All posts by Paul Moore

Accenture acquires ATI Solutions group to enhance OT offering

Communications in mining, Equipment maintenance, IoT, Mining equipment, Mining services, Mining software

Accenture has acquired ATI Solutions Group (ATI), a Perth-based consulting service provider to the mining, energy and rail industries. ATI will enhance Accenture’s capabilities in West Australia, where specialised digital and industrial talent is in high demand. Terms of the transaction were not disclosed.

ATI Accenture said offers clients “a broad skill set and has experience across a wide range of capital projects. It helps clients automate and remotely run mines and rail networks, set up smart maintenance workflows, analyse data from the field, and optimise their operations. The company excels at implementing operational technology (OT) – which companies use to run assets like mining equipment – and connecting OT to enterprise IT systems. Better IT and OT integration allows companies to identify issues and automate processes in their field operations faster and more efficiently.”

Steven Walsh, Industry X lead for Accenture in Australia and NZ, said: “Digital technology and automation in operations are a pivotal part of how leading asset-intensive companies drive value in their front-line operations. ATI’s long-standing expertise strengthens our capability to support our clients in these critical areas.”

Pete Burns, who leads Accenture’s business in Australia and New Zealand, added: “The acquisition of ATI reflects our ongoing focus and commitment to building our presence in the West Australian market, and delivering total enterprise reinvention to our clients.”

Matt Andrews, Director and Co-Founder, ATI, commented: “By joining Accenture, we will bring new value and scale to our clients and provide new opportunities to our people to grow their careers.”

ATI’s approximately 60 employees and contractors in Perth and other locations across Australia will join Accenture’s digital engineering and manufacturing service, Industry X. Accenture continues to build this service in Australia and New Zealand, having also acquired Perth-based OT service provider Electro 80 in 2021, and grown the team across the market in recent years. Recently, Accenture acquired US infrastructure advisory and management company Anser Advisory to help clients complete their large, long-term infrastructure projects more predictably and efficiently.

Boart Longyear launches new IMPAKT line of drill bits

Mine shafts and equipment, Mining consumables, Mining services

Boart Longyear, the leading provider of drilling equipment and performance tooling, has announced the launch of a new IMPAKT™ line of drill bits. The Rock Tools team at Boart Longyear used advanced computational modelling to identify a deadpool at the centre of traditional bit designs. This deadpool it says results in significant wasted energy due to inefficient flushing.

The solution Boart Longyear argues is its IMPAKT top hammer bit, featuring a patent pending ‘Raceway’ face profile. “Immediately recognisable as unique, the new IMPAKT bit eliminates the deadpool, improving drill string energy transfer and overall drilling performance.”

After development and global third party testing, this design innovation it says has been proven to actively clear cuttings from the entire cutting face. With flushing speeds increased by 25%, the resulting penetration rate has been improved by an average of 18%.

“We were fortunate to work with a major third party customer during development and testing,” says Jeff Hogan, Global Product Line Manager for Rock Tools at Boart Longyear. “Real world trials using a range of OEM drifters demonstrated alignment with our developmental testing and validated our innovation to deliver value for our customers.”

The IMPAKT line of tools will launch with a concise range of bits designed specifically for underground long hole drilling. These bits are available with hemispherical or parabolic carbides in sizes ranging from 64 mm to 89 mm.

Gainwell delivers first shield hauler in Australia to Kestrel Coal

Bulk handling, Coal technology, Metallurgy, Mining equipment, Mining services

Gainwell Engineering has delivered its first shield hauler, a 60 t class SH660 G, to metcoal mining customer Kestrel Coal in Australia. Gainwell’s Australian manufacturing hub, Gainwell Engineering Pacific Pty Ltd is in Gateshead, a suburb of Newcastle, NSW. The manufacturing business headquarters of the company is based in Kolkata, India, while the global business is managed through Gainwell Engineering Global Pte Ltd, Singapore.

In early 2022, Gainwell entered into a technology licensing agreement for underground mining equipment with Caterpillar covering the manufacture of select models of continuous miners, face haulers, roof support carriers (shield haulers), scoops/multi utility vehicles and feeder breakers under the Gainwell brand. This followed an earlier 2018 agreement with Caterpillar to produce highwall miners.

The SH660 was Caterpillar’s heavy capacity shield hauler, designed to carry 60 t on the cookie plate. The machine is used for haulage of roof supports and the heavier ancillary components of longwalls. Vehicle dimensions are crucial in underground roadways, so the SH660 was designed to be compact, with a minimum profile and roadway presence.

The Kestrel coal mine is located in Emerald, Queensland. Kestrel is a single longwall mine – the longwall is 415 m wide, and up to 3.5 km long. The operation has a peak production of over 1 Mt a month, utilising 198 shields. Kestrel is a joint venture formed in 2018 between EMR Capital and Adaro Energy (80%) and Mitsui Coal (20%). EMR Capital owns a 52% share and PT Adaro Energy owns 48%.

Cummins approves renewable diesel for all industrial high-horsepower engines

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

Cummins Inc has announced approval of its entire line of diesel high horsepower engines across all ratings for use with unblended paraffinic fuels (EN15940), often referred to as renewable diesel, including hydrotreated vegetable oil (HVO). It states: “Utilising renewable diesels like HVO are shown to reduce net greenhouse gas (GHG) emission by up to 90% compared to conventional diesel, dependent on the exact feedstock and fuel pathway.”

This approval applies to all high-horsepower (19L-95L, V903, ACE) engines for all applications in use across a variety of industries, such as mining, marine, rail, defense and oil & gas. All industrial engines currently in the field can be fuelled with 100% renewable diesel, or any blend of renewable and traditional diesel, with no engine modifications required. Any renewable diesel used must meet the EN15940 standard, as defined by the European Committee for Standardisation (CEN).

“As we work alongside our customers toward a carbon neutral future, bridge solutions like alternative fuels are critical in decarbonising existing equipment,” said Gary Johansen, Vice President, Power Systems Engineering. “Approving unblended renewable diesel use in all high horsepower engines is one more step on our path of continued innovation to help our industrial customers reduce their carbon footprints while upholding performance and reliability standards.”

Prior to this announcement, Cummins allowed up to 25% renewable diesel for high-horsepower engines for industrial applications, as well as up to 100% renewable diesel for the QSK95 engine for rail. Additionally, Cummins was first to market in fourth quarter of 2021 with the approval of 100% renewable diesel use in standby generator sets used in data centres and other key applications.

Technical evaluations of all high-horsepower engines utilising renewable diesel included emissions cycle, performance, transient, fuel consumption testing as well as field testing. “The trials showed that exhaust emissions output continued to be comparable to engines operating on conventional diesel fuel and within established EPA targets with no changes to engine hardware and software.” The trials also showed that, when compared to conventional diesel, the use of renewable diesel can serve as a drop-in replacement, as well as:

  • Reduce well-to-work greenhouse gas (GHG) emissions up to 90%
  • Reduce tailpipe emissions of particulate matter and smoke up to 50%
  • Experience only ~1-2% power loss
  • Provide no impact to service/maintenance intervals
  • Be stored for longer duration

Cummins high-horsepower engine platforms now approved for unblended HVO include the QSK19, K19, QSK23, QST30, QSK38, K38, QSK45, QSK50, K50, QSK60, QSK78, QSK95, V903 and ACE for all industrial segments. It says operators should contact their local Cummins distributor for more information and the most recent fluids manual.

The company concludes: “This  announcement is a strong example of Cummins’ commitment to advance the company’s current technology to achieve industry-leading emissions reductions. Through Planet 2050, Cummins pledges to address climate change, support communities and use resources wisely.”

XCMG deploys more than 350 methanol powered mining trucks in Xinjiang

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

In the summer in Chinese mines in Xinjiang, high heat conditions of over 40°C and sandstorms are frequent which represent a major test to equipment along with high altitude; with temperatures in the winter dropping to an average of -20°C in January. Even in these conditions, Xugong-headquartered global mining equipment major XCMG says it has been successful in deploying a large fleet of XKT136 wide body extended range methanol powered mining trucks, part of the OEM’s push to use new and greener energy resources.

XCMG states: “​​​Methanol has the characteristics of a high octane rating but with very low emissions. It can reduce hydrocarbon emissions by 40% in the complete combustion state, and greatly clean carbon deposits in the engine and oil scaling in pipes. Compared with the equivalent traditional diesel fuel vehicle, the XKT136 truck can also save more than 35% in energy consumption, representing more than 400,000 yuan [US$55,000] a year.​​​​”

The XKT136 has a dual-motor extended range power generation module and dual-motor drive system allowing it to achieve around-the-clock operation. It has a maximum output power of 1,088 hp, so that the gearbox can operate efficiently without interrupting the automatic shift of power under full working conditions.

The methanol tank capacity is 1,200 L which XCMG says is the largest in the industry​ and can last for over 12 hours. At the same time, it is equipped with an efficient and intelligent energy recovery system, which can maximise the cruising range of the vehicle. XCMG says it is part of a “historic leap” in achieving green mining from standard emissions to near zero emissions and finally zero emissions.

XCMG says despite the climatic extremes, the new methanol mining trucks have achieved excellent performance since deployment in January 2023.​​ ​​​”This truck has performed very well at the operation, with over 95% availability and high transportation efficiency. If it is extended to the whole of Xinjiang, the emission reduction benefits will be obvious.” To date more than 350 units have been deployed.

The OEM adds: “Green intelligence, safety and efficiency have become the requirements of these times for the sustainable development of the mining industry. XCMG will continue to innovate with green development concepts, upgrading of technical solutions, provision of green mining equipment, and striving to make resource extraction more efficient.​”

 

Live xtonomy operational AHS demo on Bell ADT at Steinexpo

Automation, Bulk handling, Industrial minerals, Mining equipment, Mining services, Sustainable mining

xtonomy provides an advanced next-gen autonomous solution for mining and quarrying and argues: “xtonomy’s AI is the only commercially available system that is capable to navigate freely in unstructured and ever-changing environments such as in quarries. This enables autonomy for the first time also in complex dynamic sites and opens the technology to a wide range of customers.”

In a first for mining events, xtonomy is also demonstrating a fully operational AHS live in a quarrying show at this year’s Steinexpo 2023 in Germany, from August 23-26 in cooperation with Germany’s Bell distributor Kiesel GmbH on a Bell B30E 4×4. The event is held in Europe’s largest basalt quarry in Nieder-Ofleiden, which is operated by Mitteldeutsche Hartstein-Industrie AG.

Visitors have been able to observe how the machine operated in full autonomous cycles around the show grounds of the Quarry Vision area. The company told IM: “It was an eye-opener to the industry that AI can be leveraged today to solve the biggest industry challenges such as safety, labour shortage, OEE, cost and ESG factors.”

On the wider market, after many years of development xtonomy adds that its AHS for trucks is now transitioning to full production and is currently being rolled out to several applications. “The xtonomy AHS is designed for smaller truck fleets that may be fully orchestrated by the excavator or loader operator. Although the autonomous trucks automatically follow the excavator position on the bench and adapt queuing position, cusp point and loading position automatically, the operator may adapt all points to facilitate the process if needed.”

No additional personnel is required to supervise the fleet as all underlying processes are fully automated. The system uses robust radar onboard mapping and object detection to continuously perceive the environment and with motion planners that freely plan the best routes and dynamically react to changes as opposed to driving from one fixed point to another on virtual rails.

xtonomy adds: “Furthermore, it handles the interaction of multiple trucks in such unstructured environments. This is only possible through a very high degree of autonomy at highest system levels. Several safety layers guarantee a safe operation with safe radio comms, high-precision GPS, radar and Ultra-Wideband (UWB) localisation. Manned machines may be integrated into the ecosystem for safe interaction in complex scenarios.”

Finally, xtonomy says its autonomy system does not require uninterrupted coverage of high-bandwidth comms throughout the mine-site which dramatically reduces the system implementation effort.

XCMG designed and developed CUMT Nanhu mining satellite launched

Automation, Environmental, IoT, Mine surveying, Mining safety, Mining services, Sustainable mining

China’s XCMG says it is leading the next revolution of mining machinery development with cutting-edge equipment products and advanced workplace technology. On July 23, CUMT Nanhu, China’s first mining satellite, which was jointly designed and developed by XCMG, the China University of Mining and Technology, and Skysight, was successfully launched at the Taiyuan Satellite Launch Center.

The X-Band, sun-synchronous satellite is a co-orbit, multi-means remote sensing satellite constellation combining SAR, optical, and thermal infrared with excellent performance and a long service life. XCMG says it will be applied in the fields of mine exploration and design, mining industry development, intelligent mine operation, geological disaster early warning, safe mining scheduling, mine site slope management, comprehensive utilisation of abandoned pits, and green mine rehabilitation.

XCMG says it has participated in the full design and development process of CUMT Nanhu and will be one of its future users. “The satellite will enable unified planning of personnel, vehicles, and sites to achieve integrated dispatching, command platform visualisation, and intelligent deployment, which will improve the safety level, reduce operation costs, and lower manual input. It will play a key role in constructing safe, intelligent, green, and ecological mines.

“XCMG Mining Machinery focuses on the application of information technologies, including the Internet of Vehicles, the Internet of Things, cloud computing, and big data. We organically converge all operation links from R&D and process, manufacturing and assembly, equipment and application scenarios, market, sales, and services to realize full-cycle management and establish a solid foundation of digital infrastructures that is catalysing the digital transformation of the traditional manufacturing industries,” said Yang Dongsheng, CEO and Chairman of XCMG.

Multotec expands capacity and capability with new modern press installations at mill lining factory

Base metals, Comminution of minerals, Equipment maintenance, Mineral processing, Mining consumables, Mining maintenance, Mining services, Precious metals

Multotec says it has expanded its facilities and capacity of its mill lining factory in Spartan, South Africa, to meet the rising demand, enabling the company to manufacture larger mill liners for clients around the globe. The expansion consists of the installation of three new presses at the factory that will boost manufacturing capacity by 15-20% to meet the demand for larger mill liners, as well the increasingly demand for Multotec’s new integrated mill liners that are replacing steel liners in the market.

Thando Makhoba, Managing Director – Rubber at Multotec, explained that the installation of one new press has already been completed, while the other two will be installed during August this year. The new presses enable Multotec to manufacture larger mill liners, that are between 10 m and 15 m in diameter, whereas previously the company focused on 3 m to 7 m diameter mill liners.

“Most commonly used for platinum and copper applications, the new presses are more modern and offer greater manufacturing capacity, enabling us to produce integrated mill liners – consisting of lifter bars and shell or grate plates – as one piece. Previously, these components were manufactured separately and then installed at a customer’s site, which involved a considerable amount of time,” says Makhoba. “Because we can now produce mill liners as a single unit that is then installed at a mine, it cuts down installation time by at least 24 hours, thus reducing plant downtime and saving clients’ time and money.”

Makhoba says that the growth in demand for mill liners, which prompted the installation of the new presses, was twofold. On the one hand, Multotec benefitted from winning the business of several competitors who have either left South Africa or have scaled down their local manufacturing capacity. On the other, the company has also seen a huge increase in demand for its integrated rubber liners, which are replacing steel mill liners in the market.

Another important feature of the new presses is that they are much safer, as this modern equipment allows operators to have less physical engagement with the machine during production. “The new presses come with a digital Manufacturing Execution System (MES) enabling the operator to log in on an app and monitor what the machine is producing via live data, that shows what is being produced, whether a specific press is running or not and how much capacity a particular machine has available,” says Makhoba.

He adds: “Because of the digital MES, there is no need to print job cards anymore, as all the specifications are displayed on the user interface. This plays well into our push towards a paperless shop floor. Furthermore, as part of our commitment to continuous improvement, we have employed a specialist who is an industrial engineer and is very well versed in lean manufacturing principles. Currently, we are also looking for new production and quality engineers, who will be on the factory floor to train our operators on the new technology.”

“With the installation of the new presses, our mill lining factory has become more efficient and we are able to manufacture increasingly bigger mill liners. Ultimately, we don’t provide mill liners, but rather provide solutions,” Makhoba concludes.

Komatsu’s 4800XPC starts to bed in

Bulk handling, Environmental, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, Precious metals, Sustainable mining

Designing, building and launching the next generation of the world’s largest mining equipment represents huge commitment, cost and risk. Komatsu Mining took that step in 2013 when it launched the P&H 4800XPC AC – then and now the world’s largest electric mining rope shovel with a 135 ton payload, designed to three pass load 400 ton ultra-class haul trucks. The design leveraged new Adaptive Controls technology with ultra-class machine structures to enable the larger payload and increase efficiencies.

The shovel is capable of up to 9,000 t/h with other attributes including very robust machine structures and systems such as a wider boom and handle, a new dipper with a higher weight to payload ratio and a new modular counterweight system. The first unit was deployed to Teck’s Fording River coal operation in British Columbia, Canada in 2019 following detailed analysis to understand the potential ripple effect that increased production might have across the mine site.

Specifically, data was collected and assessed to determine how significant gains in shovel productivity might affect the truck allocation, life-of-mine planning and ongoing maintenance. And it has performed very well there working with the 400 ton 980E, displaying high productivity with high availability.

Since then, there has been no news of the 4800XPC AC until now – IM can report that the second unit of the shovel will be going to Anglo American Platinum’s Mogalakwena platinum mine in Limpopo Province, South Africa in 2024. Beyond that a larger order for multiple 4800XPC units has also been placed by a Tier 1 copper miner – on which more details will emerge in the coming months.

Back to the unit for Mogalakwena, first off, how did this come about? The mine’s existing large shovel is a Chinese TYHI WK-55 shovel which restarted operations in June 2023 after an extensive upgrade and partial rebuild to increase its performance levels. This machine has been operating at the mine for a number of years but in 2021 Anglo American also began looking for a second large shovel to help meet the needs of its ongoing expansion project.

Initially discussions with Komatsu centred on the 4100XPC AC – this unit weighs 1,500 t and has a payload of 109 t so is more than capable of three pass loading the mine’s 321 t class Komatsu 930E trucks. The 4100XPC would be able to produce around 6,000 t/h with a 930E truck fleet.

But Komatsu South Africa had a novel solution to handle the challenging hard rock mine conditions at Mogalakwena – why not deploy the 4800XPC instead, and take advantage of its considerable extra power – 20% more – but with a scaled down 4100XPC sized dipper to achieve a 7,400 t/h production rate?

Essentially it is still three pass loading the 930Es – but doing so faster with better dig performance. So the higher initial cost is quickly justified in this application. An order for the machine was placed in March 2022 after detailed simulations and TCO determinations, with handover of the units – the second 4800XPC ever built, the first outside North America and first in Africa, is due in April 2024.

And these were not the only considerations in Anglo American Platinum opting for the 4800XPC AC. Charl Coetzer, Strategic Account Manager, Mining at Komatsu South Africa added to IM: “The 4800XPC AC leverages new Adaptive Controls technology with optimised machine structures to enable its larger payload and increase efficiencies. Adaptive Controls is a series of control functions that optimise shovel power usage in different phases of the dig cycle ie crowd, hoist and swing, leading to improved shovel performance while lessening the effect of operating impacts on the machine. Adaptive Controls combined with a stable, optimised structural platform in conjunction with efficient sight lines and refined ergonomics contribute to improved operator effectiveness and reduced operator fatigue. Through the application of innovative engineering and advanced technologies, Komatsu has designed the 4800XPC to be the industry’s most productive electric mining shovel.”

He adds: “The need for the new shovel was a direct requirement due to the mine’s ongoing expansion. The shovel will load ore and waste, but its main focus initially will be on waste. The major factor was the higher production rates available from the 4800XPC shovel, especially with the down-sized dipper. The digging conditions at Mogalakwena are very challenging, due to the nature of ore bodies and formations found in the region.”

Going forward the future for the 4800XPC AC seems bright – in recent months and years large commitments have been made worldwide for new electric drive 400 ton class truck fleets, especially in Latin America, plus Komatsu has just launched its highest powered truck to date – the 980E-5SE equipped with a Cummins QSK95 4,400 hp engine.

Siemens agrees to acquire fast charging specialist Heliox

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

Siemens AG has signed an agreement to acquire Heliox, a Netherlands-based technology leader in fast charging solutions, serving e-Bus and e-Truck fleets and passenger vehicles. It said the acquisition will complement Siemens’ existing eMobility charging portfolio, adding products and solutions for DC fast-charging focused on eBus and eTruck fleets.

Heliox’s portfolio will also extend Siemens’ market reach, primarily in Europe and North America, while improving capabilities in power electronics. The transaction is subject to customary regulatory approval. “This is an important milestone that adds value to our fast-growing eMobility charging business. In addition to expanding our offering, we see digitalisation and software potential with regard to energy and depot management and services,” said Matthias Rebellius, Member of the Managing Board of Siemens AG and CEO of Smart Infrastructure.

Siemens eMobility is part of Siemens Smart Infrastructure. It offers IoT-enabled hardware, software and services for AC and DC charging from 11 to 300 kW for a broad range of applications. Headquartered in the Netherlands, Heliox employs around 330 people. Siemens is acquiring the company from private equity firm Waterland and an entity owned by a group of employees and individual shareholders.

While Siemens has combined its business activities in the areas of low- to high-voltage motors, geared motors, medium-voltage converters and motor spindles into the spin-off company Innomotics, trolley-assist technology and infrastructure come under Siemens Mobility along with solutions for rail. Siemens eMobility on the other hand offers electric vehicle charging solutions for numerous applications.

In 2022, Shell named Heliox as part of its consortium to create electrification solutions for mining sites along with Skeleton Technologies, Microvast, Staubli, Carnegie Robotics, Spirae, Alliance Automation and Worley. Heliox, Staubli, and Damen have already collaborated to design and develop a new integrated charging system for ferry port terminals. In May 2023, Cummins and Heliox also announced the signing of a written agreement to provide both the sale and service of EV chargers in North America.