Tag Archives: ABB

Epiroc whets the electrification appetite for MINExpo 2024

Environmental, Mining equipment, Mining events, Mining services, Power supply for mines, Sustainable mining, , , , , , , , , ,

Less than a month out from MINExpo INTERNATIONAL 2024 in Las Vegas, Jérôme Cloué, Vice President of Electrification for Epiroc, talked up numerous electrification launches/debuts at the show that would go a long way to helping its customers achieve their sustainability targets.

During a visit to Boliden’s Rävliden mine, part of the Kristineberg complex, in in northern Sweden in late August to highlight the Epiroc Minetruck MT42 SG Battery vehicle running on an 800-m trolley test track underground, Cloué said the company was expecting to make many announcements at the show, including some that fit into the “zero carbon” category.

Epiroc, as part of its sustainability goals, has outlined 2025 and 2030 dates for having fossil-free options in place for its underground and surface mining product lines, respectively. Cloué was confident the company would meet these targets, however it is unlikely these will be exclusively battery-electric options – especially at the top end of the surface drilling product line where the company is leveraging cable-electric power for each drill in the Pit Viper series, for instance.

In the meantime, Epiroc is also working with clients on certifying the use of biodiesel in its existing diesel-powered fleet for “immediate” decarbonisation benefits. Cloué said the surface drilling fleet is already compatible with biofuel (HVO100), with the underground load and haul, and drilling fleets set to follow shortly.

The company is also continuing to advance its work on repurposing batteries used in its mining equipment for secondary life applications. Outside of mining, the company has signed a partnership with Renewmic, whereby a battery previously used to power one of Epiroc’s battery-electric vehicles is helping to support and stabilise the Swedish power grid through frequency containment reserve services. Cloué expects to see more of these examples crop up in mining in the future, strengthening the business case for battery-electric machines through an extension of the battery’s working life.

He is also expecting further collaborations such as the one Epiroc highlighted with Boliden and ABB at the Kristineberg operation last week.

“Mining houses and suppliers are realising that the way to accelerate the [electrification] transformation is through collaboration,” he told IM. “We are looking to work with other partners like ABB on future projects.”

ABB set for eMine truck fast charging leap

Environmental, Mining equipment, Mining services, Power supply for mines, Sustainable mining, , , , , ,

ABB is working on a new fast charging solution under its eMine™ ecosystem that will represent a 10-fold increase in capacity compared with its previous 600 kW solution, Nic Beutler, Global eMine Solutions Manager, told IM this week.

Speaking on the sidelines of a trip to Boliden’s Rävliden mine in northern Sweden, Beutler said ABB is extending the capability of eMine FastCharge, explaining the previous solution it showcased in 2021 with MEDATech Engineering and Staubli would be far surpassed by this.

This 600 kW eMine FastCharge charger requires no machine operators to charge up the vehicle. Drivers station their vehicles next to the charger, the FastCharge system senses its presence and then moves the connection pin into position, inserting it into the receptacle and charging the vehicle. The solution was demonstrated on a Western Star 4900XD-e machine that MEDATech’s ALTDRIVE division had retrofitted with a battery (see below).

“What we’re working on is a more than 10-fold increase in charging power from the 600 kW fast charge solution we have previously showcased whilst keeping interoperability and flexibility in mind,” Beutler said.

“The increase in power is representative of how fast the industry has moved in these three years. Where we were once looking at charging battery vehicles in the 100-t-class and below, we’re now looking at supplying charge to vehicles with payloads of 240-280 t with a 6C charge rate.”

The news also comes on the back of Staubli announcing that it would present a charging connection device built for 7.5 MW capacity chargers at MINExpo INTERNATIONAL 2024, in Las Vegas, next month.

While Beutler couldn’t provide further specifics on the exact charging capacity and charge time, he did acknowledge the new fast charger would retain the containerised and modular nature that ABB established for the original 600 kW pilot system.

“There will be more containerised components than what we previously highlighted,” he said.

“It will require a larger footprint and some further application engineering depending on the site conditions, but the modularity element remains to also allow the integration of various manual and automated connection interfaces.”

ABB’s Dittakavi looks forward to more Real Progress with eMine ecosystem

Automation, Environmental, Mining equipment, Power supply for mines, Sustainable mining, , , , , , , , , ,

Three years after the launch of ABB’s eMine™ ecosystem, the results speak for themselves: six operational trolley systems, a proven fast charging system and numerous project leads in the offing.

Speaking to Ratna Kanth Dittakavi, Global eMine Sales Manager, it is clear the best is still yet to come from the ABB business line.

In the lead-up to a showcase of the company’s underground trolley capabilities at Boliden’s Rävliden mine in northern Sweden this week, Dittakavi was effusive about the company’s prospects – both with OEMs and mining companies.

He was able to share such foresight with numerous eMine consultative studies ongoing.

“We have about a dozen of these studies going on at the moment,” he told IM. “These are all in various stages of development – from prefeasibility study and feasibility, through to engineering.”

Such studies underpin the company’s eMine execution strategy, considering all electrification options for clients and coming up with a tailored, technology-agnostic plan for the company.

ABB’s close ties with a growing number of OEMs and suppliers – it recently signed a collaborative agreement with Komatsu, for example – plus its ability to carry out the majority of electrification, automation and digital work on its own, differentiates this offering from the standard engineering or consulting services available to mining companies or contractors.

“When we come up with an electrification plan for a client, say, 3-5 years ahead of production with 10-15% contingencies, we have to execute it for them,” Dittakavi says. “We don’t devise these studies for someone else to enact them. It goes beyond project execution too, as we’re often supporting the electrical infrastructure on site throughout the life of the mine.”

Ratna Kanth Dittakavi (left) speaking with IM Editor, Dan Gleeson (right) this week

Early engagement is the key to being able to devise these strategies with clients, according to Dittakavi, however when looking at the six trolley projects the company is currently able to talk about – Aitik, Aitik Extension, the second trolley line at Kevitsa, Copper Mountain, Los Pelambres and Rävliden – he admits that the engagement timeframe hasn’t always been consistent.

“Just as we look to come up with a tailored solution for the client depending on their green energy inputs, site-wide infrastructure and load and haul fleet, for example, we also have to work within the constraints of the project timelines we are given,” he says.

Outside of the existing trolley projects the company is working on – including the 800-m test track at Rävliden – ABB is also working on a Robot Automated Connection Device (ACD) to charge future battery-electric trucks. This is planned to be a fully automated interoperable connection device working in tandem with the ABB eMine Fast Charge solution.

The ACD is set to be showcased in some form at next month’s MINExpo INTERNATIONAL 2024 event in Las Vegas IM understands, with a prototype also set to arrive at Boliden’s Aitik mine shortly for testing with a “dummy plug” connection, Jonas Ranggård, Program Manager at Boliden Mines, confirmed this week.

ABB launches Trendex, aims to boost uptime in GMD processing applications

Automation, Comminution of minerals, IoT, Mining equipment, Mining services, Mining software, Sustainable mining, , , ,

ABB has developed a new tool within its ABB Ability™ Predictive Maintenance for Grinding (PMG) platform, designed to make troubleshooting and diagnostics in mineral processing faster and more efficient than ever before, it says.

Traditionally, troubleshooting for grinding technology has required the on-site presence of an engineer or a direct remote access to the plant to identify the source of problems. The all-new cloud-based application named Trendex™ will give users of the platform visibility of fault data in high resolution three seconds before and 1.3 seconds after the event, ABB claims. Trendex works by automatically pushing event files to the cloud and linking event data with the transient records, providing users with near-instant access to operational data from any internet-connected device. It also delivers improved diagnostic and visualisation features to help engineers quickly restore production.

Eliminating the need for a direct remote connection while granting almost immediate access to the event-related signals in high resolution results in significantly faster response times in case of a trip.

In a process such as grinding, where every operational minute counts, unplanned downtime has a significant impact on the business, damaging profitability and productivity. Trendex’s addition to the ABB PMG platform will empower users, regardless of location, with real-time data to identify faults when they happen, pinpoint the root cause quickly and swiftly return operations to full production, ABB says.

ABB says Gearless Mill Drives (GMDs) are vital to efficiently extracting critical minerals, such as copper, from increasingly low ore grades in global locations.

“Unscheduled downtime is a challenge anyone in the mining industry is familiar with,” Carlos Miguez Fernandez, Global Product Manager for Service, Business Line Gearless Mill Drive, ABB, says. “However in recent years, we are seeing systems are under increasing pressure to operate with maximum uptime due to market demands. At ABB, we are constantly looking for ways to improve equipment availability and reduce operational costs – Trendex is the latest development in this ongoing mission. It will enhance our predictive maintenance platform for grinding, providing additional advanced real-time insights.”

The ABB Ability PMG platform is an advanced digital service to maintain, assess and analyse GMD systems. It provides easy access to GMD system parameters and allows visualisation of performance, considering past activity and real-time data and assesses future maintenance requirements. It aims to extend the life time of grinding assets through better use of resources, support non-stop operation and avoid unforeseen downtime. When paired with the Grinding Connect mobile app, users can expect live notifications for precise fleet management and monitoring, ABB says. With the addition of Trendex, users will now be able to get instant access to the event-related signals in high resolution as long as they have an internet connection, anywhere, anytime.

Komatsu and ABB align on interoperable solutions to achieve net-zero operations

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Komatsu and ABB have signed a Strategic Collaboration Agreement to, they say, jointly develop and bring to market integrated solutions that will help move net-zero emissions for heavy industrial machinery a step closer to reality.

The two global leaders will leverage industry expertise and equipment in a bid to create world-class interoperability, ranging from renewable energy generation to fully electrified mining equipment for customers, through an open platform.

Komatsu is known as one of the world’s largest providers of construction and mining machinery and will now link up with global leader ABB for its expertise and technologies for automation and electrification. Both companies bid to accelerate decarbonisation in mining alongside customers, partners and suppliers, enabling continued productivity, energy efficiency and value across the industry.

ABB and Komatsu’s collaboration is geared towards reducing diesel consumption and ultimately eliminating it through the electrification of mine operations.

The companies are developing innovative solutions such as fully-electrified mining machinery and advanced energy management systems. “Innovation is the primary catalyst for ABB and Komatsu to help the industry reach carbon reduction goals,” they said. “Each company will nominate specialists from their teams for a working group to develop recommendations and strategies on what the road to net-zero emission systems for grid to wheel could require.”

Dan Funcannon, Senior Vice President of Surface Haulage for Komatsu, said: “We’re pleased to embark on this collaboration with ABB and are excited to leverage one another’s industry leading products and technological expertise to help move mining operations toward net zero emissions, empowering a sustainable future where people, business and the planet thrive together.”

Joachim Braun, Division President, ABB Process Industries, said: “By working together, we will tackle electrification and make a revolutionary difference to the way mining companies operate their sites in the near future. We recognise the strategic importance of this agreement and believe there will be mutual business benefits and potential technology solutions for the mining market. Collaboration across the industry has already been proven to enable real and faster progress and we look forward to driving what happens next.”

ABB’s Robot Automated Connection Device (ACD) will be featured on the Komatsu MINExpo 2024 booth from September 24 to 26. The Robot ACD is planned to be a fully automated interoperable connection device working in tandem with the ABB eMine™ FastCharge solution for future battery-electric trucks.

From left to right: Dan Funcannon, Senior Vice President of Surface Haulage, Komatsu; Joachim Braun, Division President, ABB Process Industries; Brian Fox, Senior Vice President of Mining Strategy & Innovation, Komatsu; and Max Luedtke, Global Business Line Manager for Mining, ABB Process Industries

ABB identifies mine hoist maintenance strategy to boost annual production

Mine shafts and equipment, Mining equipment, Mining services, ,

ABB has completed a study to benchmark current hoisting maintenance strategies, reporting that, on average, mining companies have the potential to achieve more than a month of additional production time annually by following recommended predictive maintenance strategies.

The benchmark report includes inputs from mining companies across six regions and eight different industry sectors including diamonds, gold, copper and potash, to better understand the state of hoist maintenance strategies around the world. Collaborating with customers, ABB reviewed every key aspect of the hoist system. The results highlighted that mining companies using reactive maintenance could make up a gap of around 15% in availability compared with those already following more proactive approaches.

As ore grades in established sites become depleted while demand for resources grows, the industry is shifting to deeper mining to reach these critical resources. Mine hoists offer the most efficient way to transport heavy loads of ore from the depths, and therefore must operate at the highest possible levels of reliability and productivity, ABB says. The company identified a need for greater standardisation and insight regarding optimal maintenance strategies to help its customers keep mine hoists running.

The value of predictive maintenance was reinforced through this project. Those faced with the highest levels of availability loss had, on average, dedicated less of their maintenance strategy to proactive approach versus reactive (75% and 25%, retrospectively). While periodic maintenance has been implemented across hoist systems, continuous monitoring and assessment were much further behind. Of those surveyed, only 16% had applied continuous predictive monitoring to their mechanical systems, ABB says.

Using these insights, ABB devised its ‘World Class Maintenance Standard’ for hoists. While every mine hoist maintenance system should be designed for the specific requirements of individual hoists, the standard aims to provide mining companies with a baseline for devising the optimal solution for hoist longevity, ABB says. The standard recommends that 90% of maintenance strategy be focused on predictive maintenance to achieve the highest availability levels.

John Manuell, Global Service Manager for Hoisting, ABB Process Industries, says: “Hoists are one of the most expensive and vital assets within a mining operation, so keeping them running optimally is crucial for an effective mining operation. Without a thorough maintenance program, replacing these systems can be costly, risky and time-consuming. We designed the World Class Maintenance Standard to give users a benchmark to design the right program for their assets and reinforce the value, which, when fully utilised, can keep hoists running for several decades. From here, we are devising a framework to simplify maintenance services, which will be available to customers later this year.”

The Electric Mine Consortium calls time as it looks for members to take the electrification lead

Environmental, Mining equipment, Mining services, Power supply for mines, Sustainable mining, , , ,

The Electric Mine Consortium has announced that it will “wrap up” on September 30, four years after the consortium was created with the aim to accelerate progress towards the fully electrified zero CO2 and zero particulates mine.

Made up of a group of leading mining and service companies, the EMC has made significant progress towards achieving this vision and has been a catalyst for significant change within the broader industry, it says.

It was built out of the State of Play report from 2020 simply titled, ‘Electrification’. The State of Play platform was initiated by VCI in partnership with The University of Western Australia; the report was sponsored by The Future Battery Industries Cooperative Research Centre, METS Ignited and Project 412. It covered extensive research aimed to understand the drivers and barriers of mine electrification, identify the key enabling technologies and enable collaboration to accelerate its adoption.

“With electrification kick-started, it has become clear that now is the time to pass the baton on to the individual companies and their leaders to continue the work,” the EMC says.

“The members are well placed to accelerate electrification. Roadmaps have been established and a deep understanding of the available technology is in place. Operational needs have become varied and specialised, so individual companies will drive their own bespoke partnerships and trials with suppliers.”

Given the advancements in technology, and the development of industry capability, it is now feasible to transition to an all-electric fleet, the EMC argues, referencing a white paper released by EMC members Perenti and IGO, along with ABB, in May.

The EMC added: “Members have worked collaboratively over the last few years to raise each other’s maturity levels. It is now up to each company to continue investing in their unique course of electrification.”

The EMC says it leaves a strong legacy of advancing electrification through the member aspirations it has influenced, the initiatives it has developed and the networks it has created.

Over 200 people from participant organisations have been involved in the EMC across many dozens of workshops and meetings annually. CEOs have gathered on multiple occasions to collectively understand the challenges and provide direction, while the EMC has liaised with a wide range of government agencies to help them understand industry needs, particularly in supporting the transition.

Some of the projects the EMC has delivered include:

  • Multiple supplier engagements, such as expressions of interest, to establish member understanding of key technologies across energy storage, energy management and all fleet types;
  • The identification of multiple simulation technologies applicable to mine design, through open-source challenges and supplier engagement, bringing capability to the industry;
  • The development of financial modelling for electric mine design for multiple member assets, demonstrating the electrification business case and design trade-off;
  • Undertaking over 50 member equipment trials across all fleet types, supplemented by an industry first data sharing platform, leading to accelerated equipment adoption;
  • Playing a lead role in progressing shared energy infrastructure in the broader Kalgoorlie Goldfields region; and
  • Introducing carbon measurement trialling resulting in the acceleration of direct tracking of emissions.

Moving forward, EMC companies are committed to continuing the journey through focused collaboration, building on the networks established through the EMC. Members will continue to work with suppliers to develop equipment and progress trials at their sites, according to State of Play. In the coming months members will also communicate how they will continue their electrification plans.

ABB on the final piece of the electrification puzzle

Environmental, Mining equipment, Mining events, Power supply for mines, Sustainable mining, , , , , , , , , ,

Every train, industrial, or transportation vehicle needs a unique traction powertrain for operation, with ABB, through its Traction division, holding a complete and flexible product portfolio that, it says, allows it to build the perfect electrification solution for operators to transition businesses to more sustainable and lower cost operations.

Each of these solutions can be tailored to customer requirements and the operating conditions of each vehicle that it powers, enabling maximum energy efficiency, zero carbon emissions and high reliability.

The company is able to leverage high-tech e-mobility and rail system traction converters, energy storage systems and electric vehicle charging solutions as part of its offering, complementing this with enhanced expertise to help accelerate the transition to all-electric operations.

One project where its impact has been felt is at Nuh Cement in Turkey where ABB is working jointly with the company to convert 10 mainly Euclid/Hitachi dump trucks with an average 160 ton capacity, which have completed their 30-year service life, from diesel engine power to electric.

This is one of the first mining truck battery conversion projects of its kind in the world and will be discussed in more detail during a presentation at The Electric Mine 2024.

Ahead of the event, taking place at the Crown Perth Complex, on May 21-23, we spoke with Fabiana Cavalcante, Head of Mobile e-Power at ABB, to find out more about the offering.

IM: ABB’s Traction division is working within a very competitive landscape when it comes to e-mobility in mining. What would you say are your unique selling points to the industry?

FC: We bring over 130 years of experience in mining electrification, combined with extensive expertise in electrification and charging infrastructure for cars, buses and trucks. This allows us to extend our capabilities to the final piece of the puzzle: electrifying mobile equipment.

Fabiana Cavalcante, Head of Mobile e-Power at ABB

Our journey began by utilising our unique knowledge in rail propulsion systems and adapting it to the harsh environment of mining. Our roots in electrifying the Swiss railway network over a century ago have established us as leaders in sustainable transportation solutions. We have translated this experience to increase energy efficiency, reliability and reduce emissions across rail networks, electric buses and other heavy vehicles. The building blocks of the technology are similar, making for a smooth transition.

Besides this, what truly sets us apart is our capacity to execute customised customer projects. Battery-electric propulsion requires more personalisation compared to diesel, and our history as an independent supplier has equipped us with the skills, mindset and a perfect portfolio of proven base components to adapt quickly and in larger quantities than any other company.

IM: You work with multiple OEMs and solution providers across the globe looking to electrify their operations. Are most of these companies looking to electrify their offerings during a similar timeframe?

FC: Many mining operators have ambitious sustainability targets, aiming to reduce their Scope 1 and 2 emissions by at least 30% by 2030. By 2050, many operators aim to achieve net-zero emissions, and the only path to that is by electrifying their mining vehicle fleets. If every truck in every mine were electrified, we could remove 198,000 tons of CO2 from the atmosphere each day. Mining operators and OEMs recognise the potential to minimise their carbon footprint, and while this transition won’t happen overnight, we’re excited to partner with them and guide them on their electric journey.

IM: How often are you interacting directly with the operators during these types of projects? At this stage, is it often a collaboration between ABB, the OEM and the client?

FC: The level of interaction varies from project to project. In some cases, we have limited direct engagement with the mine operator, while in others, we are heavily involved. A recent example is our collaboration with Boliden and Epiroc, where we worked together to create the first battery-electric trolley truck system for underground mining. This close partnership was crucial to bringing this innovative project to life.

IM: In this regard, how does your work with Nuh Cement on converting its diesel powered fleet to electric power stand out from the work you normally carry out? Why is Nuh Cement able to collaborate directly with ABB on such a project?

FC: Nuh Cement approached us with the goal of converting their existing mining fleet of Euclid/Hitachi dump trucks to electric power and we officially began the project in 2022. We have vast experience in retrofitting vehicles for the rail business and we followed the same approach and procedures for the haul trucks.

The steep ramps with up to 20% gradient required us to pay close attention to ensure that the electric trucks could meet the expected performance and efficiency levels. This involved intense collaboration between both parties to translate simulations into practical, real-world solutions. Working closely with Nuh Cement, we tailored our solutions to fit their specific operational requirements and made sure our technologies aligned with their vision for a sustainable future. We hope many more mine operators will soon start to electrify their fleet and we’re excited to closely partner with them throughout their journey.

IM: Are you able to provide a sneak preview of what you will present at The Electric Mine 2024 in Perth about the Nuh Cement project? How has this project advanced since it was announced back in 2022?

FC: I’m excited to share the results of our groundbreaking collaboration with Nuh Cement at the event. Our partnership led to the successful electrification of a haul truck, demonstrating ABB’s ability to retrofit diesel-powered vehicles into fully electric ones – a milestone with significant implications for the mining industry. This transformation of a 30-year-old vehicle into a net-zero haul truck sets a new standard for sustainable mining practices worldwide.

Additionally, attendees will hear from Nuh Cement’s CEO, Kamil Gökhan Bozkurt, who will provide insights into this key project.

IM: In addition to what you have already discussed above, what can attendees of The Electric Mine 2024 look forward to hearing about next month?

FC: I encourage everyone to visit our team at booth 58 during the conference. Attendees will have the chance to explore our latest technology and innovations, including a preview of our new energy storage system, which offers exceptional lifespan, power and safety. We look forward to seeing you all there!

ABB is a Gold Sponsor of The Electric Mine 2024, with the company having a major indoor display in the exhibition hall. Fabiana Cavalcante will be on stage at the event presenting, ‘Powering progress: ABB and Nuh Cement’s zero emission dump truck’ during Day 1 of the event. Find out more about The Electric Mine 2024 by going to www.theelectricmine.com

ABB and EcoHoist to work on low carbon, low cost vertical material transport solution

Mine shafts and equipment, Mining equipment, Sustainable mining, , , , , ,

ABB and EcoHoist have executed a Memorandum of Understanding (MoU) to collaborate on the development of a vertical material transport solution for underground mines.

The solution combines EcoHoist’s technology with ABB’s technical capability and experience in vertical ore haulage in mining, they say.

The EcoHoist aims to improve on traditional vertical hoisting systems, by substantially reducing the size of the required mine shafts. This reduction in mine shaft size leads to a reduction in capital cost and construction time compared with skip hoist systems, the company says. The EcoHoist operates on electricity and provides the opportunity for mines using conventional diesel powered load and haul fleets to simultaneously cut production costs and decarbonise.

“As mines go deeper underground, and as external pressures to decarbonise mining operations increase, the EcoHoist is a compelling solution,” EcoHoist says.

The collaboration will see experts from both companies contributing to solutions for the future of underground ore haulage systems and provides opportunities for further commercial arrangements. This collaboration aims to expedite EcoHoist’s delivery of a subscale demonstration of the technology, by leveraging ABB’s expertise in engineering and hoist safety systems.

ABB has a strong reputation for delivering solutions for the mining industry, with more than 600 active production and service mine hoists within its global installed base, and EcoHoist hopes this collaboration will accelerate the adoption and deployment of the EcoHoist pilot.

Björn Jonsson – Global Business Line Manager for Hoisting at ABB, said: “The mining industry globally is poised for a sustainability step change and ABB is excited to work with EcoHoist in support of new technologies in this journey.”

Aaron Trueman – Australian Business Line Manager for Hoisting at ABB, added: “No matter the mine in Australia, the challenge is how to get ore out of the ground safely and efficiently with high availability in very remote locations. Hoists are a critical mine asset to achieve this, and novel approaches to ore haulage such as EcoHoist are what the industry needs to deliver minerals essential to modern technology.”

Matthew Forrest – Managing Director of EcoHoist, said: “I look forward to continuing to work with Björn, Aaron and other talented people at ABB. ABB’s proven track record delivering electrical drive, automation and safety systems to the resources industry provides strong synergies with EcoHoist.”

Michael Short – Business Development Engineer at EcoHoist, says the EcoHoist offers an opportunity for mining leaders interested in integrating a low-cost solution into their operation.

“We are now in early conversations with interested mining companies for collaboration projects to trial this innovative technology, aiming to increase production rates while reducing both operating costs and carbon footprint.”

BHP BMA’s Goonyella met coal mine receives ABB electrification upgrade

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Sustainability, employee protection and operational insights are the drivers of a cutting-edge electrification upgrade at BHP BMA’s Goonyella Riverside Mine in Queensland, Australia, ABB says in a recent case study.

At the BHP-Mitsubishi Alliance (BMA) conjoined metallurgical coal mines Goonyella and Riverside in Queensland’s Bowen Basin, Subra Nedunuri, Senior Project Manager, Goonyella Riverside Mines (GRM), is responsible for delivering capital electrical projects without compromising environment, safety, quality, or mining schedules.

When a 43-year-old section of Goonyella Riverside’s power infrastructure became unreliable, Nedunuri began designing an upgrade with ABB capabilities, which protect employees, equipment and the environment, and enable predictive maintenance of 16 pumps critical to the mine’s operation.

Nedunuri said: “A rehabilitation project to move earth from one side of the mine to the other may cost $20 million, but in contrast this $3 million electrical upgrade can save lives and hundreds of millions of dollars in downtime.”

To power the coal wash treatment plant, pumps are used to direct water for reuse or into tailing dams: without them the plant can’t operate. In the past, the now obsolete electrical system communicated only three states of condition for the pumps operation – “On”, “Off” or “Fault”. The system had no protection against arc flash incidents (explosive releases of energy when an electrical arc travels through ionised air to ground or another part of the electrical system), which endanger the lives of service technicians and nearby workers.

For the upgrade, BMA wanted not only the safest switchgear to protect its employees, but a human-machine interface (HMI) that would enable remote and on-site monitoring and control of the electrical system and pumps around the clock.

ABB’s system-integrated Ultra-Fast Earthing Switches (UFES) formed the basis of GRM’s upgrade with safety, and protection of the people within the vicinity of the equipment in mind.

“The switch is installed into the panel to prevent an arc flash, if it occurs it will be detected and switch off the power in less than four milliseconds,” Nedunuri said. “In addition to UFES-enabled switchboards, the mine wanted to take advantage of new and trending technology in the form of digital communications between the switchboard and the plant.”

ABB Ability™ Electrical Monitoring and Control for Distribution Networks, known as ZEE600, integrates diverse devices from a variety of suppliers, under the IEC 61850 standard of communication preferred by BMA, ABB explained. At GRM, this condition monitoring solution harnesses the real-time diagnostic data of substation equipment and electrical assets – primarily the pumps – to alert on-site teams to respond with preventive maintenance.

“Via the HMI, you can actually see the health of the pumps, motors and starters – everything. Our analysis and improvement team also continuously collect the data and analyse it for troubleshooting and future enhancements,” he said.

Nedunuri said it’s all connected back to plant supervisory control and data acquisition (SCADA).

Installation and commissioning of the upgraded system took place during the mine’s biannual three-week-long scheduled maintenance shutdown in August/September 2022.

Prior to the shutdown period, Nedunuri constructed the system at ABB premises in Brisbane. Together with the ABB technicians, they matched cabling inlets and outlets with a template of the GRM system.

Henry Lin, Project Manager for Electrification Service at ABB in Brisbane, says ABB customers need to reduce the risk of costly downtime. “Our main objective in these projects is to ensure that our customer’s assets operate at peak performance levels and are available as required,” he said.

BMA has performed much research on the digitalisation of its mines and the ongoing upgrade of infrastructure involves a constant rollout of individual projects. When it comes to the safety and reliability of electrical infrastructure, Nedunuri said the company doesn’t compromise, regardless of the cost.

“All upgrades must not only comply with Australian Standards, but also require ongoing modifications to meet the higher bar set by BHP BMA to make sure it runs efficiently and effectively into the future,” he said.

“I feel proud that I eliminated a huge risk to the business through the pump electrification project. We are protecting people using the new system with arc flash mitigation and at the same time, the monitoring and control enabled by ABB ZEE600, not only improves pump efficiency, but also adds a lot of functionality – it’s easy to operate and easy to maintain.”

BMA and ABB are collaborating on a pipeline of further potential upgrades to existing on-site installations, with each project planned to deliver greater safety, reliability and sustainable growth, ABB says.