All posts by Paul Moore

Elphinstone launches new E15 hard rock support vehicle

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

Elphinstone has introduced its new E15 model to the Elphinstone Underground Hard Rock Support Vehicle range. The low-profile E15 it says is a welcome addition to the existing range of E10 (formerly WR810) support vehicles, with both base platforms sharing a high level of interchangeability of parts and components.

The significance of the model number is the letter ‘E’ represents Elphinstone, and the numeral ’15’ indicates the nominal capacity in metric tonnes (depending on the configuration).

The first machines to be released include the E15 Agitator 7m3 (pictured), E15 Delivery (nominal 15 t capacity and 8.8 tm crane), E15 Flat Deck (nominal 16 t capacity), E15 Water Tank (nominal 13,000 L capacity), and E15 Fuel & Lube (diesel, lubricants, grease, coolant, DEF, water & air). Additional models will be released in the future.

Headlining the E15 series is the Agitator 7 m3, built to thrive in harsh underground hard rock mining conditions, providing outstanding ride and handling with excellent manoeuvrability and turning circle, says Elphinstone. At 2.4 m high, the front-mounted operator cabin features three-person seating, climate-controlled air conditioning, ergonomic central driving position with a clear 180-degree view, and dial controller for the retarder, speed and implement controls. Operator comfort and convenience is further enhanced with an air-cooled compartment for lunch box storage, cupholders and smartphone charging ports.

The combination of the A-frame front axle suspension, oscillating hitch and air-suspended seats, deliver a high level of machine comfort to the operator and passengers. The oscillating hitch ensures 4-wheel ground contact and reduced wear on the hitch and steering components. Nitrogen charged hydraulic suspension cylinders and A-frame provide superior front axle ride quality over rough terrain.

Common to both the E15 and E10 range, the engine front frame can accommodate optional Cat C7.1 Tier 3 or Tier 4 Final engine arrangements featuring Caterpillar’s breakthrough ACERT™ Technology to meet exhaust emission reduction standards.

The engine’s efficient fuel delivery combined with air management and electronic control lead to high productivity and exceptional service life. An optional full-flow DPF may be fitted in place of the standard muffler and catalytic converter on Tier 3 models.

All engine and machine isolation functions are conveniently located on one panel accessible from ground level on the left-hand side. All service points such as tanks, filters, lubrication points and compartment drains are conveniently located at ground level for servicing.

The monitoring system and alarm strategy provides a 3-tier warning and shutdown functionality alerting the operator of any abnormalities and automatically limits the machine’s functions. Onboard advanced machine diagnostics provide the operator and maintenance staff valuable information which simplifies machine servicing. All the application modules pin and or bolt to the common rear frame, including the 7 m3 agitator bowl. With 16.00R20 tyres, heavy-duty axles and different weight distribution, the machine has greater carrying capacity.

An optional feature of the E15 are the front and rear hydraulic jacks. The front jacks operate with a ‘park’ function to enable the operator to safely exit the cabin with the engine operating. The rear jacks are used to level or lift the machine for discharge. All jacks can lift the machine off the ground for changing tyres.

Fitted as standard to the rear frame is a high-capacity electromagnetic retarder which provides superior braking performance on grade, and diagnostic capabilities with alarm and fault conditions reported back to the 12-in touch screen operator display.

The integrated Retarder Control System (iRCS) combines both the control and power functions into a single unit. The innovative electronic design significantly reduces the retarder’s energy consumption, preserving electric circuits.

The E15 also features ‘speed control’ whereby the operator can set the maximum speed on grade and the machine uses the retarder and the inertia of the powertrain to maintain the speed. When on flat ground the operator can accelerate over the maximum set speed, but when the accelerator pedal is released, the machine speed will revert back to the original maximum speed setting.

Downtime during service and maintenance is reduced markedly on the E15 due to clever engineering and design features, incorporated with service personnel in mind.

Quick change air filters and 500-hour oil service intervals reduce downtime and keep machines in operation longer for greater productivity. A centralised onboard service centre includes fast fill, evacuation, and fluid sample points for analysis.

The 24 V electrical system features colour-coded wiring circuits with individual circuit breakers. The wiring is sealed to prevent dirt and moisture and enveloped in fire-resistant material. The onboard diagnostic system checks all critical machine functions for faults, with all data recorded for analysis.

Operator safety is a high priority in mining machine operations. Integrated into the E15 and E10 operator station is an ISO 3471:2008 standard ROPS and ISO 3449:2005 standard FOPS that offers protection to the operator.

Other safety features include fuel water separators made of non-flammable material, firewalls and heatshields, machine interlocks, centralised isolation points (engine disconnect switch, starter isolation switch, jump-start receptacle and fire system activation, if fitted), and an optional integrated fire suppression system.

As an authorised Caterpillar OEM, all machine sales, technical assistance and access to spare parts are available and supported through Elphinstone and the global Cat dealer network.

AMSA signs deal with Colbun for Nueva Centinela project 100% renewable energy supply

Base metals, Environmental, Mineral processing, Mining consumables, Mining services, Power supply for mines

Minera Centinela, part of Antofagasta Minerals, and Colbun have signed a 100% renewable energy supply contract for up to 912 GWh, with the objective of delivering emission-free electrical energy to the Nueva Centinela project, the largest mining investment announced in the last five years in Chile. Centinela produces copper cathodes and copper concentrates containing gold, as well as molybdenum, at its facilities located in the Sierra Gorda mining district, Antofagasta Region.

The Nueva Centinela project will significantly expand the operations of Minera Centinela, both in terms of its mineral processing capacity and its life (until 2056). It consists of a second concentration plant for the treatment of minerals from the Esperanza Sur and Encuentro pits. In addition, it will include a new system for pumping undesalinated seawater and sending concentrate to the shipment port, located in the town of Michilla.

The electricity supply agreement will have a duration of 15 years and will come into force in 2025, thus supporting the development of this $4.4 billion mining project with certified renewable energy. The agreement is in addition to  one that Colbun currently has with Minera Zaldivar, also part of Antofagasta Minerals.

Ivan Arriagada, Executive President of Antofagasta Minerals, stated that “with this agreement for the Nueva Centinela project, we are ensuring that we continue using energy exclusively from renewable sources, as we currently do in all our operations, since reducing emissions is one of our main objectives to produce copper and other metals in a sustainable and responsible manner for the benefit of the environment and society.”

Jose Ignacio Escobar, CEO of Colbun, highlighted the role of clients, particularly in the mining sector, as drivers of the energy transition. “The main driving force of the energy transition in Chile is customers, especially companies like Antofagasta Minerals, which have prioritised environmentally sustainable operational management and continually increase their demand for renewable energy. This motivates us to lead a responsible energy transition, supported by a growth plan in renewables and long-term storage. It is imperative to promote and safeguard this process, always with a comprehensive vision of the considerable challenges it entails.”

The awarding of this supply was carried out after a bidding process in which Antofagasta Minerals called on different industry players to present offers for an electrical supply of renewable, reliable, sustainable and competitive energy. For Colbun, this agreement places Minera Centinela among its three contracts with the highest volume of renewable energy and consolidates Colbun as one of the main energy suppliers to mining in Chile.

The use of this energy will allow the Nueva Centinela project to avoid the emission of 274,000 to of CO2/year, which is equivalent to taking around 68,500 gasoline (petrol) cars off the road.

The execution of Nueva Centinela reflects Antofagasta Minerals’ interest in continuing to invest in mining and above all its confidence in copper and the role it plays in the transition to a low-emissions economy, with technologies that help combat climate change and pollution. The initiative will increase Centinela’s mineral processing capacity and extend its useful life for at least 30 more years.

To date, Colbun has 17 hydroelectric plants running equivalent to 1,600 MW and three photovoltaic farms operating, totalling around 250 MW: Diego de Almagro Sur, Machicura and Ovejería. In the construction stage is Horizonte, the largest wind farm in Chile (816 MW, Antofagasta Region), which will gradually begin operating in 2024, and in the final testing stage for commercial operation is the Diego de Almagro Sur battery storage project (8 MW/32 MWh; Atacama Region). In addition, the company is developing green hydrogen projects in Chile and Peru, as well as energy solutions initiatives.

 

Artemis presses ahead on Blackwater in BC; over 59% complete & five Cat 793 trucks on site

Mineral processing, Mineral project development, Mining equipment, Mining project news, Mining services, Precious metals

Artemis Gold Inc has provided an update on Q4 construction progress at the Blackwater mine in central British Columbia. The project remains fully funded, within the guidance for initial capital expenditure, and on schedule for first gold pour in H2 2024.

At December 31, 2023, overall construction was 59% complete, and approximately C$389 million of the guided initial capital expenditure of C$730 to C$750 million had been spent. It says the lag between the spend and percentage of completion is as planned and consistent with a typical project S-curve. By the end of Q4 2023, the company had entered into contractual commitments for C$615 million (or 84% of the lower end of the guided initial capital expenditure). The majority of the balance of uncommitted expenditures for the guided initial capital relate to owners cost and earthworks associated with mining pre-strip and construction of the tailings storage facility (TSF) and other civil structures.

Artemis Gold Chairman and CEO Steven Dean commented: “We remain focused on a disciplined approach to development and remain on track for the first gold pour in H2 2024.”

Earthworks continued in priority infrastructure areas, with approximately 640 hectares logged and cleared. All access roads needed for Phase 1 construction are now operable. Construction of the site water management facilities, including the water management pond, and Davidson Creek diversion, is well advanced. Work associated with the transmission line is progressing in accordance with the project schedule. Total major works hours worked up to December 31, 2023, surpassed 1.1 million hours with a zero LTIFR and an AIFR of 91.86.

Process plant construction progressed well on a number of fronts, including the mill building foundation preparation, reagents building foundations, ball mill pedestals, carbon in leach (CIL) and detox tank erection, advancement of the primary, secondary, and tertiary crushers structures, and the reclaim tunnel civil works. Hydro testing within the CIL tank area commenced.

Construction of the run-of-mine (ROM) wall and the initial ROM dump slab earthworks have been completed. The focus has now moved to concrete formwork to allow for the installation of the primary crusher ROM slab and crusher vault. Steel structures for the secondary and tertiary crusher and screening station have been advanced and installation of the crushing mechanical packages commenced in Q4. The erection of the mill building and installation of the ball mill also commenced in late Q4.

The construction fleet now includes 60 and 100 t rigid frame haul trucks and 150 t excavators, providing more material movement capability to key areas. Assembly and commissioning of the owner’s mining fleet is well advanced, including two 400 t Cat 6040 hydraulic backhoe excavators. Five Caterpillar latest generation 793 240 t rigid frame haul trucks have been delivered to site, four of which have been substantially assembled. The remainder of the fleet to support operations will arrive predominately across the first half of 2024. Fleet assembly is expected to be completed well before the commencement of pre-stripping, and equipment will be made available to support earthworks if needed.

At the end of December 2023, the Sedgman EPC contract work was 75% complete overall, with engineering, design and procurement substantially complete. Key mechanical equipment packages, including the primary, secondary and tertiary crushers, conveyor assemblies, dry screens, and ball mill are all on site and are in various stages of installation. The electrical machinery control centres are also in various stages of delivery and installation.

Key mining-related contracts have been executed with detailed mobilisation plans for production drilling services well advanced. In addition, equipment supply contracts have been awarded for the oxygen plant and water treatment plant. Q4 also marked the arrival onsite of the first delivery of the 225 kV transmission line conductor and poles.

The company’s staffing numbers surpassed 320 employees in Q4 2023, with approximately 20% of the team female and over 30% identifying as Indigenous. Approximately 50% of the development team is from the local region and over 80% are BC residents. The total workforce at the Blackwater mine, including staff and contractors, surpassed 550 towards the end of December.

With Phase 1 fully funded and 59% complete at the end of December 2023, a study to evaluate the benefits of advancing the Phase 2 expansion earlier than contemplated in the September 2021 Feasibility Study is progressing well. The results of this expansion study are expected to be released later in Q1 2024.

Artemis Gold President and COO Jeremy Langford commented: “The fourth quarter was highlighted by our workforce eclipsing one million hours worked without an LTI – an important achievement that reflects the hard work and commitment of our dedicated workforce. As we enter Q1 2024, our short-term priorities will be to further progress the TSF infrastructure areas, advance the construction of the 225 Kv transmission line and complete all essential concrete works within the process facility. In parallel with this the teams will look to progress the structural, mechanical, platework, piping and electrical construction activities within the process plant and electrical substation areas. Operations team members are scheduled to commence pre-production planning, which will prepare the teams for initial mining operations and plant commissioning.”

Future Element JV to perform tailings dewatering studies using ATA® technology for BHP

Environmental, Mining consumables, Sustainable mining, Water management

Clean TeQ Water JV, Future Element, has joined Unearthed’s Think and Act Differently (TAD) program. The TAD program is powered by BHP and allows innovators to engage in short experiments designed to de-risk ideas and fast-track technological breakthroughs. Future Element has joined the Essentials Minerals Cohort and will receive funding, mentoring, access to subject experts, and samples needed to undertake the testing.

Future Element, together with Clean TeQ Water, will be participating in a three month program of testwork to prepare conceptual flowsheets, which can be applied to BHP’s existing and future operations, for tailings dewatering based on the ATA® technology. The testwork aims to rapidly dewater slurries to produce dry stack tailings, while making the critical minerals contained immediately available for recovery. The successful completion of the 3 month program would lead to on-site piloting and eventual commercial-scale demonstrations.

The ATA technology was developed to offer a secure and low-cost mine tailings treatment process by rapidly separating water and solids to produce stackable dry tailings and recycled water. The technology uses smart chemistry to rapidly agglomerate the solids in ore slurries. The solids dewater under their own gravity, removing the need for high capital and operating cost pressured filtration used in the industry today. The resulting materials can be compressed and stacked, with the extracted water being returned to recycle (or sent for recovery of dissolved metals), dramatically reducing water usage. In underground mining operations the compact material may also be used for backfilling, with or without binder.

Mine waste dewatering presents an enormous market opportunity for Clean TeQ. Tailings management is a significant environmental and safety challenge for the industry, particularly for mines in tropical climates where natural evaporation rates are low, or where seismic activity increases geotechnical risks. “As environmental bonding requirements increase in response to higher perceived risk in managing tailings storage facilities, ATA’s unique rapid and low-cost dewatering offering will enhance the mining industry’s environment credentials while lowering operating and mine site rehabilitation costs.”

Clean TeQ Water established a 50/50 Joint Venture (JV) Future Element Operations Pty Ltd (FEJV) with mine tailings management company Future Element Pty Ltd. FEJV provides holistic solutions to rehabilitate tailings and water and is targeting sites with the potential for production of valuable products from current and historic tailings at both operating and legacy mine sites. FEJV’s bespoke and end-to-end solutions will use Clean TeQ technology for the recovery of metals and minerals, treatment of water to be discharged or recycled and rehabilitated land ready for release back to communities.

Liebherr on the story so far with its record R 9100 excavator fleet at Thar Block-1 in Pakistan

Bulk handling, Coal technology, Equipment maintenance, Mineral project development, Mining equipment, Mining maintenance, Mining services

In 2019, China’s Shanghai Electric placed the largest ever order for Liebherr excavators in number of machines – 28 R 9100s in total. The reliability of both the R 9100s and the support provided by Liebherr (China) Co Ltd resulted in the customer placing an order for four more of the excavators in 2022. The journey so far was recently reviewed by Liebherr in an article titled ‘Partners in Pakistan.’

These 28 R 9100 excavators were put to work for Shanghai Electric – one of the world’s foremost suppliers of smart systems – at the Thar Block-1 coal mine in Pakistan [where the operating company is Shanghai Electric owned Sino Sindh Resources Private Ltd]. Thar Block-1 is a key project of the China-Pakistan Economic Corridor (CPEC) and Shanghai Electric’s first Build-Own-Operate enterprise. The mine is part of an integrated mining and power project that aims to strengthen electricity infrastructure in the local area.

While Liebherr Mining says it is incredibly proud of this excavator deal, the company takes even greater pleasure in being a reliable, long-term partner for Shanghai Electric. Liebherr (China) Co Ltd has worked alongside Shanghai Electric at the Thar Block-1 coal mine since 2020, the very first year of the mine’s construction.

Thar Block-1 is located within Pakistan’s Thar coalfields in the Thar Desert. There are an estimated 175 billion tonnes of lignite – also known as brown coal – located within the Thar coalfields, making it one of the largest reserves of lignite in the world. Thar Block-1 is also one of the key projects of the CPEC, a bilateral trade agreement between China and Pakistan that was established in 2013 as part of the Chinese government’s larger Belt and Road Initiative. The goals of the CPEC are to improve Pakistan’s national infrastructure, secure better trade with China, and further strengthen ties between the countries of South Asia.

The relationship between Liebherr Mining and Shanghai Electric began well before any monumental excavator orders were placed. “Liebherr (China) Co Ltd understands that deciding to enter into a business arrangement with a new company is not a choice made lightly. As such, in the year before the tender for the 28 excavators was won and a contract was signed for their supply, Liebherr (China) Co Ltd – along with its agent on the ground in Pakistan – provided Shanghai Electric with all of the information the customer required. This involved frequent seminars and technical communication as well as providing fast responses to Shanghai Electric’s queries. The customer also visited Liebherr’s excavator factory in Colmar, France, to assess all aspects of the R 9100 – from design to manufacturing, quality control, logistics, and support – and thus gain an in-depth understanding of the machine and Liebherr’s capability and commitment.”

“Each mining operation has unique requirements based on factors such as location, ore type, and environmental conditions,” says Armin Natter, General Manager, Liebherr (China) Co Ltd. “Liebherr (China) Co Ltd. and our customer service teams needed to provide Shanghai Electric with solutions that would address the specific needs of the site’s desert conditions while also ensuring maximum machine uptime. This involved offering training and educational resources to help operators understand how to use their equipment efficiently and safely in a desert climate.”

These 28 excavators were commissioned from early 2020. Once onsite at Thar Block-1, Liebherr (China) Co Ltd continued to offer Shanghai Electric exceptional customer service and equipment support during the mine’s construction phase. As a crucial part of the CPEC, the Thar Block-1 project had to adhere to tight deadlines in difficult conditions.

“Ensuring machine availability in a desert area such as this is a big challenge,” says Kurt Chen, Mining Service Inspector, Liebherr (China) Co Ltd. “To ensure Shanghai Electric’s daily power generation, machine failures must be solved within shortest possible timeframe. This requires both experienced and devoted onsite engineers as well as customer cooperation regarding appropriate spare parts and preventive maintenance for the machines.”

In a letter of thanks, Shanghai Electric praised Liebherr’s leading role during this time. “Your business carefully organised, fully utilised its management and professional advantages, eliminated difficulties, promoted project construction in an orderly manner, standardised project management, and put in place risk prevention and control measures,” the letter reads. “We would like to expression congratulations and thanks to all staff involved.”

Construction of the Thar Block-1 mine ended in February 2023 and it is now in commercial operation. The mine will produce 7.8 Mt of lignite per annum, which will in turn fuel the power generation aspect of the Thar Block-1 operation. The project will generate nine billion kilowatt-hours of electricity for the local power grid every year – enough to power almost four million households.

PROK unveils state-of-the-art conveyor equipment manufacturing facility in Salt Lake City

Bulk handling, Equipment maintenance, Mining maintenance, Mining services

PROK, a global leader in conveyor equipment solutions, has announced the official opening of its highly anticipated specialist manufacturing facility in Salt Lake City, Utah. This cutting-edge facility it says is poised to revolutionise the production of conveyor rollers, catering to the evolving needs of the mining industry worldwide.

Strategically located near major mining operations in the US, the new facility it adds underscores PROK’s commitment to being close to their customers. The facility’s location ensures access to local engineering expertise, responsive operational and maintenance assistance, and round-the-clock service.

The statement said: “The cornerstone of this state-of-the-art facility lies in its capability to manufacture PROK HDPE, a high-tech composite roller featuring groundbreaking visual wear-indicator technology – a world-first in the industry. PROK HDPE has redefined conveyor roller maintenance practices, offering enhanced efficiency and cost-effectiveness for mining operations globally.”

PROK’s expansion into Salt Lake City marks a significant milestone in the company’s longstanding history of supplying high-quality components to the US market. The new facility it says not only enhances PROK’s local presence but also establishes a manufacturing hub that aligns seamlessly with the evolving demands of the mining sector.

“The opening of our Salt Lake City facility is a testament to PROK’s commitment to innovation, and excellence in the conveyor equipment industry,” said Paul Byrne, Managing Director of PROK. “This expansion reinforces our dedication to providing cutting-edge solutions and being close to our customers.”

The official opening ceremony, held on Wednesday, January 24, was attended by key mining representatives from around the world. Approximately 100 industry leaders and stakeholders had the opportunity to witness firsthand the advanced manufacturing operations housed within the facility.

The company concluded: “As the global mining community continues to evolve, PROK’s new manufacturing facility stands as a testament to the company’s dedication to providing cutting-edge solutions, fostering local partnerships, and contributing to the advancement of the mining industry on a global scale.”

STRACON’s Dumas gets five year development & production contract for SilverCrest’s Las Chispas

Equipment maintenance, Explosives and blasting, Mine shafts and equipment, Mineral project development, Mining equipment, Mining maintenance, Mining services, Precious metals

STRACON Group, a leading provider of state-of-the-art underground and surface mining services to the Americas, today announced that its subsidiary, Dumas Contracting Ltd, has been awarded a five year service contract covering all underground development and production activities at SilverCrest Metals Inc’s Las Chispas mine in Sonora, Mexico.

“I want to thank SilverCrest for the opportunity to showcase Dumas’ operational expertise and decades of experience in underground mining, including in Mexico,” said Steve Dixon, CEO of STRACON Group. “We are absolutely invested in the success of SilverCrest, and as their strategic partner, are committed to delivering services that enhance the predictability and performance of operations at Las Chispas. We will actively collaborate with SilverCrest to bring best practices and innovative solutions to further develop the Las Chispas Mine in an efficient, safe, and sustainable manner.”

The Las Chispas Mine is an underground silver and gold mining operation wholly owned by SilverCrest through its Mexican subsidiary, Compañía Minera La Llamarada.

Dumas has been contracted to provide a wide range of services including all of the underground development and production mining. Dumas, a STRACON Group company, is a leading, full-service mining contractor that specialises in underground mine construction, lateral and vertical mine development, shaft sinking, production mining, and engineering.

Agreement renewal marks Wartsila’s long-term relationship with Indonesian nickel miner Antam

Base metals, Mineral processing, Mining services, Power supply for mines, Steel and iron ore

Technology group Wartsila has signed a second renewal of its Guaranteed Asset Performance (GAP) agreement with Indonesian state-owned mining company PT Aneka Tambang (Antam). Wartsila has had a full Operation and Maintenance agreement with Antam since the power plant’s commissioning in 2005, and a GAP agreement since 2017. This latest agreement renewal order was booked by Wartsila in June 2023.

The captive power plant supplies 60% of the electricity needed to operate the Antam ferronickel ore mine and processing plant located in Pomalaa in Southeast Sulawesi. The 137 MW plant was delivered by Wartsila under an engineering, procurement and construction contract. It operates with eight Wartsila 50DF dual-fuel engines.

“We appreciate the ongoing support that Wartsila has delivered since the power plant was commissioned. This support is provided with both remote monitoring and onsite advisors, and it ensures that we have a reliable supply of energy, which is essential for us to reach our production targets,” said Desryantho Tandi, Diesel Power Plant Manager at Antam.

“This agreement renewal emphasises the importance of long-term customer relations. A high level of trust and understanding benefits both companies. Through working in close cooperation, we can ensure operational efficiency, while the agreement provides cost predictability,” commented Erwin Vanderkerff, Director, Regional Operations Australasia at Wartsila.

In addition to remote monitoring and on-site advisory services, the renewed agreement also includes a full power management system, along with a spare parts supply for the engines and auxiliaries. Furthermore, Antam benefits from the latest design and upgrade information, expert technical advisory, analysis and audits, as well as improvement recommendations for the installation.

 

Rolls-Royce Power Systems opens major new mtu engines reman and overhaul centre at Aiken

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

Rolls-Royce Power Systems Division has announced that it has opened a new Remanufacturing and Overhaul Center on its mtu Aiken campus in South Carolina, US. The new facility is connected to the existing manufacturing operations and represents a low double-digit million dollar investment. It supports the company’s service initiative and sustainability approach.

This has a lot of importance for mining maintenance given the volume of high horsepower mtu engines running at minesites in North America, including trucks and excavators in key mining hubs like the Minnesota Iron Range, Arizona copper, Nevada gold and Wyoming coal industries that host numerous large open pit mining operations.

The new 69,000 sq ft. (6,400 m2) facility, which was announced in 2021, brings formerly outsourced workshop and warehouse operations in-house and expands them to provide remanufacturing and overhaul of mtu Series 2000, Series 4000 and Detroit Diesel 2-Cycle engines and components, plus internal and external rework services. Initially focused on parts remanufacturing for after sales support, the facility targets to remanufacture 20,000 parts per year once fully operational, thus greatly improving spare part availability and customer support in the region.

Dr Joerg Stratmann, CEO, Rolls-Royce Power Systems, said: “We have more than 150,000 engines in the field and our service business is growing. Service is not just maintenance and repair, but also upgrades, remanufacturing and digital services for predictive maintenance. Our customers trust us, and we want to fulfil this trust throughout the product lifecycle and into the next. To achieve this, excellent service is essential – and our Remanufacturing and Overhaul Center in Aiken will be a main pillar for serving our customers in the Americas.”

Remanufacturing the company says offers a wise lifecycle investment for customers, returning equipment to like-new condition and resulting in lower acquisition, maintenance, and operation costs. “It is also a smart choice for sustainability; reusing existing equipment and components to save on raw materials and energy consumption compared to new engine manufacturing. It creates a circular economy, where instead of disposing of an engine or component at the end of its useful life, they are overhauled giving them a second or even third life.”

Stratmann continued: “Remanufacturing is yet another part of our energy transition and sustainability story. With engines approved to run on sustainable fuels, we are significantly reducing emissions, and with remanufacturing we can get a second, third or even fourth lifetime from basically the same raw materials. It’s a total story of emissions and consumption reduction.”

The new Remanufacturing and Overhaul Center in Aiken will follow proven processes and procedures already established in global plant locations such as the facility in Magdeburg, Germany. This very thorough process ensures used engines and assemblies are fully disassembled, cleaned, and inspected, and then reworked and reassembled using new or remanufactured parts to replace any outdated, worn, or damaged components.

Since its opening in the fall of 2010, the mtu Aiken campus has been the site of continuous innovation, investment, and expansion. What began with the production of mtu Series 2000 and Series 4000 engines, has grown to include the assembly of military engines, the machining of parts and even the production of energy through its solar field and microgrid. With an onsite Research and Development Center and now a new Remanufacturing and Overhaul Center, the mtu Aiken campus covers the full circle of life for an mtu engine – from concept to second life (ie overhaul).

Epiroc rounds off 2023 with positive mining figures; more battery launches to come

Automation, Base metals, Bulk handling, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Precious metals, Steel and iron ore

Epiroc released its Q4 2023 results today, and the overall trend with regard to mining was very positive. In the quarter, Epiroc’s order intake increased to MSEK 14,388, corresponding to an organic growth of 7%. Within mining specifically, the activity levels were high, and the OEM won several large orders. Mining customers represented 84% (79) of orders received in the quarter and construction customers 16% (21). The higher share of orders from mining customers reflected weaker demand from construction customers. Overall revenues increased 12% to MSEK 15,568, an organic increase of 8%; while operating profit increased 4% to MSEK 3,349.

IM Editorial Director Paul Moore caught up with Epiroc President & CEO Helena Hedblom following the Q4 results release. On the order intake increasing and positive mining results she stated: “I would say there has been good activity within copper, gold and iron ore; we saw a 13% organic increase on equipment orders and we have won several large equipment deals in the quarter. But also the parts and service business is going strong within mining so we are up 6% organic there. We also have good development on consumables towards mining but not towards construction so that is what is pulling that overall number down for us. Overall, mining has been seeing high activity and we have been landing more large orders – almost SEK 1.2 billion – more so than we have seen historically for this quarter.”

Three orders are cited in the Q4 results. Two relate to mining equipment – Shandong Gold Group, one of China’s largest gold mining companies, has ordered a fleet of mine trucks, loaders, and drill- and rock reinforcement rigs to expand production at the Jiaojia, Xincheng, and Sanshandao gold mines. The order is valued at about MSEK 350. Then Epiroc won a large order, MSEK 280, for underground equipment that will be used for a new copper mine in Türkiye. Eti Bakir, Türkiye’s largest mining company and a long-time customer of Epiroc, has ordered a fleet of face drilling rigs, production drilling rigs, mine trucks and loaders.

Of course it is worth pointing out that these are still traditional diesel fleet orders, though Eti Bakir as part of its deal will get to test run one of Epiroc’s battery-electric Minetruck MT42 SG haulers at the Kastamonu Küre underground copper mine. But overall is diesel still very dominant? Hedblom responded: “Yes battery still forms a small proportion of overall sales, and traditional diesel machines still dominate for now. But these traditional machines are quickly becoming much more advanced and automation ready – that is certainly a clear trend that we see across the different mining regions. And moving forward of course we see that battery will gradually increase its overall share.”

Hedblom added that Epiroc will have several “exciting” launches in the battery area going forward, including for the heavier truck segment. “But if we start to look at surface mining such as on our larger drills, then we are also looking at other alternatives and combinations from a technology standpoint as these machines are much heavier and require more power.”

What about hybrid machines as a bridge to battery? Hedblom acknowledged these as playing a role but says the focus remains squarely on the battery machines in terms of the complete solution – Epiroc is aiming at having a complete BEV underground line up by 2025: “We are well underway with electrifying our full underground equipment line up and will continue to do so with a focus on battery electric. But we also continue to explore all opportunities and use of different technologies, including hybrid offerings, to make sure we are always well positioned.” In November, Epiroc signed a MoU with Byrnecut, one of the world’s largest underground mining contractors, to partner on the development of the next generation of diesel underground loaders with electric drive.

The third big order is significant as it does not relate to machines, but instead to digital solutions. Epiroc has won a multi-year order, its largest ever for digital solutions, from the mining company Codelco in Chile. The package of advanced digital solutions will strengthen safety and productivity at the El Teniente copper mine. The five-year project is valued at about MSEK 250, and the first phase was booked in the fourth quarter 2023 at a value of about MSEK 50.

Is it significant that this is a standalone digital deal? And is interest in collision avoidance a part of what is driving that? Hedblom told IM: “Yes we are starting to see more digital focused tenders coming out from customers. These are now often separate from the machines and cover a broad suite of digital solutions that our customers need. It could be a combination of things – mixed fleet automation, collision avoidance technology, positioning and fleet management all in one tender. This one with Codelco covers our full suite of products. Looking at collision avoidance specifically, now we have a Level 9 solution, and we are seeing good interest and demand from many parts of the world now because the technology is available to improve safety very significantly in mining operations. We think collision avoidance will play a really central role, together with automation.”

VP Electrifiation at Epiroc Jerome Cloue also had some interesting insights in a late 2023 Electrification webinar on Epiroc battery machine uptake. Interestingly Epiroc saw a two times higher average BEV utilisation rate for 2023 versus 2022 which it said was indicative of the machines moving from trial phases into full production with the early adopters. As of end September 2023, Epiroc said it had 28 BEV sites globally, up from 25 in April 2023, plus there was a Batteries as a Service contract with 80% of the units. The number of recurring orders was up to 10.