All posts by Paul Moore

Aeris Resources adds Jameson Cell technology at Tritton Copper operation

Base metals, Mineral processing, Mining consumables, Mining services

Aeris Resources says it is always looking for ways to improve the quality of its concentrate and recently its processing teams at its Tritton Copper Operations near the towns of Nyngan and Cobar in central New South Wales had a visit from Glencore Technology to install Jameson Cell technology at the mill.

Tritton’s Processing Manager Jamie Barrow said: “The Jameson Cell increases the copper content of our concentrate by creating small bubbles, but not too small to create operational problems. The fine bubbles are mixed with our slurry at high intensity – this all leads to better particle attachment. The bubbles are then washed to remove unwanted rock, increasing the percentage of copper in the remaining slurry.”

Glencore Technology told for the IM October edition with a focus on flotation that the Jameson Cell has continued to evolve so that operations can better adapt to lower grade ores, larger volumes of throughput with less energy and smaller footprints.

The Jameson Cell’s continued evolution in the last two years it says has created the largest boom in Jameson Cells since the coal boom of the 1990s. In the first half of 2023, alone, 18 units were sold. The Americas, in particular, are discovering the Jameson Cell as a major source of flowsheet improvements and embracing the technology in all duties including full circuits.

First Quantum contracts MESC for new copper off-gas recovery sulphuric acid plant at Kansanshi

Base metals, Environmental, Metallurgy, Sustainable mining

Global copper company First Quantum Minerals Ltd has contracted with MECS Inc, a subsidiary of Elessent Clean Technologies, for the Kansanshi Smelter Expansion at the Kansanshi Mine in Solwezi, Zambia. The MECS scope will include a redesign of the existing sulphur-burning sulphuric acid plant into a copper smelter off-gas recovery sulphuric acid plant.

This transition to a copper smelter off-gas recovery acid plant will enable First Quantum to reduce emissions from the existing copper smelter, increase production at the mine, and supply more copper to the global market which will enable the adoption of greener technologies.

“The expansion of the Kansanshi Mine and transition to a smelter off-gas recovery sulphuric acid plant is an integral step to the extended life of the mining operation. It was important for Kansanshi and First Quantum to embark on this expansion by using environmentally sound practices, and MECS is honoured to play a part in this project. The MECS technology, products and equipment used in the plant’s design are world-class and will ensure their commitment to sustainability and social responsibility are met,” said Brian Blair, MECS Global Licensing Manager, Elessent.

The MECS sulphuric acid design for First Quantum incorporates state-of-the-art products and technologies, such as MECS catalyst for low emissions and high conversion, Brink mist eliminators for superior mist elimination and ZeCor alloy towers, ZeCor pump tank and UniFlo acid distributor technology for operational reliability and efficiency. The sulphuric acid plant conversion will also facilitate increased capacity for First Quantum to better serve their clients, as well as benefit the region by contributing to a more competitive and cleaner global supply chain of copper and gold.

“Supporting the Kansanshi Smelter Expansion with First Quantum and the Kansanshi Mine has been an exciting opportunity. Not only is MECS helping to extend the life of the mine and optimise operations, but we are also in a unique position to help make a tremendously positive impact on the environment by helping reduce emissions,” said Eli Ben-Shoshan, CEO, Elessent.

Startup of the Kansanshi Smelter Expansion at the mine site in Solwezi, Zambia is expected to take place in 2025. The MECS sulphuric acid technology has been in use for nearly a century in the phosphate fertiliser, non-ferrous metals (leaching & smelting), oil refining and general chemical industries. MECS technologies feature breakthrough solutions, many of which have revolutionised the performance, quality and cost-effectiveness of customer operations. They include MECS heat recovery systems (HRS), MECS SolvR regenerative SO2 scrubbing and MECS MAX3 sulphuric acid production technology.

Integrated into these MECS technologies are proven specialty products such as catalysts, Brink mist eliminators, DynaWave scrubbers, ZeCor corrosion resistant alloy products, and acid coolers all of which are specifically designed for the most demanding operating environments. Marketed by Elessent Clean Technologies, the MECS technology it says is the world-leading sulphuric acid production technology with more than 1,000 sulphuric acid plant licenses and projects.

Vale on key Northern System investments for the future plus automation progress

Automation, Bulk handling, Comminution of minerals, Environmental, Equipment maintenance, IoT, Mineral commodities, Mining consumables, Mining equipment, Mining maintenance, Mining services, Steel and iron ore

Global iron ore and base metals mining major Vale recently gave its 2023 XXIII Investor and Analyst Tour of its Northern System operations, which is its high volume iron ore hub in the state of Pará, Brazil and which includes three main mining areas: Serra Norte, Serra Leste, and S11D. It also includes its Morro do Azul manganese operations. The presentation was given on September 5 by Marcello Spinelli, EVP Iron Ore Solutions; Carlos Medeiros, EVP Operations; and Gustavo Pimenta, CFO. Long term Vale wants to ensure its premium iron ore portfolio can support the transition to net-zero emission steelmaking.

At Serra Norte, the world’s largest iron ore mining area, the N4W, N4E, N5 and Morro1 mines are currently operating – 12 open pits in total – generally referred to together as the Carajas mining complex, with N3 due to come online in 2025 and beyond that N1/N2 after 2030. Serra Norte produces 140 Mt/y and is distinct from the other two Northern System mining areas in Para – Carajas Serra Sul or S11D, one of the world’s largest in-pit crushing and conveying mines with four separate truckless systems, and Serra Leste in the municipality of Curionopolis. IM recently got some additional direct insight into the major mining related investments Vale is making at S11D, as well as an update on its automation progress both at its Northern System operations but also elsewhere such as at Brucutu and Itabira mines in its Southeastern System.

At Carajas Serra Sul (S11D) capacity is now 90 Mt/y but a major expansion is underway known as Serra Sul 120, referring to the fact that the project will see production reach 120 Mt/y by 2026. Work has now reached 51% physical progress. The project consists of the opening of new mining areas with the installation of a semi-mobile crusher in Area 5, the implementation of new processing lines, the expansion of storage areas and mine equipment, the expansion of the maintenance workshop, as well as other new buildings and works. The project also includes the duplication of the long-distance belt conveyor, parallel to the current one and with the same capacity. With a length of 9 km, the conveyor is responsible for transporting iron ore from the mine to the plant, given that it was built in an area outside the Carajás National Forest, and ensures less interference with the environment. The total investment for Serra Sul 120 stands at about US$1.5 billion.

With a separate investment of US$755 million, the Compact Crusher Project at S11D will enable the processing of various minerals, including harder jaspilite and transition material. The scope involves the implementation of primary crushing, secondary crushing and a belt conveyor system with a capacity of 45 Mt/y. In addition to mine equipment, support facilities, new substations and a drainage system. An investment in maintaining the existing operation, the project for now is 13% complete and when finished will give S11D more flexibility and should be operational in H2 2026. Jaspilite is a hard rock from the Carajas formation containing bands of jasper and iron minerals with 42% average Fe and 36% average SiO2. It is a challenge due to its high abrasiveness and compressive strength.

On autonomous fleet progress, Vale has reached 87 autonomous equipment units in operation, of which 82 are in Brazil. This includes 14 Caterpillar haul trucks in Brucutu and 14 Komatsu haul trucks in Carajas. The Carajas trucks are Komatsu 930E-ATs using its FrontRunner technology & Modular DISPATCH fleet management system while the Brucutu units are Caterpillar 793F CMD models using Command for hauling, part of its MineStar™ suite of technology. Onto drill rigs, and it now has 13 auto drilling rigs in Itabira, two in Brucutu and eight in Carajas. These are mainly a mix of existing Epiroc and Caterpillar drills that have been retrofitted using FLANDERS ARDVARC technology. In addition, Vale has 18 autonomously operated stockyard machines in Sao Luis and 13 in Carajas. There are also five autonomous stockyard machines in operation in Malaysia. These are mainly rail-mounted bucketwheel stacker-reclaimers.

A final note on mining trucks and Vale’s decarbonisation strategy. The miner was originally looking at deploying a trolley assist line in Carajas on which initial installation had been earmarked for 2023 – however – the company told IM that its outlook has now changed and that it is  instead focused on developing alternative fuels for its mines and railways, such as green ammonia for locomotives and ethanol for haul trucks, as well as testing electric batteries for smaller equipment units.

Metso expands process piloting capabilities in Finland to meet the needs of the battery industry

High tech minerals, Industrial minerals, Mineral processing, Mining services

Metso has modernised its pilot facility at Metso Research Center in Pori, Finland, with expanded capabilities for lithium hydroxide (LiOH) and other battery chemicals process testing. The unique pilot line serves mining and battery industry customers processing battery minerals. In connection with the expansion, Metso has also opened a battery materials precursor (pCAM) pilot plant, available now for customer trials.

“Pilot run requests for battery minerals like lithium, nickel and cobalt have increased significantly during the last three years. Currently, we are working on several battery black mass recycling and precursor projects and have several lithium and other battery chemicals project pilots on our laboratory schedule,” says Janne Karonen, Director for Hydrometallurgical Research & Development at Metso.

Process simulations are essential in the piloting phase, supporting process and equipment design, training and plant operation. For this purpose, Metso uses its unique metallurgical digital twin Geminex™, which is based on the company’s proprietary HSC-Sim software for predictive process simulations. Pilot plant and real-time plant data enrich the simulation model to accurately predict plant behavior.

Metso has developed sustainable hard rock lithium soda leaching technologies for 20 years already. The pilot facility expansion it says “complements Metso’s frontrunning piloting capabilities for minerals processing and metals refining, enabling minerals and battery industry customers to have end-to-end testing, piloting services and technology and equipment deliveries from one supplier.”

Metso’s expertise in battery minerals covers the extraction of lithium from brines and pegmatite ores up to battery-grade lithium salts. These patented processes are designed to meet the needs for high-end lithium-ion battery chemicals production. Metso can provide sustainable technology and equipment for the entire lithium, nickel and cobalt production chain – from the mine to battery materials and black mass recycling – with project scopes ranging from equipment packages to plant deliveries.

Orica and Fertiberia sign MoU on low-carbon Technical Ammonium Nitrate

Environmental, Explosives and blasting, Mining consumables, Mining services, Sustainable mining

Orica and Fertiberia have announced a collaboration to bring low-carbon Technical Ammonium Nitrate (TAN) to customers interested in sustainable blasting solutions in the region. This innovative approach is part of both organisations’ commitment to utilising and developing cleaner alternative products and supporting the energy transition, together.

At the EFEE conference in Dublin, Orica and Fertiberia signed a memorandum of understanding to work together to explore solutions to bring low-carbon TAN, produced by Fertiberia in a pioneering way with green hydrogen to replace natural gas, to the mining and civil infrastructure markets across Europe, Middle East, and Africa. The collaboration aligns with both organisations’ net zero sustainability ambitions, and wide-ranging customer benefits are expected to be realised through two leading players in their respective industries working together.

Across its various uses, the demand for TAN is expected to continue to grow steadily into the future. Low carbon TAN has the potential to transform the industry, as it provides a more sustainable and efficient solution to traditional TAN.

Javier Goñi, CEO of Fertiberia, commented: “This is a unique collaboration in Europe. We are the first company to produce low-carbon TAN on an industrial scale from green hydrogen – instead of natural gas – in Europe and the world. The collaboration with Orica shows us that we are on the right track to lead an initiative that demonstrates nowadays what the industry of the future will look like. Our collaboration will be an important development in the worldwide effort to become as sustainable as possible.”

Orica President for Europe, Middle East and Africa James Bonnor said: “This is another step towards achieving our sustainability goals and collaborating for progress with like-minded organisations. For the first time, low-carbon TAN for use in the mining and civil infrastructure industries will ensure operations are more sustainable into the future, and we’re excited for this next chapter and supporting our customers overall ESG goals. We believe the combination of technology, decarbonisation, and sustainability will drive the next phase of growth for Orica and the entire industry.”

Komatsu expands national field services for North America mining customers

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

As Komatsu continues to enhance offerings for mining customers in North America, it has announced that it is acquiring certain assets of Matfield Machining to support the growth of its national field service teams, which support mining operations at customer sites throughout the United States and Canada.

Assets acquired through this purchase will include a 14-acre site including a shop and warehouse in Safford, Arizona, US, which will serve as the hub for Komatsu’s US National Field Service team, as well as equipment to expand the team’s milling and machining capabilities. Komatsu anticipates hiring the former Matfield employees to help expand the service team.

The National Field Service team of experienced product experts facilitates planning and performs assembly of new machines and major overhauls of existing machines. This team leverages its broad experience base and standard work practices to optimise major projects, enabling Komatsu branches to better support the daily needs of its customers.

“The asset purchase will expand the capabilities of our National Field Service team to provide mining customers a full-service, turnkey offering for major equipment rebuilds and field work,” said Josh Wagner, VP and GM of North America mining distribution for Komatsu. “Acquiring these heavy machining assets and adding skilled operators and technicians will fulfil that need.”

The enhanced team will be available to service large mining equipment in the US including electric and hydraulic shovels, electric drive trucks, drills, electric wheel loaders, mechanical drive trucks, large format dozers and support equipment. The closing date of the purchase is anticipated for mid-October 2023.

Largest BEV underground mining truck begins trials at Sunrise Dam

Bulk handling, Environmental, Equipment maintenance, Mine shafts and equipment, Mining consumables, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Precious metals, Sustainable mining

A three-party agreement between AngloGold Ashanti, Barminco and Sandvik has resulted in Australia being the testing ground for Sandvik TH665B, the largest battery-electric underground mining truck. Western Australia’s Sunrise Dam mine is hosting the world-first trial as the Sandvik TH665B is put to work in Australian conditions. 

Under an agreement between mine owner AngloGold Ashanti, hard rock underground contract miner Barminco and Sandvik, the gold operation near Laverton began trialing the prototype 65-metric-ton Sandvik vehicle on September 14 – with the wider industry keeping a close eye on the results. As well as producing zero diesel emissions underground and generating 80% less heat, the Sandvik TH665B is expected to be up to 25% faster on a 1:7 ramp than regular diesel trucks. 

Darren Kwok, Head of Electrification and Technology for Barminco’s parent company Perenti, said he is excited to see just what the new Sandvik BEV can achieve. “As a business we are focused on how we can support our clients to decarbonise their mines and trialling equipment to support this is a critical part of our strategy,” he said. “Battery-electric vehicles (BEVs) not only have the potential to lower carbon emissions, they can also improve the underground environment for mine workers and boost the efficiency of operations. We’re extremely pleased that the first Sandvik TH665B to be built has come to Sunrise Dam for real world trials with us and AngloGold Ashanti. With the longer haul ramps and the harsh Australian operating conditions, it will be put to the test. We’re looking forward to trialling the Sandvik TH665B and putting it through its paces.”

Andrew Dawson, Business Line Manager for Load and Haul at Sandvik, added: “We’re delighted to be working with AngloGold Ashanti and Barminco on these trials. The data that we gain from seeing the prototype interacting with Australian conditions will be invaluable as Sandvik continues to develop its battery-electric range and as the Sandvik TH665B moves into commercial production phase.”

The local mining industry got its first glimpse of the Sandvik TH665B when it made its Australian debut at the World Mining Congress in Brisbane, earlier this year. Developed on the back of more than 40 years of electrification experience, the machine uses lithium-iron phosphate (LiFePO4 or LFP) battery technology. The electric driveline delivers 630 kW (858 hp) of continuous power, allowing for high acceleration and shorter cycle times. It produces zero diesel emissions underground and significantly less heat than a comparable conventional truck. 

Sandvik will have four local technicians on site who will support the machine throughout the trial and will provide operator and maintenance training to the teams on site. Kwok said Barminco’s parent company, Perenti, is working in collaboration with a number of partners towards a fully electrified, zero CO2 and zero diesel particulate mine.  

“We believe BEVs like this one have a critical role to play in the electric mines of the future and supporting decarbonisation,” he said. “In this trial, two areas we will be monitoring closely are the ramp speed and the contribution to emissions reduction. Sandvik has said that a fully loaded Sandvik TH665B will be up to 25 percent faster on a 1:7 tramp than a conventional diesel truck – so we will be keen to see that in action.”

Dawson said another key feature of the Sandvik TH665B is battery self-swapping. “It is equipped with AutoSwap, our patented self-swapping system which makes the battery changing process extremely fast and easy, usually taking only three minutes,” he said. “It also allows the operator to stay in the cabin during the process, and there’s no need for major infrastructure like overhead cranes.”

Dawson said Sandvik BEVs offer a range of economic, sustainability and health and safety benefits. From an economic perspective, they can increase productivity and muck pile performance, reduce cycle times, and lower operating costs and ventilation and cooling costs. In terms of sustainability, BEVs can reduce greenhouse gas emissions, increase energy efficiency and promote fuel independence. “Finally, there are major benefits from Sandvik BEVs for operator health and safety thanks to reduced diesel particulates, less noise and vibration and a reduction in heat generation,” he said. 

Both AngloGold Ashanti and Barminco are proactive about increasing mine efficiency, improving conditions and safety for mine staff, and reducing emissions. AngloGold Ashanti’s 2022 Sustainability Report released earlier this year charted a course to achieve net zero Scope 1 and 2 GHG emissions by 2050. The company aims to achieve this with a combination of renewable energy projects, fleet electrification and lower-emission power sources.

NMG on its roadmap to zero-exhaust emission mining with Caterpillar

Environmental, Equipment maintenance, Industrial minerals, Mineral project development, Mining consumables, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Sustainable mining

Since 2021, future graphite mining major Nouveau Monde Graphite (NMG) and Caterpillar, one of the world’s largest manufacturers of construction and mining equipment, have been collaborating to develop, test, and supply an integrated all-electric fleet for the Matawinie mine.

In a recent review of its roadmap to zero-exhaust emission mining, NMG said it and Caterpillar’s technical teams are actively engaged in assessing technology opportunities and planning the all-electric fleet development and testing for the Phase-2 Matawinie mine. The goal is to deploy a complete and integrated zero-exhaust emission solution that covers fleet, infrastructure, and service by the fifth year of commercial operation at Matawinie.

Caterpillar is set to be NMG’s exclusive supplier of heavy mining equipment, supporting the progressive transition from traditional models to Cat® all-electric machines as they become available. The agreement encompasses machines such as hydraulic excavators, mining trucks, wheel loaders, dozers, and motor graders, but also charging and energy storage infrastructure as well as equipment maintenance services.

Moreover, NMG and Caterpillar are advancing commercial discussions targeting NMG’s active anode material. A full circular value chain could be established whereas NMG would supply carbon-neutral graphite materials to Caterpillar for the development of its secure, resilient, and sustainable battery supply chain that would serve to electrify heavy vehicles, including NMG’s Matawinie fleet.

“Not only will we benefit from Caterpillar’s stellar expertise, renowned products, and latest technological developments, but our team will also be at the forefront of the electric revolution in the sector, sharing insight, testing equipment for further optimisation, and providing battery materials to support electrification beyond our mine. This collaboration truly reflects our vision for leadership and unified efforts to advance responsible mining practices and global decarbonisation. I salute the commitment of Denise Johnson, Group President, Resource Industries, and Caterpillar’s team, without which our ambition would not have materialized so efficiently,” said Eric Desaulniers, President & CEO of NMG.

NMG leaders attended Caterpillar’s Sustainability Showcase in February 2023 where new equipment and technologies, such as the battery‑electric Cat® 793 mining truck, were displayed. Through this leading collaboration, NMG says it is directly contributing to the technological advancement of emission-free heavy vehicles.

Coeur mining achieves key milestones in Rochester mine expansion project

Mine operation news, Mineral processing, Mineral project development, Mining project news, Mining techniques, Precious metals

Coeur Mining, Inc has announced the achievement of several critical milestones at its major Rochester expansion project in Nevada, including the production of the first silver and gold ounces. Following a ramp-up period expected to last into early 2024, Rochester is expected to drive a step-change in the company’s overall production levels, cost profile, and cash flow.

Metal production from the new Stage VI leach pad and Merill-Crowe process plant leach began mid-month with initial doré poured September 19. Approximately one-third of the eight million tons of ore on the new pad are currently under leach. The Merrill-Crowe plant is achieving a flow rate of roughly 3,500 gallons per minute of solution. Full ramp-up to commercial production of around 13,000 gpm is expected to be achieved in early 2024.

With the primary gyratory crusher now installed, construction of the new three-stage crushing circuit is now substantially complete. Once fully ramped-up, throughput is expected to average 32 Mt/y, which is approximately 2.5x higher than historical levels, making Rochester one of the world’s largest open pit heap leach operations.

A multi-day test of truck and loading capacity was completed earlier this month to ensure that the mine can support the higher throughput rates associated with the newly-configured Rochester circuit. This test confirmed the mine’s ability to safely support the designed capacity of up to 100,000 t/d in 2023 and up to 132,000 t/d in 2024. Data gathered during the test will be used to refine processes and identify opportunities for additional efficiencies in cycle and load counts.

“The achievement of these three critical milestones marks the beginning of a new growth phase for Coeur,” said Mitchell J. Krebs, President and Chief Executive Officer. “The focus is now shifting to commissioning, ramp-up, and mine optimisation initiatives as well as prioritising several adjacent exploration targets located on Rochester’s prospective 69-square mile land package. Coeur’s project team has overcome numerous challenges over the last three years to arrive at this key inflection point and deserves thanks for their resilience and commitment.”

Innovative new Cat® 785D Water Truck efficiently manages haul road dust by using less water

Automation, Environmental, Equipment maintenance, IoT, Mining consumables, Mining equipment, Mining maintenance, Mining services, Water management

Proper haul road dust management at mine sites is paramount for the health and safety of workers. Built on the proven Cat® 785D truck platform, the new Cat 785D Water Solutions Truck from Caterpillar infuses technology with the Cat Water Delivery System (WDS) to offer a smarter way to maintain haul roads, using less water.

The new 785D water truck solves overwatering and underwatering issues and features an integrated 121,133 l (32,000 gal) Cat branded water tank, complete with spray system, splash guards, fill chute and rock ejectors. Combined with Cat MineStar Edge™ connectivity with both basic and premium plan options to fit site needs, the Cat WDS helps operations manage watering at the site more safely and productively.

Offering a maximum water flow reaching up to 3,785 l/min (1,200 gal/min), the truck’s AutoMode spray controls determine water coverage automatically based on the activated number of heads and truck speed. Manual mode allows the operator to set a constant waterflow rate, regardless of speed. Featuring exclusive variable active spray heads to regulate water spray and flow, the 785D delivers a waterflow rate ranging from 130 to 2,270 l/min (35 to 600 gal/min) per spray head. The spray system automatically controls the head opening to achieve AutoMode coverage or manual mode flow rate.

Exclusive to Cat water trucks, the Cat WDS is integrated into the 785D’s cab. The system continually adjusts waterflow during operation to achieve the desired coverage and flowrate, reducing the risk of accidents due to poor visibility while conserving water. Featuring soft start-ups, the system’s water pump starts and stops automatically when the truck slows or stops to prevent overwatering and poor traction at intersections. The pump automatically turns off when the tank empties to prevent system damage from the pump running dry.

WDS system components include the water cannon, oil cooler, variable displacement pump, hydraulic oil tank, electronic control boxes and hydraulic motor/water pump. Water cannon operation is integrated into the cab’s joystick controls and can be discharged while idling to conserve fuel. It features a maximum flow rate of 4,732 l/min (1,250 gal/min) at high idle and sprays at a maximum distance reaching 61 m (200 ft). Complete with auto shut-off to prevent overfilling, remote tank fill control enables the operator to remain inside the cab during refilling to reduce accidental slips and falls.

Scalable to meet specific site needs, MineStar Edge integrates with the WDS to collect and communicate truck data, so the fleet can be monitored to meet production targets. Collected in real-time, the data includes truck location and utilization, fuel and water levels, volume of distributed water, coverage area, and waterflow rate, among other metrics.

The 785D water truck is built to deliver durable performance in some of the toughest applications around the world. Easy maintenance procedures help to ensure high reliability and long life with low operating costs. Reducing time spent on regular maintenance, easy access to all daily service points simplifies servicing.

The new Cat Water Solutions Truck is fully supported by the extensive Cat dealer network. Including tank and components, the integrated water truck is covered by the Caterpillar factory standard warranty and is eligible for Cat equipment protection plans and customer value agreements. Retrofit kits are available for existing Cat 785D truck platforms in the field.