All posts by Paul Moore

Boart Longyear Releases an Upgraded Surface Roller Latch Head Assembly and Overshot

Mineral exploration, Mining services

Boart Longyear, the leading provider of exploration equipment and performance tooling, has announced the launch of an upgraded Surface Roller Latch Wireline System. Extending the successful Roller Latch family of wireline tooling, Boart Longyear says it focused on safety, reliability, and productivity. Since its original release, Roller Latch technology has been adopted by the industry’s largest drilling contractors. The newest release of the system improves usability, serviceability, and overall performance.

Boart Longyear has introduced several system improvements. These new features include a new housing that reduces typical drop times by 20% and, up to 60% when paired with W-Wall drill rod. In addition, a new 360º swivel joint enables easier handling, and a new release system eliminates the jar staff. The system improvements continue with a redesigned head, improving core recovery times. This is a surface wireline solution that incorporates dozens of refinements that eliminate spearheads and lifting dogs completely.

“We invented wireline coring, including the outdated spearheads and latches used by our competitors,” says Chris Lambert, Global Product Manager at Boart Longyear. “Our patented technology has been in use for a decade, and we’ve continuously improved the system based on end-user feedback. Our engineers have created a wireline system that completely eclipses every core barrel we’ve released over the last seventy years.” The Roller Latch family of wireline systems now delivers turnkey solutions for all underground and surface drilling.

Chrysos Corporation, Barrick Gold and MSALABS form global partnership for deployment of PhotonAssay

IoT, Metallurgy, Mineral exploration, Mineral project development, Mining services, Mining software, Precious metals

Chrysos Corporation has announced that it has forged a partnership with one of the world’s largest gold miners, Barrick Gold, and fast-growing international laboratory business MSALABS, to deliver its PhotonAssayTM technology to Barrick mine sites across four continents.

The partnership will commence with the deployment of three MSALABS contracted PhotonAssayTM units to the Nevada Gold Mines (NGM) complex in the United States of America (USA), with the potential deployment of up to 10 more PhotonAssayTM units to other Barrick projects by the end of 2025, subject to finalising due diligence. The partnership is an extension of an already successful relationship between the three companies at Barrick’s Bulyanhulu mine in Tanzania and its Kibali operations in the Democratic Republic of the Congo (DRC).

The single largest gold-mining complex in the world, NGM is 61.5% owned and operated by Barrick, and 38.5% owned by the world’s largest gold miner, Newmont. The assets at the complex include 10 underground mines, 12 surface mines as well as multiple related facilities.

Chrysos Managing Director and CEO Dirk Treasure commented: “Barrick’s global adoption of our technology is a watershed moment for us, underlining PhotonAssay’s superiority to outdated and hazardous fire assay methods. Together with the team at MSALABS, we look forward to bringing the same operational and environmental benefits being delivered at Bulyanhulu and Kibali in Africa to more of Barrick’s gold mines.”

Striking a similar tone, Barrick Mineral Resource Management & Evaluations Executive Simon Bottoms, said: “PhotonAssay has already been delivering faster, safer, more accurate and environmentally-friendly analysis to our African operations, so we are more than pleased to broaden the partnership with Chrysos and MSALABS to take advantage of this innovative technology in our global operations.”

On leveraging PhotonAssay’s previous successes Stuart Thomson, MSALABS CEO, enthused “This partnership reflects the teamwork that’s driven the highly successful integration of PhotonAssay technology into Barrick’s mine sites since the first hybrid lab commissioned in Bulyanhulu in 2021. MSALABS’ holistic approach including design, construction and process components has resulted in seamless transitions from fire assay to PhotonAssay at Bulyanhulu and Kibali. Development has continued with copper assaying and innovations in sample logistics and robotics, extending the capability, safety and productivity of the entire system.”

Bis HUGO 80 t underground mining truck reaches Proof of Concept testing stage

Bulk handling, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services

Bis Industries says it has reached the next stage in the commissioning process of its innovative HUGO underground mining truck – Proof of Concept testing. Last week HUGO was loaded up with payloads of 80 t, testing the diesel electric hybrid power train in a range of situations to mimic underground hard rock mining haulage. HUGO stands for Hybrid Underground Operations.

The company outlined key reasons why HUGO is disruptive in this market – first off of course it brings a 40% increase in productivity compared to today’s largest available 60-65 t trucks. It also meets the current need for lower emission solutions, while providing a platform for decarbonisation and development in using alternative energy sources.

In operation it says it delivers a 50% increase in speed-on-grade capability. A 25% increase in payload results in 25% fewer truck movements and interactions; plus it has to potential to bring approximately 15-25% less overall haulage costs. Bis added: “We’re looking forward to seeing this low-cost-per-tonne hybrid haulage solution take charge underground.:

The truck had already been put through its paces at a quarry during including extensive durability testing to test the robustness of its electrical system. It has also undergone shake/vibration testing on rough rutted surfaces (mirroring conditions underground) together with running continuous laps to verify its hydraulic system performance.

HUGO’s engine, supplied by Volvo Penta, can use HVO fuels derived from waste materials like residue oils and fats, reducing HUGO’s carbon footprint even further and broadening its range of application. The design also means users don’t have to change the way they mine, as rather than being all battery powered, it is equipped with an advanced hybrid electric powertrain technology supplied by Danfoss Editron.

ABB, Boliden & LKAB complete successful testing of industry-first automated robot charger

Automation, Explosives and blasting, Mine shafts and equipment, Mining consumables, Mining safety, Mining services, Steel and iron ore

ABB says it has successfully completed testing of its industry-first automated robot charging technology for underground mines in partnership with mine operators Boliden and LKAB. The goal is to make mines safer by automating one of few manual processes left in mining: charging the blasting holes with explosives.

Blasting schedules in underground mines can vary, but the process takes place up to 15 times per day in larger mines as miners expand the chambers to extract mineral and metal ores. The ABB Robot Charger automatically detects boreholes and fills them with charges without the presence of humans, removing the need for people to be near the unsupported rock face during blasting sequences.

The completed testing phase confirms the effectiveness of integrating the robot charger with a carrier vehicle, communication with bulk emulsion and vision systems and incorporation of a second robot arm to assemble prime and detonator. It ensures full reach to all borehole levels and areas of the rock face and remote control for operators. The program has been undertaken at Boliden Garpenberg, which is the world’s most productive underground zinc mine and is located 180 km northwest of Stockholm.

ABB is now embarking on the final stage of development that aims to execute the full blasting sequence in the underground mine with full control of the robot handed over to the customer. ABB is also starting discussions with other mine operators to eventually join the co-development project, so that the technology can be tested in different mine environments and in regions beyond Northern Europe with varying climate and rock composition.

“This is a significant technology development for ABB and the wider industry where safety is part of overall ESG commitments,” said Vedrana Spudic, Head of Technology, Business Line Mining, ABB. “The robot locates the drilled holes on the rock face using a vision system, and these recent tests show all can be reached and charged with the cycle fully automated. This removes the need for human operators in a small, unsupported area right at the face.”

ABB developed the robot charger technology with vision systems and automation solutions to communicate with the truck, crane and ABB industrial robotic arm. The solution can be retrofitted to any truck.

Mineral Sizer pioneer MMD celebrates 20 years in China

Automation, Base metals, Bulk handling, Coal technology, Comminution of minerals, Environmental, Equipment maintenance, Industrial minerals, Mineral processing, Mining services, Precious metals, Steel and iron ore, Sustainable mining

Founded in 1978, Mining Machinery Developments (MMD), a global producer of mining solutions, has grown considerably over the last 45 years. This month is celebrated its 20th anniversary in China, recognising the achievements and dedication of personnel with a variety of different activities.

MMD was set up to design and produce mining solutions for the underground UK coal industry, initially designing and manufacturing inline breakers. After years of expanding into different countries around the world, MMD opened its first office in China in the 1990s. It then created a representative office in 1997 and registered Beijing Mining Machinery Developments (BMMD) in April 2002.

Since then, BMMD has grown from zero to its present state. BMMD now has two purpose-built factories and offices, with sales and service teams dedicated to servicing our customer’s needs.

Throughout its 20 years, BMMD has worked closely with MMD offices in South Africa, Europe, and Mauritius. BMMD has achieved many accomplishments over the past 20 years; they have sold over 700 MMD Sizers and Feeders, including more than 70 Semi-Mobiles. In 2022, BMMD sold 12 Semi-Mobiles to a single customer and this year, they had their biggest single order received in MMD Group’s history worth approximately £24 million (equivalent to 220,000,000 Yuan).

MMD states: “During this journey, we have been fortunate enough to have continued support from our dedicated customers. They are one of the main reasons for our success and are the reason we continually deliver excellence. Our dedication to quality and innovation is down to the collaborative work we do with our customers.”

It adds: “BMMD’s dedicated sales teams continue to work hard to produce new and exciting relationships with brand-new clients whilst remaining energetic and persistent in delivering our unequalled service and assistance to our existing customers.”

It continues: “As a company, we recognise our employee’s efforts and how instrumental they’ve been in our journey, helping us build a reputation for excellence and reliability. The success is not solely about the magnificent equipment BMMD provides but also about the people who make it happen. The employees have shown consistent commitment, innovative thinking, and a tireless work ethic, ensuring that they meet and exceed the customers’ expectations.”

MMD concludes: “With this in mind, as we celebrate the 20th Anniversary of our journey within the industry in China, let us not only honour our achievements but also look forward to the exciting and incredible potential that lies ahead. Here’s to the future of supplying the mining industry with innovation, excellence, growth, and prosperity in China.”

 

Imperial Oil’s Kearl achieves full autonomy of 81 strong Cat 797 fleet

Automation, Bulk handling, Energy minerals, Equipment maintenance, Mining consumables, Mining equipment, Mining safety, Mining services, Mining software, Sustainable mining

In its recently announced third quarter 2023 results, Imperial Oil revealed that it has now completed its autonomous haulage program with all 81 of its Caterpillar 363 t class 797F heavy haul trucks at its Kearl oil sands mine in Alberta now fully converted to autonomous operation.

CEO Brad Corson stated: “With this, we now operate the largest autonomous fleet in our industry and one of the largest autonomous mining fleets in the world, which enables us to capture improvements in truck productivity, further enhance our safe operating environment, and also reduce operating costs. I’m very proud of what we have achieved to date with this program, and we continue to look at other potential opportunities to expand our autonomous concept to other areas of our mine fleet. This program reflects our commitment to safety, technology and innovation and becoming the lowest cost operator.”

The fleet is also making real contributions to production successes at Kearl. The mine’s production in the third quarter averaged 295,000 barrels per day gross, which was up 78,000 barrels per day versus the second quarter and up 24,000 barrels per day from the third quarter of last year. Corson: “I’m excited to highlight that this represents another production record and the best ever quarterly performance at Kearl, surpassing the previous record, which was set in the fourth quarter of 2020 by 11,000 barrels per day gross, and there’s more. Kearl has also set a number of other production records in the quarter, including the highest ever single month production of 322,000 barrels per day in September.”

In the Q&A he added: “We have been working on this now for several years, and to finally complete all of the conversion of the trucks allows us to really make a step change and all of those kind of beneficiary components that have been driving us. I mean, things around truck productivity, things around unit operating costs. And of course, there is this broader safety benefit that comes with it.”

Overall the higher production at Kearl was primarily driven by improved reliability as a result of the successful rollout of a winterisation strategy, the absence of extreme cold weather, increased plant capacity utilisation, and mine equipment productivity. On winterisation, this has included adding another shovel in the mine that has stronger capability in the colder temperatures, and ability to dig through the frozen ore. Kearl is also trialling grizzly bars on top of one of the crushers to better handle frozen lumps during the winter months.

The company said it has looked to minimise any headcount reduction as part of the autonomous haulage program. Simon Younger, SVP, Upstream: “As we have autonomised the truck over  years that there has been a headcount reduction, we have also, as Brad said, redeployed a number of truck drivers onto other mining equipment. Some of them have gone into the autonomous control room and are now delivering value that way.”

Younger added that it is already well into a remote control dozer trial focused on its tailings area and is seeing promising results.

When Imperial Oil made the decision to implement autonomous haulage at its Kearl operation in the oil sands, the company pulled together a team of experts from Imperial, Finning and Caterpillar to apply the technology.

Finning has previously pointed out that Kearl was the first application of Cat MineStar Command for hauling in the oil sands, in a remote northern location with unpredictable weather and ground conditions. And it was the first time Command for hauling was used on a Cat 797F.

The team utilised a combination of the MineStar suite of software including Fleet which is the dispatch system, Terrain which is the loading and grading system, and Command, which allows the truck to haul autonomously.

”We had to leverage the expertise of Caterpillar and Finning and Imperial Oil and we had to come together as one team, I think that’s why we are successful,” says Mansoor Hussain, Autonomous Project Manager for Imperial Oil. “You can assemble the world’s smartest people and they won’t be able to accomplish what we have if they’re not working together as one team. We’ve broken down the barriers between the different companies. It doesn’t matter if you’re an Imperial person, a Caterpillar person or a Finning person, you have the right to speak up, you have the right to call out things that aren’t safe, you have the right to be emboldened to come up with new ideas, new ways of doing things and I think that’s what made us successful, that one team approach.”

idoba rolls out its Mine Performance Navigator at 12 Australian underground mines

Base metals, Communications in mining, Equipment maintenance, IoT, Mine shafts and equipment, Mining equipment, Mining maintenance, Mining services, Mining software, Precious metals

Mine Performance Navigator (MPN), idoba’s AI-powered decision-support and analysis tool, has now been rolled out to a dozen underground mine sites.

MPN is significant as it is the first product fully conceived, designed, developed and delivered by idoba, and now it is live across 12 major mining projects Australia-wide.

idoba states: “MPN integrates the KPIs that drive business value with the ability to easily forecast future performance against three month schedule (3MS) target. That means you can move from reactive firefighting to proactive planning. It means your engineers can focus on mine improvements and productivity gains instead of preparing countless spreadsheet reports about yesterday.”

MPN works by applying AI, in the form of cutting-edge deep learning models, to each mines’ production logs (commonly referred to in industry as PLOD data) and instantly forecasts future performance.

“You don’t need more data, or better data collected from sensors on your fleet, our AI takes care of that. Even if you collect your PLOD data on paper, MPN can get to work – dramatically cutting your time to value. MPN is self-training too, so it adapts to emerging trends to constantly improve forecast accuracy.”

Accuracy inevitably depends on each individual situation but idoba says it is already seeing results within 5% on the quarter for some clients. At one mine site, forecast vs actuals accuracy is within 4% for bogging tonnes and 5% for truck haulage TKMs.

Across a mining operation, idoba says MPN empowers people, removes bias and democratises data so that, whatever their role, site engineers, operation managers and execs can rapidly make data-driven decisions instead of reactively scrambling. They can also focus on strategic mine planning rather than manual recalculations plus answer boardroom questions with confidence and clarity.

“It’s a game-changing tool to help mine operators drive performance. That’s why we’re so excited. Deploying to a dozen underground sites – from Western Australia to Queensland, producing gold, copper, nickel and cobalt – is a big deal. Doing it all – from initial onboarding and training in just 15 minutes, to fully connected, live and adding value at every site – in just four weeks is a huge project.”

 

Thiess makes history at Pembroke Resources’ Olive Downs with Cat auto trucks and drills

Automation, Bulk handling, Coal technology, Equipment maintenance, Explosives and blasting, Mineral project development, Mining equipment, Mining maintenance, Mining services, Mining techniques

Thiess says it has made history at Pembroke Resources’ Olive Downs Complex making it the world’s first mining operation to deploy Cat® MineStar™ Command for hauling and Command for drilling solutions simultaneously.

Thiess recently commenced fully autonomous hauling and drilling operations at the Olive Downs metcoal operations from a purpose-built facility on site. This includes deploying 21 haul trucks and three drills fitted with autonomous technology. Additionally, Thiess has established a private LTE network on Pembroke’s onsite communication infrastructure, enabling the safe operation of more than 85 connected assets within the autonomous operating zone.

Thiess Head of Autonomy and Operations Technology Trent Smith said: “We’re pleased to achieve this milestone in collaboration with Pembroke Resources, Hastings Deering and Caterpillar and remain committed to operating the Olive Downs Complex to a global standard.

“This achievement also highlights Thiess’ ability to safely and efficiently transition from a greenfield site to a fully autonomous operation within 18 months, including exceeding our target of 6,500 annualised hours within two months of kicking off autonomous hauling operations.”

The start of autonomous operations is also anticipated to enhance sustainability efforts for Thiess and Pembroke Resources, through skill development, lowered diesel consumption and prolonged life of consumable components.

Pembroke Resources CEO Barry Tudor said: “With a dedication to achieving cleaner, more energy-efficient operations, Thiess, in collaboration with Hastings Deering and Caterpillar, is an ideal partner for Pembroke Resources as we seek to lower emissions. This achievement is a major step towards the goals of a sustainable autonomous mining solution and builds on our already strong environmental practices.”

Thiess has upskilled more than 280 team members to support the delivery of autonomous operations at the Olive Downs Complex to enable improvements in safety, operating hours, cycle efficiency and cost.

At full capacity, this includes the operation of 15 autonomous Cat 794 AC trucks, six autonomous Cat 793F trucks and three autonomous Cat MD6310 drills.

Hastings Deering Executive General Manager – Resources Industries Jason Smith said: “The results of autonomous operations are game-changing. Workers are safer, machines move more efficiently, and operations run more consistently and productively. Already we’re seeing these benefits at the Olive Downs Complex with zero autonomous related incidents and increased effective hours.”

First of Liebherr T 264 mining trucks deploy to Fortescue’s Eliwana mine ahead of battery conversion

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

This week Fortescue celebrated the launch of the first 240 t class Liebherr Mining T 264 trucks at its Eliwana iron ore mining site. This incoming fleet of haul trucks will be the first to be converted to Fortescue’s in-house battery solution developed by WAE, a key step in its green fleet transition as it works towards its Real Zero by 2030 strategy. The trucks are also autonomous ready.

The aim is Real Zero terrestrial emissions (scope 1 and 2) across Fortescue iron ore operations by 2030. “Real Zero means no fossil fuels, and where possible, no offsets. Offsets must only be used as a temporary solution while the technology or innovation required to completely eliminate fossil fuels is developed.”

These Liebherr trucks represent the latest development in a lot of zero emissions testing and trial work by Fortescue. First in 2021 was a battery-hydrogen fuel cell (FCEV) mining truck using a Terex Unit Rig MT4400 AC electric drive truck informally known as “Europa.” Then came the “Roadrunner” truck in 2022, another MT4400 AC electric drive truck that was converted to all battery operation by Fortescue using WAE’s 15 t, 1.4 MWh battery system – it is already at the Christmas Creek mine site for trials.

The agreement between Fortescue and Liebherr involves a phased supply of T 264 haul trucks for integration with Fortescue’s proprietary-owned battery electric and battery electric-fuel cell electric power systems, into Liebherr’s proprietary-owned base truck. Under the partnership, Fortescue is purchasing a fleet of 120 haul trucks from Liebherr, with delivery aligned to its fleet replacement and sustaining capital expenditure forecast. The commitment represents approximately 45% of the current haul truck fleet at Fortescue’s operations. Truck haulage consumed approximately 200 million litres of diesel in FY21 and accounted for 26% of Fortescue’s Scope 1 emissions.

XCMG strengthens Vale mining cooperation with delivery of XE2000 mining excavator

Bulk handling, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Steel and iron ore

China’s XCMG recently successfully delivered a 200 ton class XE2000 mining excavator to global mining company Vale’s Serra Leste iron ore operations in Brazil, marking the latest strategic cooperation between the two parties. XCMG is already developing a zero emissions grader for XCMG, while 72 t XDR80TE battery electric wide body trucks are already in use at XCMG mines in Brazil and Indonesia. An MOU signed between XCMG and Vale in 2021 also envisaged the delivery of a battery electric 240 ton truck from XCMG.

As the latest generation mining machinery product of XCMG, the OEM says the XE2000 mining excavator has advanced technology and excellent performance and is designed to meet the needs of efficient, safe and sustainable development of modern mining production. Jieshan Zhang, XCMG Overseas Mining Equipment Product Strategy Director: “The delivery of this excavator will further enhance Vale’s competitiveness in the mining field and provide strong support for its pursuit of higher quality and higher output mining production.”

The XE2000 mining excavator XCMG says is known for its excellent digging capabilities and high stability. Its powerful power system and advanced oil control technology enable it to perform well in complex mining environments. At the same time, the equipment’s intelligent design and automated control system “improve the efficiency and safety of operators and reduce the risk of human errors and accidents.”

Double boarding passages on the XE2000 ensure convenient and quick operation and maintnenance, while a 200L grease cylinder and centralised lubrication system guarantee ten days use after one refill. An exhaust gas injection device can automatically discharge dust out of the air filter and reduce daily maintenance time. The 6 m high cab provides the operator good visibility and a comfortable working environment for greater working efficiency. The bucket and bucket rod have stronger digging forces, more adaptable to complicated mining conditions. The electrically controlled positive flow system well matches XCMG’s independently developed control system ensuring smooth digging and loading movements.

In the process of delivering the XE2000 mining excavator, XCMG says it carefully organised a professional team to provide customised solutions for Vale, and through training and after-sales service, ensure that Vale can fully realise the potential of the equipment. Zhang adds: “The successful holding of this delivery ceremony marks the strong cooperation between XCMG Mining Company and Vale in the mining field, injecting new impetus into the joint development of both parties.”