All posts by Paul Moore

BHP rolls out hybrid Normet technology at Olympic Dam

Base metals, Equipment maintenance, Mine shafts and equipment, Mine ventilation, Mining consumables, Mining equipment, Mining services, Sustainable mining

BHP has announced that it has a new low emissions equipment trial underway at the Olympic Dam copper-gold-uranium mine in South Australia. It includes two Normet machines – the Utimec XL 1100 Agitator ED, the first in Australia, and the MF 050 VC Spraymec.

The Utimec machine is built on the new low-emission Normet ElectroDynamic platform – which Normet says combines the best features of its battery-electric Normet SmartDrive platform and state-of-the-art low-emission engine technology. The architecture “allows for increased payload capacity with astonishingly compact outer dimensions while also ensuring superior driving dynamics, high performance, superb fuel efficiency and less need for maintenance.”

The engine generates electricity, which is then used to drive the electric motors at the axles. This power conversion decouples the engine RPM from the speed of the machine and, consequently, enables optimising it for both best possible fuel economy and performance. The need for a driveshaft and gearboxes are eliminated through driving the externally cooled mining axles directly with permanent magnet motors in a highly efficient direct-drive configuration. This not only renders a low and compact load end design, instant torque and economical electric retardation possible, but also significantly increases component lifetime.

The Spraymec MF 050 VC is an electrohydraulic self-propelled mobile concrete sprayer which can be operated either with electric hydraulic power-pack or with diesel engine. It features a new Normet NSP 30 concrete spraying pump with maximum theoretical concrete output of 27 m3/h with electric operation. “What sets these machines apart is the ability to operate on electricity instead of diesel while spraying,” said David Johnson, Mine Development Olympic Dam.

Ma’aden opts for FLSmidth paste thickening tech for new phosphate mines in Saudi

Bulk handling, Comminution of minerals, Equipment maintenance, Industrial minerals, Mineral processing, Mining services, Sustainable mining

Following a long-standing relationship with Ma’aden, FLSmidth has been chosen to supply the key technologies and services for Ma’aden’s phosphate 3 phase 1 mine site in the Northern Province of Saudi Arabia. The order is valued at approximately DKK 530 million (over US$78 million) and was booked in Q3 2023. The equipment is expected to be fully integrated during 2025.

FLSmidth has partnered with Ma’aden from the onset of the new phosphate mine operations starting with initial laboratory testing of samples retrieved from the ore body in 2019 through to the development of the flowsheet and pilot scale testing. The focus of the collaboration has all along been to ensure that the integrity of the flowsheet is maintained, while ensuring that the technology is well integrated into the overall plant design to deliver best possible performance from the  process plant operations.

With this new order, FLSmidth will supply of all the key equipment associated with the phosphate beneficiation plant as well as technical support services through the design, construction, commissioning and ramp-up phases. The order includes both primary and secondary sizers, apron and HAB feeders, cone crushers, screens, cyclone clusters, ball mills, paste and high-rate thickeners, horizontal belt filter, slurry pumps knife-gate valves and flotation columns.

“We are pleased to collaborate with Ma’aden on this expansion, as this order sets another strong standard for our MissionZero agenda. In particular the incorporation of our paste thickening and dewatering technology at this important mine site plays a key role in reducing emissions and water spend from the beneficiation process,” comments Mikko Keto, CEO FLSmidth.

Dyno Nobel reports record blast with its TITAN bulk emulsion at Caserones

Base metals, Bulk handling, Explosives and blasting, Mining consumables, Mining services

Dyno Nobel was recently part of the largest blast ever performed at the Caserones copper-molybdenum mine and the third largest ever in Chile. The products used in the blast were TITAN DIFFERENTIAL ENERGY bulk emulsion and the DigiShot Plus 4G initiation system. Some 3 Mt of material were successfully blasted.

Lundin Mining Corporation is now the majority owner and operator of Caserones after acquiring 51% of the operating company SCM Minera Lumina Copper Chile earlier this year from JX Nippon Mining & Metals, with the Japanese firm retaining a 49% stake.

With the objective of bringing its DIFFERENTIAL ENERGY technology to the Chilean market, in 2019 Dyno Nobel Explosivos Chile (DNEC)completed an emulsion plant in Coquimbo in Chile’s Fourth Region which started operations in March 2020 with production and sales of its TITAN 1000ΔE and TITAN 5000ΔE explosives for open pit mines followed by the manufacture of TITAN 7000 RU to meet the needs of underground operations. This facility built on Dyno’s first plant in Chile which was set up in 2010, also in Coquimbo, under the name Planta Austral. This facility is for assembly of non-electric detonators (NONEL) and electric detonators (DigiShot Plus). DNEC’s head office is located in the Chilean capital, Santiago.

The Caserones open-pit operation uses 33 haul trucks loaded by a combination of two electric rope shovels, two hydraulic shovels and two large front-end loaders. The process plant consists of a conventional crush, grind and flotation processing with a nominal capacity of 105,000 t/d, producing both copper in concentrates and molybdenum in concentrates, as well as a solvent extraction and electrowinning plant and leaching facilities for processing oxide and low-grade sulphide ore with a production capacity of 34,500 t/y of cathode. In 2022, the concentrator plant produced 109,100 t of copper in concentrate. In addition, 15,001 t of copper cathodes and 3,100 t of molybdenum in concentrate was produced.

Metso collaborates with MPM in Chile to deliver a FIT™ Recrushing plant

Base metals, Comminution of minerals, Mineral processing, Mining services

Metso has developed and supplied a FIT™ Recrushing plant to Mantencion Proyectos Montajes (MPM), a contractor customer located in Chile, which operates the plant for a copper producing end mining customer.

The project kicked off in 2021 when the customer approached us about a need for a new crushing and screening plant. The FIT Recrushing plant capacity had to be able to handle between 400-450 t/h. The application was to help the end customer to boost the SAG mill capacity in the main circuit.

The main challenge from MPM was the delivery time. The FIT Recrushing plant would process hard SAG pebble material and send the product back to the main circuit.  Therefore, the sooner the FIT Recrushing would be in operation, the sooner both MPM and the end producer would start to see the benefits.

There were two additional challenges: the plant was running with a material different from what was originally specified, and the number of steel media balls coming from the SAG mill was much higher than expected. Both were limiting the efficiency of the operation.

“This was a very collaborative effort with the customer. Knowing a holistic view on the challenges they were facing was key to know exactly the optimal solution to recommend,” says Fábio Watanabe, Project Manager, at Metso Brazil.

“The FIT™ station was designed for this pebble crushing application. With the modularity of being able to easily select the crushing and screening equipment required, and quick delivery and installation schedule, the customer was confident with what we recommended,” says Edis Nunes, Manager, Product & Sales Support.

The sustainability benefits were also of interest to the customer. With the FIT stations, due to the modular design, installation was expeditious and minimum welding was required, which helped the customer lower the emissions and create less waste on site. Another distinguishing feature that the customer requested was to have the equipment painted a certain color to promote gender equality. With this, certain components of the plant painted in a pink colour.

“It was amazing to be a part of supporting our customer to promote this area of inclusivity. With this being such a big initiative in South America, it was great to partner with MPM to make this so visible on site,” says Fernando Samanez, VP, Minerals Sales.

Training sessions were applied by Metso experts to MPM operational and key people to understand, plan and follow procedures and instructions applied for the operation and maintenance based on a fully descriptive manual.

“The teamwork between Metso and MPM to achieve a record time for installation, commissioning and start up was an amazing feat,” says Daniel Vega, General Manager at MPM. “Even with the difficulties that were presented to us, such as the COVID pandemic during the development period, we were still able to efficiently coordinate virtually with Metso’s Engineering team in Brazil and Chile. This lead to minimizing engineering, manufacturing and construction time required and ultimately, a very successful result.”

The crushing plant operation during start-up phase faced challenges related to the processing of pebbles containing substantial amount of non-crushable material. The collaborative development of comprehensive studies and subsequent implementation of process adjustments by MPM and Metso were crucial to improve the plant availability and achieve the performance targets, while being able to minimise the delivery time. To overcome these challenges, Metso and MPM say they have firmed up their commitment to deliver exceptional results and maintain a market-leading global presence.

Komatsu’s Operation Guidance Monitor for smaller mines and quarries

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

Away from very large open pit mines Komatsu offers digital solutions for smaller mines and quarries. Operator Guidance Monitor (OGM) it says is a revolutionary tool designed to optimise fleets of rigid dump trucks, and to reduce unit production costs. Its easy-to-use, clear program allows users to set Key Performance Indicator (KPI) targets and adjust operating parameters, to let Komatsu trucks operate in the most efficient way possible.

The OEM states: “OGM is a tool thanks to which operators control and optimise their work in real time. It helps raise and refine their skills, resulting in higher fuel savings and productivity, and increased safety on the jobsite.” Marek Skrzydel, Quarry Manager at Heidelberg Materials says: “This system allows us to analyse data in real time and we can analyse production and discuss the achieved goals by operator on an ongoing basis.”

Customers can quickly set parameters such as payload, planned duration and fuel consumption for each work cycle, idle time, and production (tonnes per hour), target by loading and dumping location. The OGM screen also shows real-time warnings for dangerous operating events, such as excessive speed and sudden braking.

“Thanks to a unique login ID, operators’ performance can be analysed individually. Can-bus data from the machine’s operation are sent automatically, the user has access to them via a webbased dashboard.” The data can be filtered by date, machine, shift, operator and loading and dumping locations.

“Operator guidance monitor is one of the new digital Komatsu solutions to support our customers with their daily quarry operation,” says Wouter Boon, Telematics Specialist at Komatsu Europe. “Operator guidance monitor gives a possibility to set visualised KPI for the operators and follow up and adjust if needed in real time.”

In the back office, target KPIs and event thresholds such as speed limits are set up for each haul road from any remote location. The status of each target can be followed by date, time, shift, or operator. The automatic data acquisition from the machine allows remote reporting of production and event data via the dashboard.

Each operator has his own OGM account. Before starting work, he or she logs directly into the tool’s easy-to-operate 8 in monitor installed inside the cabin. After logging in, the system automatically detects and displays the haul road specific KPI’s on the monitor, according to which the operator adjusts the pace and dynamics of the hauler’s work. Thanks to real-time feedback of operation data, each operator can follow up on individual KPI, as optimal values when loading, transporting, and unloading material.

With parameter values updated in real time, the operator learns how to operate the machine at its best. No input from the operator is required and self-learning is encouraged through this ‘visualisation’ of operation performance. This all results in fuel savings and more efficient production, achieved in the safest way possible. With real time operator alarms for unsafe operation, such as over speeding or sudden braking, job site safety is improved and can be monitored continuously.

MinRes invests in Binding Solutions for its cold-bonded, low energy use iron ore pelletising tech

Mineral commodities, Mineral processing, Mining consumables, Mining services, Steel and iron ore, Sustainable mining

Binding Solutions Ltd, a UK-based metals processing technology company has agreed a major US$17.5 million strategic investment from Mineral Resources Ltd, the leading Australian mining services company with a growing world-class portfolio of mining operations in iron ore and lithium.

BSL says it will use the funds raised to progress the design and construction of a demonstration plant for its innovative technology which it says is capable of producing approximately 50 t per hour of cold-bonded iron ore pellets. BSL’s patented process uses minimal heat and very limited energy to produce high quality pellet or briquette products primarily for the global iron ore and steel industry. T

The technology reduces energy usage and CO2 emissions by up to 95% and 93% respectively compared to traditional induration processes, while also virtually eliminating SOx and NOx. At the same time, BSL’s technology enables reductions in capital investment costs of approximately 90% per 1 Mt/y of production.

BSL and MinRes have also agreed to partner on several initiatives that leverage their respective strengths in technology development and industrial scale materials handling as well as mining services. BSL is considering a number of potential locations for the demonstration plant in the UK, EU and Western Australia and expects to make a decision on site selection by the end of 2023.

MinRes has the right to licence the BSL technology to manufacture cold-bonded pellets from iron ore at its own mines and will become the preferred builder of BSL pellet plants in global markets. MinRes will also provide design and engineering, project management, as well as procurement support for the demonstration plant. MinRes also has the right to appoint a member of the BSL Board of Directors. BSL has recently installed a 2 t per hour pilot plant in its lab at the Materials Processing Institute in Teesside with the intention of running batches for customers.

MinRes Managing Director Chris Ellison said: “BSL’s technology has the potential to rapidly play a major role in the decarbonisation of the global steel industry. MinRes has a track record of using innovation to solve problems and unlock value, and we are excited to partner with BSL to support this innovative technology.”

Julian Lee, CEO of Binding Solutions said: “The partnership with MinRes is a hugely significant step for BSL and further validation of the innovative technology we have developed in the UK. Working with such a respected player in the global mining industry has the potential to rapidly accelerate and de-risk the roll out of our technology by giving us access to the deep expertise and networks that MinRes has built with some of the industry’s largest players over many years. We are now focussed on rapidly progressing plans for our demonstration plant and exploring the potential to apply our technology to lithium, a critical battery material.”

Metso reduces its carbon footprint at Codelco’s Gaby through installing solar panels

Base metals, Mineral processing, Mining services, Power supply for mines, Sustainable mining

Mineral processing solutions major Metso has taken the innovative step of installing its own solar panels to self-supply its electricity consumption for its facilities within Codelco’s Gabriela Mistral copper mine, commonly known as Gaby.

The mine is an example of innovation and sustainability for Chilean mining. The Codelco division located in the Sierra Gorda region, at 2,660 m above sea level, has a fleet of Komatsu 930E autonomous haul trucks, while 20% of its workforce is female and 8% of the staff belong to indigenous groups.

With a production of 109,524 t of fine copper in 2022, the operation has also promoted concrete actions in terms of environmental sustainability. In terms of energy, since 2013 it has covered part of its demand with solar energy thanks to a solar farm at the mine, reducing the use of fossil fuels in the processes of obtaining copper.

Metso says this is why it wanted to reinforce that sustainability strategy by recently inaugurating solar panels with an electricity generation that will cover all the demand of its facilities within the mining unit. The company is providing screen repair services for Gabriela Mistral from October 2018 to June 2025. With the installation of these new photovoltaic panels, Metso will eliminate the use of a stationary diesel generator, eliminating diesel fuel consumption.

Gabriela Mistral’s Operations Manager, Rodrigo Ocedin, commented that this initiative is an important part of Codelco’s divisional and corporate commitment to reduce the impact of greenhouse gases by 70% by 2030 and its Sustainable Development Policy. “We must move forward together with our collaborators to give more value to our process and we hope that more companies join with this type of project.”

Manuel Guzmán, HSEQ Director for South America and Macarena Vallejo, Marketing Director for South America at Metso, who have led these initiatives, explained at the inauguration ceremony of the photovoltaic panels that “with these solar panels, we will reduce our carbon footprint within Gabriela Mistral. For us it is an important milestone, since this and other initiatives in our factories contribute to reaching our goal of reaching zero CO2 emissions by 2030.”

North American Lithium ships first 20,500 t of spodumene concentrate

High tech minerals, Mineral commodities, Mining project news

Piedmont Lithium has announced this week the first commercial shipment of spodumene concentrate produced by North American Lithium (NAL), which is wholly owned by Sayona Quebec, a JV between Piedmont (25%) and Sayona Mining (75%). NAL made the initial 20,500 t shipment of spodumene concentrate via a trading company to international parties.

Piedmont owns a 12% equity interest in Sayona Mining and holds an offtake agreement with the JV to purchase the greater of 113,000 t/y or 50% of SC production at a ceiling price of $900 per metric tonne (SC-6.0%) on a life-of-mine basis. As 2023 is the start-up year for NAL, the parties have agreed that Piedmont’s allocation this year will be the greater of 56,500 t or 50% of 2023 SC production. Sales by the JV to its customers are expected to support JV operating expenses, while sales under the Piedmont Offtake Agreement are planned to fund the company’s broader strategic initiatives, including development of its projects in Tennessee, Ghana, and North Carolina.

Following this initial JV shipment, the parties have agreed that the next two shipments will be to Piedmont customers via the Offtake Agreement. Piedmont expects to deliver 15,000 t to a major international trading company in August 2023; these tons are already produced and stocked at the port. A further 15,000 t are planned for shipment in September-October to LG Chem as the initial component of the four-year, 200,000 t agreement announced in February 2023.

Keith Phillips, President and CEO of Piedmont, said the first set of shipments marks a pivotal period for the company as it continues to transition from a developer to a lithium producer. “For the last seven years, Piedmont Lithium has focused on developing a supply of crucial lithium resources, and we are excited to begin generating revenue and cash flow as we see our plans come to fruition,” said Phillips. “Our products will help our customers meet the requirements of the Inflation Reduction Act and, in turn, the growing demands of the US electric vehicle and battery supply chains.”

Pronto and Whittle study says bigger not better for autonomous mining trucks

Automation, Bulk handling, Mining services

Whittle Consulting, a global expert in integrated strategic planning for the mining industry, and Pronto, the Silicon Valley-based autonomy pioneer producing it says “the world’s leading Autonomous Haulage System,” have released a joint study titled: ‘Autonomous Swarm Haulage: The Economics of Autonomous Haulage with Small Trucks.’ The study, which can be read here, they say presents “a groundbreaking analysis demonstrating that when mining haul trucks are automated, bigger is no longer always better.”

Whittle Consulting modelled the net present value (NPV) of mining a representative copper orebody through four different scenarios, taking into account all facets of the mining value chain over an 18 year life-of-mine (LOM) horizon.

The modelled mine operating with a fleet of autonomous 40-ton haul trucks they say would realise a 31% greater NPV than if the mine were operated with a fleet of manually driven 100-ton off-road haul trucks. Autonomy significantly improved effective utilisation by reducing truck downtime, standby, and operating delays to 5% of availability versus 20% for manual vehicles.

One theorised flaw in the small truck logic was the prospect of traffic congestion caused by the increase in the number of trucks operating in the mine, potentially overcoming the efficiency gains of small truck and automation. In the study’s simulations, such traffic congestion did not materialise, according to Pronto and Whittle Consulting.

“The industry has long debated whether mining economics shift to favour smaller trucks when autonomous,” said Gerald Whittle, CEO, Whittle Consulting. “We’re excited to publish the first rigorous analysis that demonstrates that for most mines – the answer is yes.”

The study also concluded that converting an existing fleet of haul trucks to autonomous operations increased NPV irrespective of truck size. Both conclusions are consistent with industry experience and past studies, including Whittle Consulting’s 2018 Autonomous Haulage Report.

“This study is exciting because it clearly articulates one of the many ways in which autonomy is revolutionising the global economy today,” commented Anthony Levandowski, CEO of Pronto. “The results also illustrate why our strategy has been centered around making automation accessible to the majority of mines and quarries around the world that aren’t running the ultra class trucks that the legacy AHS providers have been focused on.”

Pronto had previously demonstrated the commercial benefits of an AHS capable of scaling down to the smallest trucks and smallest operations, and the Pronto-Whittle study it says substantiates that by identifying the specifics of why small trucks are favoured when autonomous: lower maintenance costs, better fuel efficiency, faster haul speeds, narrower benches/steeper pit walls are possible, and better overall fleet utilisation, among others.

Excelsior Mining announces option agreement with Rio Tinto’s Nuton leaching venture

Base metals, Bulk handling, Mineral exploration, Mineral processing, Mining consumables

Excelsior Mining Corp has entered into an Option Agreement with Nuton LLC, a Rio Tinto venture, to further evaluate the use of its Nuton copper heap leaching technologies at Excelsior’s Johnson Camp mine in Cochise County, Arizona.

Under the agreement, Excelsior remains the operator and Nuton funds Excelsior’s costs associated with a two-stage work program at Johnson Camp. Nuton will provide a US$3 million pre-payment to Excelsior for Stage 1 costs and a payment of US$2 million for an exclusive option to form a joint venture with Excelsior over the Johnson Camp Mine after the completion of Stage 2.

“We are very pleased to be moving Johnson Camp forward with Nuton. With their support and technologies, we have the potential to realise the value of the sulfide resources at Johnson Camp in a way that is both economical and beneficial to the environment. Johnson Camp has the potential to progress towards cash-flow whilst we continue to develop our other assets, including progressing Gunnison towards well-stimulation trials later this year,” comments Stephen Twyerould, President and CEO of Excelsior Mining. “The strength of this agreement is that it allows both Gunnison and Johnson Camp to advance in parallel.”

Rio Tinto has developed the Nuton™ Technologies, an extensive portfolio of advanced copper heap leaching technologies targeted at primary sulphide minerals (including lower grade mineral deposits), which could not otherwise be processed using traditional leaching or sulphide processing technologies. These technologies offer the potential to produce additional copper in a cost-effective manner that has significant environmental benefits and reduces waste from new and ongoing operations.

Under the terms of the Agreement, the Stage 1 work program involves Excelsior completing diamond drilling, permitting activities, detailed engineering, and project execution planning. Nuton will complete mineralogy, predictive modelling, engineering and other test work. Based on the results of the Stage 1 work program, Nuton has the option to proceed to Stage 2. The Stage 1 work program is expected to commence in August and take 6 to 9 months to complete.

If Nuton proceeds to Stage 2, it will make a US$5 million payment to Excelsior for the use of existing infrastructure at the Johnson Camp mine for the Stage 2 work program. Nuton will also be responsible for funding all of Excelsior’s costs associated with Stage 2. The full Stage 2 work program is anticipated to take up to five years but will proceed based on milestones related to engineering and mobilisation, infrastructure and construction, mining, leaching, copper production and post-leach rinsing. Mining is expected to commence in year one. The completion of all milestones would result in full scale commercial production over several years at Johnson Camp utilising Nuton™ Technologies. Revenue from operations will first be used to pay back Stage 2 costs to Nuton and will then be credited to Excelsior’s account.

After the completion of Stage 2, Nuton will have the right to form a joint venture on Johnson Camp per mutually agreeable terms whereby Nuton will hold an initial 49% and Excelsior an initial 51%. The purpose of the joint venture is to continue the development of the Johnson Camp Mine using Nuton™ Technologies. Should Nuton not exercise their joint venture rights, Nuton and Excelsior will discuss in good faith Excelsior’s continued use of the Nuton Technologies at the Johnson Camp Mine subject to certain licensing terms and conditions. The infrastructure arrangement at Johnson Camp under this Agreement are non-exclusive. During Stages 1 and 2, Excelsior may continue to use the Johnson Camp infrastructure for processing Gunnison solutions and other copper sources not related to the Stage 2 work program so long as capacity requirements for the Stage 2 work program are met.