Tag Archives: automation

Advancing maintenance in underground mining through digitalisation and automation

Automation, Equipment maintenance, IoT, Mining equipment, Mining maintenance, Mining services, Sustainable mining, , , ,

Underground mining, essential for global raw material supply, and here especially for the majority of critical raw materials, faces significant challenges, including worker safety, operational efficiency and environmental sustainability, Christel Füllenbach and Professor Helmut Mischo*, write.

Traditionally, maintenance strategies in this sector relied heavily on manual inspections and time-based preventive maintenance schedules. However, these conventional approaches have often proven labour-intensive, costly and insufficient in predicting or preventing equipment failures effectively. Recent advancements in digitalisation and automation – specifically through condition monitoring, predictive maintenance and automated inspections – are now offering transformative potential for maintenance strategies in underground mining, addressing core industry challenges.

Limitations of traditional maintenance in mining

For decades, underground mining maintenance depended on manual inspections and predetermined maintenance schedules, with equipment servicing occurring at fixed intervals regardless of its actual condition. While useful, these time-based preventive measures are inherently limited, often leading to unnecessary maintenance tasks or, conversely, to unexpected equipment failures. For example, skilled personnel conduct regular checks based on experience and judgment, which can lead to inconsistencies and the potential for missed early warnings of equipment issues (Kruczek, P., et al., 2019, p. 459 ff.). Moreover, traditional maintenance is resource-intensive, involving substantial manual labour in hazardous underground environments, which increases safety risks and operational costs (Salami, O., B., et al., 2023, p. 617 ff.).

Digitalisation and automation: Transforming maintenance strategies

During the last 15 years, the continuous shift toward digitalised and automated solutions in maintenance marks a fundamental evolution in underground mining. Condition monitoring, predictive maintenance and automated inspection systems each bring specific advantages in enhancing operational efficiency and reliability.

The implementation of condition monitoring enables real-time data collection on equipment parameters, including temperature, vibration and pressure, via sensor networks. By analyzsng this data, mining operators can determine the precise maintenance needs of machinery, rather than relying on inflexible schedules. Case studies indicate that condition monitoring reduces unexpected downtime significantly; for instance, in one South African underground mine, implementing this approach led to a 30% reduction in downtime, offering clear benefits for reliable, uninterrupted operations (Aqueveque, P. et al., 2021, p. 17365 ff.; Rihi, A., et al., p. 2483 ff.).

Building on this, predictive maintenance applies advanced machine-learning algorithms to forecast machinery failures before they occur, effectively shifting maintenance from a reactive to a proactive stance. By anticipating equipment issues, predictive maintenance reduces the need for emergency repairs and limits personnel exposure in high-risk zones. Studies have shown that predictive maintenance can reduce machinery downtime by up to 20%, while also improving safety standards (Putha, S., 2022, p. 160 ff.). In one notable instance, a mining operation utilising predictive maintenance algorithms experienced a significant drop in operational disruptions, illustrating the potential of data-driven maintenance in high-stakes environments like underground mining (Dayo-Olupona, O., 2023, p. 12 ff.).

As one of the most recent developments, automated inspection systems, including drones and robotics, offer further advancements by conducting inspections in hazardous or hard-to-reach areas without requiring direct human involvement. Drones, equipped with high-resolution cameras and other sensors, perform routine inspections with exceptional speed and accuracy, contributing to reduced inspection times and enhanced data precision. A mining company, for instance, achieved a 50% reduction in inspection time after deploying drones for regular equipment checks, thus underscoring both the efficiency and safety improvements achievable with automation (Weyers, E., 2021, S. 55 ff.).

Benefits and sustainability of digitalised maintenance strategies

The implementation of digitalised and automated maintenance strategies offer distinct advantages across safety, efficiency and sustainability metrics. Enhanced safety is one of the primary outcomes, as digital and automated tools reduce the need for personnel to conduct inspections in hazardous areas, lowering accident rates associated with traditional manual checks. Efficiency gains are equally significant; with precise maintenance scheduling enabled by data analytics, companies minimise unnecessary downtime and maximise machinery lifespan. Furthermore, this approach contributes to cost reductions, as predictive and condition-based maintenance reduce both emergency repair costs and the long-term expenses of equipment replacement (Jasiulewicz-Kaczmarek, M., 2019, p. 91 ff.).

From a sustainability perspective, automated and predictive maintenance models contribute directly to resource conservation. The reduction in maintenance frequency and improved operational efficiency lower energy consumption and material waste, aligning with circular economy principles. Automated inspections and predictive models foster an eco-friendlier mining operation by reducing carbon emissions and minimising waste outputs, which is increasingly critical for an industry under pressure to meet stringent environmental standards (Firoozi, A., et al., 2024, p. 2 ff.).

Current R&D and outlook

Current research in underground mining maintenance is focused on refining digital and automated solutions to enhance predictive accuracy and operational efficiency. Advances in machine learning are boosting predictive maintenance models, allowing improved anticipation of equipment failures by analysing large, complex data sets, such as vibration and acoustic signals (Chimunhu, P., et al., 2024, p. 30 ff.). Additionally, IoT-enabled sensors are becoming more resilient and effective in extreme underground conditions, facilitating real-time equipment monitoring and environmental data collection (Wu, Y., et al., 2019, p. 9 ff..).

Robotics also continues to improve automated inspection capabilities, with drones and autonomous vehicles now better equipped for navigating hazardous underground areas. Future developments are likely to see fully-autonomous drones that can perform inspections without operator intervention, significantly reducing human risk exposure (Zhang, R., et al-. 2023, p. 2460 ff.).

Looking forward, emerging innovations may lead to self-diagnosing and even self-correcting systems that will enable continuous operation with minimal manual maintenance. Collaboration between mining companies, technology providers and academia is also advancing universal digital standards, supporting broader adoption of automated maintenance technologies worldwide (Suhail A.H., et al., 2024, p. 150 ff.).

The integration of digitalised and automated maintenance strategies represents a critical evolution in underground mining, enhancing safety, operational efficiency and sustainability. These technologies allow mining companies to optimise their maintenance practices, reducing operational risks and improving equipment longevity while minimising environmental impacts. As digital and automated solutions continue to evolve, their transformative impact on underground mining will likely deepen, setting new industry standards for safety, productivity and environmental responsibility.

*Christel Füllenbach is Global Operations Manager at Epiroc; and Professor Helmut Mischo is from TU Bergakademie Freiberg’s Institute of Mining Engineering and Special Civil Engineering

Aqueveque, P., Radrigan, L., Pastene, F., Morales, A. S., & Guerra, E. (2021). Data-Driven Condition Monitoring of Mining Mobile Machinery in Non-Stationary Operations Using Wireless Accelerometer Sensor Modules. IEEE Access, 9, 17365-17381. https://doi.org/10.1109/ACCESS.2021.3051583.

Chimunhu P, Topal E, Asad MWA, Faradonbeh RS, Ajak AD. (2024). The future of underground mine planning in the era of machine learning: Opportunities for engineering robustness and flexibility. Mining Technology.

Dayo-Olupona, O., Genc, B., Celik, T., & Bada, S. (2023). Adoptable approaches to predictive maintenance in mining industry: An overview. Resources Policy, 86(Part A), 104291. ISSN 0301-4207. https://doi.org/10.1016/j.resourpol.2023.104291.

Firoozi, A. A., Tshambane, M., Firoozi, A. A., & Sheikh, S. M. (2024). Strategic load management: Enhancing eco-efficiency in mining operations through automated technologies. Results in Engineering, 24, 102890. ISSN 2590-1230. https://doi.org/10.1016/j.rineng.2024.102890.

Jasiulewicz-Kaczmarek, M., & Gola, A. (2019). Maintenance 4.0 Technologies for Sustainable Manufacturing – an Overview. IFAC-PapersOnLine, 52(10), 91-96. ISSN 2405-8963. https://doi.org/10.1016/j.ifacol.2019.10.005.

Kruczek, P., et al. (2019). Predictive Maintenance of Mining Machines Using Advanced Data Analysis System Based on the Cloud Technology. In Widzyk-Capehart, E., Hekmat, A., & Singhal, R. (eds), Proceedings of the 27th International Symposium on Mine Planning and Equipment Selection – MPES 2018. Springer, Cham. https://doi.org/10.1007/978-3-319-99220-4_38.

Putha, S. (2022). AI-Driven Predictive Maintenance for Smart Manufacturing: Enhancing Equipment Reliability and Reducing Downtime. Journal of Deep Learning in Genomic Data Analysis, 2(1), 160–203. Accessed Nov. 11, 2024. https://thelifescience.org/index.php/jdlgda/.

Rihi, A., Baïna, S., Mhada, F.-Z., Elbachari, E., Tagemouati, H., Guerboub, M., & Benzakour, I. (2022). Predictive maintenance in mining industry: grinding mill case study. Procedia Computer Science, 207, 2483-2492. ISSN 1877-0509. https://doi.org/10.1016/j.procs.2022.09.306.

Salami, O. B., Xu, G., Kumar, A. R., & Pushparaj, R. I. (2023). Underground mining fire hazards and the optimization of emergency evacuation strategies (EES): The issues, existing methodology and limitations, and way forward. Process Safety and Environmental Protection, 177, 617-634. ISSN 0957-5820. https://doi.org/10.1016/j.psep.2023.07.012.

Suhail, A.,H., Guangul, M., Nazeer, A. (2024). Advanced System Diagnostics Tools: Innovations and Applications. IntechOpen. doi: 10.5772/intechopen.114378.

Weyers, E. (2021). The use of drones to improve downtime management on South African mines [University of Johannesburg]. https://ujcontent.uj.ac.za/esploro/outputs/graduate/The-use-of-drones-to-improve/9918409407691#file-0.

Wu, Y., Chen, M., Wang, K., and Fu, G. (2019) “A dynamic information platform for underground coal mine safety based on internet of things,” Safety Science, vol. 113, pp. 9-18, https://doi.org/10.1016/j.ssci.2018.11.003.

Zhang, R., Hao, G., Zhang, K., & Li, Z. (2023). Unmanned aerial vehicle navigation in underground structure inspection: A review. Geological Journal, 58(6), 2454–2472. https://doi.org/10.1002/gj.4763

Maptek presents new platform for automation and orchestration, Vestrex

Automation, IoT, Mining services, Mining software, , , , , ,

On the back of successful demonstrations at MINExpo International in Las Vegas in September, Maptek has announced that its Maptek Vestrex ecosystem for automation and orchestration is open for early access customers.

Vestrex creates extraordinary value by making connections between diverse data sources without constraints of product, application, process or format, Maptek says. Data in the cloud encourages stakeholders across mining roles, teams and organisations to collaborate and explore new use cases for their technical data beyond traditional applications.

Automation streamlines operations through real-time data and process integration and accelerates decision making processes, while orchestration builds on computational power and automated workflows to unlock value from technical data and mining systems.

Global Strategy Manager, James Mackenzie commented on the interest surrounding Vestrex during MINExpo: “Everyone we spoke to could immediately think of a way they could apply Vestrex to their organisation. All of the ideas were different and all of them were achievable, because Vestrex enables collaboration on many levels, limited only by imagination!”

Mackenzie added: “Customers can expect effortless data transfer between cloud and desktop environments, with data managed securely from a centralised platform. They will also be able to work with Maptek to orchestrate custom processes that handle their particular challenges.”

The new platform is based on three key pillars – data services, cloud computing and orchestration – sharing a common vision for solution integration and inter-process workflows.

Maptek Data Systems (MDS) is the integration hub for ingesting data from anywhere through open APIs. MDS enables native in-app integration with Maptek desktop solutions and manages version control and publishing permissions through Maptek Account.

The second pillar in the Maptek ecosystem, Maptek Compute Framework (MCF), is already powering machine learning and optimisation in Maptek scheduling and domain modelling solutions, according to the company. Time-consuming calculations can be completed on scalable resources for on-demand results.

The third and newest pillar, Maptek Orchestration Environment (MOE), is the key to unlocking value through collaboration, according to Mackenzie.

“Vestrex connects algorithms, executables and transformations to leverage computational power, scalability and parallelisation across business and technical systems,” he said. “If you can get your data into Vestrex, Maptek can help transform it into value.”

An important feature is the flexibility to incorporate ‘human in the loop’ review and analysis at any stage within automated processes, Maptek says. Customisation of decision trees and unrestricted complexity mean the use cases are limitless. Robust data security includes encryption and backup protocols that protect sensitive information for operational continuity.

Mackenzie sees the true power of Vestrex as the ability to bind data and computations to create automations that streamline processes and data pipelines, integrating them within broader business workflows.

Mackenzie concluded: “Making data accessible and consumable across multiple stakeholders, including non-technical users, at every stage of the mine life cycle fosters collaboration that can discover new and unexpected use cases in a way that redefines industry standards.”

Orica setting digital groundwork to open up new mining frontiers

Automation, Explosives and blasting, IoT, Mining equipment, Mining events, Mining services, Mining software, Sustainable mining, , , , , , , , , , , , , , , , , , ,

The integration of a digital backbone into the explosives, blasting and related processes will continue to result in miners accessing new deposits and potentially developing new mining methods, Orica’s Angus Melbourne and Rajkumar Mathiravedu told IM at last month’s MINExpo 2024 in Las Vegas.

Reflecting on a digitalisation journey that started eight years ago, Melbourne – Orica’s Chief Technology Officer – said the original ambition was about taking a very manual process like blasting and digitising the workflows.

“Essentially what we wanted to do was anchor into the design and connect the on-bench activities for a verification process as to where the drill pattern was and how this reconciled with the actual outcome,” he said. “The key was always to link this back to the hub of the machine.”

Bringing data and insights into this equation resulted in better placement of energy (ie explosives), which has since become part and parcel of Orica’s aim of “mobilising the Earth’s resources in a sustainable way”.

The second element underlying this digitised push was the acceleration of automation.

“You cannot automate unless you have a digital foundation,” Melbourne said.

This led to the company – both organically and through M&A – building up a suite of software, sensors and data science applications to enable processes within the explosives and blasting process to be automated.

Just what processes to automate has always been dictated by safety and productivity.

“Getting people off the bench, face, voids, high walls, etc becomes a clear motivator for automating certain processes,” Melbourne said. “It is a bit more difficult on the productivity side of things; you have to be generating value, not just automating for the sake of it.”

From Orica’s initial point eight years ago, the company has progressively moved into adjacencies such as post-blast outcomes, geology and more, bringing the same mindset to each part of this distinct process, while integrating it into the wider work patterns.

Mathiravedu (Orica Digital Solutions Senior Vice President) explained: “What we are seeing in the digital space is the fact that, with blasting, you can either create or destroy value. With all the tools and expertise we have, plus the ability to connect the physical and digital components, we are making the whole process more productive, as well as optimising the use of consumables like water and energy.”

Rajkumar Mathiravedu presenting Next Gen SHOTPlus at MINExpo 2024

And as Orica has opened further to the wider mining ecosystem – think of recent tie ups with Epiroc on the Avatel™ semi-autonomous explosives loading solution showcased at MINExpo or Caterpillar on a potential integration between Rhino™, BlastIQ™ and FRAGTrack™ technologies with Cat® MineStar™ Terrain – its influence across the whole flowsheet continues to expand.

Melbourne said: “If I go back a decade, Orica would have been doing a lot of these things itself…but both Raj and I have worked in other industries that, for various reasons, were collaborative. As a result, we were far more open to working with others.”

This openness is seen with one of Orica Digital Solutions’ latest launch, Next Gen SHOTPlus™, which unlocks the power of the Model Through Time; a cloud hosted, spatiotemporal, digital replica, Orica says. Incorporating the proprietary physics engine, Helfire Damage Model and Advanced Vibration Management solution, Next Gen SHOTPlus enables drill and blast engineers to model and predict blast movement, damage and vibration.

Predictive blast movement modelling is enabled by Predict Physics Engine, allowing engineers to understand the impact of decisions on the post-blast muck pile. The Blast Damage, meanwhile, feature provides 3D damage modelling, allowing engineers to evaluate the predicted damage generated on both blasted and in-situ rock masses.

As the Avatel system loomed over the Orica booth at MINExpo (it was on the adjacent Epiroc stand, see below), it seemed only right to ask about the potential to fully automate the explosives loading process based on the safety and productivity drivers Melbourne outlined.

“The goal is to go fully autonomous,” he replied. “If you look at the safety and productivity drivers, semi-automation advances both of those, but there are opportunities to improve upon both – we are clearly still underground at the moment, which comes with risk, and there are other elements of cleaning, priming and loading that could be accelerated in the development headings through full automation.”

One of the underlying technologies of the Avatel platform is the WebGen™ wireless initiation system, which has been key to unlocking new mining methods and techniques, with numerous case studies detailing a strong value case.

A fully autonomous Avatel unit could do similar, according to Melbourne, ticking that productivity box.

“With full autonomy, you can start to employ new mining methods and go to different parts of the mine you couldn’t previously,” he said. “On a case-by-case basis, you can look at individual mines where they understand the mineralisation that, because of safety constraints, cannot currently be classified as a resource or reserve.

“If we’re able to remove that constraint, we can start to tangibly assess bringing that into a resource or reserve and mining that.”

WesTrac expands autonomous training centre to help shape future workforce

Automation, Careers in mining, Mining equipment, Mining services, Sustainable mining, , , , ,

Caterpillar® dealer WesTrac has announced that construction of new facilities at the WesTrac Technology Training Centre in Collie, Western Australia, will be complete by November, offering further training opportunities.

Speaking during a visit to the facility by the Premier of Western Australia, WesTrac CEO, Jarvas Croome, said the State Government supported the project by providing A$1 million ($672,764) from the Collie Futures Industry Development Fund.

“It is fantastic to have Hon Roger Cook MLA at the WesTrac Technology Training Centre to see the progress we have made with our expansion of this state-of-the-art facility,” Croome said.

“As the only autonomous training centre in the Southern Hemisphere, our centre offers industry-leading practical training on machines like the Cat® 789D Autonomous Haul Truck in a safe, controlled, and authentic environment. Demand for our world-class training has skyrocketed as mining and construction companies look to educate the next generation of their workforce.

“The expansion of our facilities will ensure WesTrac can meet this demand, as well as offer new courses and pathways for workers in the resources and civil construction sectors.”

The expansion includes construction of two new buildings, with an additional five new training rooms, a virtual reality room, a remote operating station room, reception and practical labs tailored to deliver training in Cat MineStar Technology.

WesTrac is also in the process of commissioning a new Cat D10 Dozer with remote operating capabilities, allowing students to operate the machine from a classroom located 500 m away or further – replicating a real-world mine site environment.

Croome said the new addition at the centre will replicate the latest technology available on a mine site which is designed to keep operators safe.

“WesTrac and Caterpillar are leading the charge when it comes to delivering world-class training by utilising the latest technology and equipment to provide a second-to-none level of education,” he explained. “Since our centre opened in 2020, we have delivered training to more than 900 people from Australia and overseas, and we expect to see even more come through the door as industry demand increases for technology and electrification experts.

“The WesTrac Technology Training Centre and the team of experts who deliver our world-leading education and training are a beacon for the mining and construction industries as they look towards tech-driven operations of the future.”

Construction of the new facilities was also supported by the Motivation Foundation, a not-for-profit organisation dedicated to providing hands-on training and practical experience for young people, as well as securing future employment opportunities.

Croome says the group played a vital role in the expansion performing key earthworks as part of their on-the-job practical training, including developing the new dozer training area and building footings.

He added: “Since commencing in Collie, Motivation Foundation have successfully helped over 50 local young people gain employment. Through our partnership with the Motivation Foundation and this expansion of the WesTrac Technology Training Centre, we hope to ensure this pathway continues for young people continues.”

The WesTrac Technology Training Centre was recently recognised during the WA Training Awards last month, when WesTrac was awarded Large Employer of the Year for its industry-leading approach to education and training.

Scania’s autonomous trucks to debut at Element 25’s Butcherbird manganese mine

Automation, Environmental, Mining equipment, Mining services, Steel and iron ore, , , , , , , ,

Scania and Australia-based services provider Regroup say they will launch the world’s first fleet of Scania autonomous in-pit mining trucks in the Pilbara in 2025 with a rollout planned at Element 25’s Butcherbird mine.

Building on the recent announcement of the start of sales for commercially-available autonomous trucks, Scania today announces it will supply its first fleet of autonomous trucks to Regroup.

The world-first fleet of 11 autonomous rigid G 560 8×4 tippers, transporting manganese ore for Element 25 at its Butcherbird site, is planned to start work in late 2025 in Western Australia’s Pilbara region. Scania, Regroup and Element 25 will now work collaboratively to finalise the particulars regarding this solution, and to align with the expansion of the Butcherbird mine.

“Scania in Australia has been working closely with several partners in the local mining industry over recent years to finesse our autonomous truck programme in advance of this announcement,” Scania Australia Managing Director, Manfred Streit, says. “We are delighted that this historic event, the first order globally for a fleet of Scania’s new autonomous trucks, has been made by a privately-owned Australian company, which will provide these trucks for use in an Australian mining environment.”

Peter Hafmar, Head of Autonomous Solutions, Scania, said: “With this fleet order, we bring to commercial reality the concept of an autonomous fleet working at scale in demanding real-world conditions. We anticipate the Regroup fleet deployment will be the first of many, as operators around the world see the safety, productivity and ease-of-use benefits of Scania’s technology.”

Regroup, a fully integrated civil, mining and bulk commodities haulage partner, sees the autonomous truck fleet as the first critical stage in its path towards a zero-tailpipe emissions mining fleet future.

Regroup Managing Director, Michael Still, says: “Along with Scania, we are excited to be establishing our first fleet of autonomous vehicles in the Australian mining industry. It is not lost on us that we are able to collaborate with one of our key, and long-standing partners in Element 25 as we look to roll this solution out across their site. We have always been aligned in our values in supporting industry innovation and the electrification of the global vehicle fleet. It is great that we can demonstrate this on site.

“Regroup has excelled at initiating and delivering sustainable and renewable practices, and these new autonomous trucks are just the first step in our transport plan. We are looking forward to adding Scania zero emission autonomous mining trucks as the next step. In addition to the autonomous trucks coming next year, we have also ordered a driver-operated battery-electric Scania rigid 8×4 truck that we will look to incorporate into the Element 25 Butcherbird operation which will serve as a water cart, underlining our overall aim of decarbonising our mining activities.

“We’re investing eight figures with Scania to establish a fully autonomous onsite mining haulage fleet. Regroup has a track record in investing in innovative fleets.”

Still says he views the autonomous Scania fleet as being able to also reduce its diesel consumption, as the operator moves from a larger capacity fleet of 100-200 t vehicles to a smaller class unit. From a decarbonisation perspective, Regroup is also expected to burn less fuel on site.

Regroup has grown tenfold over the past four years. It provides plant, people and expertise across several construction and mining sectors.

“We worked out early on that we needed to develop into a full-service offering,” Still says.

“We’ve grown quickly from 22 staff to 250. In that same time, we have spent and committed over A$100 million ($68 million) on new assets. So, we’re very serious about fresh fleet…When new technology and opportunity comes along, we’re able to invest. Our aim longer term is to fully electrify the fleet.”

Regarding the new autonomous fleet, Still says there will be no reduction in the driver cohort, because the new fleet will be operating as an expansion of a current program, so no additional drivers will be sought.

He said: “We’ve certainly done our homework in terms of people that are using the Scania product. But there is a leap of faith involved with commercialising an autonomous solution from Scania for the first time in the world. With anything that you do for the first time there’s going to be a leap of faith because there’s no baseline data, but one of our values is to think big.

“Looking at our data projections, against maybe a small site, autonomous is more expensive, but the more volume you’re required to move, the cheaper the solution becomes, because your operator numbers don’t increase.

“Yes, your trucks increase, but your operators don’t necessarily increase because you’ve got a control room with the same setup. Your setup costs are in fact locked. So, it’s then spread out over more trucks and more volume and then the trucks made complete sense.

“But even at the lower volumes, whilst it looked like on paper there was an increased cost to us providing the solution, when you consider the cost of flights, the cost of transporting people to sites, and the cost of accommodating people, almost got it to a cost neutral point, even with four trucks.

“But at 10 to 11 trucks running, there is a financial benefit to our client. And even while still a diesel truck, just in fuel economy and reduction in carbon emissions, there’s a benefit to our client,” he says.

Robert Taylor, Head of Mining at Scania Australia, said: “Regroup is a business on a rapid path to expansion, having been voted the top regional business of the year in Western Australia.

“We can see that Regroup and Element 25 will benefit from reduced operating costs using our autonomous trucks, decarbonising their operations, and transferring labour requirements from the field to remote control room locations, which are also safer working environments. So, this fleet will provide a win-win for all parties.”

Epiroc focused on ‘connecting the dots’ to create mine of the future

Automation, IoT, Mining equipment, Mining events, Mining software, Power supply for mines, Sustainable mining, , , , , , , , , , , , , , ,

Ahead of Epiroc’s Capital Markets Day (CMD) and MINExpo 2024 at a hotel just outside of Las Vegas, Helena Hedblom, Epiroc President and CEO, was happy to tackle the industry’s big three: automation, digitalisation and electrification.

Hedblom, like the heads of her fellow OEMs, has big ambitions for these three technology pillars, but the way Epiroc is looking to meet these ambitions is different.

The company’s “agnostic” philosophy has been a key differentiator for the past years, and even as more OEMs start to open up their architecture and platforms to the wider vendor marketplace, it is this attitude that is likely to help it lead from the front.

“Our ambition is to provide mixed fleet automation,” Hedblom told IM last week. “That is what we have invested in quite heavily over the last two years; we have acquired two companies in RCT and ASI Mining to allow us to achieve this.

“This is how we see the future of mining when it comes to automation, having the capabilities to operate whatever type of equipment there might be in that mine, including utility vehicles.”

Epiroc has, as of the CMD last week, 3,100 machines running without drivers. This is up 29% from the last CMD in June 2023, with the company noting that there was “great potential to connect an even larger fleet” via Epiroc machines and/or units from other OEMs.

RCT, underground, has a track record of achieving such autonomy on a wide range of machines, while, on surface, ASI Mining has proven it can do the same with the fleet at Roy Hill, in Western Australia.

Epiroc is currently converting Roy Hill’s mixed fleet to driverless operation in Australia, with 78 autonomous haul trucks made up of Caterpillar and Hitachi trucks, and over 200 utility vehicles.

Roy Hill remains the sole case study on surface, but Hedblom says the company will soon transition to the ‘scale’ of its “nail and scale” process that leads to adding more mine sites to its agnostic automation platform.

Hedblom is convinced the ability to automate the entire fleet – whether the machines are “digitally connected” or not – plus integrate the highest levels of collision avoidance solution, will go far in eradicating the need to allow autonomous and staffed equipment to operate in the same zones underground and on surface.

“If you have all the utility vehicles automated, that is the key,” she said. “It is more than just automation; through the Mernok acquisition, we’re now able to bring in Level 7, 8 and 9 collision avoidance technologies.

“Technology-wise, it is all coming together.”

IM Editor, Dan Gleeson, met with Epiroc President & CEO, Helena Hedblom, ahead of the company’s CMD and MINExpo 2024 in Las Vegas

Electrification

The big stats in terms of electrification include:

  • 42% of the offering in “fossil free” versions;
  • Battery-electric vehicles deployed at 34 sites;
  • An active electric fleet of rigs, loaders and trucks totalling over 600 units (of which a large portion is historical fleet, including cable);
  • Recurring battery-electric vehicle orders from 12 sites; and
  • A three times increase in the utilisation rate of battery-electric vehicles during the last 12 months.

The other statistic of note is that, as it stands, Epiroc group revenues related to electrification amount to just 4%.

This indicates both Epiroc and the industry are still in the initial stages of this transition; an opinion backed up by claims from the Electric Mine Consortium that Sandvik’s battery-electric truck population across the globe represents only 15% and, as it stands, no battery-electric load and haul equipment has been sold commercially in one of the biggest underground markets: Australia.

Hedblom, here, sees parallels with the automation uptick in the industry.

“This transformation is happening in the same way that automation evolved,” she said. “A couple of years ago, we had some customers that had greenfield operations and decided to go fully electric. Now we see more customers looking at repeat orders.”

The automation analogues also come with the fact that Epiroc – unlike other OEMs – is offering a mid-life rebuild option to convert some of its existing diesel-powered load and haul fleet to battery-electric operation.

Epiroc has plans to offer this conversion option across its full existing diesel-powered load and haul fleet by 2030.

The addition of ‘fossil free’ in the Epiroc lexicon over the last few years reflects the need to put multiple options on the table for miners.

“We see that there will be different types of solutions needed during the coming 10 or 20 years, depending on mining method, type of application, etc,” Hedblom said.

This was made apparent on the floor at MINExpo where Epiroc showcased the MT66 S e Drive, a Pit Viper 271 E and a SmartROC D65 BE. The former is a diesel-electric haul truck that uses both diesel engine and electric drivetrain to reduce fuel consumption and emissions, the SmartROC D65 is a battery-electric down-the-hole drill demonstrator that trams on battery yet is plugged in for drilling, while the Pit Viper 271 E is currently envisaged as a unit connected to the site’s renewable electricity infrastructure for that ‘fossil free’ operation.

The Minetruck MT66 S e Drive

“We believe there will be a combination of different energy sources in this mix,” Hedblom said, reeling off the likes of battery-electric, cable, trolley and hybrid options. Additionally, biofuel ‘drop-in’ solutions are already available for conventionally powered machines in its offering.

She added: “Sometimes the discussion is all about benchmarking diesel against a fossil-free machine, but the reality is that every machine we are developing now cannot just be on par with its diesel counterpart. It must be better – faster up the ramp, filling the bucket faster, etc – to ensure we provide productivity benefits and a lower total cost of ownership for customers.”

Digitalisation

From an M&A perspective, digitalisation has been a key focus area for Epiroc since the Atlas Copco spinoff in 2018, with many of the 27 acquisitions since listing tied to this trend.

This, as well as many organic initiatives, has led to the company building up a revenue base for its Digital Solutions division of SEK2.4 billion ($234 million).

“Our digital solutions are agnostic, working on different types of machines and systems, so this opens up many ways to engage with our customers,” Hedblom said, noting that the platforms it had created are being used by existing Epiroc equipment customers, as well as those with fleets from other OEMs.

“The areas of high interest are around collision avoidance, situational awareness and mixed fleet automation,” she said. “I see that digitalisation creates that transparency needed to drive productivity.”

Digitalisation, itself, represents an easier ‘sell’ for Epiroc due to its seamless nature – ie not creating multiple change management issues – when compared with adopting automation and electrification technologies, Hedblom added.

Going forward, she is convinced a digital backbone will become more important with the increasing uptake of automation and electrification.

“Today, a lot of the different tools mining companies are using – for the mine plan, for maintenance, etc – are still not connected,” she explained. “You don’t use all data at the same time for the best type of decision.

“A lost hour of productivity is a lost hour of productivity; we are seeking to avoid this through increased digitalisation.”

This is where the individual solutions Epiroc has acquired through the likes of Mernok (collision avoidance), RCT and ASI Mining (agnostic automation solutions), Meglab and JTMEC (battery-electric chargers and infrastructure) could combine with its digitalisation platforms to optimise the overall mining process.

“By connecting the dots, there are many more optimisation opportunities to be had,” Hedblom said.

The difference here is that Epiroc is willing to look outside of its own four walls to the broader industrial space to ‘connect these dots’, meaning the idea of a fully-electric, fully-autonomous, fully-digitalised mine could be much closer to becoming a reality.

Fortescue, Scania to develop fully integrated autonomous road train solution

Automation, Environmental, Mine operation news, Power supply for mines, Steel and iron ore, Sustainable mining, , , , , , , ,

Fortescue and Scania have agreed to jointly develop and validate a fully integrated autonomous road train solution, leveraging Scania’s technology in truck automation and Fortescue’s own Fleet Management System (FMS).

The autonomous solution would be developed, tested and validated in partnership at Fortescue’s iron ore operations at Christmas Creek.

“By utilising Scania’s extensive knowledge in supplying trucks to the mining industry and our expertise in autonomous driving, the Road Train solution will reduce the overall mining footprint,” Manfred Streit, Managing Director at Scania Australia, said.

With Scania’s technology in truck automation, the autonomous solution would be integrated with Fortescue’s FMS designed to optimise fleet utilisation and maximise productivity, while ensuring efficient fuel and energy consumption to reduce carbon emissions. The solution would also integrate Scania’s on-board autonomation hardware and technology for the Scania R770 prime mover platform, coupled with three trailers weighing 120 t with a payload of 240 t.

“This is a great opportunity for Scania to learn more about autonomy in demanding conditions with an innovative partner,” Peter Hafmar, Head of Autonomous Solutions, Scania, says.

Fortescue Metals Chief Executive Officer, Dino Otranto, says: “Our deep expertise in autonomous haulage has enabled us to jointly develop a unique autonomous solution that unlocks high grade, satellite deposits for us to mine economically. This project would help us maximise productivity with unique low-cost solutions in our mining value chain.”

Scania Australia has been working closely with Fortescue for many years, and is pleased to see this joint development project become a reality.

Robert Taylor, Head of Mining at Scania Australia, said: “Their heavy haul trucks operate in an incredibly harsh environment. The local and global mining specialists have devised a solution that will bring both efficiency and safety.”

Cat’s Denise Johnson on solidifying the electrification solution set

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

In the leadup to this week’s MINExpo 2024, Caterpillar has been making headlines across the mining technology space with a string of announcements related to mine site electrification. IM got a chance to sit down with Caterpillar Resource Industries Group President, Denise Johnson, to talk through these and more.

The following Q&A picks up from a discussion Editorial Director, Paul Moore, had with Johnson and Brian Weller, Vice President of Electrification, in the leadup to MINExpo 2021, in Las Vegas.

IM: When comparing where the industry is now with the electrification trends and indicators seen just before MINExpo 2021, what do you view as the major energy sources for ultra-class haul trucks to allow miners to achieve some of their net-zero, scope one emission targets? Has your viewpoint changed over that three-year period?

DJ: I don’t think it has changed. Three years ago, we had a vision of the predominant choice for zero exhaust emission haul trucks being battery-electric. Three years later, that vision has been maintained.

You could argue that the battery chemistry has evolved over that time frame, but the expected solution set has broadly remained the same. If anything, we have been able to further validate battery-electric trucks as the optimal choice over that three-year period.

What has changed though is the approach to this from mining companies. There is much more of an interest in ‘stepping into’ the electrification journey, versus just ‘flipping a switch’. In other words, we’re seeing more customers being interested in transitioning over time, which is one of the reasons why we have accelerated the development of our Dynamic Energy Transfer (DET) solution, which can already be leveraged with diesel-electric (AC) trucks. This allows customers to start to transition their site infrastructure now, without having to progress all the way to where they need to from an electrification perspective. It allows them to hit their interim greenhouse gas (GHG) reduction targets at the same time, ahead of those longer-term net zero ones.

I think that strategy is very appealing to many customers as they start to look at how to implement electrification effectively over time.

IM: Does this approach differ from region to region (as well as site to site) based on, for example, diesel price benchmarking, access to renewables, energy infrastructure, etc?

DJ: Absolutely. There are some places in the world where sourcing renewable energy is very easy – whether that is through hydropower, solar, wind, etc – and there are others where it is much more challenging. So, we still see that spread with our customers; everywhere from wanting to continue with traditional equipment, all the way to going fully electric.

I would say Australia is probably leading the movement towards electrifying and going all out to achieve zero GHG emissions. A lot of that is driven by carbon tax, government incentives and other aides.

IM Editor Dan Gleeson with Caterpillar’s Denise Johnson

IM: Of the solutions out there, do you see diesel-electric, progressing to battery-electric integrated with stationary charging and DET as the most viable commercialisation route?

DJ: I think mining companies are interested in exploring all the solution sets. From an economic perspective, there is still a lot to figure out in terms of how those will be commercialised.

While I don’t think the commitment towards electrifying has changed, the timeline around when they want to introduce electrification remains the biggest question mark. That is something we are working on, especially with our Early Learner customers. We want them to give us feedback on what timeline they would like to move forward with commercialising. We, in turn, want to make sure we’re meeting what our customers dates are.

IM: Within this electric haulage evolution, is there also a case to be made for exploring a ‘hybrid’ electric solution including battery pack, energy storage component and a smaller on-board engine?

DJ: We’ve studied that heavily and it depends on the mine site as to whether it would be an effective and economically viable option. We have done a lot of simulations around what would be required and, for some mines – especially deep pit mines – the amount of energy you need to pull the truck out of the pit would require the same size engine as you have on a diesel-electric truck today. A smaller engine, combined with an acceptably sized battery and an energy storage source, would not allow you to achieve that same haulage route.

There are other applications that could technically work, but the economics do not make sense now.

We really look at the DET with the diesel engine as our ‘hybrid’ solution. As you see today, we’re basically taking the engine down to idle when it is being propelled on the DET line. The ability to do that allows you to hit that hybrid ‘sweet spot’.

A Cat 798 AC on a DET line at Caterpillar’s Tucson Proving Grounds in Arizona

IM: And DET could also, in theory, allow you to use a smaller battery on board these trucks in certain applications…

DJ: Yes, which allows you more payload potential in those applications as well.

IM: I read that you have now built and tested seven Early Learner 793 XEs to date. What stages are these at in terms of getting to site for testing? Am I right in thinking the one at Newmont’s Cripple Creek & Victor has now been assembled?

DJ: Yes, that one [the Early Learner 793 XE at Cripple Creek & Victor] is going to start running soon. Another one has just arrived in Western Australia too; they are in the midst of transporting that to the test site.

IM: In terms of those Early Learner mine sites, how selective have you been able to be with the applications chosen to give you a wide breadth of knowledge as to how these battery-electric trucks may perform across different types of mine sites?

DJ: We, with our customers, have intentionally chosen the Early Learner site locations to hit ‘corner cases’ for battery truck validation: we have deep pit, we have high altitude, we have cold temperature, we have hot temperature, etc. We are really trying to ensure we hit all those corner cases so the validation that we are doing of not only the technology, but also the application, allows us to understand and learn. We have full confidence that iterations will be required, and we want to do that as soon as possible, so that is why we are sending these machines to the broad corner cases we are.

The customers are also looking for reassurance, as well. One of the things we are doing with the Caterpillar Early Learners is sending engineers to the site to help with that learning cycle. Our team will be right there at the mine site watching, first hand, the development and evolution of the technology as it iterates.

IM: Is that information – in terms of application performance – going to be shared across the Early Learner partner framework as well?

DJ: So, both our Early Learner customers and our Pathway to Sustainability customers are going to be learning with us and finding out what we are seeing at these sites. It is intended to be an industry learning opportunity. There are certain details that cannot be shared, but, when it comes to things like change management for people, and certain processes, technology and infrastructure, we will be sharing that information. It is important to spread this across the industry, and that is the intention of these specific programs.

IM: Might some of these Early Learners and Pathway to Sustainability customers also use DET within this process? Is that part of the conversation?

DJ: In some of these applications, yes, DET will be part of the solution. We will be carrying out field-follow trials on DET in 2025, intending to go into production with it in 2026, so that aligns well with our Early Learner trials.

IM: When it comes to batteries, has your thinking around the supply chain and creating the volumes needed to rapidly bring down the cost changed over this time period (2021 vs 2024)? Could you, for instance, look to acquire more off-the-shelf battery packs/modules, instead of creating customised battery solutions, to lower the cost of the overall battery truck?

DJ: No, our thinking hasn’t changed. We have a number of development agreements with various companies around battery technology that we’re continuing to build on. We think deep integration in this supply chain is important. We won’t be manufacturing cells; we will procure those from a variety of sources around the world, not just one source. The intention would be for us to take the battery cells, make the battery packs and racks, integrate that into our software, the cooling and all the controls. We think it will be a competitive advantage for us, and benefit our customers best, if we do it ourselves. That control system will allow deeper integration into the machine platform and the energy management component. We think it is a core part of what will make our product the optimal solution for our customers.

IM: Does that also come with an extra cost element?

DJ: It could. Caterpillar could buy battery packs off the shelf, but then, what would be the difference between Cat’s solution and anyone else’s? If we think Caterpillar’s control system – through cooling and battery management, for instance – will allow batteries to last longer, then that will allow our customers to achieve the lowest total cost of ownership (TCO). This is important as the battery represents a substantial cost, especially with the scale of the machines we are talking about. We need to be mindful of trying to make them last longer, while servicing and repairing them in an optimal manner.

The lifecycle of the battery is important to achieving this low TCO – from procurement of the cell through to secondary use, which we can leverage oftentimes in a stationary energy storage system application, through the recycle process. We may not do every piece of this – the recycling piece, for instance – but we want to be able to operate that complete lifecycle ecosystem in the way that makes the most sense and provides the best customer value.

IM: How advanced are you in terms of simulation, design and fleet management integration for the deployment of battery trucks? How important will this element be for customers achieving the results they want?

DJ: We have developed a completely in-house simulation software for this, which I am really excited about. The simulation tools will help us in ways we would never have imagined before, and it will be integrated into our autonomy solution as well. This will allow it to be used for advanced planning of the mine site itself, but also for decision support as to when to, for example, move the DET around the site, select how many trucks will be needed around the site, and how to optimise productivity within those confines.

We have already learned a lot from the Early Learner customer sites as a starting point for simulations, visualising their mine sites to help inform them of what they might need from a site infrastructure and energy management perspective. This is where we’re pulling in our energy & transportation expertise to help such analysis, as well as our digital team. It is an enterprise-wide focus that allows us to pull in a lot of skillsets from the entire team.

IM: Could such a solution be rolled out to customers as well?

DJ: We think it will be a very important tool for our customers. We think it will drive down the cost and ensure site optimisation is done at a much broader level than it is today.

IM: Lastly, you mentioned to Paul three years ago that you did see cabless trucks coming in the future. How far away from this future are we now?

DJ: It will depend on our customers pull for it; right now, we’re still putting cabs on trucks! Customers still want that versatility.

But there is a huge advantage to taking the cab out of the equation – in terms of weight and cost. It also allows much greater freedom in design iteration. Additionally, payload increases could be reaped.

We have some cabless designs out there already, but we are waiting for the customer pull. It is the customers that will ultimately help us decide when they are ready for those.

IM: I guess you could give the ultimatum of, ‘You can have a cab on the truck, but you’ll have to forego, say, 500 kW of additional battery capacity to have that cab.’ That may also focus their minds…

DJ: That sort of trade-off may be an option for our customers to consider. I also think as autonomy adoption continues to increase; it will help facilitate the likelihood of that taking place. There will have to be a way to remotely recover those units, but we already do that today.

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

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

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

Komatsu and Rio Tinto herald delivery of 300th autonomous haul truck

Automation, Mine operation news, Mining equipment, Mining safety, Steel and iron ore, , , , , ,

Komatsu and Rio Tinto have reached a historic milestone, with Rio Tinto’s Pilbara operations in Western Australia accepting delivery of its 300th autonomous haulage system (AHS) truck this month.

Komatsu and Rio Tinto initially signed a Memorandum of Understanding in 2011 to deploy 150 AHS trucks to the Rio Tinto site, and, 13 years later, the partnership continues with both companies looking to accelerate the pace of mining automation.

Garry Povah, Komatsu Australia’s General Manager − Mining Automation, says this milestone gives both organisations the opportunity to reflect on the success of this groundbreaking partnership.

“We’ve led the industry in mining automation since 2008, when we commenced the Rio Tinto trial,” Povah said. “We delivered the first five AHS trucks to Rio mine sites in Australia in 2011, and it’s incredible to see how much the business has embraced this technology over the years, helping to make their mines safe, and also highly productive.

“AHS trucks are a crucial solution to both mine safety and addressing labour shortages in the sector. By removing human operators from potentially hazardous environments, AHS trucks significantly reduce the risk of accident and injury, and while enabling continuous operation that considerably impacts site productivity.”

The AHS fleet at Rio Tinto sites have completed 8.9 million operating hours and have moved over 4.8 billion tonnes of material, according to Povah – “all while improving their sites effective utilisation (EU%) by 15% – a remarkable feat.”

Currently, the 300 AHS trucks are spread across 10 of Rio Tinto’s Australian mine sites, and contribute to approximately 80% of the miner’s daily production capacity.

Jamie Sanders, Rio Tinto’s Global Head of Procurement, says: “This significant milestone is an excellent example of the partnership approach that Rio Tinto takes with its suppliers.

“Komatsu is a fantastic partner that has helped us improve our operations from a health and safety, and efficiency perspective,” Sanders says. “From the initial trial in 2008 to the work we do with Komatsu today, they have played a major role in helping us accelerate the automation of our mining processes. We look forward to continuing our collaboration into the future.”

The 300th delivery was marked with a special ‘Daruma doll’ ceremony, a Japanese ritual where one eye of the doll is painted to symbolise the setting of a goal and the beginning of a journey. Once the goal is successfully achieved, the second eye is painted