Tag Archives: battery-electric

Intramotev deploys ‘world first’ self-propelled battery-electric railcar at Cumberland mine

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

Intramotev, the technology company building autonomous zero-emissions rail solutions, says it has successfully deployed the world’s first self-propelled battery-electric railcar in a traditional freight train.

In a major step forward, Intramotev has deployed its railcar retrofit, known as the ReVolt, at Iron Senergy’s Cumberland mine in Waynesburg, Pennsylvania, USA. The car has run for over 1,000 miles (1,600 km) between the Cumberland Mine and its Alicia Harbor facility.

“We’re excited to deliver the fuel savings and environmental benefits of the ReVolt to our customer Iron Senergy,” Tim Luchini, Intramotev’s CEO, said. “Today’s news marks an important milestone in our work to decarbonise mining and freight transportation, and we’re just getting started.”

Iron Senergy CEO and owner, Justin Thompson, said: “We’re thrilled to have partnered with Intramotev to deploy their forward-thinking technology. We’re always searching for ways to double down on our commitment to innovation and sustainability, and this partnership helps accomplish that in a big way.”

Intramotev says it continues to build momentum with customer deployments in the mining sector. Later this year, the company will deploy its locomotive replacement, known as the TugVolt, at a calcium mine in northern Michigan, USA.

TugVolt is a proprietary kit that can retrofit/upfit existing rail cars to become battery-electric, while ReVolt captures waste energy in traditional trains via regenerative braking, and automated safety systems including gates and hatches. TugVolt can decouple to independently service first- and last-mile legs, providing the type of flexibility that, Luchini says, will allow the system to more readily compete with trucking. ReVolt, meanwhile, stays in the consist to capture energy via regenerative braking and reduce the overall diesel consumption of locomotives.

South32 signs off on ‘next generation’ Taylor mine development plan at Hermosa

Automation, Base metals, Environmental, Mineral project development, Mining equipment, Mining services, Power supply for mines, Sustainable mining, , , , ,

The feasibility study for the Taylor deposit, part of South32’s Hermosa project in Arizona, USA, has lived up to the mining company’s expectations, with final investment approval to develop this resource granted to the tune of $2.16 billion.

Hermosa was the first mining project added to the US Government’s FAST-41 process and is currently the only advanced project in the USA, which could supply two federally designated critical minerals, according to South32.

It is a project that is also set to apply ‘next generation mine’ design principles using automation and technology to drive efficiencies and lower operational greenhouse gas emissions. This includes a plan to incorporate battery-electric LHDs, drilling and ancillary fleets. This strategy, included in the feasibility study, results in improved efficiency, reduced diesel consumption and greenhouse emissions compared with the prefeasibility study on the project.

As well as this, the company plans to develop an integrated remote operations centre (iROC) in Santa Cruz County. The iROC will monitor and control mining, processing, maintenance and engineering to ensure the integration of activities and to optimise the entire value chain. Dry-stack tailings are also included in this development plan.

The feasibilty study highlighted a circa-4.3 Mt/y operation with average payable zinc-equivalent output of circa-253,000 t/y over a 28-year mine life. First production could occur in South32’s 2027 financial year.

The mine design for Taylor is a dual shaft underground mine, employing longhole open stoping with paste backfill. The mine development schedule has been aligned to a federal permitting process under FAST-41, which enables earlier access to multiple mining areas and an efficient ramp up to nameplate processing capacity of 4.3 Mt/y, it says. Shaft sinking is on-track to commence in the first quarter of South32’s 2025 financial year.

South32 Chief Executive Officer, Graham Kerr, said: “Final investment approval to develop Taylor is a major milestone aligned with our strategy to reshape our portfolio toward commodities that are critical for a low-carbon future.

“Taylor is expected to deliver attractive returns over multiple decades, with the feasibility study confirming the potential for a long-life, low-cost, low-carbon operation, with an initial operating life of circa-28 years, an average EBITDA margin of circa-50% and an internal rate of return of circa-12%.”

Kerr added: “As the first phase of a regional scale opportunity at Hermosa, Taylor’s infrastructure including dewatering, power, roads and site facilities, will unlock value for future growth options. These include Clark, our battery-grade manganese deposit, and potential discoveries in our highly prospective regional land package, which has already returned high-grade copper and zinc results from Peake and Flux.”

CatR1700XE

Cat R1700 XE battery-electric loader set to be showcased at major technology conference

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

Attendees at CES 2024 are set to experience the “Power of Possible” at Caterpillar Inc.’s roughly 9,600 sq.ft (892 sq.m) exhibit on January 9-12 in Las Vegas, Nevada.

This year’s display focuses on Caterpillar’s electric machines and energy solutions to meet the evolving needs of customers as they electrify their job sites, Caterpillar says, with the OEM continuing to innovate and invest in electrification, alternative fuels, connectivity and digital solutions as part of this focus.

Rod Shurman, Senior Vice President of Caterpillar’s Electrification + Energy Solutions division, said: “We are delighted to return to CES to showcase our advancements in energy solutions. This event is known as the proving ground for breakthrough technologies and global innovators which makes it the ideal place for us to showcase our leadership in power systems and integrated service solutions to help our customers in the energy transition. We’re putting our expertise to work on multiple advanced power technologies to enable the energy transition solutions that our customers need to be successful in a reduced-carbon world.”

The exhibit’s centrepiece, the Cat® R1700 XE LHD underground loader, offers a 15-t payload. The zero-exhaust emission loader includes the industry’s only on-board battery, eliminating the need to handle or exchange batteries, Caterpillar claims. It charges in less than 20 minutes when paired with two of the Cat MEC500 chargers, a standalone charging system designed to charge quickly and safely as needed.

Also on display is the company’s 301.9 mini excavator, the first machine with a Caterpillar battery.

Alongside this, the company is set to showcase lower-carbon intensity on-site power production solutions, such as generators running on a variety of renewable fuels, solar panels and hydrogen powered fuel cells, plus battery energy storage solutions, including the compact XEX60.

The on-board battery pack on display at CES is designed to power the 301.9 mini excavator with a total capacity of 32 kWh and a nominal voltage of 48 V. Cat battery packs consist of a modular design with factory integrated telematics and a rugged structure to endure the use on our heavy equipment, the company says.

Additionally displayed at CES will be a Cat 750 V electric motor and inverter, components that support a variety of machines and power systems. A 750 DC motor provides mechanical power for the machine movement when commanded by the operator. The inverter transfers power to the electric motor from an onboard Caterpillar machine power source like a generator or battery.

Lastly, Cat digital solutions will feature at CES, showcasing the ability to monitor Caterpillar equipment and power solutions for the provision of advanced analytics, transforming data into customer insights making it easier for customers to own and operate their equipment, the company said.

Wabtec-RoyHill

Wabtec premieres Roy Hill FLXdrive battery locomotive

Environmental, Mining equipment, Mining services, Power supply for mines, Steel and iron ore, Sustainable mining, , , , , , , , ,

Wabtec and its launch customer, Roy Hill, have celebrated the debut of the FLXdrive battery locomotive, the world’s first 100% battery-powered, heavy-haul locomotive for mainline service.

The ceremony unveiled the unique, striking pink-coloured locomotive at Wabtec’s design and development centre in Pennsylvania in front of employees, customer executives, and government and community officials.

“This FLXdrive locomotive represents a major step in the journey to a low-to-zero-emission future in the rail industry,” Rafael Santana, President & CEO of Wabtec, said. “The FLXdrive is driven from within by our battery technology and the innovative spirit of our employees. Roy Hill is an ideal customer to partner with given their leadership and excellent operational record.”

Roy Hill’s FLXdrive battery-electric locomotive will feature an energy capacity of 7 MWh. Based on the route and company’s rail operations, the FLXdrive is anticipated to provide a double-digit percentage reduction in fuel costs and emissions per train. Once Wabtec completes the final battery installations and track testing, the locomotive will begin its 17,000 km journey in 2024 for delivery to its new home in the Pilbara region of Western Australia, one of the world’s premier mining precincts.

Gerhard Veldsman, Chief Executive Officer, Hancock Prospecting Group Operations, owner of Roy Hill, said: “The foresight of our Executive Chairman, Mrs Gina Rinehart AO, has been instrumental in establishing an environment in which we can successfully leverage the ingenuity of our people alongside key partners like Wabtec to transform our rail and mining operations through nextgeneration technologies.

“The FLXdrive locomotive represents not only a first for the Pilbara, but a first for the mining industry. The technological smarts that have gone into the development of the loco makes it well suited for our rail network. By using regenerative braking, it will charge its battery on the 344 km downhill run from our mine to port facility and use that stored energy to return to the mine, starting the cycle all over again. This will not only enable us to realise energy efficiencies but also lower operating costs.”

Today, Roy Hill uses four Wabtec ES44ACi “Evolution Series” diesel-electric locomotives in a consist to pull trains that are typically 2.7 km in length carrying more than 33,000 t of iron ore. The addition of the FLXdrive will form a hybrid locomotive consist with Wabtec diesel-electric locomotives, and recharge during the trip through regenerative braking. The FLXdrive manages the overall train energy flow and distribution through its state-of-the-art energy management software. It is also designed with a unique battery thermal management system using liquid cooling to withstand the Pilbara heat, where ambient temperatures can exceed 55°C (131°F).

Roy Hill’s iconic pink livery symbolises the company’s commitment to assisting research and those suffering from breast cancer. To commemorate the FLXdrive’s premiere, Roy Hill, and Breast Cancer Awareness Month, Wabtec donated $50,000 to Linked By Pink, a non-profit organisation consisting of Erie area survivors diagnosed with breast cancer before the age of 45.

Epiroc registers robust mining demand in Q3

Environmental, Mining equipment, Mining finance, Mining services, , , , , , ,

Epiroc continued to register high demand from the mining sector in the September quarter, as several large mining equipment orders were won over the three-month period, leading to a 17% year-on-year rise in orders received.

This total of SEK14.36 billion (US$1.29 billion) was supported by strong organic growth and acquisitions, Epiroc said, as well as its largest order ever received – a SEK700 million agreement to supply the Kamoa-Kakula copper operation in the DRC with Minetruck MT65 S haulers, Scooptram ST18 S loaders, Boomer 282 face drilling rigs and Simba E70 S production drilling rigs.

In a quarter that included no acquisitions, Epiroc saw its operating profit increase 12% to SEK3.26 billion, while its operating margin was up at 21.7%.

Helena Hedblom, President and CEO of the company, said the quarter saw particularly strong demand for its automation and connectivity solutions, which was reinforced by a recent agreement with Boliden, Algoryx and Örebro University to evaluate autonomous face drilling options, plus a separate strengthened cooperation with Newcrest Mining to take a holistic approach towards the entire mining process at several Newcrest mines.

Outside of these financial specifics, Hedblom said the company was also looking to consolidate several functions – transactional and human resources, among them – into new regional centres of excellence to better serve customers in certain markets as part of its wider operational excellence pursuit.

“These will be rolled out region by region,” she told IM.

One such change is happening in South Africa, with the company moving production of its low-profile machines from Örebro, Sweden, to South Africa. This move follows the acquisition of Aard Mining Equipment in April of this year, and recognition of a substantial portion of the low-profile market being in southern Africa, Hedblom acknowledged.

Aard, based in Chamdor near Johannesburg, designs, manufactures, services and supports a wide range of mining equipment, specialising in low-profile underground machines for mines with low mining heights. Its products include drill rigs, bolters, loaders, scalers, and more.

BEV retrofits on the up

A key differentiator in the Epiroc electrification portfolio that has been covered extensively by IM is the company’s battery-electric retrofit options.

Launched in the March quarter of 2021 – with the first retrofit kit offered for the ST1030 underground loader – the solution was viewed as a sustainable way to electrify machinery, with the conversion kits expected to be fitted during a midlife service rebuild.

Hedblom said interest for these retrofits continued to build from the mining community, with the company scaling up the number of retrofit kit models available, the expertise and resources to enact these changes, and the “standard operating procedures” required to offer this.

“It is still early days…but over the coming years we expect to have a mix of both new [battery-electric] equipment sales and retrofits coming through,” she said.

Aeris Resources doubles its Rokion battery LV fleet at Tritton

Base metals, Environmental, Mine operation news, Mining equipment, Mining services, Power supply for mines, Sustainable mining, , , , ,

As part of its efforts to reduce greenhouse gas emissions and energy consumption at its mining operations, Aeris Resources has added a second battery-electric light vehicle to its Tritton fleet in New South Wales, Australia.

In the company’s just released annual report, it said an “electric LV troop carrier” had been delivered to Tritton in the year to June 30, 2023. It clarified that this was a Rokion R400 vehicle able to seat nine people built for underground conditions. Rokion states that, as standard, the R400 platform is able to accommodate three passengers in a utility vehicle setup or up to 12 in a passenger crew variant.

Earlier this year, Aeris confirmed it had been testing a Rokion R100 at Tritton, a vehicle that includes a four-passenger crew truck and a two-passenger utility truck.

Aeris’ Tritton operation has also previously used the battery-electric retrofit ‘TRITEV’ 20 t underground Integrated Tool-Carrier/Loader following a collaboration between 3ME and Aeris that started all the way back in 2017.

Aeris said in its annual report that the Rokion 100 vehicle is now also operational on site.

3ME Technology, UMS partner on mission to electrify Australian heavy-duty equipment space

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

3ME Technology and UMS have announced what they say is a groundbreaking partnership to electrify Australian heavy-duty equipment and revolutionise energy storage in the country with a partnership that sees UMS Australia established.

The partnership Memorandum of Understanding (MoU) is looking to solve the problem of competitive, turnkey, battery-electric solutions for the Australian heavy-duty vehicle market.

The primary objectives of UMS Australia are to deliver market-leading electrification solutions tailored to the Australian construction sector, surface mining equipment and residential energy storage systems.

Initially, UMS Australia will offer production-ready, battery-electric solutions for OEMs and distributors of heavy-duty machines. Electrification kits immediately available include the Liebherr A916 and R922/924, Bobcat E19, DAF LF Electric, Dakar MKR, DYNAPAC SD2500CS, HAMM HW90, Hyundai HX85A, Hyundai HX260AL, Junttan PMX22, Knikmops 130 & 180, Manitou, Magni RTH 6.25 and PV-E Cranes EC 80 & 160.

On top of this, the joint venture will introduce innovative battery swapping solutions, ensuring a continuous power supply while reducing emissions at construction sites and for equipment generators, the partners say.

Justin Bain (second from right), CEO 3ME Technology, said: “This partnership has been six years in the making, and we’re thrilled to kick off production and scale up in the Australian market. The timing is perfect. With our joint expertise and strong OEM customer demand, we’re set to begin production immediately. The combined capabilities will solidify UMS Australia / 3ME Technology as Australia’s premier off-highway electrifier.”

This alliance represents a significant stride toward a cleaner and more sustainable future for the Australian construction and mining industry, they say, underscoring the commitment of 3ME Technology and Urban Mobility Systems (UMS) to environmental stewardship, innovation and the delivery of practical solutions that instigate transformative change.

Boliden Garpenberg receives Sandvik’s first automation-ready battery-electric Toro LH518iB LHD

Automation, Base metals, Mine operation news, Mining equipment, Mining safety, Mining services, , , , , , , , , , , ,

Boliden’s Garpenberg zinc operation in Sweden has taken delivery of Sandvik’s first Toro™ LH518iB with AutoMine® as part of a 12-month collaborative trial of the new automation-ready 18-tonne battery-electric loader.

Considered one of the most modern mining operations, Garpenberg is the world’s most productive underground zinc mine and Sweden’s oldest mining area still in operation. The mine is now set to become the first in Europe to trial a Sandvik battery-electric loader, the OEM says.

The Toro LH518iB will support Boliden’s efforts to improve sustainability by reducing greenhouse gas emissions underground. The company’s climate targets include a 40% reduction of absolute CO2 emissions in Scope 1 and 2 and 30% reduction of Scope 3 emissions by 2030.

Jenny Gotthardsson, Garpenberg’s General Manager, said: “We are proud to be recipients of the very first Toro LH518iB with AutoMine. The unit has already undergone extensive factory testing in Finland and we look forward to really putting it through its paces now in our operation. We’re on a journey to reduce fossil fuel usage and CO2 emissions and increase productivity, and we are happy to work towards these goals with long-time partner Sandvik.”

The Toro LH518iB marries battery-electric and automation technologies. Building on the predecessor Sandvik LH518B, the Toro LH518iB features several design updates and significantly improved field serviceability. The latest version of Sandvik’s intelligent control system enables AutoMine readiness, and AutoMine compatibility will be available for Garpenberg’s Toro LH518iB in the March quarter of 2024.

The Toro LH518iB has dimensions equivalent to the 14-t size class, enabling it to fit in a 4.5-by-4.5-m tunnel. Its ground-up design, powerful electric motors and innovative electric driveline result in a compact size with higher payload capacity and increased visibility, Sandvik says.

Sandvik’s patented self-swapping battery system, including the AutoSwap and AutoConnect functions, minimises infrastructure needs and enables the loader to return to operation significantly sooner than ‘fast-charge’ mining BEVs, the company claims. The battery swap is performed by the loader itself, controlled by the operator in the cabin, without need for overhead cranes or forklifts.

Johanna Øygard, Territory Manager for North East Europe at Sandvik Mining and Rock Solutions, said: “We’re excited to see the productivity and sustainability benefits Garpenberg will gain from Toro LH518iB with AutoMine as we monitor the loader’s performance and production metrics over the next 12 months.”

In Mexico, Torex Gold is set to receive 11 Toro LH518iB battery-electric loaders as part of a 35-unit-strong hybrid fleet for its Media Luna project.

The Electric Mine Consortium and EPCA to run Cat 777 electric truck trial

Environmental, Mining equipment, Mining industry recognition, Mining services, Power supply for mines, , , , , , , , , , , , , , ,

The Electric Mine Consortium is looking to bridge the gap between the testing of electrified ultra-class haul trucks and continued rollout across industry of battery-electric underground trucks with a project to develop and trial a retrofitted 100-ton (91 t) haul truck as part of its consortium work in Australia.

It has teamed up with Electric Power Conversions Australia (EPCA), an Indigenous electric battery conversion company in Australia, to run a Caterpillar 777 haul truck electric vehicle demonstrator project.

The consortium explained: “The Electric Mine Consortium are focused across all fleet sizes when it comes to electrification. In our recent work, we have uncovered that in the area of larger surface in-pit trucks, there are some trials underway, however there is a lack of focus on the smaller trucks. Making sure we understand and trial electric technologies in smaller fleets is important to our members, and we were recently presented with an opportunity to do so by Electric Power Conversions Australia, an Indigenous electric battery conversion company in Australia.”

The conversion of the vehicle – one of the most commonly used surface trucks across the Tier 2 and Tier 3 mining company market, according to the consortium – will see the 750 kW diesel motor switched out with a 1,000 kW electric motor and 2 MWh of batteries, according to Clayton Franklin, founder and CEO of EPCA.

Franklin said he was expecting this configuration to allow for an eight-hour average run time, providing 30% more power than the diesel equivalent and the ability to move material quicker. He also predicted a 50% reduction in total cost of ownership on the battery-converted truck when compared with the diesel truck.

EPCA was founded in 2021 with the vision of providing a practical solution to the growing environmental impact of the Australian mining industry. Franklin himself was the lead engineer on a 220-t hydrogen-battery hybrid mining truck and also for an Epiroc D65 drill rig that was electrified.

The Electric Mine Consortium is a growing group of leading mining and service companies. These companies are driven by the imperative to accelerate progress towards the fully electrified zero CO2 and zero particulates mine. Mining companies Gold Fields, South32, OZ Minerals, IGO Ltd, Evolution Mining, Iluka Resources, MMG and Sandfire Resources are among the participants.

In the short time since the establishment, the consortium’s membership has grown almost two-fold, with over 40 ongoing equipment trials in 15 different locations having been mobilised.

WAE to open new facility in Oxfordshire focused on zero-emission, off-road solutions

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

Fortescue Future Industries says it is significantly expanding its battery and electric powertrain production operations in the UK with the announcement of an additional state-of-the-art facility in Oxfordshire.

Fortescue Chairman, Andrew Forrest, said the expansion is part of Fortescue’s commitment to grow its British presence through the recent integration of British manufacturers WAE (formerly Williams Advanced Engineering).

“With Fortescue’s investment, British engineering will be at the cutting edge of the green energy economy with WAE’s battery systems providing world leading technology to the entire global industrial sector,” Dr Forrest said.

Following entry-into-force of the Australia-UK Free Trade Agreement, Fortescue will open a new state-of-the-art site in Banbury, Oxfordshire, significantly expanding its UK manufacturing capability, supplying advanced batteries and electric powertrains globally.

The new location will be focused on production of a wide range of zero-emission products for the off-road sector including trucks and trains. It will form part of a new global business aimed at driving decarbonisation in all fields of economic activity, while building sovereign capabilities in emerging technology.

The factory will cover over 13,500 sq.m in total and employ over 120 highly-skilled engineers, technicians, apprentices and graduates, with recruitment for the industrialisation program starting now, FFI said.

The integration follows Fortescue gearing up to meet growing global demand for the development, manufacture and supply of advanced electrification technology solutions to the off-highway sector.

The new Banbury facility will operate alongside Fortescue’s other Oxfordshire facilities including the Kidlington factory, which will open later this year. The Banbury site will be a purpose-built facility focusing primarily on manufacturing of heavy industry, electric/zero-emission powertrain systems. It will offer automated assembly for battery modules and packs, assembly of power conversion and power systems, as well as truck and train production support.

The first prototype build is targeted for July/August 2023 with the first mining haul truck module due for completion in August 2023.

The site will officially open in 2024 and will create job opportunities across all levels, including apprentices and graduates, acting as showcases for a future rollout by WAE of further global high-tech manufacturing hubs.