul Moore caught up with Juan Lorenzo, Liebherr-Australia National Sales and Marketing Manager, Mining. Liebherr is the Lunch Sponsor at the conference plus has an exhibitor booth and is attending with a large delegation. Plus Derek Alband, Equipment General Manager – International Sales at Liebherr Mining will present ‘Redefining sustainability in the electric age’ on Day 3, May 23. You can still register at www.theelectricmine.com

Juan Lorenzo, Liebherr-Australia National Sales and Marketing Manager, Mining

Q How is Liebherr mining equipment perceived in Australia in terms of quality, performance and support?

The Australian market knows that Liebherr equipment is synonymous with quality engineering. However, I would say that the support behind the equipment is what really sets us apart from other OEMs. And while our portfolio of machines is not the largest, our products are very well thought out for what the market needs. They perform at a very high level of productivity and efficiency, which is what our customers have now come to expect and why they keep coming back to us. The performance of our machines is also reflected in their popularity in diverse use cases from new purchases to contractor fleets plus wet and dry hire rental, such as with National Group and others.

Q Is the high performance of Liebherr machines partly linked to robustness and component performance?

They are very robust machines and have been proven in the most challenging applications in Australia from magnetite iron ore to hard rock lithium. They outperform others in terms of productivity, such as the fastest cycle times for mining excavators. Our engines are also very tough. In fact, today we are a one stop shop for major components, including engines, electric drive systems and even wear parts. This means customers have one point of contact plus they can be confident everything will work together as it should.

Q Can you talk more about Liebherr’s vertical integration in mining?

Of course there was some initial conservatism but our new level of vertical integration has been very well received, including our new D9812 and D9816 engines. When you really look underneath it all, big customers don’t want to have to deal with too many vendors. Our components are all designed to work in harmony for the highest possible performance over a long working life. Integrating a lot of components from diverse manufacturing sources can mean a lot of rework at those interchanges and connections, so you can lose power and productivity. It is also worth remembering that Liebherr engines are not a new thing – they are just new in big mobile mining machines and have actually already been deployed in our dozers and a wide range of Liebherr construction equipment for a number of years as well as in gensets used in mining. The engines that we have put into our mining excavators in Australia have already proven themselves in the R 9400 and R 9600.

Q Looking at individual excavator models, can you talk about where each one finds its niche and why?

The R 996 was a class leader for a long time, but the R 9600 has really filled its shoes well, breaking numerous production records even to the point of almost getting into R 9800 performance territory. This is quite a result for an excavator that was only introduced in 2021. Plus today, unlike in the past, we have more excavators going into hard rock as we have going into coal which is really being driven by the R 9600, such as the units that are at BHP South Flank, which were repowered to D98 engines. Contractors also see this machine as being very versatile as it sits just as easily in coal as it does in hard rock. The R 9800 also has applicability in hard rock but its big market is for high tonnage overburden removal in coal – with numerous big miners and contractors having deployed it for that purpose including Mt Arthur, Olive Downs, Boggabri, Moolarben, Carmichael and many others. The new R 9300 is also a versatile machine that finds a home in many hard rock mines, such as gold, lithium and other metals – the first unit in Australia went to Maca for the Karlawinda gold project. The R 9400 is a real workhorse and is also used in metallic mines but also in coal as a coal clean up and back up machine.

Liebherr T 264 mining truck at a customer site

Q What about the evolution of your trucks usage in Australia?

Our trucks are really proving themselves in different commodities including iron ore and coal and with both owner operators and contractors. The zero emissions agreement with Fortescue is taking things to another level in terms of both volume but also Liebherr helping to lead the way in mining with new technology. Under the partnership, Fortescue and Liebherr are developing mining haul trucks integrating the zero emission power systems developed by Fortescue WAE. Delivery of a minimum 120 haul trucks will follow, aligned with Fortescue’s fleet replacement and sustaining capital expenditure forecast.

Q How does the new Perth facility reflect market changes and growth for Liebherr, especially for new technology?

We have invested in expanding our facility in Perth to respond to market growth in Western Australia. We are also supporting the roll out of the zero emission T 264 trucks with Fortescue from that location. The first trucks are currently going their validation phase and it has been publicly stated that these are expected to be operational in 2025.

Q What has your strategy been when looking to future mining equipment needs?

Our development has been very drivetrain and powertrain agnostic using a modular approach. That is because our focus will be wherever the customer’s focus is – we are not pushing any particular technology to them. If they want to go battery or fuel cell, we will be able to support them. But there are also other technologies down the track that Liebherr is also putting a lot of work into – including hydrogen and methanol combustion engines. Plus all our engines are HVO compatible and we are also looking at ammonia and sophisticated E-fuels. Lastly it is worth noting the work we are doing with excavators – we are ready to meet demand for electric excavators and our first new electric unit in Australia, a R 9400 E in backhoe configuration, achieved 1 Mt moved in March. Plus we successfully converted a diesel R 9400 to electric for Fortescue, so we are also ready to meet conversion needs as well.

Sandvik inaugurates new load and haul factory in Malaysia

Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Sustainable mining

Sandvik this week inaugurated its new production unit in Malaysia dedicated to manufacturing underground load and haul equipment. The first equipment model assembled at the new factory is Sandvik’s Toro™ LH517i loader, with production expected to ramp up over the coming year. The facility will commence production of Toro™ TH545i trucks later in the year, as part of a cross-manufacturing plan.

Production volume allocation among existing factories will be based on machine specification, sales area distribution and production capacity.  Battery product manufacturing is slated to begin by Q3 2024, with BEV unit assembly scheduled for 2025, aligning with future electrification goals.

“This expansion marks a significant milestone for Sandvik,” said Patricio Apablaza, President of Sandvik Mining and Rock Solutions’ Load and Haul division. “This production unit enables flexible manufacturing of both conventional diesel and battery-electric loaders and trucks while adhering to Sandvik’s stringent global standards for sustainability, quality and safety – all with the aim to reduce lead times for mining customers in the Asia Pacific region.”

Spanning over 8,000 square metres, the new facility is situated in the Sendayan TechValley industrial park, strategically positioned approximately 70 kilometres south of Malaysian capital Kuala Lumpur and 15 kilometers west of state capital Seremban. The factory comprises 15 versatile assembly bays and sits 90 kilometres southeast of Port Klang, Malaysia’s largest seaport and one of the busiest container terminals in the world.

Private equity firm FalconPoint invests over US$250 million to grow JENNMAR

Equipment maintenance, Mine shafts and equipment, Mining consumables, Mining maintenance, Mining safety, Mining services

FalconPoint Partners, a private equity firm focused on investing in North American middle market companies in the business services and industrials sectors, has announced its inaugural investment in JENNMAR, a leading global provider of infrastructure products and specialised services to to mining and other industries. In underground mining & tunnelling it is particularly known for supplying rock reinforcement and ground control solutions including rock bolts, beams, mesh, rebar and resin.

It says JENNMAR will continue to be led by CEO Tony Calandra and the rest of its “industry leading, tenured management team.” FalconPoint has invested and committed in excess of US$250 million of equity to support the company’s expansion and global growth.

The statement said: “Since its founding in 1922, JENNMAR has provided mission-critical products and essential services to the civil infrastructure, solar, mining, and construction industries. The company maintains a broad product and service offering, with a modernised asset portfolio that enables it to meet customers’ needs across manufactured products, resins and chemicals, diversified industrial manufacturing, and specialised services such as engineering support and staffing. JENNMAR now has more than 4,000 employees across nearly 80 locations in North America, Australia, Asia, and Europe, and serves a roster of blue-chip customers comprising industry-leading companies around the globe.”

“I am tremendously proud of the work the JENNMAR team has accomplished in recent years, as we’ve broadened product and service capabilities and accelerated our international expansion while continuing to deliver best-in-class quality to our customers,” said Calandra. “We are incredibly excited to be partnering with the FalconPoint team. I have a deep respect for their capabilities, and I look forward to their support in bringing the right resources, experience, and expertise to drive our ongoing growth. The transaction brings our liquidity position to over $500 million and positions us to continue investing heavily in developing and deploying innovative and cost-efficient solutions for our customers.”

Russ Gehrett, Founder and Managing Partner of FalconPoint said: “Built on the Calandra family’s 100-year track record of operational excellence in manufacturing and value-added services, JENNMAR has an irreplicable role within its end-markets, and we are thrilled for the opportunity to partner with them and help fuel their growth across the globe. Tony and his team have executed on a range of compelling opportunities during the past six years, transforming JENNMAR into a scaled, global company that meets the needs of customers around the world. I look forward to continuing to leverage FalconPoint’s capital and strategic resources to capture significant upside through both organic and inorganic growth.”

The announcement said that JENNMAR “has leveraged its category-defining market expertise in the US to fund significant reinvestment in the business – including growth capex and new acquisitions. In recent years, the company has executed on a robust deal pipeline, expanding its production capacity and strengthening its foothold in growing markets around the world. Since 2018, the company has invested over $450 million, completing over a dozen M&A transactions, opening numerous greenfield facilities, and installing cutting-edge automation throughout the global facility footprint.”

BofA Securities and Truist Securities, Inc. served as financial advisors, and Lowenstein Sandler LLP and Paul, Weiss, Rifkind, Wharton & Garrison LLP provided legal advice to FalconPoint. Jones Day served as legal advisor to JENNMAR.

Komatsu’s focus on across the board flexible electrification solutions

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

It was back in March 2021 that IM first revealed Komatsu’s power agnostic strategy for its mining truck future. It committed to the development of ‘power agnostic’ dump trucks that could operate with a variety of power sources – such as engines, batteries, trolley systems and hydrogen fuel cells – by 2030. Since then it has made significant progress, working closely with its mining company partners that form part of its GHG Alliance, which includes BHP, Rio Tinto, Codelco, Boliden, Glencore and others.

Dan Funcannon, Senior Vice President, Electric Drive Trucks, Komatsu

This progress has been made both in testing and development of the truck iterations as well as through strategic moves – notably its November 2023 acquisition of American Battery Solutions, Inc (ABS), a battery manufacturer headquartered in Detroit, Michigan and the December 2023 announcement that it is co-developing a hydrogen fuel cell power module for Komatsu’s 930E electric drive mining truck with General Motors.

At its Arizona Proving Grounds (AZPG) near Tucson working with Siemens Mobility it built a test trolley line, on which in mid-2023, the GHG Alliance members saw a prototype battery version of the Power Agnostic truck – the EVX truck – running a circuit on battery, static charging of the battery with the truck hooked up to the trolley line via pantograph, and a run up the trolley line highlighting the battery being charged and increased speed in the dynamic environment.

New trolley projects to help lower emissions from Komatsu diesel trucks are underway at Glencore’s Lomas Bayas copper mine in Chile and other sites, plus have been successfully built and operated at Copper Mountain in British Columbia, now part of HudBay, using 830E trucks; and at Swakop Uranium’s Husab mine in Namibia using the 960E.

In addition, in the mining shovels space, Komatsu is pushing the envelope with its largest cable electric models – the P&H 4800 XPC having been successfully commissioned at Teck Fording River Coal and at Anglo Platinum Mogalakewna, with another order from a major copper mine for multiple units in place. In hydraulic cable electric excavators it remains the market leader – since its inaugural electric hydraulic mining excavator deliveries in 1983, as of February 2024 it had supplied over 260 units, which had accumulated more than 12.5 million operation hours. This includes units from its PC3000 to PC8000 models; and it will soon expand its range again with the addition of the 900 t class PC9000. Added to that it already has significant experience in conversions from existing diesel hydraulic excavators over to cable electric.

Underground, Komatsu has now introduced the second generation of its Z2 product line of small-class development drilling & bolting equipment with unique enhancements and additions, including the first battery-electric offerings within Komatsu’s underground hard rock portfolio – plus underground BEV loaders and trucks are part of its roadmap.

At the Electric Mine 2024 conference at Crown Perth in Western Australia next week, May 21-23, Komatsu will have a major presence, including a large delegation plus it is a Gold Sponsor with a prominent exhibitor booth, and it is bringing a battery-electric PC210E excavator to the Outdoor Showcase. And it has two speakers in the event line-up – on Day 1 in the Surface Mining stream, Thomas Harsk, Komatsu Germany Business Development Manager, and Martin Luckock, Oceania Sales & Support Manager will present: ‘Digging deeper – electrification in hydraulic mining excavators. On Day 1 in the Underground Mining stream, Komatsu Mining’s VP Hard Rock Business Development, Rudie Boshoff will present ‘Navigating the shift to electrified mining: critical considerations for mines of the future.’ You can still register to attend at www.theelectricmine.com.

Ahead of the much anticipated conference, IM recently caught up with Dan Funcannon, Senior Vice President, Electric Drive Trucks, Komatsu, to get some insights into its electrification journey.

Q Back in 2021, Komatsu  unveiled its power agnostic strategy closely followed by the Power Agnostic truck at MINExpo 2021 and then the EVX. While all battery, hybrid and hydrogen fuel cell options all seem to still be in the mix, where at this stage does Komatsu see the greatest potential and demand?

Komatsu continues to be dedicated to the power agnostic platform. This approach will enable us to stay adaptable as the market responds to and identifies the most viable power source. Currently the market is heavily leaning toward full electrification through battery power, but hydrogen fuel cells are starting to gain traction with select customers.

Q Can you summarise the main challenges that remain whether technical or practical, delivering a functioning, multi-unit electric fleet?

Komatsu realises that the change to all-electric fleet is mainly focused on the entire ecosystem. We are working on multiple projects with key partners to offer an entire ecosystem for mining. Autonomous, fleet management and energy management all play a crucial role in making the transition to zero emissions successful.

Q When does Komatsu expect to deliver its first ‘hands on’ pilot units for customers to test and trial at their own sites? Do you see these as running as part of main fleets to get a handle on capabilities?

Komatsu is working with select customers to test different technologies. The first pilots of Power Agnostic Diesel are planned for Q1 2025 and Power Agnostic Battery for Q2 2026. The battery pilots will first be introduced in a dedicated area until miners are comfortable with the new technology and the associated processes. Once they are ready, there will be a plan for integration into the main fleet to prove out fleet interoperability.

Q Dynamic charging is set to play an important role in the electric mine, as evidenced by the number of new trolley projects that have been announced for some of the world’s largest mines. Do you expect most or all of the first electric surface mines to involve trolley in some form, easing any transition to greater use of fixed charging?

Komatsu sees dynamic charging as a key to maintaining productivity in mining. Being able to charge dynamically will allow haul trucks to continuously operate to maintain productivity compared with the current diesel fleet. We are working with industry leading partners to enhance the product available today, while also looking to the future for more flexibility, lower cost and enhanced productivity options.

Q Can we expect any movement in full battery vehicles from Komatsu underground and can you give us a flavour of the Komatsu ‘green fleet’ roadmap for its underground portfolio?

We’re in the process of developing battery-electric equipment to support various underground applications. To learn more, visit us at The Electric Mine 2024 at booth 30 next week and in September at MINExpo 2024 in Las Vegas at booth 7132, Central Hall.

Slovenia’s Velenje among underground mines looking at Gravitricity’s shaft-based energy storage system

Bulk handling, Coal technology, Environmental, Mine shafts and equipment, Mining consumables, Power supply for mines, Sustainable mining

Mine owners across Europe are looking at a new form of underground energy storage to offer a low carbon future as operations wind down. Active deep mine operators in Slovenia, Germany, The Czech Republic and Finland are all examining how underground gravity energy storage – provided by Edinburgh firm Gravitricity – could offer green opportunities to mining communities facing a downturn in employment.

Gravitricity has developed a unique energy storage system, known as GraviStore, which uses heavy weights – totalling up to 12,000 t – suspended in a deep shaft by cables attached to winches. It says this offers a viable alternative future to end of life mine shafts, which otherwise face costly infilling and mine decommissioning costs.

It has teamed up with energy multinational and winch specialist ABB alongside worldwide lifting specialists Huisman to commercialise the technology for mine operators. Gravitricity say its GraviStore system is ideally suited to recently decommissioned mines, where existing shafts and winches can be repurposed. Their technology is now generating interest among mine operators keen to find green alternatives to decommissioning.

Current projects include the Velenje underground lignite mine in the northeastern part of Slovenia, operated by Premogovnik Velenje;  the Pyhäsalmi mine – Europe’s deepest zinc and copper mine – in northern Finland, owned by First Quantum Minerals; the Darkov coal mine in the Czech Republic, formerly operated by OKD; and the Grube Teutschenthal former potash and salt producing mine, in Germany, now owned by Geiger Group.

At Velenje, Gravitricity engineers have already visited the site to assess the technical feasibility of installing systems in two specific shafts – one of which is a ventilation shaft which may become available for a potential pilot project next year. Studies are also ongoing at the Pyhäsalmi, Darvok and Grube Teutschenthal mines, with potential to advance pilot projects in the near future.

Commenting on the projects, Gravitricity Founder and Executive Chairman Martin Wright said: “Gravity energy storage offers a powerful green opportunity to mine operators looking to extend a mine’s life beyond the extraction of materials. As well as being a genuine alternative to decommissioning, new underground energy storage schemes can provide economic and employment opportunities in communities where traditional jobs are in decline. Our work with mine operators is underlining the interest in our technology, and we are in dialogue with both mine owners and public sector organisations to turn these studies into operational plans.”

Gravitricity has already demonstrated its GraviStore technology with an above-ground 250 kW demonstrator, where the company successfully raised and lowered two 25 t weights to generate full power and verify the system’s speed of response.  The £1 million, 12-m high test rig proved the system can go from zero to full power in less than a second – which can be extremely valuable in the frequency response and back-up power markets – plus its ability to continuously vary power output dependent on demand.

The GraviStore system uses heavy weights suspended in a deep shaft by cables attached to winches. When there is excess electricity, for example on a windy day, the weight is winched to the top of the shaft ready to generate power. This weight can then be released when required – in less than a second – and the winches become generators, producing either a large burst of electricity quickly, or releasing it more slowly depending on what is needed.

Gravitricity says its system offers many of the best characteristics of pumped storage hydro and lithium-ion batteries – but unlike batteries, the Gravitricity system can operate for decades without any reduction in performance. It adds that it has an expanding portfolio of intellectual property in underground energy storage including eight granted patents and a further two pending. The idea of using gravity to store energy is not new. Britain already relies on a number of pumped storage hydro schemes, such as Cruachan Power Station, where water is pumped uphill to be released when required.

Komatsu launches battery-electric versions of drilling and bolting rigs

Environmental, Equipment maintenance, Mine shafts and equipment, Mining consumables, Mining equipment, Mining maintenance, Mining services, Sustainable mining

Komatsu has introduced the second generation of the company’s Z2 product line of small-class development drilling & bolting equipment with unique enhancements and additions, including the first battery-electric offerings within Komatsu’s underground hard rock portfolio, an innovative pumpable resin system solution, optimised ergonomics and more.

The small-class ZJ21 jumbo drill and ZB21 bolter initially launched in 2020 with a common platform. The new Z2 bolters and jumbos also feature optimised operator ergonomics designed to maximise comfort and visibility, user-friendly intuitive controls and engineering for ground-level maintenance.

The bolter also introduces an optional Komatsu pumpable resin system using J-LOK P by Jennmar. The unique solution allows resin to be pumped into the drilled hole prior to bolt installation, permitting the use of more economical bolts and helping to decrease overall installed cost.

The second generation ZJ21 jumbo drill is a single-boom development drill with a fully enclosed ROPS/FOPS-certified operator cabin, innovative drilling feeds, advanced pilot hydraulics and renowned drifters manufactured by Montabert.

Both product lines now include battery-electric versions featuring Komatsu’s innovative approach to BEV with onboard, smart, opportunistic charging and designed for seamless integration and compatibility with existing mine infrastructure. The ZB21 and ZJ21 are the smallest size-class drills and bolters to offer a BEV option and feature a modular battery driveline with 83 kWh of onboard energy designed for demanding tram cycles and the challenges of hard rock mining.

“As underground mining operations increasingly shift toward electrification of their fleets, our innovative, battery-powered Z2 jumbo drills and bolters will support that pivotal transition. By integrating into existing infrastructure, we can help enhance productivity while helping to reduce operating costs,” said Johan Kempe, Product Director for Underground Drilling at Komatsu. “The rollout of our second generation Z2-class marks a milestone in our commitment to advancing mining technologies and building upon the proven success of our products to empower the future of mine operators.”

Epiroc releases fourth generation of Titan Collision Avoidance System

Equipment maintenance, IoT, Mining equipment, Mining safety, Mining services

Epiroc, following its acquisition of Mernok Elektronik (Pty) Ltd in December 2022, has released the fourth generation of the Titan Collision Avoidance System (CAS), it says bringing significant advancements to enhance safety and operational efficiency in mining environments. The latest iteration, Titan CAS Generation 4, builds upon the success of its predecessors by incorporating several key improvements tailored to meet the evolving needs of the mining industry.

“The Generation 4 Titan CAS is an advanced system that raises the bar for safety and efficiency. It has been designed to meet the latest industry requirements and incorporates state-of-the-art technology to ensure optimal performance. By harnessing the latest advancements, we’ve engineered a system that surpasses requirements while offering unmatched cost efficiency. At the heart of our commitment to safety is the Generation 4 Titan CAS, which delivers top-tier safety solutions to the mining sector,” says Eric Baker, Global Product Manager.

Cited functional enhancements include an advisory zone addition which introduces an effective advisory zone (Level 8) preceding the intervention zone (Level 9), enabling operators to react promptly to slow down and stop advice. It also has logging redundancy – both the HMI100 display and the Gateway control units now log operational event data, ensuring reliable backup information.

It uses dedicated RF channels allocated for vehicle-to-vehicle (VTV) and vehicle-to-pedestrian (VTP) detection, enhancing detection capabilities. Increased sensor data bandwidth from enhanced low-frequency sensors with increased data bandwidth provides improved responsiveness and a higher device detection count. Finally, time-of-flight for vehicle-to-person detection enhances safety by precisely identifying pedestrians, further reducing the risk of accidents.

Epiroc says Titan CAS “combines low-frequency, time-of-flight, and sub-GHz RF technologies for superior vehicle-to-vehicle and vehicle-to-pedestrian detection. With additional technologies such as AI vision and GNSS, the system ensures unparalleled performance, reliability, and scalability.”

“We’ve been developing and improving our system for more than ten years and believe continuous updates are imperative to ensure that we remain on the forefront of technology thereby offering our customers the best solutions possible. Titan CAS generation 4 is no different, with safety, modularity and reliability at the core of this range, we hope to continue saving lives and support a zero harm work environment for our customers,” says Schalk Janse van Rensburg, General Manager for Mernok Elektronik.

The modularity of the system allows for adaptable technology implementation as on-site needs evolve, ensuring sustained safety and efficiency improvements. Additionally, Epiroc says the system offers seamless integration and user experience enhancements.

Latrobe Magnesium successfully produces world’s first MgO from brown coal fly ash

Environmental, Industrial minerals, Mineral commodities, Mineral processing, Sustainable mining

Latrobe Magnesium Ltd has announced the completion of commissioning for the first phase of its 1,000 t/y, Stage 1 Demonstration Plant, successfully producing the world’s first environmentally sustainable MgO from fly ash – a waste resource from brown coal power generation.

It says this marks a significant milestone in pioneering a sustainable magnesium extraction method, at an industrial scale, using its patented, world-first hydromet process demonstrating the significant value of LMG’s intellectual property. “The successful production of MgO from the Demonstration Plant is a testament to our innovative process and commitment to sustainable manufacturing. Following this achievement and validating the hydromet process, LMG can now officially commence a bankable feasibility study and financing discussions, in relation to the 100%-contracted, 10,000 tonnes per annum Stage 2 Commercial Plant. MgO production from the Demonstration Plant will be sold to Rainstorm Dust Control Pty Ltd in accordance with the MoU between the parties.”

LMG’s patented hydrometallurgical extraction/thermal reduction technology is the only process capable of extracting magnesium from brown coal fly ash, and ferro-nickel slag tailing feedstocks. Converting nearly 100% of this unwanted waste resource into saleable products, this low-emission process produces magnesium metal with accompanying valuable secondary products at no incremental cost (which are expected to account for ~25% revenue), including magnesium oxide, supplementary cementitious material (SCM), silica, char, iron oxide, agricultural lime (calcium carbonate) LMG’s patented process not only reduces the operating cost of traditional magnesium and cement production methods but simultaneously reduces carbon emissions by as much as 60% compared to the industry average.

LMG adds: “Our patented process produces no further downstream tailings, ensuring environmental sustainability. The Demonstration Plant is to produce magnesium metal and associated secondary products. A saleable magnesium metal is expected to be produced in the coming months.”

LMG’s 1,000 t/y Demonstration Plant will have a similar flow sheet to the larger-scale 10,000 t/y Commercial Plant. The Commercial Plant is to be constructed using similar engineering as the Demonstration Plant. Equipment will be larger scale, however, the scale required is not proportionate to the 10 times greater annual production of the Commercial Plant and therefore will be significantly relatively less capital intensive. The Demonstration Plant was constructed by several local contractors, including Mechanical Maintenance Solutions Pty Ltd (structural, mechanical, and piping services), O&M Pty Ltd (electrical and instrumentation services) and Stirloch Constructions Pty Ltd (civil and earthworks services).

These three contractors, amongst other vendors and suppliers being Tenova, Steuler-KCH Australia Pty Ltd, Fast Automation Pty Ltd, Coregas Australia, Stable Engineering, Custom Agency Services Pty Ltd, and Rockwell Australia Pty Ltd are formative of LMG’s Strategic Supplier Program (SPP) for the Commercial Plant. The SPP will provide greater certainty of cost input and fast track information utilised in the feasibility study, which will inform the final investment decision at calendar year’s end.

Commenting on the significant milestone, CEO of Latrobe Magnesium, David Paterson, said: “We are incredibly proud of the results from our Demonstration Plant and the achievement of MgO production. The world’s first flow sheet using a hydromet process is a testament to our technology, our staff and contractors involved in the process to date. As the only new Western producer, the importance of Latrobe Magnesium’s production is globally significant, and this achievement validates our patented hydrometallurgical technology and years of research and development to get to this stage. I would also like to take this opportunity to thank all the aforementioned employees and contractors, who have worked tirelessly to make this achievement possible and look forward to our continued success.”

 

Orica to expand fully lead-free detonator technology to its electronic blasting systems range

Comminution of minerals, Explosives and blasting, Mining consumables, Mining services

Orica is set to expand its lead-free Non Primary Explosives Detonator (NPED) technology to manufacture what it says is the world’s first lead-free electronic blasting system range at its plant in Gyttorp, Sweden. This follows the successful introduction last year of the world’s first fully lead-free non-electric detonator range, Exel™ Neo, with early adopters reaping the benefits.

The lead-free alternative will be made available across the full range of electronic blasting systems, including the new eDev™ II Neo, uni tronic™ 600 Neo and i-kon™ III Neo, with the same proven performance and results as the current electronic blasting system range. The new fully lead-free variant will integrate Orica’s NPED technology, eliminating lead azide in the detonator. The product range will not contain any Substances of Very High Concern (SVHC) according to the European Union’s Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH) regulation.

Orica Chief Technology Officer Angus Melbourne said: “With the expansion of our lead-free NPED technology to our market-leading electronic blasting systems range, Orica takes another step towards a more sustainable future for the industry. It’s a testament to Orica’s 150-year history of innovation and commitment to safer and more responsible solutions that deliver positive economic, social, and environmental outcomes. I would like to thank our teams around the world for their outstanding commitment to delivering innovative solutions to our customers and the industry.”

The development of the new technology has been underway for several years, with field trials and testing for compliance with the European Union’s (EU) mandatory conformity marking for goods sold within the European Economic Area (EEA) ie Conformité Européene, or CE testing to be conducted in the coming months. It is expected that the new lead-free electronic blasting systems range will be available for shipment in Europe by early 2025.

Among some of the key benefits, the new product range is manufactured close to our customer base in Europe and includes distinct safety and environmental benefits with all lead removed from the production process and from being released into the environment during the application. Orica is also investigating options for the reduction of plastics in the development of the new lead-free electronic blasting systems, further reducing its environmental footprint.

Orica’s Group Executive and EMEA President James Bonnor said: “This is the first time Orica’s electronic blasting systems are being manufactured at our new state-of-the-art facility in Sweden, close to customers in Europe, ensuring supply security and optimisation. The facility will initially be used to assemble Orica’s standard EBS detonators before it will become the world’s first assembly line for the fully lead-free electronic blasting range based on NPED technology. Trials with our customers will get underway in July-August 2024 and we look forward to continuing to explore how Orica can use innovative technologies to assist our customers achieve their environmental, social and governance goals.”