Tag Archives: automation

Major Drilling demos new robotic rod handler and drill analytics to miners

Automation, Mining equipment, Mining services, , , , , ,

Major Drilling leaders in Salt Lake City, Utah, USA, recently unveiled new drills with specialised robotics and rod handling equipment for both surface and underground operations at two special innovation demonstrations for senior partners.

A Smart 8 drill, already part of Major Drilling’s updated automated underground fleet, outfitted with a sleek robotic arm, used high-powered magnetic, hands-free technology to lift and load drill rods. Teams also displayed a mobile 6M underground core drilling rig equipped with a rod presenter.

The semi-autonomous rod handling robot, developed in Utah, addresses the growing need for hands-free rod handling while supporting Major Drilling’s safety initiatives, the company says. This versatile unit can be used across various underground drills. Being fully electric, it eliminates concerns about hydraulic leaks or repairs.

Innovating these semi-autonomous drilling solutions is an important part of the future of mining. Led by VP US Operations, Kevin Slemko, the robotic arm was developed with partner Elite Automation during early 2024. Deploying robotic rod handlers is one more indicator of Major Drilling’s embracement of emerging technologies to improve efficiencies for mining partners.

At an additional demonstration event, Major Drilling teams showcased the Apex 100 ultra-advanced RC mineral exploration rig with hands-free rod handling and the LF90 rod handling conversion rig with FREEDOM™ Loader. The latter is a rod handling platform from Boart Longyear.

Customer expectations have always pushed Major Drilling to lead change and bring results. This is evident as senior mining partners regularly collaborate to test and give feedback on developing technologies which enhances not only their individual drill site but also Major Drilling’s overall performance, the company says. Present at the testing in Utah was Rio Tinto (Kennecott) and Nevada Gold Mines (Barrick & Newmont).

“As a trusted mining supplier for our USA customers, we’re always looking for ways to give them innovative answers to their challenges,” Slemko said. “So, we’re very excited to demonstrate this new semi-autonomous robotic rod handling technology along with our Rock5 drill analytics because it truly shows how our solutions are making a difference in safety, productivity and efficiency.”

Major Drilling says it is developing a new innovative suite of services that is revolutionising the use of artificial intelligence, survey tools and data analytics. Drillside GeoSolutions by Major Drilling combines the company’s traditional drilling services with borehole imaging by DGI Geoscience and automated core logging from KORE GeoSystems.

During one demonstration event, members of Major Drilling’s innovation team, David Clarke, Senior Advisor – Geological Technologies, and Christopher Klinger, Automation Technician, exhibited the complementary TrailBlazer Rock5 drill data analytics system and console being outfitted on drills fleetwide. Rock5 gathers real-time data that enhances drill team and customer safety, productivity and efficiency – a key part of Major Drilling’s suite of geosolutions delivered drillside with innovation partners DGI Geoscience Inc and KORE Geosystems.

“It all starts with the Rock5 analytics,” Clarke said. “With our integrated data, imaging and automation solutions, we’re putting together a better geological model and better downstream benefits for all.”

Epiroc’s Simba production drill rigs reach 1 million drill meters at LKAB’s Malmberget mine

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

Four of Epiroc’s teleremote-controlled Simba E6 C WL production drill rigs have surpassed 1 million drill meters at LKAB’s Malmberget mine in northern Sweden.

This achievement was made possible largely thanks to consistent high-quality service along with well-implemented automation features, the company says.

Björn Öderyd, Production Manager Drilling at LKAB’s Malmberget mine, said: “We are very happy that our Simba drill rigs keep delivering results year after year. Epiroc’s high level of service, performed by skilled technicians, is exactly what is required for today’s automated and sophisticated drill rigs.”

Four out of six Simba production drill rigs in LKAB’s Malmberget mine have now reached the milestone of 1 million drill meters, with the two remaining machines not far behind.

Initially purchased in 2012, the rigs have been operated using Epiroc’s automation solution Automatic Boom Control, ABC Total, together with teleremote control system, enabling an operator to run multiple machines at the same time. By controlling the rigs remotely, operators can enjoy a safe and comfortable work environment and increased production during night shifts and shift changes.

Rickard Johansson, Vice President Marketing at Epiroc’s Underground division, said: “This is twice the performance of the average production drill rig, showing the consistency of the operation and operators at the Malmberget mine. We are proud to see the achievements LKAB have made with our Simba drills, they are truly among the top performing mining operations in terms of Simba productivity.”

LKAB have placed an order of six additional Simba drill rigs with the first machine to be delivered by the end of 2024. The Simba rigs come equipped with the customer-unique LKAB Wassara hammers, as well as smart automation functionality.

KSB GIW breaks ground on new IoT and Automation Lab for slurry transportation

Automation, IoT, Mineral processing, Mining equipment, Mining services, Water management, , , , , , , ,

KSB GIW, a leader in the design, manufacture and application of heavy-duty centrifugal slurry pumps, has marked a significant milestone with the groundbreaking ceremony for its IoT and Automation Lab.

The event celebrated KSB GIW’s commitment to advancing sensor and automation technologies in slurry transportation. Attendees experienced live demonstrations of the company’s GIW® SLYsight and GIW RAMSL technologies, while executives Wolfgang Demmler, Head of KSB Mining; Jonathan Samuel, KSB GIW President and CEO; and Robert Visintainer, KSB GIW Vice President of Engineering, shared their visions for the lab’s impact on the company and the industry.

In his remarks, Demmler underscored the company’s commitment to customer-focused solutions, stating, “KSB GIW’s investment in the new lab is an investment in our customers. We are committed to helping customers achieve their objectives, with a key priority being the digitisation of their entire mining process. This lab will be an incubator for technologies that make this objective a reality.”

The lab’s initial focus will be on enhancing KSB GIW’s flagship IoT-enabled offerings, GIW SLYsight and GIW RAMSL. GIW SLYsight, a pump wear monitoring solution, uses proprietary sensors to measure real-time wear rates in slurry pump parts. This data helps operators make safe, effective adjustments during operation, ultimately extending pump life. GIW RAMSL is a mechanical system that automates pump adjustments, allowing engineers and maintenance teams to optimise pump performance.

With the new lab, KSB GIW plans to integrate these two technologies, creating a combined solution that provides mining operators with accurate recommendations for pump maintenance while reducing downtime and increasing efficiency.

The IoT and Automation Lab will also offer dedicated space and resources to explore new technologies that improve operational decision-making, according to the company. Visintainer highlighted the lab’s potential to deliver breakthrough mining solutions, noting, “This lab represents a significant step forward in providing innovative IoT solutions to the mining industry. With a dedicated space for R&D around IoT and automation, KSB GIW can significantly accelerate its development of these technologies. The goal is to give our customers the ability to maximise uptime and reduce costs.”

KSB GIW says its investment in the IoT and Automation Lab underscores its commitment to remaining at the forefront of mining technology and delivering industry-leading solutions in slurry transport. Samuel reiterated the lab’s alignment with KSB GIW’s mission to lead in IoT-driven innovation, stating, “We are differentiating ourselves as a slurry pump company by providing IoT technologies. When customers visit KSB GIW, Inc. and view the new lab, they’ll see that we are more than a mechanical pump company and foundry – we are a technology-driven hub for mining solutions.”

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

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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

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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.”