All posts by Paul Moore

Green Gravity and CEVJ partner on application of energy storage tech in 17 Romanian mine shafts

Environmental, Mine shafts and equipment, Mine ventilation, Power supply for mines, Sustainable mining

Green Gravity and Complexul Energetic Valea Jiului SA (CEVJ) have executed a Cooperation Framework Agreement to explore the application of Green Gravity’s innovative energy storage technology in 17 mine shafts at four mining operations in the Valea Jiului in Romania. The agreement outlines the scope and objectives of a joint study to assess the technical, economic and environmental aspects of converting CEVJ’s existing coal mines into energy storage facilities, using Green Gravity’s proprietary technology and expertise.

The study will also evaluate the potential benefits and challenges of integrating the energy storage system with the existing power grid and renewable energy sources. The agreement represents a strategic partnership between Green Gravity and CEVJ, as both parties share a common vision of advancing the energy transition and reducing greenhouse gas emissions, while creating new opportunities for economic development and social welfare. The agreement also aligns with the European Union’s Green Deal, which aims to make Europe the first climate-neutral continent by 2050.

Romania is undergoing a major energy transition, aiming to increase the share of renewable energy in its energy mix and reduce its dependence on fossil fuels. Romania has set ambitious renewable energy targets for 2030 and has committed to phase out coal by 2032.

Mark Swinnerton, CEO of Green Gravity, said: “We are delighted to collaborate with CEVJ on this innovative project, which has the potential to transform Romania’s coal sector into a renewable energy storage hub, creating jobs, growth and innovation. Our technology offers a unique solution to store excess renewable energy using gravity, which can help balance the power grid and support the EU’s climate goals. Successfully implementing gravitational energy storage in the Valea Jiului will provide a leading example for successful transition of a coal mining region. This project has global implications for climate, jobs and investment.”

He adds: “Green Gravity’s energy storage technology represents a breakthrough in the search for economic long-duration storage of renewable energy. By re-using mining assets, costs can be kept low. By using gravity as the fuel, we dispense with consuming the critical water, land, and chemicals which other storage technologies rely on.”

Eusebiu Durbaca, Managing Director of CEVJ, said: “We are pleased to partner with Green Gravity, a world-class company in the field of clean energy. This project is part of our strategy to diversify our energy portfolio and explore new opportunities for value creation from our coal assets. We believe that gravitational energy storage is an innovative approach to energy transition, and we are committed to contributing to Romania’s and Europe’s energy transition and green recovery.”

Sebastian-Ioan Burduja, the Minister of Energy from Romania, stated: “I welcome this initiative, which demonstrates the potential for cooperation between Romania and Australia in the field of clean energy and climate action. I support the efforts of CEVJ and Green Gravity to explore the feasibility of gravitational energy storage using old mine shafts, which could provide a viable solution for enhancing the flexibility and resilience of our energy system, ensuring a future for the Jiu Valley, and progressively reducing our dependence on fossil fuels.”

XCMG signs cooperation agreement with autonomous haulage company WAYTOUS

Automation, Bulk handling, IoT, Mining equipment, Mining services, Mining software

On November 11, Chinese mining equipment major XCMG Group held an open-pit mine green and intelligent construction exchange conference in Xinjiang, with the theme of “advancing with wisdom and moving towards new lines” to seek new ideas for the development of the mining industry. Autonomous haulage & loading technology company WAYTOUS, which is closely tied to the Chinese Academy of Sciences, was invited to attend the and says it reached a strategic cooperation with XCMG at the meeting. WAYTOUS supplies the YUGONG intelligent mining system, which includes autonomous transportation and autonomous fleet management sub-systems.

The two sides will integrate their respective strengths and carry out in-depth cooperation in the green and intelligent construction of mines. XCMG have already worked together at mining operations where WAYTOUS has supplied its technology on XCMG equipment. These include AHS retrofits on XCMG XDE120 trucks for a demo project at China National Gold Group’s Wushan copper-molybdenum project near Hulunbuir City in Inner Mongolia along with contractor China Railway 19th Bureau.

Geng Jiawen, General Manager and Party Secretary of XCMG Mining Machinery Company, and Wang Jian, Co-Founder of WAYTOUS, signed the contract as representatives of both parties. Peng Qiming, President of the China Mining Association, Chen Gang, President of the Xinjiang Foreign Economic and Trade Association, Bian Zhengfu, Vice President of the China University of Mining and Technology, Li Xiaojun, Vice President of the China Industrial Development Promotion Association, Meng Wen, Vice President of XCMG Machinery, and other nearly 350 leaders and experts witnessed this important moment.

As a smart mining technology and services provider, WAYTOUS has more than 30 years of experience at more than 40 mining projects. It says it is committed to promoting the in-depth development of China’s new energy security strategy with scientific and technological innovation, “serving the high-quality development of China’s industry with intelligent construction, promoting China’s mining industry to grasp the global voice in the digital era, and making mines safer, greener, smarter and more efficient.”

XCMG says it is the only company in China to enter the top five global open-pit mining equipment manufacturers along with Caterpillar, Komatsu, Hitachi and Liebherr. XCMG “focuses on the construction of smart mines and safe mines, actively plans to explore new models and new paths for mining machinery, forms three series of full product lines, and has more than 2,000 service locations worldwide.”

Based on the shared vision and goals of both parties in the field of intelligent mining, Zhongke Huituo and XCMG formally signed a strategic cooperation agreement. On the one hand, they will give full play to their respective technical advantages, carry out in-depth cooperation in mining machinery and equipment, unmanned driving and other levels, and use the mode of joint development to drive innovation to reduce personnel and increase safety in mines; On the other hand, they will fully release the advantages of both sides in the Chinese market as well as abroad, plus realise resources integration and information sharing, and promote mutual benefit and “win-win” at a commercial level through various forms of innovative cooperation.

In recent years, WAYTOUS and XCMG says they have always maintained close exchanges and cooperation, and cultivated a cooperative partnership of mutual trust and tacit understanding. As far back as 2017, at the beginning of the unmanned operation of China’s smart mines, WAYTOUS began working with XCMG Group.

Epiroc launches electric-driven Pit Viper 230 Series

Automation, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software, Sustainable mining
Epiroc last week announced two additions to its Pit Viper family, the Pit Viper 231 E and Pit Viper 235 E. These new electric-driven blasthole drills it says offer operators safer, cleaner, and more sustainable operations “while maintaining the legendary productivity and reliability that the Pit Viper line is renowned for.”
Equipped with Epiroc’s proprietary operating system, Rig Control System (RCS), these drills “offer advanced on-board and off-board automation that significantly enhances safety, accuracy, and productivity.”
Epiroc’s electric-driven blasthole drills are zero-emission machines, making operations cleaner and more sustainable. “These drills contribute to a healthier planet by significantly reducing carbon emissions. With electric power at the core, these machines eliminate the need for traditional fuel, leading to substantial savings in operational costs. The Pit Viper 231 E and Pit Viper 235 E are a cost-effective solution for any mining operation.”
“The Pit Viper 231 E and Pit Viper 235 E are part of our vocation to create greener drills that enable our customers to produce metals and minerals in the most sustainable way possible,” said Yara Hussein, Global Product Manager – Midrange Blasthole at Epiroc’s Surface division.
The Pit Viper 231 E can drill 152 mm – 250 mm (6 in – 9 7/8”) holes with up to 16.1 m (53 ft) capability. At the same time, the Pit Viper 235 E can drill holes up to 171mm to 270 mm (6-3/4″ to 10-5/8″) diameter. Both provide a full range of options to meet current and future needs, “delivering unmatched efficiency without compromising safety, environmental responsibility, or operational cost-effectiveness.”
The Pit Viper 231 E and Pit Viper 235 E drill rigs support Epiroc’s core mission of driving innovation in the mining industry for the benefit of customers and the environment, as it aims to reduce by half the CO2 emissions from their operations, transportation and the use of products by 2030.

First Mode completes battery at Perth plant to integrate into next retrofitted Komatsu 930E FCEV

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

First Mode has completed a large 8 t mega battery module at its Perth, Western Australia battery R&D operation for its next generation fuel cell demonstration mining truck. The truck is based on a Komatsu 930E which is already at its Centralia, Washington test site in the US. The battery will be integrated into the truck along with Ballard hydrogen fuel cell modules. Next year will see First Mode also convert a Komatsu 830E to zero emissions operation.

This is another major step in First Mode’s path to decarbonising heavy equipment – and will be the second retrofitted mining truck after the initial nuGen™ Haulage Solution truck, converted 930E truck DT74, which is still running at Anglo American’s Mogalakwena platinum mine in South Africa 18 months after introduction and is now part of the commercial fleet. During its first year, operating under typical mining conditions, the truck demonstrated full payload capacity of 300 tons during pit runs, achieving performance parity with its diesel counterparts, while its increased efficiency allowed for high operational speeds with the same power. Pit runs included loading under a 100 ton capacity shovel, climbing a 10% grade fully loaded, and traveling a typical haul route distance of 11 km before successfully dumping loads into the crusher.

The latest First Mode battery packs are being designed to be able operate in all of the harsh conditions faced in mining, from +50°C in the Pilbara to -50°C in northern Canada. They are equipped with tailored battery and thermal management systems with energy delivery controlled using dedicated software. Earlier this year, First Mode and ABB announced that ABB’s BORDLINE® ESS batteries are being assembled into the larger battery packs used in the construction of hybrid hydrogen and battery powerplants to power First Mode’s new ultra-class haulage trucks.

The FCEV option is just one of three retrofits First Mode offers. It is also offering a Hybrid Electric Vehicle (HEV) option with regenerative battery pack. When the truck is descending a hill, it uses its wheel motors as brakes. The energy generated is captured by the batteries and later used to help power the truck. This regenerative braking and power reuse cuts down on fuel usage and carbon dioxide emissions by up to 30%, depending on conditions. The HEV diesel engine, radiator, and fuel tank are untouched by the HEV retrofit. No new support infrastructure is needed, so the HEV is aimed at being a first step in the miners’ decarbonisation journey.

Then it is offering a full Battery Electric Vehicle or BEV retrofit. The BEV main batteries are charged through regenerative braking and through a static multi-megawatt fast charging system. The radiator is used to maintain acceptable operating temperatures for the batteries and their associated power electronics.

 

 

Bridgestone supplies new service to BHP’s Spence using proprietary tyre durability algorithm

Automation, Base metals, Bulk handling, Environmental, Equipment maintenance, IoT, Mining consumables, Mining equipment, Mining maintenance, Mining services, Mining software

Bridgestone Corporation has announced a new mining solution service to estimate tyre durability using a proprietary algorithm originally developed by Bridgestone. The new offering was introduced in July 2023 to the Spence copper mine (Pampa Norte operation) in Chile, which is part of BHP. This service will be used to propose the optimal tyre maintenance timing and driving routes for the mine.

Based on Bridgestone Mastercore, Bridgestone supplies a range of mining solutions that help maximise the productivity and economic value of mining operations by combining real and digital capabilities. Now the company’s mining solution is evolving to a new stage, which is to strengthen tyre wear life estimation using the algorithm originally developed by combining Bridgestone’s extensive tyre knowledge, industry experience, and digital capability.

This solution service’s algorithm utilises fleet operating data securely provided by customers to help estimate tyre durability, prevent tyre damage caused by inappropriate tire maintenance, and propose the optimal tyre maintenance timing and driving routes. The data used in these evaluations includes vehicle tyre replacement history, as well as on tyre temperature and pressure, vehicle location, driving speed and other data collected from Bridgestone’s iTrack next-generation mining vehicle tyre monitoring system.

The service thereby contributes to customer value in the forms of lower tyre-related costs and reduced vehicle downtime. It also contributes to sustainability through improved resource productivity and longer usage of tyres.

The Spence mine now using Bridgestone’s new mining solution service produces copper, which is an essential ingredient for electrification and is used in electric vehicles, housing and the manufacturing of products including white goods. The world needs more copper supply to meet expected demand over coming decades. Operations at the copper mine are required to optimise productivity to ensure reliable efficient supply to customers around the world.

Under such circumstances, unplanned tyre repairs or changes caused by unpredicted tyre damage can diminish efficiency of fleet operation, increase cost, and potentially increase environmental impacts. Bridgestone’s algorithm provides notification of the optimal timings for maintenance by combining and analysing vehicle operating data from the mine with data from Bridgestone iTrack and Bridgestone’s tyre-related expertise to predict tyre abnormalities. Bridgestone is also providing tools that help achieve the best tyre pressure for various temperature ranges.

“At the Spence mine of BHP-Pampa Norte, we want to improve productivity and reduce waste while also improving the performance and extending the lifespan of our tyres. In this context, we have partnered with Bridgestone to improve monitoring and management in order to sequence optimum maintenance and prevent unscheduled stoppages. We have thus started a new project that is incorporating management tools that are available through Bridgestone’s new technology. We recognise Bridgestone’s willingness to take the challenge, do what needs to be done, and propose improvements,” said Carlos Ruz, Mine Production Manager, BHP.

“This mining solution service is a new challenge for Bridgestone to take on. It combines our ‘DanTotsu’ products with data analysis based on our tire expertise to deliver new value to customers. I am incredibly pleased that this solution, which was realised through co-creation with the Spence mine of BHP-Pampa Norte, is contributing to improvements in operations. Going forward, Bridgestone will continue working to optimise mining operations and improve resource productivity with unique solutions that are closely tailored to client needs,” said Nobuyuki Tamura. Vice President and Senior Officer, Global Mining, Industrial, Construction and Aviation, Bridgestone Corporation.

Through the provision of mining solutions that combine digital technologies and services, Bridgestone says it strives to achieve the corporate commitments of ‘Efficiency: Committed to maximising productivity through the advancement of mobility’ and ‘Ecology: Committed to advancing sustainable tyre technologies and solutions that preserve the environment for future generation’ described in the ‘Bridgestone E8 Commitment.’

Sandvik’s Rotary Drilling Division introduces sims to training repertoire

Careers in mining, Equipment maintenance, Mining maintenance, Mining people, Mining safety, Mining services

A constantly evolving training technique is essential. And no company understands that more than Sandvik’s Rotary Drilling Division which will soon include another training technique to it’s repertoire – simulators. “It’s just another key piece to the puzzle,” said Keith Wallace, Technical Training Manager.

Training operators on new equipment can then start while Sandvik is on-site assembling the equipment with the Digital Driller. “We can introduce to them how the machine should function,” Wallace said. The company has also created a suitcase simulator that the sales team can set up and use it in meetings to demonstrate and let their customers see it. “It’s a very good gateway,” Joseph Troy, Technical Trainer, said. “Everyone wants to get into it. It’s a good introduction in a more fun way and in a learning safe environment.”

The simulator was introduced at a customer day with several people from Nevada Gold Mines and the software is currently in the final testing stage and will be deployed to offices in Canada, Brazil, and Kazakhstan shortly. “There’s a big need for it,” Wallace said. Pre-training with the simulator improves safety as an operator gets familiar with the equipment functionalities, supervised by an experienced trainer nearby, prior to entering the production environment.

The simulator is just one of the many training options Sandvik offers. And training begins with its own employees from day one. The company opened the Sandvik Training Academy in May 2022. It is 3,600 square feet of shop space equipped with cranes, grinders, hydraulic presses, etc – all the same tools that are in the assembly area.

After onboarding, employees are sent to the academy so they can assemble items in a safe environment, ask questions and make mistakes. It removes the pressure of being on the actual floor. “The idea is, from day one, we try and equip our assembly staff to be more successful on our shop floor,” Wallace said. “We are trying to take away some of that newness and set them up for success.”

Troy trains them face to face and they also offer safety training and an onboarding e-learning package, which is available in a computer lab with eight workstations. One employee said the onboarding was “delivered in about 60 minutes and cleared up a lot of uncertainty.” Employees can hone their skills and they are seeing these employees move up the ladder in their careers. When the trainers see an employee excelling on the floor, they will bring them in for additional training. All their competencies are tracked to aid in that career progression.

An assembler was introduced to some front-line personnel and ended up getting a job and moving to Minnesota. “For us, seeing that career progression is just awesome,” Wallace said. “It’s changing people’s lives.” The company also offers mentorships, which weren’t always available. “There are dedicated people who are focused on improving this person’s competencies and skills,” Troy said. This began last spring and is growing. “We are changing how we look at developing our workforce.”

Patricia Bambace, E-Learning Developer, agreed and said it is a coach-friendly atmosphere. “Our training academy has been focusing on creating a shift to that learning culture within manufacturing,” she added.

The company also recently held its first technology conference back in December 2022. The five-day conference was held for frontline employees from seven different regions/sales areas. The focus was to build a foundation of knowledge that will improve the frontline support for the technology components that are quickly being received and requested by the end-user. Most of the training was blended with theory and hands-on applications. The conference was supported by Technical Services, Engineering, and Automation teams. The conference received such positive feedback that they are holding another training conference in March 2024.

“The networking and the team building and all that goes along with the face-to-face training,” Wallace said. “It’s very powerful for us because we are such a huge global organisation. I’m trying to link these key players from all around the world.”

The company also understands that everyone learns differently. So, they offer online training as well. “It’s repeatable and people can attend that at their own pace,” Wallace said. “And they can reach it from anywhere in the world. All of our e-learning is set up to function on a phone, a tablet, a desktop, whatever device you may use.”

The market is receiving e-learning extremely well. It’s also a resource that is always available. Employees can go back to a training if they have an issue on a rig and reference it to help diagnose the problem. Bambace said it’s important to look at the employee and see what approach would work best for them: audio narration, reading and seeing photos, videos, etc. The e-learning environment also takes into account individual learning styles and optimises traditional classroom training.

E-learning is not only available to employees but customers as well. The customers have options when it comes to training: face-to-face, virtual and on-site. Customers can also choose a blend of all three. Sandvik can tailor its training packages to the needs of the customer. One customer in Wyoming needed a local Sandvik representative to travel to the site on three separate occasions to train three different crews on two different drill models. The company can’t afford any downtime and Sandvik will accommodate them. “We said, OK, what do you need?” Wallace said.

“A poorly trained operator can affect the entire machine,” Wallace said. Proper operator training affects the entire system, from productivity numbers to creating technical problems. All the types of training that Sandvik offers touch on each other and complements one another, from the beginning with the onboarding of assembly employee to the shop floor, pushing it to its front-line personnel, such as sales and support representatives, all the way up to the end user. “All three pieces of the puzzle are in an effort to make Sandvik successful,” Wallace said. “The better workforce that we have, the better our frontline, the better experience our customer has.”

Employees get the proper training on assembly procedures, safety, tool selection, corporate compliance, etc. Then the front line is trained so they can assist customers with commissioning, troubleshooting, and maintenance. Lastly, they offer customer-specific training to make sure they understand how to properly operate and maintain their equipment.

“That’s what the vision is now – a whole circle approach to training, from those working on the floor to those who are maintaining or operating the rigs out in the field,” Bambace said. Wallace has a vision of expanding his training team and expanding their offerings. Just a few years ago, training was a one-man job. “I would like to grow an entire training program, not just for our products, but all Sandvik products,” he added. The team is trying to drive organisational change and Sandvik is getting there.

Industrial minerals giant Sibelco to develop Separation Rapids hard rock lithium mine with Avalon

Environmental, Industrial minerals, Mineral project development, Mining mergers and acquisitions

Following previous announcements made on June 15 and November 2, 2023, Avalon Advanced Materials Inc and SCR-Sibelco NV have announced the closing of their joint venture transaction. The new joint venture company, Separation Rapids Ltd (SRL), has a mandate to advance mining activities at the flagship Separation Rapids hard rock lithium (petalite) deposit near Kenora, Ontario, as well as at the Lilypad Project located near Fort Hope, Ontario.

SRL is jointly owned by Sibelco (60%) and Avalon (40%) and is well positioned with a unique dual-market strategy to supply petalite-lithium to both the global glass & ceramics industry, as well as to the North American EV battery manufacturing market.

SRL, the new joint venture company, will own and work to commercialise the mineral assets at Separation Rapids and Lilypad. Sibelco has the sole funding responsibility for the first €34.8 million (approximately C$50 million) of joint venture operations expenditures. Mineral output of petalite-lithium at Separation Rapids is expected to be sufficient to supply both the global glass & ceramics and North American EV battery markets. The development is a real tribute to the work over decades carried out by Don Bubar, former Avalon President and CEO, who passed away in July this year and had been tirelessly working on driving the project forward since he acquired it in 1996.

For Avalon, this transaction represents an exciting new path towards generating revenue from long held assets and unlocking real value for shareholders. “Establishing this exciting new joint venture achieves a significant objective in our evolution as a clean energy company and enables the unique petalite deposit at Separation Rapids to be commercialised at a pace that will help position Canada in important international markets,” said Scott Monteith, Avalon CEO. “We are unlocking the potential of Separation Rapids and other projects, and in so doing, taking another key step in establishing the end-to-end lithium supply chain we envision for Ontario.”

Located 70 km north of Kenora, Ontario, Separation Rapids is a flagship deposit of petalite-lithium which in addition to its traditional uses in the glass & ceramics markets can, using new innovative technology processes, also economically yield EV battery-grade lithium at scale. On August 10, 2023, Avalon released an updated Mineral Resource Estimate (MRE) for Separation Rapids, conducted by SLR Consulting (Canada) Ltd, an independent global mining advisory and consulting firm. The MRE revealed a measured and indicated deposit 20% larger than earlier estimates.

The MRE, compliant with NI 43-101, showed a measured and indicated resource of 10.08 Mt of petalite, grading on average 1.35% Li2O. The resource is primarily from an open pit, while a smaller amount is from an underground resource. A new C$3.6 million drilling program commenced on September 26, 2023, which will seek to upgrade the amount of inferred ore to indicated, and add more resource to the deposit as well as perform geotechnical drilling within the pit area. The drill program is expected to be completed by February 2024.

Antwerp-based Sibelco is an international leader in supplying silica sands and flours as well as nepheline syenite and other minerals to the glass & ceramics market, with deep expertise in the mining, processing and recycling of specialty industrial minerals. “Separation Rapids represents a unique opportunity for Sibelco to enhance a core business we know extremely well, while at the same time, provides us with an entry into the promising North American EV battery market,” said Ian Sedgman, Sibelco’s Chief Strategy and Business Development Officer. “It is a dual-market strategy we are confident will create long-term value for all stakeholders.”

Located near Fort Hope, Ontario, the Lilypad Project consists of claims totalling over 3,299 hectares (8,152 acres) of lithium, tantalum and caesium mineralised pegmatites. Lithium pegmatite occurrences have been discovered in the area as spodumene and lepidolite. Encouraging for the future development of the project is the fact that significant mineral discoveries to the north (Ring of Fire) have prompted the development of road access. This will greatly enhance the economic viability of any mineral deposits in the region, including Lilypad. Economic resources of caesium are very rare and Lilypad represents one of the very few known significant occurrences of this mineral in the world. With declining production from traditional sources, new producers are needed for this scarce advanced material to meet growing demand.

WEG motors and drives key players in South Africa’s energy solution strategy

Equipment maintenance, Mining consumables, Mining services, Power supply for mines, Sustainable mining

With the continued energy poverty being experienced in South Africa, motors and drives are set to play an ever more crucial role in industry’s energy solution strategy. The manufacturing and processing sectors, which include minerals processing plants, are energy-intensive industries, and finding ways to reduce energy consumption while increasing efficiencies is essential for both economic and environmental reasons.

This is according to Jaco Brits, Projects and Technical Manager at WEG Africa, who says that the company has the knowledge and expertise as well as the technology solutions to assist operations in reducing their operating costs and increasing their productivity while guarding their energy security.

“Electric motors and drives are used across industries to operate pumps, mixers, conveyors, vibrating screens and feeders, crushers, and other machinery including automated packaging systems,” Brits says.

“Advancements in motor and drive technology, underpinned by WEG’s extensive research and development, have seen substantial improvements in energy efficiency, both equipped with advanced control algorithms to optimise motor performance based on real-time conditions,” he explains. “These algorithms assist in ensuring motors operate at peak efficiency levels, even in complex processes.”

“By upgrading to newer technology and installing higher efficiency motors such as the WEG IE3 or IE4 electric motor, customers can significantly lower their energy consumption. In addition to this,” he adds, “by combining high efficiency motors with WEG variable-speed drives (VSDs), better control and optimisation of equipment can be achieved. This ensures that equipment operates at its most energy efficient speed and power level, and will reduce operating costs significantly.”

Commenting on the use of VSDs, Brits explains that traditional fixed speed motors run at a constant speed regardless of the actual load requirements. In contrast, VSDs are most effective in controlling the speed and torque of motors based on the actual load requirements. This level of precision facilitates the adjustment of the motor’s speed to match the load, thereby ensuring that equipment operates only as needed. VSDs also have faster reaction to load changes and better integration with equipment. “All these factors reduce unnecessary energy consumption during periods of low demand and enhances overall equipment efficiency and performance,” says Brits.

Unpacking advancements in drive technology, Brits points to the WEG CFW11 VSD line, which incorporates some of the most advanced technology in the world for alternating-current three-phase induction motors.

“Incorporating WEG Vectrue™ technology, these new generation WEG drives combine variable frequency, sensorless and closed-loop vector (with encoder) control techniques in a single product. This facilitates high torque and a fast dynamic response with the self-tuning function allowing automatic configuration of the drive to adjust it to the motor and load in vector modes,” Brits says.

With most industries looking at sustainable energy resources including renewables such as wind and solar, motors and drives will continue to play an important role in facilitating the integration of such systems. VSDs can be used to balance power supply and demand, and ensure stable operation in hybrid energy setups.

“Substantial efficiency improvements are possible by leveraging the latest motor and drive technology, and the significant savings in energy consumption more than justify the capital cost of replacing old technology equipment with higher efficiency technology,” Brits concludes.

RC exploration drills go auto – Perenti’s Ausdrill & Epiroc’s partnership on the Explorac RC30 Smart

Automation, Equipment maintenance, Mineral exploration, Mining services, Steel and iron ore

A joint-development project by Australian and Swedish engineers is changing the working environment for exploration contractors at the same time as it offers faster, more efficient operations for the mining industry. For decades, automation technology has mostly been focused on production drilling, for obvious reasons. Exploration, on the other hand, has lagged behind. In fact, with automation now at an advanced stage in virtually all other areas of the mining process, exploration is now viewed by many to be the last frontier.

However, that will soon be a thing of the past largely due to a unique collaboration between two of the world’s leading exploration specialists – Ausdrill of Australia and Epiroc of Sweden – who together have enabled exploration to transition into the automation age.

It was in 2018 when Ausdrill, part of Perenti Group and Australia’s leading drilling services provider, experienced strong demand from the exploration industry to “go auto”. Some mining clients, the company noted, were aiming for a technology shift within a specific time period. Eric Gobbert, the company’s Senior Manager Business Development and Improvement, says:  “As a leader in the drilling industry in Australia we are always looking at how we can use innovation to improve the safety of our people and the efficiency of our operations.”

Established more than 35 years ago in Kalgoorlie, in the heart of the Western Australia mining region, Ausdrill has about 40 exploration rigs, both RC and diamond/core units, and decided it needed to partner with a leading manufacturer to meet the growing demand.

Having previously worked closely with Epiroc in the development of its drill and blast rigs, Ausdrill proposed that the two companies join forces to collaborate on solving the automation challenge, specifically for RC (Reverse Circulation) technology. Today, the success of that collaboration is manifested in the latest exploration rig from Epiroc – the Explorac RC30 Smart – an RC drill rig that is the first of its kind.

Launched in October 2023, it features fully automated rod-handling, high-speed operation, process monitoring, remote control and a range of other improvements that make the job faster, safer and more efficient than ever.

The project set out to solve very specific issues, recalls Gobbert. “We wanted to keep the operator outside of the drop zones around the rigs. We wanted advanced interlocks and safety monitoring, continuous monitoring of the process as well as improvements to reliability and maintenance, and we wanted to get it done as fast as we could.”

Automating the rod handling function of an exploration rig is a considerably more complex task than for a production drill rig. For one thing, rod handling on production rigs is isolated to the mast as they carry enough drill rods on board, allowing for permanent safety barriers to be installed so that the rods cannot fall out.

In contrast, exploration rigs drill to much greater depths than production rigs, requiring access to multiple drill rods from outside the mast area which increases the risk to the operator. This means that for deeper holes using rods supplied from a truck, the rod handling system needed to be ‘taught’ to start from a new position for every hole.

The Explorac RC30 Smart therefore represents a major step-change for exploration in surface applications, significantly raising exploration technology to the next level, explains David Benton, Epiroc’s Global Product Manager for Exploration. “The rig seamlessly combines automated sequences and embedded interlocks to eliminate high risk and repetitive tasks while offering the largest pullback capacity of any Epiroc exploration rig to date.”

Another clear advantage of automation, besides increased safety, is less wear and tear on consumables given that tasks such as rod handling are repeated with the exact same performance every time. This increases equipment uptime and means that predictive maintenance becomes much easier.

Gobbert highlights Ausdrill’s initiative to engage in a long-term project to introduce hands-free technology and automated drilling processes. “We call this ‘Hands Off Steel’ which also became our catchphrase for bringing automation into the reverse circulation drilling industry here in Australia. In terms of automating the rod handling function, it was obviously a fitting motto.”

Speeding up the automated sequences was a key consideration in the development phase of the Explorac RC30 Smart, he notes. “We had to ensure that the rod handler system would be faster than the operators, otherwise they would simply continue doing the job manually. There are a million benefits to be achieved with automation, and we still don’t know where it ends. We were very keen to engage in this design and development as it meets all our Perenti principles of ‘Enable Tomorrow and ‘Smarter Together’. Our goal is to minimise risks in the workplace and remove our teams from unnecessary hazards.”

The Explorac RC30 Smart not only improves operating performance and safety, but it has been designed in a manner that supports future scaling of rig features and functionality. As a result, Ausdrill and other contractors can easily upgrade the equipment when new automation features become available. This ensures that contractors can keep pace with industry changes and get the highest possible return on their investment throughout the life of the drill rig.

Besides a technology breakthrough, the new Explorac RC30 Smart represents a meeting of minds that has been praised by both partners. Ausdrill’s Eric Gobbert says, “We were very impressed with Epiroc’s commitment to this project and how they built an understanding of our requirements. We felt we really had the scope to influence the design of this new rig with the specifications we provided. There were a lot of issues in the first year or two of the collaboration, such as parts wearing more quickly or the rig not staying in auto mode, but all of these challenges were overcome.”

For Epiroc’s part, David Benton says the project exemplifies the company’s core values of innovation, commitment, and collaboration. “A great deal of effort has been put in on both sides, particularly when you take into consideration the delays caused by the Covid pandemic,” he says. “But our communications have been open and Ausdrill has been very understanding throughout.”

The prototype has now been delivered to Ausdrill. So what has the new rig meant for Ausdrill’s operations? “We basically had to relearn how to drill with this rig as it was so different to what the operators were used to,” says Gobbert. “They had to learn how to drill in auto mode, and that took time. Our maintenance team also had to get their heads around how the rig works, and Epiroc has been helpful with this too.”

“There’s no doubt that the development of the Explorac RC30 Smart has enabled us to advance the technology roadmap according to our clients’ requirements, so hopefully it will enable us to tender for projects with Tier 1 clients that some of our competitors can’t deliver on because they do not have the technological capabilities.”

Although the project has put exploration drilling firmly on the road to automation, both partners agree that more work needs to be done. As Benton puts it: “With a strong foundation for further development now in place, we are focused on innovating towards the complete automation of the RC drilling process from start to finish.”

TAKRAF signs major IPCC deal with Rio Tinto for Simandou in Guinea

Bulk handling, Comminution of minerals, Environmental, Equipment maintenance, Mineral commodities, Mineral processing, Mineral project development, Mining consumables, Mining services, Mining techniques, Steel and iron ore, Sustainable mining

In a notable achievement, TAKRAF Group has announced the signing of a major contract between Rio Tinto and TAKRAF concerning development of the Simandou iron ore complex in Guinea. The Simandou complex is one of the largest unexploited high-grade iron ore deposits in the world.

The contract entails the design, fabrication and delivery of an advanced and integrated IPCC and material handling system. Highlights include two primary IPCC systems incorporating two TAKRAF X-TREME class sizers to crush extracted ore received by truck. It also includes a secondary In Pit Secondary Crushing & Conveying (IPSCC) system incorporating four TAKRAF sizers for further ore processing.

Further downstream it also covers two rail mounted stackers for ore stockpiling and two rail mounted reclaimers for ore reclaiming plus two wagon loading stations with buffer silos. It also covers a complex conveyor system with transfer stations for the above equipment, including a technically sophisticated long downhill conveyor between the secondary IPSCC system and the stockyard; as well as electrical and control equipment and stockyard auxiliaries.

In order to achieve the desired annual production rate, the crushing system has been sized with a design capacity of up to 13,200 t/h. Importantly, all stockyard equipment have also been designed with scalability in mind, laying the foundation for future expansions. A separate contract for technical assistance for installation and commissioning of the system, as well as for assistance in longer-term maintenance and spare parts supply will also be concluded.

Thomas Jabs, TAKRAF Group: CEO, regarding the award of the contract: “First and foremost, this is an important project for the country of Guinea and we are proud to play our part. Secondly, as steel producers adopt various initiatives to reduce their carbon emissions, the demand for lower-impurity and higher-grade iron ore – essential feedstock for steel production – is growing. Simandou’s premium quality ore will thus play an important role in the global energy transition. Lastly, I would like thank Rio Tinto and all stakeholders for their trust in TAKRAF’s solution offering. We boast significant experience in IPCC systems and an esteemed history in delivering solutions that overcome some of the most complex engineering challenges. We are proud to have been selected as important partners to this project and look forward to our engineered solutions delivering upon their promise.”

TAKRAF already has a very successful project history in Guinea, having supplied for example primary and secondary sizing and materials handling solutions for Compagnie des Bauxites de Guinée (CBG)’s bauxite expansion project in the country. CBG was formed in 1963 by the Government of Guinea and Halco (Mining), Inc to develop bauxite in the Boké region – the Government of Guinea owns 49% and Boké Investment Company owns 51% of CBG. Halco owns 100% of Boké Investment Company. Halco is a consortium comprised of Rio Tinto (45%), Alcoa (45%) and Dadco Investments (10%) – so ultimately as a major player in CBG, Rio Tinto has been happy with its experience of TAKRAF there.