All posts by Paul Moore

LKAB deploys battery electric & autonomous Sandvik LH518iB at Malmberget

Automation, Equipment maintenance, Mine shafts and equipment, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Steel and iron ore, Sustainable mining

In late November, the world of autonomous and battery electric underground mining got another step closer as a Sandvik automation ready 18 t class LH518iB LHD was unloaded at iron ore miner LKAB’s Malmberget mine in Sweden. The machine is now 1,250 m underground and being prepared for operation. This deployment in Europe follows the delivery of another LH518iB to the Boliden Garpenberg zinc mine, also in Sweden, back in August.

Sandvik launched the LH518iB in March 2023. The LH518iB is the first Sandvik underground battery machine equipped for full automation, being compatible with its AutoMine Lite and AutoMine Fleet offerings as well as its Manual Production Monitoring system. Sandvik’s patented self-swapping battery system, including the AutoSwap and AutoConnect functions, minimises infrastructure needs and enables the loader to return to operation significantly sooner than ‘fast-charge’ mining BEVs, the company claims.

The battery swap is performed by the loader itself, controlled by the operator in the cabin, without need for overhead cranes or forklifts. In the future the whole process is likely to be automated, and Sandvik is working on this. Sandvik is additionally developing battery management systems to enable operators and supervisors to see what level of charge the on-board battery has and the expected time to full charge of spare batteries to enable critical decision-making around when to swap the on-board battery.

IM caught up with LKAB’s Peter Gustavsson, Project Manager Electrification at LKAB for more information on the plans for the machine. He comments: “Our transformation to emission free mining value chain demands us to break conventional way of working and work with new technologies. LH518iB will be supporting us in that journey. We are looking forward to testing the machine in an operational environment.”

Gustavsson added that work environment improvement for operators is its core focus. Operationally, he says that productivity from the LH518iB’s highly efficient electric motors will be evaluated and that assessment of work routines around battery management will be performed.

He summarised the thinking behind the machine deployment as follows: “Mining at deeper levels may require us to rethink our processes to ensure the safety of our workforce, so we are looking into automation as a solution with this machine to further develop our learnings.
Secondly, we understand the low operational cost with an electric fleet and through automation we can increase our availability and utilisation as well.”

The LH518iB is not the only electric loader solution LKAB is looking at for Malmberget – it has also agreed to acquire a LF-19EB tethered-battery electric loader from Germany-based GHH. It has a 34 kWh on-board battery for panel-to-panel electric tramming, and while initially designed for feeder breaker loading in the soft rock, salt and potash mining industries, the model for Malmberget has been upgraded for hard-rock applications with input from LKAB.

Kenmare plans for the future with new IHC Mining dredges & move to Nataka ore zone

Environmental, Equipment maintenance, Mineral processing, Mining project news, Mining services, Mining techniques, Sustainable mining

Kenmare Resources PLC, one of the leading global producers of titanium minerals and zircon from the Moma Titanium Minerals Mine in northern Mozambique, has provided an update on some of its capital projects. A statement from Michael Carvill, Managing Director said: “The Board has given further approvals for the upgrade of Wet Concentrator Plant (WCP) A and transition to the Nataka ore zone. The project is expected to deliver consistent production volumes for decades to come and maintain Kenmare’s low operating costs, targeting the retention of a first quartile industry position.”

Production expectations for the full year 2023 remain in line with revised guidance provided in July: 980,000-1,040,000 t of ilmenite; 51,000-57,000 t zircon; and 8,000-9,000 t; plus 37,000-41,000 t secondary zircon and mineral sands concentrate. Guidance for 2024 will be provided with the Q4 2023 update in mid-January, with production expected to be broadly in line with the 2023 revised guidance range.

WCP A will complete mining at Namalope in late 2025, and commence its transition to the Nataka ore zone, where it is expected to operate for the remainder of its economic life, exceeding 20 years. The principal components of the project include the replacement of WCP A’s two existing dredges with higher-capacity dredges, the addition of a desliming circuit, and the construction of a TSF. The DFS for these elements have now been completed and execution has been approved by the Board. The DFS for the supporting infrastructure is underway and is expected to be completed in Q2 2024. Capital expenditure to the end of 2026 on the upgrade of WCP A and ancillary infrastructure is now expected to be between $316-331 million.

The Final Investment Decision (FID) for an upgrade of WCP B has been deferred while the WCP A investment is prioritised. A DFS to upgrade WCP B is currently underway and is expected to be completed in Q2 2024. The upgrade would add an additional 1,000 t/h of capacity to the existing 2,400 t/h plant, increasing its capacity by almost 42%. Following the FID, the WCP B upgrade would take approximately 15 months.

Kenmare and IHC Mining signed a contract in September for the delivery of two large customised mining dredges. The two dredges will each have a total installed power of 6,800 kVA and a cutter power of 1,350 kW. As they are electrically powered by using renewable hydro-electric power, these dredges will contribute to Kenmare’s goal of reducing the carbon footprint of their operations. The vessels are being built concurrently at Royal IHC’s yard in Kinderdijk, the Netherlands.

IHC Mining has already delivered three dredges to the Moma mine in the past, with the JULIA the most recent (2019). The two new dredges will operate at Nataka, a newly extended mine site, expected to operate for several decades. Kenmare is going to upgrade and transition their Wet Concentrator Plant A to Nataka, and the two dredges are an important element in the new operation. Managing Director IHC Mining Hans Greve, commented in November: “We are very proud of our long-standing relationship with Kenmare. The award of this contract underlines how we continuously strive to develop and deliver sustainable and responsible solutions that meet our clients’ needs.”

First of three new Liebherr R 9400 E excavators gets to work at Fortescue Cloudbreak

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

Australia’s first new factory built Liebherr electric excavator is now operational at Fortescue’s Cloudbreak mine site, marking a significant milestone in Fortescue’s decarbonisation journey. Powered by a 6.6 kV substation and more than 2 km of high voltage trailing cable, this is the first of an initial three new R 9400 E electric excavators that Liebherr will deliver to Fortescue over the next 12 months.

The R 9400 E is equipped with the Liebherr cable reeler. This automated and hydraulically driven solution enables management of the excavator’s electric cable during operation. The Liebherr cable reeler offers better mobility of the machine, optimises safety, and reduces the number of crew required for cable handling. A separate electric R 9400 E at Christmas Creek, also cable operated, was a retrofit of an older diesel machine first delivered in 2010 and is being used for testing, including with hydrogen fuel cell derived power using Fortescue’s patent-pending Offboard Power Unit.

The delivery of the new electric excavators demonstrates Liebherr’s and Fortescue’s strong commitment to decarbonising heavy industry. Liebherr Mining has committed to offering fossil fuel free solutions for its digging, hauling, and dozing equipment by 2030, through its Zero Emission Mining Program. Liebherr Mining has extensive experience with electric-drive excavators, having offered the solution to its customers for over 40 years. Fortescue has committed to eliminate emissions across its mining operations, with all electrified mining equipment eventually powered by renewable energy.

“The commissioning of this fully electric excavator is a massive achievement by the team,” said Fortescue Metals Chief Executive Officer, Dino Otranto. “It’s a true demonstration of industry collaboration where we’ve been fortunate enough to work with industry experts who have been using trailing cable for decades, and then repurpose this in our own operations as part of our decarbonisation journey. Already, our Chichester operations which include Cloudbreak run partially off solar enabling this first excavator to be powered using renewable electricity. Once we decarbonise our electricity grid, all these excavators will be operating on renewable electricity in the future.”

Liebherr-Australia’s Managing Director, Mining, Trent Wehr, continued: “This R 9400 E excavator marks a significant milestone, with our decarbonisation partnership with Fortescue now extending to electric excavators. The debut of Australia’s first operational Liebherr electric excavator is a big achievement for our local team who will provide ongoing service and support for these machines. Our local teams are actively enhancing their skills to keep pace with the changes that accompany our expanding lineup of zero emission mining equipment, and we’re excited to see what the future holds.”

Vale Canada completes 350 Return Air Raise project at Thompson Mine, Manitoba

Base metals, Mine shafts and equipment, Mine ventilation, Mining services

The new 350 Return Air Raise (RAR) at Vale Canada’s Thompson Mine in Manitoba, Canada, is now up and running, marking a crucial milestone for the C$150 million Thompson Mine Extension Project (TMEP). The ventilation upgrade doubles available airflow to active areas of Thompson’s T3 mine and uses a silencer system to reduce noise.

TMEP will allow to the operation to extend current mining activities by 10 years. The initial C$150 million investment represents Phase 1 and includes critical infrastructure such as new ventilation raises, booster fans, a new sandfill plant, increased power distribution and an underground garage that will enable mining at lower depths and help strengthen the business case for Phase 2 investment. Phase 2 will include developing two new orebodies: Hangingwall High Grade and Hangingwall Deep. Aggressive exploration drilling holds the promise of mining well past 2040 and a total investment projected at more than C$1 billion.

Vale Canada operates two connected underground nickel mines, T1 and T3, collectively known as Thompson Mine. The project was required to remove the failing 345 RAR (which exhausts via two discharges) from service and construct the 350 RAR (which also exhausts via two discharges) to provide required additional ventilation capacity for the existing mining facilities at the Thompson Mine. There are now five Return Air Raises operating between T1 and T3. Each are paired with a corresponding fresh air raise, for a total of ten air raises.

Cementation Canada team at Vale’s Thompson mine with the Strata 950

Cementation Canada carried out the raising for 350 RAR using its own Strata 950 model of raise borer. These are the longest continuous raise bored pilot holes in the Americas at 3,529 ft, the first of which broke the previous record of 3,312 ft that was set in 2021. The project began in February 2022, and the breakthrough of the second raise to surface was completed on September 9, 2023, after a total of 587 days achieved with zero harm.

The overall project involved constructing twin 10 ft diameter raises with surface fans, variable frequency drives, and underground ventilation controls, as well as an associated electrical building (E-house), access road, and associated ditching and culverts around the 350 RAR fan station’s graded pad. Following construction and commissioning of the 350 RAR, 345 RAR is being removed from active service.

 

Nokia & i.safe MOBILE to provide mining with intrinsically safe 5G-smartphone solutions

IoT, Mine ventilation, Mining people, Mining safety, Mining services

i.safe MOBILE, a leader in explosion-proof mobile devices and solutions, and networks and telecomms major Nokia, have announced an international partnership. The intrinsically safe industry 5G-smartphone IS540.x from i.safe MOBILE will be incorporated into the market leading Nokia end-to-end platform for industrial digitalisation along with Nokia Private Wireless and edge applications.

Nokia provides network infrastructure, devices and solutions that connect people and machines to enable the digital transformation of industries including mining. In hazardous areas, such as many underground mines, it is vital that workers are connected using devices that are Ex certified. As a result of this international partnership, Nokia will extend its Industrial device portfolio with i.safe MOBILE’s products to support the connectivity needs of organisations including those in the chemical, pharmaceutical and mining sectors.

The world’s first 5G smartphone for ATEX and IECEx zone 1/21, the IS540.1, and the IS540.2 for Zone 2/22 have both been recognised with the prestigious Red Dot award for product design, and are now part of the Nokia end-to-end solution for private wireless infrastructures.

Nokia offers 5G industrial devices deployed over Nokia Digital Automation Cloud (DAC) in a subscription-based ‘as-a-Service’ (aaS) model. Application bundles include Nokia Industrial device management, which allows administrators to remotely manage devices and apply group policies to scale management of devices to their entire fleet, Nokia Team Comms and Nokia Network Digital Twin. Moving forward, Nokia will continue to add more types of devices to the managed aaS model.

The IS540.x offers best-in-class performance and is compatible with most global LTE/5G bands. The 5G industry smartphone enables powerful AI and computing functions, while the 48 MP main camera offers the highest image quality. The IS540.x is certified according to IP68, MIL-STD 810H, international Ex and mining standards. Android Enterprise Recommendation guarantees compatibility with other recommended products and services like MDM systems to manage the fleet of devices. The zero-touch rollout option to integrate communication devices automatically into MDM systems facilitates device setup for IT departments.

Martin Haaf, CEO of i.safe MOBILE, says: “We are pleased to support Nokia with our latest 5G developments thanks to our decades of expertise in the field of explosion-proof mobile devices. The combination of our devices with Nokia solutions offers companies a great added value on their digitalisation journey.”

Martin Beltrop, Head of Industrial Devices, Nokia Enterprise Campus Edge Solutions, says: “For Nokia, it is essential that we can provide our customers with reliable EX-protected devices as part of our end-to-end, Nokia one platform for industrial digitalisation. They rely on us to equip their workers with high quality, widely certified handhelds to work safely in hazardous environments. By partnering with i.safe MOBILE, the undisputed leader in this field, we can offer certified phones as part of our worldwide digital platform.”

MinRes hands over first road train to Hexagon for autonomous conversion

Automation, Bulk handling, IoT, Mining safety, Mining services, Mining software, Steel and iron ore

Mineral Resources (MinRes) recently handed over the first custom off-road triple road train for conversion to autonomous operation by its project partners Hexagon AB. The handover, which was achieved one month ahead of schedule, is another significant milestone in the development of a fleet of fully autonomous road trains.

The world-first technology has been designed and developed by MinRes and Hexagon for MinRes’ Onslow Iron project in the Pilbara region of Western Australia. MinRes Director of Technology and Innovation David Geraghty presented the keys to the highly customised Kenworth C509 prime mover at Hexagon AB’s Perth workshop. Hexagon AB Chief Synergy Officer Autonomous Solutions Gordon Dale, Executive Vice President Core Autonomy Mike Verheyn and Vice President Core Autonomy Engineering John Buszek were in Perth for the milestone.

The road trains will be converted to autonomous operation by Hexagon AB using technology developed by the autonomy specialist’s engineering team. The vehicles are being tested with check drivers at MinRes sites in the Yilgarn region. From January, ten vehicles a month will be converted over the next year to meet Onslow Iron’s requirements. Once deployed, MinRes will have a fleet of 120 fully autonomous road trains.

Each triple trailer road train will carry 330 t of iron ore approximately 150 kilometres on a private, sealed haul road from the Ken’s Bore mine site to the Port of Ashburton. Safety is at the forefront of the project’s design, with grade separation ensuring there is no interaction between the road trains on the haul road and vehicles using public roads.

MinRes Director of Technology and Innovation David Geraghty said: “This is a significant milestone for Onslow Iron, with autonomous trucks forming an essential part of the project’s supply chain. Automation brings many benefits, including enhancing road safety, increasing operational efficiencies and reducing emissions.”

Hexagon Chief Synergy Officer Autonomous Solutions Gordon Dale added: “This is a complimentary partnership, with MinRes leading the way in mining services and Hexagon leading the way in autonomous technical capability. We are excited to commence installing the autonomous technology in our Perth workshop, with the aim to complete a fit out of a truck in just two-to-three days.”

 

Codelco and Teck’s Chilean copper mines hit The Copper Mark

Base metals, Environmental, Mineral processing, Mining equipment, Sustainable mining

Two major global copper producers – Codelco and Teck – have announced that all of their copper operations have now met The Copper Mark – this means that more than 30% of the copper mined globally now comes from sites that have received the certification. To be verified for Copper Mark, operations are assessed and independently verified against 32 responsible production criteria including greenhouse gas emissions, community health and safety, respect for Indigenous rights and business integrity.

Codelco has achieved The Copper Mark certification for 100% of its operations after an exhaustive independent review. This covers the eight divisions of Chile’s main state company, which are now recognised for using production processes that meet high sustainability standards. The announcements mean that more than 30% of the copper mined globally now comes from sites that have received The Copper Mark.

Teck has also announced that its newly expanded Quebrada Blanca Operations (QB) and Carmen de Andacollo Operations (CdA) have been awarded the Copper Mark in recognition of environmentally and socially responsible production practices. Its other copper mining complex, Highland Valley Copper (HVC) achieved The Copper Mark in 2022.

“Copper is an essential metal for the transition to a low-carbon economy and our new Quebrada Blanca operation, as well as our Carmen de Andacollo operation, are contributing to helping sustainably meet growing demand,” said Jonathan Price, President and CEO, Teck. “Being awarded the Copper Mark demonstrates our operations’ commitment to responsible copper production, both for our customers and for the environment and people where we operate.”

“We are pleased to welcome Quebrada Blanca and Carmen de Andacollo among the growing number of sites that have received the Copper Mark,” said Michèle Brülhart, Executive Director of the Copper Mark. “Teck’s operations are a great example of our multi-metal approach, having achieved the Copper Mark, the Zinc Mark and the Molybdenum Mark. We are grateful for Teck’s commitment to the Copper Mark assurance framework and look forward to continuing our partnership on the responsible production of key metals supporting the clean energy transition.”

The newly expanded QB Operation is currently ramping up to full production, which will double Teck’s annual consolidated copper production. In 2022, Teck’s Highland Valley Copper Operations was the first mine in Canada to achieve Copper Mark verification. In 2023, Teck’s Trail Operations was the first smelting and refining facility globally to achieve the Zinc Mark verification.

To be verified for Copper Mark, operations are assessed and independently verified against 32 responsible production criteria including greenhouse gas emissions, community health and safety, respect for Indigenous rights and business integrity.

Back to Codelco and President of the Codelco Board of Directors, Máximo Pacheco states: “Obtaining The Copper Mark seal for all of our operations demonstrates that we are taking concrete actions to fulfil our commitments to sustainable development. At Codelco we have the most important copper reserves in the world, more than 47 million tons, equivalent to 5.3% of the planet; That, added to the challenges of the climate crisis and the energy transition, imposes on us the responsibility of guaranteeing production processes with high standards.”

The Copper Mark verification process began with a letter signed in 2022, through which Codelco committed the entry of its El Teniente Division into the program review chain. In March 2023, after going through the complete accreditation process, its southernmost work centre was the first to obtain this seal and began certification for the other seven operations, a process that was successfully completed this month.

“Our copper is part of the solution to climate change that threatens the planet and must be produced responsibly in accordance with that cause,” said Codelco Vice President of Corporate Affairs and Sustainability, Patricia Provoste. The executive highlighted some milestones of recent years, among them, the cessation of operations of the Ventanas Foundry, the awarding of the contract to build a desalination plant for the divisions in the northern part of the country, the modification of the energy contracts with Colbún and AES Andes for the provision of clean energy, and the activation of the largest fleet of electric personnel transport buses in Chile.

Epiroc’s Common Automation Panel for drills

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

Epiroc has launched the revolutionary Common Automation Panel (CAP) for the SmartROC DTH surface drill rig along with its autonomous Pit Viper range. CAP enables a transformation in remote control centres, with improved ergonomics and a platform approach to run mixed fleet operations from a single station. Epiroc says the Common Automation Panel is designed for an innovative evolution of the control room. “CAP has been created for the modern mine remote operation centre. This innovative product will help our customers to streamline the value chain of their surface drilling operations – and create a safer and more productive environment,” says Christopher Blignaut, Automation Manager at Epiroc Surface division.

CAP creates opportunities for complete transformation, including improving the layout in the control room, the way operators are trained and work, and reduced variability and spare parts costs. “The CAP station will bring value to the daily mining operations that focus on technology and automation – through direct opportunities to increase utilisation of the fleet and reducing operating costs. Operation through CAP can also prolong the effective life of the equipment by ensuring that equipment operates within optimal design parameters. This results in lowering maintenance costs overall,” says Blignaut.

The Common Automation Panel has a new design approach, which was developed in collaboration with close partners. It includes a 12″ touchscreen display and joystick configuration for different machine types, which is an important benefit when it comes to mixed fleet operations with the Pit Viper and SmartROC DTH drill rigs as well as training for new operators. For operators, this means easier adaptation between machines and more flexibility to run the fleet. The product was also designed with improved ergonomics in mind, to allow the panel to be situated comfortably in multiple positions.

The Common Automation Panel also offers a new safety system to further reduce the office footprint and increase the total number of machines that can connect into a control room in a single system. This is important for situational awareness during remote operations and will reduce maintenance and operating costs for larger fleets.

CAP will enable more consistent and predictable operations and a lower overall cost of ownership. In the long run, this will have a positive effect on decarbonisation as well as enhancing the health and wellbeing of the operators. “We see increased environmental, social, and governance (ESG) demands, tighter demands on health and safety, and the need to integrate groundbreaking digitalised solutions that boost productivity in the mining environment. CAP answers these demands directly,” says Blignaut.

To talk about the step change that CAP brings and to get more in-depth on the technology, IM caught up with Mayya Popova, Product Owner Automation, Surface division at Epiroc

Has this unified automation panel – CAP – been in the planning for some time in tune with major mines now opting to have automated surface crawler drill rigs crawler boom drills as well as large Pit Vipers?

Yes, it has been part of the automation development strategy and roadmap for the Surface division for a while. We look at it from the point of view of how we can make operations more streamlined for our customers. They want to minimise footprint in their control centres as well as reduce the differences between drill solution offerings from an operational point of view – and of course simplify control for drill operators and supervisors and helping to make their decisions quicker and easier. Customers also appreciate more commonality in terms of how the systems are designed and how they function both in the pit itself and where the pit is controlled and monitored from. CAP in many ways just part of the overall operations puzzle where the aim is for ever greater efficiency and transparency.

Mayya Popova, Product Owner Automation, Surface division at Epiroc


Where does CAP sit with Mobius for Drills that you have developed together with ASI Mining? Do you have to have Mobius for Drills to have CAP?

Mobius for Drills acts like a hub for all the mine’s drilling operations – with Mobius for Drills also enabling increased connectivity potential between autonomous drills and other wider fleet autonomous applications like Mobius for Haulage. Mobius for Drills supported both autonomous and non-autonomous drills in terms of planning, creating the drill patterns, control systems, fleet situational awareness, taking decisions on where drill assets should be deployed etc – and the ability to create dashboards summarising large amounts of drill performance data. On your last question, CAP and Mobius for Drills are not interdependent but we strongly recommend that if you go for the CAP station, then Mobius for Drills is highly complementary in terms of bringing another level of transparency to your operations.

Previous autonomous control stations looked like copies of the drill cab with similar controls, joysticks etc to allow for manual intervention with tramming, for example. As CAP unifies control and monitoring of different drill types, how has this been achieved to allow for different designs?

We can look at this from two perspectives. First we wanted to develop an operator station that could cover multiple machine types and even within the machine type, multiple models. Obviously it meant unifying the controls in some way so that it is possible to move from one machine type to another using the same panel. This applies to both autonomous drill operations but also tele-remote where the operator is controlling the machine for longer periods of time. Secondly, there is a transition with CAP from continually needing to sit at the station to more of an overview and supervisory role – that is why we often refer to supervisors today rather than operators. Intervention is only when needed – such as when the autonomous system requires attention. With CAP, on the same station, you just choose the machine you need to interact with. We did a lot of work on joystick and button mapping. The challenge was looking at what we had before and translate those functions into the new design. The CAP has only two joysticks plus an e-stop and a fire suppression button, which we have committed to have as physical buttons as they are crucial in terms of unplanned situations, for example. All other functions, buttons or levers have been brought into the touchscreen and remapped with the joysticks depending on which operational mode the CAP is in. It took a lot of work but we have made it possible to easily switch between a Pit Viper and SmartROC DTH drill. But we have kept all the major functions in the same place, for example engine on/off. This minimises navigation between screens.

Does the CAP therefore adapt automatically to the new drill model with all its functions and the appropriate responses when the operator makes the switch?

Part of the beauty and complexity of the CAP is its software architecture. The system knows when you choose the SmartROC drill rig, which software version it is running on and therefore what functions it needs to bring into the user monitor and to the joysticks themselves. The operator isn’t aware of any of this, they just choose the machine that they need to operate.

Was CAP development driven by the knowledge the autonomous SmartROC D65 was coming and that space is at a premium in operations centres? Does it also minimise training needs and time?

Initial discussions were at least five years ago. It wasn’t just requests from mining houses about having a common station, though we did have those – it was more through discussions with them about the pain points in their operations as well as our own control room observations. The space issue is not just about having multiple drill stations without CAP – it is also that you need to have a server rack next to each station table. Then as you say there are inefficiencies in terms of the training and even the spare parts that they need to keep in stock. CAP reinforces the existing values with teleremote and autonomous operations and brings the new ones that we could not achieve before

Are the first CAP users the major mines that are already using autonomous Pit Vipers and are now phasing in autonomous SmartROC D65s as well? And will CAP be the recommended station for all Epiroc autonomous drills going forward as it brings more flexibility in the future?

We think it is applicable across several segments. The obvious one as you say is the Tier 1 miners who already have autonomous Pit Viper rigs and often have off-site control rooms. They may be adding SmartROC D65 rigs or may already have them for pre-splitting work for example, so for them it makes absolute sense. But we also see potential among the bigger drilling contractors. Where they have access to the mine network and digital infrastructure and where there is a longer term contract in place – CAP can be a serious option for them as well, for both tele-remote and autonomous operations. Also you can have mid-sized mines and big quarries that might be using SmartROC D65 rigs as their primary drilling fleet for which CAP is useful. You don’t have to have a mixed fleet for CAP to make sense – it brings its own value. A good example can be when a new Rig Control Software is released. CAP allows to update the drill rigs individually and gradually introduce the new functions without a need to stop the entire fleet for this. For Epiroc, CAP brings a lot of opportunity as it allows us to develop and add more models going forward,. It also makes it easier for us to add new functions – CAP is designed in such a way that we can add a digital ‘button’ on screen without having to change anything on the physical panel.

What is the baseline for a drill being able to be hosted on CAP – is there a minimum age and minimum RCS version it has to have? Is CAP retrofittable to drills already in use if they meet these requirements?

Because it is based on the latest technology, yes there are some pre-requisites. There are a number of mechanical and automation options that the drill rig should have, eg TeleREMOTE Machine kit. For SmartROC at the moment that covers DTH models only. For the SmartROC D65 it has to be the MKII generation. And then yes, the drill has to have the RCS 6.26 software version at minimum installed. For Pit Viper drills it has to be the RCS 5 platform. It also requires the software configuration to support compatible operations with CAP. The system is retrofittable if the drill has these attributes. And we are ready to support our sales organisations of defining what is needed in every individual case, for instance, in the autonomous Pit Viper case you could potentially need an upgrade the drill from RCS 4 to RCS 5 to allow for CAP compatibility. So yes, to a certain extent CAP is backward compatible.

Does CAP bring you an additional OEM advantage over third party tech providers that independently automate drills in that they will not be able to bring to the customer what CAP brings?

CAP is only part of the bigger picture and when we look at this from the perspective of using Mobius for Drills in conjunction with CAP, we have the potential to integrate data and control layers across multiple platforms. This will give the customer new capabilities in terms of autonomous ‘missions’ including the wider mining fleet that others might not be able to offer in the same way.

Epiroc launches Grey line drill bits; plus acquires SA rock drilling parts company Weco

Mining consumables, Mining services

Epiroc says it has launched a new range of Epiroc Grey line drill bits – specifically developed for European quarrying and surface construction drilling conditions. Manufactured with high-quality steel, it adds that they help increase rock drilling efficiency and are ideal for less demanding rock conditions.

With the launch of the new drill bits also comes the rebranding of a previous product line called Essential line. A new name, but with the same Epiroc quality guaranteed. “The products are recommended for customers who want to optimise their cost per metre in less demanding rock conditions. Primarily designed for surface construction and quarrying applications, the products are a perfect match for drill rigs in this segment. Where the balance between drilling economy, less downtime, quality and reliability are in focus.”

The new drill bits are compatible with Epiroc’s industry standard T-thread drill string. They can be use on the Epiroc Yellow line rods, and on other manufacturers rods using the same common thread type.

“With the new Epiroc Grey line bits, we have a fantastic opportunity to supply the surface construction segment with a product that will boost productivity, but also provide the lowest cost per metre,” says Johan Thenor, Head of Product Marketing – Tophammer Grey Line Products, Epiroc.

The Epiroc Grey line drill string will be manufactured in four different locations, ensuring availability, and making it more accessible to customers around the world. “By utilising our global manufacturing footprint in the best way possible, we can ensure we produce closer to the market, but also secure product availability,” Thenor continues.

Separately, Epiroc has agreed to acquire the business of Weco Proprietary Ltd, a South African manufacturer of precision-engineered rock drilling parts and provider of related repairs and services.

Weco is based near Johannesburg, South Africa. The company, which has more than four decades of industry experience, has about 80 employees and had revenues in the fiscal year ending May 31, 2023, of about ZAR160 million. Weco’s customers are mainly underground mining companies in the Southern African region.

“This acquisition will strengthen our manufacturing capabilities and expand our product portfolio of spare parts in the growing and important African region,” says Helena Hedblom, Epiroc’s President and CEO. “We look forward to welcoming the strong team at Weco to the Epiroc Group.” The acquisition is subject to customary regulatory filings and is expected to be completed in the second quarter 2024.

Komatsu and General Motors to co-develop hydrogen fuel cell module for 930E mining truck

Bulk handling, Environmental, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Sustainable mining

General Motors and Komatsu have announced that they will co-develop a hydrogen fuel cell power module for Komatsu’s 930E electric drive mining truck, cited as the world’s best-selling ultra-class haul truck. GM, a leader in hydrogen fuel cell technology, and Komatsu, a global manufacturer of mining and construction equipment, will jointly design and validate the technology.

The statement said: “Lightweight and quick to refuel, hydrogen fuel cells are ideal for electrifying applications traditionally powered by diesel engines. Hydrogen provides an effective method to package large quantities of energy onboard the vehicle, without compromising payload carrying capacity. Additionally, fuel cells provide an excellent zero tailpipe emissions solution for vehicles with extreme hauling requirements, like the Komatsu 930E mining truck, with its nominal payload of 320 tons. These vehicles typically operate at a single mine throughout their life, which simplifies the challenges of sizing and deploying an effective hydrogen refueling infrastructure to service the vehicle fleet.”

“At GM, we believe fuel cells can play an integral role in a zero-emissions future, helping to electrify heavier-duty applications, beyond passenger vehicles,” said Charlie Freese, Executive Director of GM’s Global HYDROTEC business. “Mining trucks are among the largest, most capable vehicles used in any industry, and we believe hydrogen fuel cells are best suited to deliver zero emissions propulsion to these demanding applications.”

The new fuel cell-powered 930E will be powered by over 2 MW of GM HYDROTEC power cubes

Komatsu’s fuel cell-powered mining trucks it says will provide an additional pathway for decarbonisation beyond battery-trolley or battery-static charging solutions, without the need for additional charging infrastructure within mines.

Komatsu has set a target of reducing its global emissions by 50% by 2030 and a challenge target of achieving carbon neutrality by 2050. The plans for achieving these goals include reducing and eliminating emissions within the company’s product offerings, as well as in the company’s facilities and production of its products. Komatsu also works closely with its customers on reducing and eliminating emissions during product use through optimisation programs supported by Komatsu technology and service solutions. GM’s target is to be fully carbon neutral in both products and operations by 2040.

“Finding new ways to power the equipment our customers need to do the vital work of mining and construction is a critical part of our commitment to supporting a more sustainable future,” said Dan Funcannon, Vice President of North America Engineering and Development for Komatsu. “This is essential work that requires cross-industry collaboration, and we are excited to be working with GM on this important solution for a haulage offering without tailpipe emissions.”

GM and Komatsu intend to test the first prototype HYDROTEC-powered mining vehicle in the mid-2020s at Komatsu’s Arizona Proving Grounds (AZPG) research and development facility. This vehicle will be powered by over 2 MW of HYDROTEC power cubes. When asked whether the fuel cell module will be factory fitted as well as being available as a retrofit option, Funcannon stated: “We are developing what we’ve called a Power Agnostic platform…our intention is to provide the platform to be able to adapt to numerous power technologies, including hydrogen fuel cell. And our intent is to work with our customers to determine if retrofit of earlier models is technically and commercially feasible.”

Komatsu also told IM that the truck will use both the hydrogen fuel cells as well as battery power – so it will be a Fuel Cell Electric Vehicle (FCEV). The fuel cells represent the primary power source with the battery used for load balancing as well as capturing energy during retarding, similar to an automotive EV.

GM has been conducting fuel cell research and product development for more than 50 years and says it is one of the only companies with advanced, homegrown technology platforms for both lithium-ion batteries and hydrogen fuel cells. GM and Komatsu believe these complimentary technologies can help spur the adoption of lower-emission mobility solutions and help other industries beyond passenger vehicles meet their sustainability goals. Funcannon additionally told IM on why GM was chosen: “They have decades of experience in the research and development of fuel cell technology, and we believe they’re best suited to help us, help our customers meet their sustainability goals.”

That said, this is not the first time hydrogen fuel cells have been used to power a 930E mining truck – in 2021, truck number DT74 at Anglo American’s Mogalakewna platinum mine began operation using eight Ballard FCveloCity®-HD 100 kW fuel cell modules working with a WAE 1.1 MWh battery. However, that project was conducted by First Mode in partnership with Anglo American and Komatsu was not directly involved other than providing some technical assistance. First Mode is in the process of converting a second 930E at its proving grounds in Centralia, Washington, afer which it will move onto the 830E.