All posts by Paul Moore

Epiroc Batteries with Service brings key benefits from BaaS but with customer battery ownership

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

Electrification solutions from Epiroc support mining customers as they transition towards using Battery Electric Vehicles (BEV). The latest addition to the portfolio is a new type of service agreement offering an opportunity for customers to own the battery and at the same time benefit from the latest updates and service.

Batteries with Service is a service concept created for Epiroc batteries and can be applied on Epiroc battery powered equipment as well as other OEMs, using batteries from Epiroc. It makes it possible to own the complete equipment (machine and battery) and still benefit from a carefree solution for battery service, with extended warranty. The agreement Epiroc says is suitable for both surface and underground equipment and has been developed based on market demands.

“More and more customers want to have the full ownership of the complete equipment including battery. With our new concept, this is made easier,” says Daniel Jonsson, Global Product Manager – Battery at Epiroc.

Batteries with Service offers all the benefits from the already available offering Batteries as a Service (BaaS), such as battery telematics, equipment audits and extended warranty. “With battery telematics we can predict the battery health, improve and adapt based on the insights we get” says Jonsson. He continues: “We also have all battery data available at the battery for our technicians in order to always be informed of the health.”

Equipment audits are proactive, professional inspections that reduce unplanned downtime and production losses. “It boosts productivity and improves safety. Batteries with Service is offering an extended warranty that covers costs for the premature failure of parts and components. Another vital part of Batteries with Service is safety and maintenance guidance from experienced personnel, especially trained to service Epiroc batteries.”

For Epiroc, circularity is a cornerstone within the electrification business and the company offers discounts on battery subpacks when the customer returns used Epiroc batteries for recycling. This enables a circular approach on a linear business model, benefitting both the customer and the green transition.

“We are very pleased to be able to offer this service concept. With this offer we safeguard the introduction of our batteries and can give our customers peace of mind in this important technology shift,” Jonsson concludes.

Matrix Design Group introduces OmniPro® Vision AI collision avoidance system

Mining people, Mining safety, Mining services

Matrix Design Group, a leading technology provider for industrial and mining safety and productivity, is introducing OmniPro® Vision AI, a state-of-the-art collision avoidance system. This highly accurate, powerful system alerts when pedestrians, vehicles, and other potential hazards are detected in the path of mobile equipment.

OmniPro Vision AI allows for fully customisable zones and the ability to work in low-light and all-weather conditions, making it suitable for a wide range of equipment applications and operating environments.

With its high-speed processing rate, this new system minimises false positives and nuisance alerts that can desensitise workers to alarms. Operating without the need of personal wearable devices or tags, it identifies pedestrians in any posture, including standing sideways, crouching, kneeling, in partial view, and wearing PPE. OmniPro Vision AI allows for visual and audible zone breach alerts for operators and pedestrians and easily integrates with OEM controls for slowing and disabling machine movement.

OmniPro Vision AI works in conjunction with OmniPro InFocus, a cloud application delivering 24/7 access to an advanced dashboard with real-time metrics and analytics. OmniPro InFocus provides management with essential operational insights and intelligence to make the best decisions for the operation. All data, including zone breach incidents and timestamped photos, are recorded and stored. Essential reporting, including average daily breaches per machine and trending breaches over time, is available, along with custom reporting and analytics.

For over 15 years, Matrix says it has been a proven leader in collision avoidance and proximity detection system technology. From underground mines to surface operations, “Matrix has built a foundation of knowledge in the harshest mining environments and now offers solutions to customers in the industrial and commercial space.”

Mina Justa implements mine worker safety IoT solution by STRACON Tech, Abeeway and Actility

Explosives and blasting, IoT, Mine surveying, Mining people, Mining safety, Mining services

Mina Justa, the major Peruvian copper mine, has taken a significant step forward in worker safety and security with the successful implementation of an innovative IoT worker safety solution, developed by STRACON Tech in collaboration with Abeeway and Actility.

STRACON Tech, a tech wing of the STRACON group, is dedicated to fostering safety in mining through real-time personnel location solutions, leveraging its certified specialists and comprehensive portfolio to mitigate work accidents and enhance operational efficiency.

The main goal of the solution is to implement a system and necessary infrastructure for real-time and historical tracking of people in blasting zones. With a concerning 29% rise in mining accidents due to blasts, collapses, and landslides, the robust people-tracking solution is a proactive measure to prevent such occurrences and ensure safer operations.

The IoT-based worker safety solution is using Abeeway Smart Badges. These badges were seamlessly integrated with the LoRaWAN network managed by Actility’s ThingPark Enterprise platform. To ensure a robust and secure system, the solution also employed a custom-built application developed by STRACON Tech and deployed on AWS servers.

The Abeeway Smart Badge, a portable multi-mode tracker in ID card format, playes a crucial role in enhancing worker safety. This device, equipped with embedded sensors and utilising GPS, Low-power GPS, Wi-Fi Sniffer, BLE, and LoRaWAN TDoA geolocation technologies, enables precise and continuous tracking both indoors and outdoors. The Smart Badge offers various functionalities, such as SOS panic alarms, notifications for danger zones and restricted areas, safety evacuation monitoring, and location heatmaps for optimisation of supervisor-to-worker ratios in large industrial sites.

One of the key advantages of the solution is the use of LoRaWAN connectivity, which significantly reduces costs compared to other IoT connectivity technologies. Boasting extensive coverage, it offers redundancy by design, secure AES 128 encryption, and intelligent traffic management ideal for open-pit mining.

With the cost-efficient LoRaWAN network, the company was able to deploy the worker safety solution at a fraction of the expense of alternative cellular network-based solutions. This cost-effectiveness played a vital role in the swift implementation of the project, with the initial deployment of 400 Smart Badges completed within two weeks.

ThingPark Enterprise is a LoRaWAN IoT connectivity management platform that helps customers build network infrastructure by managing LoRaWAN gateways, add new LoRaWAN devices, monitor network operations, and control the flow of data to application servers.

The integrated solution allows to achieve the Real-Time Location System (RTLS) which enhances mine safety by providing real-time worker location data, issuing alerts, and aiding in decision-making. It also ensures compliance with legal norms and promotes efficient management through the establishment of virtual work zones.

STRACON Tech’s ST – TRACK platform, an integration of GIS, offers real-time personnel tracking, zone management, unauthorized entry alerts, adjustable TAG sampling rates for critical areas, low battery notifications, and provides historical data for audit purposes within mining operations.

The successful deployment and the high level of customer satisfaction led to an expansion of the project. Within just six months of the initial deployment, the mine ordered an additional 450 Smart Badges, bringing the total number of deployed badges to over 800. This expansion demonstrates Mina Justa’s confidence in the effectiveness and reliability of the solution provided by StraconTech.

STRACON Tech’s commitment to excellence extended beyond the technical aspects of the project. To ensure the utmost security and credibility of the solution, a thorough audit was conducted by Price Waterhouse to verify the robustness and integrity of the system.

In addition to the advanced technology and certifications, STRACON Tech provided comprehensive on-site training to mine workers. The training sessions covered device operation, including turning the Smart Badges on and off and utilising the SOS button. This hands-on approach ensured that the workers understood how to use the devices effectively and empowered them to take full advantage of the safety features.

“The project at Mina Justa is not only a technological achievement but also a testament to our commitment to customer satisfaction. We are proud to have partnered with them and to have delivered a solution that significantly improves the safety of mine workers. We are grateful for the support of our strategic partners, Actility and Abeeway, who played crucial roles in the success of this project,” said Jonathan Prieto Abasolo, CTO at STRACON Tech.

“It’s gratifying to see our technology contributing to the significant enhancement of worker safety at Mina Justa. This project exemplifies the power of collaboration and innovation. The success and expansion of this solution inspire us to continue pushing the boundaries of IoT for a safer and more efficient world,” said Olivier Hersent, CEO at Actility.

Tan Delta Systems launches new SENSE-2 kit for real-time oil monitoring in mining

Equipment maintenance, IoT, Mining consumables, Mining equipment, Mining maintenance, Mining services

UK-based Tan Delta Systems, a manufacturer of real-time oil quality monitoring sensors and systems, says is leading the way within the mining and mineral processing sectors with the launch of SENSE-2. The new oil condition monitoring kit provides real-time data about machine oil quality to optimise maintenance and reduce operating costs.

The SENSE-2 is plug-and-play and accurately identifies when oil reaches the end of its life, superseding traditional time-based maintenance schedules, which can result in oil being discarded prematurely – with the potential of wasting up to 50% of its useful life. The company states: “Within the mining and mineral processing industry, maximising the performance of machinery such as rock crushers, excavators, and trucks is paramount to running an efficient operation, and the SENSE-2 kit can deliver a measurable improvement in equipment operating time.”

Chris Greenwood, CEO at Tan Delta Systems said: “Our SENSE-2 real-time monitoring utilises our world-leading sensor technology and associated analytics to detect any issues before any damage occurs, identifying subtle changes in equipment condition early. It can be fitted easily and efficiently to any existing equipment in any application and is configurable to any oil type. Although oil analysis is not new, traditional lab sampling is expensive and impractical with other sensors in the market focusing on specific parameters while missing others. Our system ensures the industry has access to superior quality information in an easy-to-use format, preventing excessive wear of components and resulting in increased productivity and reduced machine downtime and maintenance costs.”

He adds: “We work with a number of mining businesses worldwide, providing tailored oil condition monitoring solutions that use our unique active molecular-level analysis to detect all changes in oil condition and any contamination. The Tan Delta sensor works by providing a full-spectrum holistic (FSH™) oil quality analysis which ensures the oil’s condition is proactively managed and is not changed prematurely, causing unnecessary cost to the site, or changed too late and causing damage.”

The system was adopted by an oil sands mine in Canada on a 785D mining truck with the aim to increase the oil service intervals, reduce the number of oil changes and wastage while maintaining the integrity of the equipment and preventing failure. The results following the installation of SENSE-2 was doubling the service intervals from 500 to 1,000 hours, reducing oil costs by 50% and eliminating the risk of failure from oil contamination or wear, this resulted in a return on investment of 160% in the first year.

The OQSx-G2 oil quality sensor within the SENSE-2 kit is also available as a Mobile Oil Tester (MOT) Kit, created with workshops and mobile maintenance teams in mind. Any oil from any equipment can be sampled and tested simply and easily on-site in seconds. The sensor is used in conjunction with the MOT software, which operates on any Windows-based laptop, tablet, or PC. Users simply install the MOT app, connect it to the sensor, collect the sample in one of the bottles provided, and follow the steps in the software to test the sample.

Thiess collaborates with Caterpillar on industry-leading AHS training

Automation, Mining equipment, Mining people, Mining safety, Mining services, Mining software

Global mining services provider Thiess recently participated in Caterpillar’s industry-leading training program, the Cat® MineStar™ Command for Hauling Sim School. Thiess is the first mining services provider to participate in the MineStar Command for Hauling Sim School training, which was delivered in-house at Thiess’s global head office in Brisbane, Queensland.

Caterpillar’s cutting-edge autonomous haulage training uses Cat simulation technology to coach and develop users of MineStar software by allowing them to get hands-on system training in a controlled and safe virtual environment.

Thiess Group Executive Transformation, People & Communication Shameelta Pratap said: “Thiess recognises that the continual development and upskilling of our people is instrumental to our success as a leader in autonomous mining services. To date, Thiess has invested in autonomous mining systems training for more than 500 employees.”

Thiess Head of Autonomy & Operations Technology Trent Smith said: “We were pleased to have participated in Caterpillar’s Sim School learning programs – the first was for our experienced Autonomous Haulage System (AHS) Controllers and Builders, and the second program was to assist in upskilling our staffed MineStar Fleet Controllers and Pit Technicians into AHS Controllers and Builders.”

Sean McGinnis, Vice President and General Manager of Technology and Global Sales Support at Caterpillar said: “Caterpillar was pleased to deliver Sim School training to Thiess. Preparing customers to enable successful autonomous haulage operations on-site is very important. This simulation environment supports free-flowing collaboration and hands-on learning, resulting in a better experience for all participants.”

BUMA Australia rolls Carlson Machine Control solutions across its mining project sites

Bulk handling, Coal technology, IoT, Mineral commodities, Mining equipment, Mining services, Mining software

Contract mining major BUMA Australia says it has implemented Carlson machine guidance technology across all of its sites. BUMA Australia was established in 2021 to acquire the open cut mining business of Downer and is part of Indonesian company Delta Dunia Group. Its current sites include the Blackwater, Broadmeadow East, Burton, Commodore, Goonyella, Meandu and Saraji coal mines.

BUMA Australia said the positioning technology “provides centimetre-accurate location data for our operators and supervisors, utilising existing systems for HPGPS corrections. This powerful tool improves overall mining operations including safety, productivity, costs and mine planning. HPGPS, or machine guidance, improves safety by providing real-time visibility of the location of the fleet vehicles.”

It added that it “ensures that ramps, batters, and benches are constructed to design to mitigate risk in open-pit mining. Additionally, HPGPS delivers accurate dig-to-plan compliance to track the movement of materials, improving mine planning and ongoing decision making.”

BUMA says it is confident this solution will deliver even better results for its customers. “We are committed to using the latest technology to improve the safety, efficiency, and profitability of our mining operations.”

The technology comes under Carlson Software’s Machine Control solutions. Carlson states: “Carlson Machine Control provides solutions that adhere to Open Positioning Architecture (OPA). We believe in promoting open support for data files, sensors, etc. We have the world’s most extensive GNSS/GPS library connecting to most GPS receivers.”

Solutions include Carlson Grade for excavators and shovels allows operators to visualise cut/fill with positioning using an onboard, ruggedised, Windows-based tablet known as the MC8 or MC10. Operators are able to view a cut/fill color map in real-time, dig to design, build simple or complex pads and slops in the field, and more.

 

Ero Copper well on track with Tucumã Project build in Brazil

Base metals, Bulk handling, Comminution of minerals, Mineral processing, Mineral project development, Mining consumables, Mining people, Power supply for mines

Ero Copper Corp has provided a construction update for the Tucumã Project, highlighting significant progress since October 2023. With physical completion now at over 85% and production of copper concentrate scheduled to commence in H2 2024, the company has initiated the transition from construction to commissioning, as outlined below in the 2024 commissioning plan.

The project is expected to produce 326,000 t of copper over an initial mine life of 12 years and is located within the Carajás Mineral Province, southeastern Pará State, Brazil.

The main substation and e-houses have now been installed and commissioned with a 16 km power line tie-in to the national grid completed ahead of schedule; this line is expected to be fully energised by the 20th of January. Mining wise, pre-stripping activities are tracking approximately 10% ahead of schedule with completion now expected at the end of Q1 2024. To date, approximately 3,200 t of sulphide ore have been placed on the run-of-mine stockpile for process plant commissioning.

Moving to the plant, mechanical completion testing and sub-component commissioning have commenced for key pieces of processing equipment including the primary crusher, ball mill, secondary and tertiary crushers, vibrating screen decks and flotation cells. The remaining steel structures, plate work and mechanical equipment installations are tracking on or ahead of schedule. Construction activities through the remainder of Q1 2024 will focus on completing piping, electric cabling, automation and instrumentation system installations.

Looking at expected commissioning milestones in advance of first concentrate production in H2 2024, they include by the end of Q1 2024 mechanical completion and sub-component commissioning (lubrication, hydraulic, electrical, instrumentation and automation systems). In March 2024 there should be first ore through the crushing circuit comprised of primary and secondary crushers as well as screening and conveyance systems. April 2024 will see first ore through the milling circuit; and May 2024 the first ore through the regrind mill circuit, concentrate and tailings filtering systems. Finally June 2024 will see integrated commissioning with flotation circuit and project ramp-up.

On the workforce there has been an opportunistic increase in construction workforce mobilisation. The recent demobilisation of a Brazilian mining project has allowed the company to add approximately 500 trained contractors on site, increasing the total workforce of employees and contractors to approximately 2,220 people. To date, there have been no lost-time injuries on the project, with over three million hours of work completed since 2022.

Direct project capital expenditures have been updated to approximately $310 million (compared to the previous estimate of $305 million) to reflect the impact of a stronger Brazilian real against the US dollar in Q4 2023, which was partially offset by reduced stripping costs.

“As we transition from construction to commissioning, the paramount achievement at Tucumã is the outstanding safety performance of our construction team. Marking a significant milestone, we have surpassed three million hours of work without a lost time incident. I extend my heartfelt congratulations to our Project leadership team, as well as the 2,200 employees and contractors on site, for their continued diligence and thoughtful execution in advancing Tucumã towards production,” said David Strang, Chief Executive Officer.

He adds: “This is an exciting phase for Ero Copper as we prepare to bring Tucumã into operation later this year and anticipate consolidated copper production reaching over 100,000 tonnes in 2025. With the recent shift in copper supply-demand fundamentals signaling supply deficits in 2024 and 2025, the timing of our growth trajectory couldn’t be better.”

Hitachi’s EH4000-based battery trolley mining truck now tested & about to ship to Zambia

Base metals, Bulk handling, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Sustainable mining

Hitachi Construction Machinery Co Ltd says it has completed the test machine version of an engineless, full battery rigid frame dump truck and on January 20, 2024, the test machine will be shipped from Hitachi Construction Machinery’s Hitachinaka-Rinko Works in Japan to the Kansanshi copper and gold mine operated by First Quantum Minerals Ltd in the Republic of Zambia. The company also confirmed to IM that this test machine is based on the EH4000 AC-3 platform and has a nominal payload of 200 tons.

The OEM stated: “With environmental awareness on the rise in the mining industry, there is growing interest in the electrification of mining machinery as part of efforts to reduce greenhouse gas emissions. To meet the high customer demand for the electrification of dump trucks in particular, which are operated in large numbers at mining sites, Hitachi Construction Machinery began collaborating with ABB Ltd in June 2021 to develop the full battery dump truck. On March 1, 2023, Hitachi Construction Machinery signed a letter of intent (LOI) with First Quantum to establish a zero-emission partnership, and the companies plan to conduct technological feasibility trials using the full battery dump truck test machine at First Quantum’s Kansanshi copper and gold mine.”

Conceptual image showing how final assembled all battery truck will look

Hitachi Construction Machinery adds that it has accelerated the development speed of the full battery dump truck by applying proven technology from the current trolley charging type rigid dump trucks. Hitachi Construction Machinery tested the basic operations of the full battery dump truck test machine at Hitachinaka-Rinko Works, by gradually combining the battery charging and discharging system, pantograph, and other power supply systems with the drive system that controls the travel of the dump truck.

After it was confirmed that all systems were operating properly, the test machine was ready to be sent to the mining site in Zambia. The technological feasibility trials, which are set to begin in mid-2024, aim to verify the basic performance of operations required of a dump truck, such as traveling, turning, and stopping under actual operating loads, as well as the battery charging and discharging cycles.

First Quantum, which presently operates 41 Hitachi Construction Machinery (diesel) trolley trucks (39 EH3500AC-II and two EH3500AC-3 rigid dump trucks) at the Kansanshi copper and gold mine, already has much of the infrastructure required for full battery dump trucks in place.

Going forward, Hitachi Construction Machinery Group says it will continue collaborating with customers while leveraging their expertise in the development of (diesel) trolley trucks, as well as their extensive delivery record, to accelerate the development speed of the full battery dump truck, thereby contributing to the achievement of virtually zero greenhouse gas emissions from mining machinery.

ABD Solutions bringing its Indigo Drive autonomy to Australian mining

Automation, Bulk handling, Equipment maintenance, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software

ABD Solutions, a subsidiary of UK-based AB Dynamics PLC, has unveils its latest milestone in strategic expansion with the establishment of its Australian operation in Perth, Western Australia. The company stated: “Leveraging the decades-long vehicle automation experience of its parent company, ABD Solutions specialises in after-market autonomy tailored for fleet vehicles across diverse industrial applications including mining, construction, materials handling, defence and agriculture.”

Building upon its existing presence in the United Kingdom and Japan, the launch of ABD Solutions’ Australian operation it says is in response to growing demand for its Indigo Drive fleet autonomy solution in the Australian market, particularly in the mining and resources sector. ABD Solutions says it is set to introduce in-country demonstrations of Indigo Drive in the coming months.

Indigo Drive its says is “an adaptable and versatile solution” which expedites the implementation of fleet autonomy by automating existing fleets and infrastructure, ensuring swift and cost-effective deployment. “In operation, Indigo Drive creates safer, more productive sites while tackling driver shortages and reducing emissions. This translates into operational savings through reduced fuel costs, better fleet utilisation, and more efficient staffing.”

As part of the Australian market expansion, ABD Solutions is welcoming Andrew Van Der Merwe as its new General Manager for Australia. “With a wealth of experience in the mining industry, Andrew’s passion for technology and the mining industry aligns with ABD Solutions’ drive to empower businesses to create safer, more productive operations through the use of autonomous fleets.”

“I am excited to bring our autonomous solution to the Australian market,” he said. “The mining industry in Australia has a huge demand for flexible automation solutions that can be implemented across a range of vehicle types from any manufacturer, while causing minimal disruption to existing operations. I believe Indigo Drive is the perfect solution for the Australian mining industry, especially with the focus on tackling driver shortages, improving fleet productivity, and the continuing drive to improve safety.”

ABD Solutions’ entry into the Australian market marks a crucial step in its global strategy. The company says it looks forward to contributing to the growth and innovation of the Australian market as it “continues to set new standards for autonomous technology worldwide.”

Epiroc wins largest ever digital solutions order for Codelco El Teniente

Automation, Base metals, Equipment maintenance, Mine shafts and equipment, Mine surveying, Mining consumables, Mining equipment, Mining maintenance, Mining services, Mining software

Epiroc has won a multi-year order that is its largest ever for digital solutions, from mining company Codelco in Chile. The package of advanced digital solutions it says will strengthen safety and productivity at the El Teniente copper mine.

Codelco, the world’s largest copper producer, has ordered a combination of digital solutions that will – among other things – optimise fleet management and ore production, provide visibility of people and machines underground, collect machine performance data, and help avoid vehicle collisions. The solutions will be used at El Teniente’s underground as well as surface operations.

The five-year project is valued at about MSEK250, and the first phase was booked in the fourth quarter 2023 at a value of about MSEK50. “Digital solutions are increasingly important to ensure mining companies can reach their full potential when it comes to safety and productivity,” says Helena Hedblom, Epiroc’s President and CEO. “Codelco has long been on the technological forefront, and we are happy to continue to support them as they further enhance their digitalisation to ensure operator safety and maximum operational efficiency.”

Epiroc, through its Digital Solutions division, says it is bundling together a wide variety of digital solutions that enhance mining companies’ operations. With this order, Codelco is upgrading its existing digital solutions and adding a collision-avoidance system and the ability to collect machine performance data.

“We are proud to expand our partnership with Codelco as they advance their digital journey, with an offering that provides an agnostic ecosystem across connectivity, automation, safety and productivity applications,” says Paul Bergström, President of Epiroc’s Digital Solutions division.

Key building blocks of Epiroc’s digital offering include Certiq, a telematics solution, which gathers, compares and communicates vital equipment information; MineRP’s enterprise mining data platform focuses on standards-driven integration of technical and business data, and interoperability of software applications; the Mobilaris product portfolio which has situational awareness at its core where real-time data and superior 3D visualisation enable transparency and awareness; and the My Epiroc digital fleet management solution for mining and infrastructure operations. My Epiroc, available for both web and mobile devices, aims at boosting fleet efficiency and safety.

On collision avoidance, Andreas Prill, Acting BLM, Digitalisation at Epiroc recently told IM: “The Epiroc CAS/PDS is very unique in the sense that it comprises of a number of sensors ranging from low frequency, sub GHz RF, time of flight, GPS, cameras and radars which can be freely combined to achieve the highest level of safety for various environments like underground or surface operations and for the individual use cases a mine wants to address.”