Tag Archives: BeltMetrics

Weir’s ore characterisation work shifts gears to value generation loop

Chris Carpenter, VP of Technology for Weir ESCO®, is on a crusade to educate the mining industry on the importance of orebody knowledge.

As an executive with more than 35 years of experience and 40 patents to his name, he has heard numerous stories about “sub-optimal operational decisions” being made at mine sites due to a lack of information.

Through an ore characterisation project under development within several teams at Weir, Carpenter shared the company is focused on developing cost-effective solutions to provide this information in real time.

He is, however, aware that the mining sector, as a whole, needs convincing.

“I can tell you that many of our customers do not yet acknowledge the full value of what we are looking to provide the sector,” he told IM.

This is changing, with industry studies on the correlation between poor orebody knowledge and negative financial impacts and risks in the mine development process coming to light – IMDEX, the Mineral Deposit Research Unit and the Bradshaw Research Institute for Minerals and Mining at the University of British Columbia and Ideon Technologies are, for instance, currently engaged on such a study.

In announcing the study, IMDEX Chief Geoscientist, Dave Lawie, hit on a similar theme to Carpenter: “For the mining industry to adopt this technology, it must have clear evidence of the financial impacts and risks of poor or no orebody knowledge and a way of assessing the most efficient methods of collecting, analysing and optimising it.”

What “this technology” is remains open to debate, with many pre-concentration and ore sorting technologies continuing to sprout up among fertile innovation soil in the mining sector.

ESCO and Carpenter believe this technology – at least in a base metals and iron ore application context – has roots in Sustainable Development Technology Canada (SDTC), an arm’s-length foundation created by the Government of Canada to fund new clean technologies. Motion Metrics International Corp received SDTC funding back in 2020 for a project using the core innovations of hyperspectral imagery (HSI) sensors, 3D particle size distribution (PSD) analysis and machine-learning algorithms to control energy-intensive mining equipment, an SDTC backgrounder from 2020 explained.

Chris Carpenter, VP of Technology for Weir ESCO

Motion Metrics, in a separate announcement, said the 3.5-year project would lead to the design, development and deployment of a commercial mine-to-mill energy efficiency solution.

“Upon successful completion, mines worldwide will be able to order and deploy this solution, without changing their daily operations, to meet their sustainability targets while reducing their comminution costs,” it said.

University of British Columbia’s Norman B. Keevil Mining Engineering Department and several other organisations partnered with Motion Metrics for this project.

A lot has changed in the four years since this announcement, with Weir Group having acquired Motion Metrics International Corp and been incorporated into ESCO.

IM initially reported on developments of what Carpenter referred to as an “ore characterisation” project in 2022. At that time, this consisted of a BeltMetrics™ trial installation using a MOTION METRICS™ advanced imaging sensor for PSD analysis and a commercial, HSI sensor positioned above a conveyor that was directly after the crusher in a mine’s flowsheet.

When IM caught up with Carpenter in late July, he could report on not only progress with the BeltMetrics installation, but also a fixed-term trial of “ore characterisation” in a TruckMetrics™ installation.

“We have now run two different applications for the technology,” he said. “The belt monitoring trial continues to operate and has demonstrated the ability to predict SAG mill throughput based on the input ore characteristics. We also ran a very successful trial of bulk sorting using similar technology looking at the content of haul trucks. The trial monitored and analysed around 1,000 trucks and several were identified as low grade. Extensive lab testing continues as we evaluate mine ore samples to understand the capabilities of our approach. Based on our lab and field evaluations we are convinced the technology will allow us to quickly and accurately monitor grade, alteration, deportment and deleterious minerals.”

The BeltMetrics trial installation uses a MOTION METRICS advanced imaging sensor for PSD analysis and a commercial, HSI sensor positioned above a conveyor that is directly after the crusher in the mine’s flowsheet

“I would say our proof of concept work has really allowed us to now pick up the pace of investment and search for more development partners to further this technology.”

The TruckMetrics ore monitoring trial – carried out on 100-232 t-payload trucks – may pique interest here, but Carpenter says the initial product development path lies in the processing plant and on the conveyor.

“We are looking to, first, put more minimum viable products (MVPs) out in the market for belt-based solutions,” he said. “While our initial entry into this space was to look at bulk sorting – and we recognise this is still the ‘big target’ – [the] voice of [the] customer research has identified a huge need to provide plant-based systems for applications in managing stockpiles and feed grades.”

These MVPs are likely to be deployed on “development partner” sites with existing separation mechanisms downstream of the crusher – ie apron feeders – where diversions can be made based on the HSI and PSD data.

This same voice of the customer research highlighted the need for an in-pit system that could boost productivity, throughput and recovery ahead of the plant, yet the financial amount estimated for a commercial system based on the HSI and PSD sensor combination did not find favour.

“This has led to our own research into what we feel is a new-to-the-world application or modification of standard HSI,” Carpenter said. “We believe this will give us a competitive edge in the market.”

Illumination restrictions and uses have often been touted as the potential drawbacks of using spectral imaging in the ore sorting space, which IM understands is one of the areas of focus for Weir’s own R&D and lab-based testing.

But there are also other factors to consider ahead of a commercial Weir proposition – whether that is in the pit or plant – landing on the market.

“We don’t just want to be sensor salespeople,” Carpenter says. “The complexity and variety of applications will require a shift to specific solutions for our customers and the need to back that up with the aftermarket service our customers expect becoming their productivity partner.

“What we are proposing is more than just technology; it needs to be a solution that validates the value on a regular basis in a continuous loop.”

That same loop comes back to Carpenter’s and Lawie’s assessment of the industry need to acknowledge the value of such data ahead of adopting the technology.

“Fortunately, our ‘Mining technology for a sustainable future’ focus at Weir is allowing us to invest the money the industry needs to provide both the value generation and value acknowledgement to make such solutions viable and effective,” Carpenter concluded. “This type of work – and orebody knowledge more widely – is critical for the future of mining.”

Weir Group marks Minerals and ESCO progress in H1 results

The Weir Group has issued its half-year results to June 30, 2023, noting some significant achievements across its Minerals and ESCO divisions.

Headline numbers for the six-month period included a 19% year-on-year jump in revenues to £1.3 billion ($1.67 billion) and a 26% rise in operating profit to £212 million.

Weir Minerals continued to execute on key strategic growth initiatives, and during the first half gained market share in its core mill circuit product categories, it said.

The company said: “We converted 100% of our competitive field trials for large mill circuit pumps, and also rolled-out our latest cyclone technology.”

One highlight in the period came at a large Brazilian iron ore mine, where Weir Minerals upgraded the cyclones to its latest Cavex® 2.0 solution. The new cyclones, which are Synertrex®-enabled, have improved separation and increased mineral recovery by more than 400,000 t/y, according to the company.

Cavex 2 cyclones were launched in 2020, introducing new geometric features to offer performance unmatched by any cyclone in operation at that point, the company claimed. The advanced LIG+ design (patent pending) enables the Cavex 2 hydrocyclones to classify up to 30% more feed slurry, while occupying the same footprint as competitor hydrocyclones, according to Weir.

Weir Minerals says it also made good strategic progress in sustainable solutions during the six-month period and delivered year-on-year growth in comminution. New orders included a pebble crushing plant for a large copper mine in South America and a crushing solution for a potash mine in Canada.

The company also said it saw “very encouraging interest” from customers for its Redefined Mill Circuit, securing orders from large copper mines in South America for coarse particle flotation (CPF) pilot circuits, in partnership with Eriez.

“Through this strategic alliance, we have integrated CPF technology with our latest generation Warman® mill circuit pumps and Cavex cyclones to provide significantly improved recoveries and process efficiencies for our customers,” it said. “Once operational in the September quarter, these plants will be important reference sites for the industry.”

Around a year ago, Weir Minerals and Eriez Flotation announced a cooperative agreement to design and develop CPF systems. This allows both companies to better connect the Eriez equipment with the slurry classification and conveying expertise of Weir Minerals, according to Ricardo Garib, Division President of Weir Minerals.

Weir Minerals also launched its new, proprietary digital intelli-solutions for pumps, cyclones and high pressure grinding rolls which, coupled with its Synertrex 2.0 platform, captures critical machine health data and enables remote condition monitoring.

It concluded: “We continued to invest in research and development of our core technologies including new materials and polymers, and upgrades and range expansions for our industry leading Warman slurry pumps.”

Weir ESCO, meanwhile, reported that the number of mines using Motion Metrics™ AI-enabled vision technology increased during the first six months of the year, with new orders including a package of five ShovelMetrics™ and five LoaderMetrics™ systems to be deployed across all large mining machines at an iron ore mine in Western Australia.

“The division made excellent progress in growing market share in mining attachments, with a 37% year-on-year increase in orders,” it said. “A particular highlight included converting four cable shovel buckets from competitor products to ESCO technology for a large North American copper miner.”

The division also provided an update on trials of its proprietary ore characterisation technology, which has been leveraging the BeltMetrics™ solution from Motion Metrics positioned above a conveyor directly after the crusher in the flowsheet at an unnamed mine. As well as using the rugged vision technology Motion Metrics has previously used, the company is also incorporating hyperspectral imaging into the mix for this trial.

It reported: “Field trials of our proprietary ore characterisation technology were successfully completed during the first half. Tests enabled critical data to be collected and validated the performance of the technology in a real-world environment.”

Development has now progressed to the next phase focused on exploring “novel illumination” technologies to enhance minerals characterisation, it added.

New Motion Metrics capabilities and functions were launched during the six-month period, including an upgraded lens cleaning solution that enhances machine vision capability and improves response times.

“Other technology investments included development of a new series of mining attachments that, once launched, will expand our addressable market,” it said.

MotionMetrics-BeltMetrics

Weir eyes game-changing energy intensity reductions with ore characterisation project

With an extensive footprint from the rock face all the way through to tailings, it was only a matter of time before the Weir Group decided to enter the ore sorting game.

In recent years, the company has re-focused as a pureplay mining and aggregates company that can provide value throughout the flowsheet.

The company ditched its oil & gas exposure and added to its process plant and tailings remit with the acquisition of ESCO, a front-end-focused mining technology company with leading market share in the ground engaging tool (GET) segment.

Having more recently incorporated Motion Metrics into the mix – now within the ESCO division – it is embarking on a project that could have positive ramifications throughout the wider Weir Group offering.

Motion Metrics is a developer of artificial intelligence (AI) and 3D rugged machine vision technology. Its smart, rugged cameras monitor and provide data on equipment performance, faults, payloads and rock fragmentation (read: particle size distribution (PSD)). This data is then analysed using embedded and cloud-based AI to provide real-time feedback to the mining operation.

Initially developed for GET applications, these technologies have recently been extended into a suite of products and solutions that can be applied from drill and blast through to primary processing. Motion Metrics has, in the process, built up an impressive customer base and income stream, performing well since the acquisition.

Weir has outlined a £500 million-plus ($604 million-plus) emerging digital market opportunity for the entity, with much of this hinged on rugged machine vision technology, its sophisticated digital platform and the ability to add ore sensing to its offering.

This became clear at the company’s recent Capital Markets Day during a presentation from Chris Carpenter, VP of Technology for Weir ESCO.

Sensing, not sorting

At this event, Carpenter said the company was combining Motion Metrics’ PSD capability with ore characterisation technology to explore high-value opportunities for its clients.

“Looking further out, we believe ore characterisation…has the potential to transform mining by moving less rock, using less energy and creating less waste,” he said during his presentation. “Ore characterisation technology, which is underpinned by sophisticated sensing systems, captures critical data on properties and composition of rock, including rock hardness and mineral and moisture content.”

“When coupled with Motion Metrics fragmentation analysis technology, it has the potential to be a game changer, giving miners a full picture of the size and characteristics of rocks.”

Weir has outlined a £500 million-plus emerging digital market opportunity for Motion Metrics, with much of this hinged on rugged machine vision technology, its sophisticated digital platform and the ability to add ore sensing to its offering

This concept is not new. Measuring the quality of ore has been spoken of for decades and, more recently, has become a reality with the likes of MineSense, NextOre, IMA Engineering, Scantech, Malvern Panalytical and Rados International, among others, all having trialled technology or deployed commercial solutions across multiple commodities and sites.

Metso Outotec, one of Weir Minerals’ big competitors in the plant and tailings arena, has also spoken of the potential for bulk ore sorting by using its existing portfolio of material handling modules, crushing stations, mobile crushing equipment and bulk material handling solutions as the basis, while incorporating sensors from other vendors.

Weir believes it is one step ahead of its OEM counterpart in its pursuit of ore sorting, even if Carpenter is only referring to the trials currently being conducted at an unnamed copper mine as “ore characterisation” studies.

“With the acquisition of Motion Metrics, what we essentially bought was the ruggedised vision systems used in both mobile and fixed applications,” he told IM in January. “While the ore sensing piece is by no means trivial, the integrated AI capabilities and digital infrastructure that allows the data to be transported via a variety of avenues is incredibly important.

“Being able to pick up the data is one thing but being able to transport that data to the right people in a secure, accurate and timely manner is something different altogether.”

With a portfolio that includes LoaderMetrics™, BeltMetrics™, TruckMetrics™ and CrusherMetrics™, Motion Metrics and the Weir ESCO R&D team had several potential applications to start its ore characterisation journey with.

The company has settled on a BeltMetrics installation for its first trial, with Carpenter confirming the sensing solution under the microscope is currently positioned above a conveyor that is directly after the crusher in the flowsheet.

“We feel we will learn quickest over a conveyor belt, so it is really an expansion of the existing BeltMetrics solution that we will start with,” he said.

The sensing options open to Motion Metrics for this trial were also vast, with the aforementioned ore sorting vendors using the likes of X-ray Fluorescence, magnetic resonance, prompt gamma neutron activation analysis, pulsed fast thermal neutron activation, and others within their solutions.

Motion Metrics has chosen to incorporate hyperspectral imaging into its PSD mix.

Carpenter explained: “When you think about ore characterisation, we are just moving from a visual spectrum base with Motion Metrics vision-based systems to the expanded light spectrum for gathering data and making decisions. This is all being built on the established digital platform the company has.”

The company is not alone in using this type of technology. MineSense has spoken of trials using multispectral sensing technologies, while Australia-based Plotlogic has been tapping hyperspectral imaging to provide precision orebody knowledge prior to mining.

Collaborating on energy intensity reductions

Safety, scalability and flexibility were three factors taken into account with the hyperspectral imaging decision, but Carpenter was also aware of the potential limitations in using such technology.

Mines will need to be willing to make some changes and invest in alternative infrastructure to leverage the most value out of the solution the company is putting forward.

“That is where productivity partnerships that we spoke about on the Capital Markets Day are going to be really important,” he said. “It is going to be essential to collaborate with customers.”

The initial collaboration with the trial mine site looks to be extensive, stretching from the back end of December throughout 2023.

The site is already equipped with a significant amount of Weir Minerals and ESCO equipment, so the collaboration appears to have started well before this trial.

“Throughout the year, we will have the opportunity to make enhancements; starting out with an initial system that is upgraded,” Carpenter said. “By the end of the year, we should have high confidence of having something ready to commercialise. It could also be that we have other trials running concurrently with this one to extend the learnings.”

The two primary key performance indicators for the trial surround accuracy and speed, with Carpenter saying the company is targeting to at least meet the metrics competing technologies have been promoting over recent years.

“In both cases, we are well equipped to measure both and – in the initial phase – we are performing well,” Carpenter said.

“Right now, when they (the mine site) carry out an assay, they have to stop the conveyor belt, take a sample off and send it to a lab. At best, the feedback takes hours, if not days. Motion Metrics has done a really good job of building the sensors, algorithms and platforms to process the data coming from above that belt very quickly.”

There are a team of very experienced, PhD-equipped personnel currently working on this trial, monitoring the real-time results from Motion Metrics’ base in Vancouver, however there is a Weir network across the globe watching and waiting for news.

A sensor above a conveyor belt able to provide ore characterisation data is step one. Step two will most likely involve leveraging this data to provide insights as well as initiate downstream actions.

Then, there is the potential to equip these sensors for the pit on an excavator or wheel loader – which introduces many additional challenges both Motion Metrics and ESCO are aware of. Understanding exactly what is in the bank or going in the bucket will be critical to improving operational efficiencies.

These are longer-term goals that Motion Metrics, ESCO, Weir Minerals and Carpenter are cognisant of – and excited about – that may provide the true value to customers throughout the flowsheet.

“What is exciting for us is that – as may be obvious – the further upstream you can make some good decisions, the more energy you can save downstream,” he said. “As you get into some of the other processing elements in the plant, there are sustainability benefits to be had – a more efficient use of reagents to liberate the elements, a more efficient grinding setup based on ore characteristics, a reduction in water use, etc.

“The driver for this has really been sustainability and energy reduction. It is all about reducing the energy intensity associated with ore.

“We feel we are well equipped and in a good position to deliver on this and provide the industry with the step change in sustainability that it requires.”