Tag Archives: coal

Pilot Crushtec talks up DoppiaTrac DR400 fully mobile double-roll crusher

Pilot Crushtec says Africa’s only locally manufactured, fully mobile double-roll crusher, the DoppiaTrac DR400, continues to perform well in the field of mobile coal crushing.

The DoppiaTrac DR400 now has a decade of success in the field, according to the company, achieving production rates of 300-400 t/h.

“We designed the DR400 from the ground up to give us the flexibility to produce a truly great crushing solution,” Jorge Abelho, Director, Technical Support at Pilot Crushtec, said. “It has proved itself through its combination of throughput, reliability and economy.”

The machine’s ability to reduce the generation of fines is thanks to the double-roll crusher. While a horizontal shaft impact crusher creates more coal fines due to impact energy, the double-roll crusher forces material through a constant gap, according to the company.

Pilot Crushtec Sales Engineer, Ben Armitage, said: “The crusher uses just enough energy to break the material down to the size of the gap. The DR400 generates less than 5% of 0-6 mm fines, compared to around 12% created by impact crushers – depending on coal hardness and crushing ratios.”

The DR400 boasts a large hopper that is readily fed by loaders or excavators. To increase the average production rate, the unit can be interlocked as part of a crushing train. Connected with a Metso LT106 jaw crusher, the two units can communicate to synchronise the feed rate. This optimises throughput by automatically adjusting the rate of material moving between the machines. The on-board hydraulic rock breaker on the Metso LT106 also allows oversize material to be quickly broken, avoiding blockages and preventing downtime, according to the company.

Crushing efficiency is enhanced by feeding material into the crushing chamber at exactly the same speed that the drums are spinning, Pilot Crushtec explains. This minimises attrition and friction, even at high throughput rates.

Armitage said: “The safety features on the DR400 ensure that it is compliant with demanding safety protocols applied by mining companies. These include full guarding around all moving parts, access points, nip points and crushing points – as well as pull cords and emergency stops to quickly isolate the unit when necessary.”

He explained that the efficient Volvo engine delivers the lowest kW per tonne of any mobile double-roll crusher working in the coal sector. Depending on coal characteristics, the engine’s 160 kW output can convert to a ratio of just 0.4 kW/t.

“The fuel consumption is also a significant factor for operators, and this crusher can run on as little as 17 litres per hour,” Armitage says. “This is achieved with a hydraulic load sensing system and an optimised crusher chamber design, which reduce the power needed to crush the coal.”

The quality and simplicity of the DR400 is demonstrated by the fact that over 25 of these machines are currently in operation around South Africa – one of which exceeds 22,000 hours of operation. Pilot Crushtec says it supports the DR400 through its service levels, stock holding and after-market offerings.

Thiess extends mining services stay at Wahana and Hanoman mines in Indonesia

Thiess says it has received contract extensions in South Kalimantan, Indonesia, at the Wahana coal mine from Bayan Resources and at the Hanoman coal mine from PT Cakrawala Langit Sejahtera , which mines the pits in the Satui area owned by Arutmin, part of Bumi Resources.

With a combined value of A$480 million ($320 million) over more than three years, Thiess will extend its mining services, including drill and blast, load and haul, and pit dewatering.

Thiess Executive Chair & CEO, Michael Wright, said: “We are excited to continue to deliver sustainable mining outcomes for our longstanding partners Bayan and PT CLS by working the two adjacent mines.

“These extensions reinforce our capability and credentials for operational excellence. They also give us opportunities to showcase our passionate commitment to diversity and inclusion, where we continue to increase the participation of women and people with disability in our workforce.”

Thiess President Director, Indonesia, Jeffrey Kounang, added: “The solutions we provide for both clients enable our team to maximise resource recoveries and optimise the reserves of both operations. We are proud to continuously live up to our clients’ expectations and deliver on our promises.

“We are also very pleased to be able to continue working with the Satui community, which started back in the early 2000s, to help create lasting social and economic values.”

These contract awards build on two separate agreements Thiess has signed in Indonesia, both announced this week. Thiess successfully extended a long-term contract with Bayan Resources to continue providing mining services at the Melak mining complex, in East Kalimantan, while it also secured an agreement with Kaltim Prima Coal to extend its current mining services contract and to provide fleet hire services at Sangatta mine, also in East Kalimantan.

Thiess extends KPC stay and bolts on hire services for Sangatta mine

Thiess has secured an agreement with Kaltim Prima Coal (KPC) to extend its current mining services contract and to provide fleet hire services at Sangatta mine, East Kalimantan, Indonesia.

With revenues of A$210 million ($141 million) and commencing in January 2023, Thiess will expand its services from land preparation, load and haul, asset management and rehabilitation, to include equipment hire and maintenance.

Thiess Executive Chair & CEO, Michael Wright, said: “The KPC mine in Sangatta has been an important part of the Thiess business for more than 30 years. We are proud to continue contributing to our client’s ongoing success, while extending our strong record of safe operations.

“We also welcome the opportunity to continue to work with the Sangatta community where we have been involved for some 30 years.”

Thiess President Director, Indonesia, Jeffrey Kounang, said: “Our team in Sangatta played a significant role in securing this extension, managing operations safely and meeting our client’s expectations, despite the often challenging weather impacts. And they did this while achieving a fantastic record of 10 million work hours injury free!

“This extension gives us the opportunity to continue delivering sustainable results for the client and the community, which we are so passionate about.”

Thiess has been working with KPC since October 2003 and currently undertakes a range of contract mining services for four of KPC’s pits including mine planning, stripping, blasting, overburden removal, mining and stockpiling.

Thiess to carry on with full mining services at Bayan Resources’ Melak complex

Thiess says it has successfully extended a long-term contract with Bayan Resources to continue providing mining services at the Melak mining complex, in East Kalimantan, Indonesia.

Starting in May 2023, Thiess will continue to provide full mining services including load and haul, drill and blast, coal hauling and road maintenance and rehabilitation.

Thiess previously announced an extension at the operation back in 2019.

Thiess Executive Chair & CEO, Michael Wright, said: “Thiess has been delivering excellent outcomes for Bayan Resources at Melak since 2008. We strive to continue providing sustainable mining solutions for Bayan, building on our long, successful partnership.

“This extension is a testament to our ability to deliver long-term safe and sustainable operations in Indonesia, while we continue to work on expanding our operations in other areas.”

Thiess President Director, Indonesia, Jeffrey Kounang, said: “We are pleased to be extending our operations at Melak where we have delivered exceptional outcomes for the client and community for the past 14 years, continuing our relationship with Bayan Resources.

“We are also excited about our collaboration with the West Kutai community in continuing to build a positive legacy.”

In 2008, Thiess was awarded a contract to develop and operate the Melak greenfield coal mine. The mine is divided into the two different mine concessions, Teguh Sinar Abadi and Firman Ketaun Perkasa.

Liebherr to deliver excavators and dozers to Tavan Tolgoi coal mine

Liebherr is set to deliver 17 units of dozers and excavators to Erdenes Tavan Tolgoi in Mongolia as part of a recently signed agreement with Monnis International, a large technology and equipment supplier within the country’s mining industry.

The deliveries to Erdenes Tavan Tolgoi, a long-term customer of Monnis, will take place throughout 2023 and 2024.

Liebherr and Monnia signed the agreement during the bauma 2022 trade fair in Munich, Germany.

Monnis was founded after signing a distributorship agreement with Nissan Motors Co in 1998, but the company quickly diversified from an automotive dealer to cover a wide range of industries – including the mining sector – and, in 2002, became an official Liebherr dealer.

This most recent supply contract is for a total of 17 Liebherr mining machines, comprised of eight excavators – three R 9250s, two R 9400s, and three R 9600s – and nine PR 776 dozers. These machines are to be delivered to the Tavan Tolgoi coal mine.

To ensure the fast and reliable delivery of after-sales services for Liebherr machinery, Monnis opened its Gobi branch in 2011, located approximately four kilometres from the Tavan Tolgoi coal mine. With the opening of this branch, those working with Liebherr equipment have access to spare parts, highly trained technicians, and a range of Liebherr mining products to meet the needs of any scenario that may arise on site, Liebherr says.

The new Liebherr excavators and dozers will support the existing Liebherr machinery on site, which includes two R 9200s and one R 9350.

Anglo American to remove steelmaking coal business Scope 2 emissions with Stanwell Corp pact

Anglo American says it has sourced the supply of 100% renewable electricity for its operations in Australia from 2025, agreeing terms for a 10-year partnership with Stanwell Corporation, the
Queensland Government-owned provider of electricity and energy solutions.

The deal will effectively remove all Scope 2 emissions from Anglo American’s steelmaking coal business in Australia from 2025, supporting Anglo American’s progress towards carbon-neutral operations by 2040, it said.

Dan van der Westhuizen, CEO of Anglo American in Australia, said: “Sourcing 100% renewables supply from Stanwell Corporation, linked to two major wind and solar projects in Queensland, is
a big step towards our target of carbon-neutral operations in Australia – and globally – by 2040. We are committed to playing our part to help combat climate change, including accelerating a number of technologies to abate our on-site emissions, from electrifying our truck fleet and other mobile equipment to capturing the methane from our steelmaking coal seams.

“I am delighted that we are able to support Stanwell Corporation in its investment in 650 MW of renewables capacity for Queensland. Today’s deal brings significant environmental benefits
and is net present value-positive compared with our current energy mix, while underwriting a large investment in renewable energy generation for Queensland.”

Anik Michaud, Anglo American’s Group Director of Corporate Relations and Sustainable Impact, said: “Combined with the agreements we already have in place for all our South America operations, from 2025 we expect to be drawing 60% of our global electricity requirements from renewable sources, transforming our Scope 2 emissions profile. We are committed to producing the metals and minerals that we need to mitigate the extent of global warming in the most responsible and sustainable way.”

The partnership between Anglo American and Stanwell underwrites investment in the two major Queensland renewable energy projects – Clarke Creek Wind Farm in Central Queensland and
Blue Grass Solar Farm near Chinchilla, Anglo American says.

Mastermyne goes back to Whitehaven’s Narrabri coal mine

Mastermyne, a subsidiary of Metarock Group Ltd, has secured a new two-year fixed term contract (plus two-year extension option) with Whitehaven Coal, a Tier 1 client, for the cut and flit mining method at its Narrabri Mine, in New South Wales, Australia.

This contract is a remobilisation of a former similar cut and flit contract which Mastermyne performed for Narrabri from 2017-2020.

The scope includes the installation and retraction of the panel conveyor belts, associated ventilation and mining services, the company said, adding that the contract reinforces its strong reputation to deliver quality development services.

Narrabri mine, which has been operating successfully since 2012, is Whitehaven’s only underground operation. It is approved to produce 11 Mt/y of high-quality thermal coal until 2031.

The Narrabri longwall is fully automated and is one of the most advanced in Australia, according to Whitehaven.

BUMA Australia extends relationship with BHP Mitsubishi Alliance’s Goonyella mine

BUMA Australia has won its third contract in 2022, with the mining service provider extending its relationship with BHP Mitsubishi Alliance’s (BMA) Goonyella Riverside mine in Queensland’s Bowen Basin for up to another five years.

This award covers delivering mining services at the operation and extends the company’s existing delivery scope at the mine.

BUMA Australia is a subsidiary of Bukit Makmur Mandiri Utama (BUMA), which, itself, is a subsidiary of PT Delta Dunia Makmur Tbk. The company’s Australia presence was expanded in 2021 with the acquisition of Downer EDI Limited’s Open Cut Mining East business.

The contract extension from BMA is valued at A$400 million ($268 million) over a three-year term, with the option to extend for another two years. Production is expected to average 36 million bank cubic metres per year.

On February 22, 2022, BUMA Australia announced it had secured a new A$550 million contract extension at BMA’s Blackwater mine and, on May 10, it announced a new A$320 million, three-year contract with Bowen Coking Coal’s Broadmeadow East coking coal project, with the option to extend for a further year.

Anglo American’s longwall automation milestone recognised in awards ceremony

Anglo American’s innovation-led approach to sustainable mining, FutureSmart Mining™, and a willingness to collaborate with industry parties, has enabled it to achieve a major milestone in longwall operation: 100% machine automation.

This work was recently recognised at the Queensland Mining Awards where team members received the METS Ignited Collaboration Award.

Billed as delivering a significant step change in the safety and efficiency of underground mining, the ability to remove people from hazardous situations at the face and, instead, relocate them to a purpose-built Remote Operations Centre (ROC), has enabled the company to deliver a breakthrough in performance being recognised across the underground coal mining industry.

Anglo American says the development of industry-first systems and technology for this project were completed through working collaboratively with partners including Restech, Aurecon, Komatsu, Eickhoff, Marco and GTick systems.

The miner achieved its first longwall shear fully controlled from surface in late 2018 at its Grosvenor mine in Queensland, Australia, with this milestone achieved on its Komatsu Mining longwall equipment.

Yet, it was the Moranbah North mine that became the first of the company’s three operating longwalls to achieve the 100% automation mark (pictured above).

This mine uses SL 900 shearers from Eickhoff, with a team of operational and engineering experts monitoring the longwall mining process from start to finish. These operators, located in the ROC above-ground, are able to analyse the data and drive safer operations, better decisions and achieve mining excellence, the company says.

Head of Transformation for Anglo American’s Steelmaking Coal business in Australia, Dan Reynolds, said Moranbah North has now become Australia’s most capable remotely-operated underground steelmaking coal mine, with the company’s other mines – Grosvenor and the recently-commissioned Aquila – following close behind.

“All three underground mines are now fully remote-capable, allowing operators to work from state-of-the-art ROCs on the surface of the mine,” he said.

Aquila, Anglo American’s most recently commissioned mine, is also remote-capable, allowing workers to work from a Remote Operations Centre above ground

Step change

The key drivers behind automating longwall operations were to improve safety by reducing personnel exposure to underground hazards; reduce operational variability, to deliver more stable operations and improve efficiency; and improve sustainability of operations, through ensuring automation resilience in various operating conditions.

Much of the technology required to achieve these improvements did not yet exist when Anglo American was considering such a move, and previous industry attempts at achieving sustainable autonomous and remote operations had fallen down, Anglo American said, due to:

  • Enablers not being defined to the level required;
  • Key operational systems being unavailable;
  • OEM operating logic not providing the required operational solutions;
  • The technology enablers not being available; and/or
  • The workforce not being suitably prepared.

Anglo American saw collaboration as a key tool able to overcome these issues, recognising that significant leaps forward in technology were required, including the development of various automation-enabling applications.

“Working with operational teams, the Underground Technology and Automation team developed a leading practice target operating model for integrated remote operations and automation and technology enablers after extensive workforce collaboration,” Reynolds said.

Anglo American says its Steelmaking Coal business has delivered a breakthrough performance in the development and implementation of autonomous longwall technology and remote operations for the underground coal mining industry

“It was identified early in the project that a step change in the supply of systems and technology would be required to achieve project goals. This was reached through working with the OEM and third-party technology providers, which ensured the technology and the software systems provided the solutions that met our mining requirements.”

This work required the team to work collaboratively across its underground operations and corporate partners to develop a series of industry-first safety and production systems that were required to “unlock” autonomous longwall operations, the company said.

The list of innovative, industry-leading processes and systems that the partners have developed, include:

  • A longwall remote operations framework
  • Autonomous shearer:
    • Auto duck – system solution
    • Auto gate road entry – system solution
    • Anglo Seam Steering – system/technology solution
  • Integrated remote powered roof support (PRS) control:
    • Integrated face controller – system/technology solution
    • Remote strata control – system solution
    • Enhanced logic solutions – system solutions
  • A Remote Operating Centre longwall system manager:
    • Integrated central interface solution for longwall remote management comprising:
      • Auto gate road entry
      • Anglo Seam Steering
      • Auto alerts
      • ROC reporting
      • Auto blockage detection
      • Longwall positional control
      • Creep management.

The high levels of collaboration between internal teams and third-party providers enabled these systems to be developed, according to Anglo American.

“The outcomes of this work are significant,” Reynolds said. “It is delivering a significant step change in the safety, stability and sustainability of underground mining.”

The company shed a bit more light on these innovations – many of which have been spoken of by suppliers and mining companies as the missing pieces of the fully-autonomous longwall mining puzzle – in its Queensland Mining Awards application.

“Auto duck”, for instance, allows the shearer to automatically cut under roof supports in challenging strata conditions.

“Auto gate road entry” involves the longwall shearer becoming more “intelligent”, using existing data from scanned files, PRS height data or manual measurements to determine the next cut height for the gate road.

“Seam steering” identifies whether the longwall is in or out of the coal seam by automatically detecting the tonstein band position. This, Anglo American says, is a valuable stratigraphic measure.

“Blockage detection” is conducted using eight cameras across the longwall face, which automatically detect if a face blockage is seen, alerting a ROC operator as necessary.

Similarly, “longwall alerting” sees a ROC operator alerted of potential events or issues. “Tailgate lag control” automatically identifies if the tailgate drive is lagging the face line, while “strata management logic” enables automation of shields.

The company says its Steelmaking Coal business has delivered a breakthrough performance in the development and implementation of autonomous longwall technology and remote operations for the underground coal mining industry.

PT. Putra Perkasa Abadi starts training operators with Immersive PRO5 simulator

PT. Putra Perkasa Abadi (PT. PPA) has became the first company in Indonesia to incorporate Immersive Technologies’ PRO5 Advanced Equipment Simulator technology, with the first two of four units commissioned in the PPA office at the PT Multi Harapan Utama mine site.

Launched at MINExpo 2021, the PRO5 Advanced Equipment Simulator set a new benchmark in realism, reliability and training value for operator training technology, according to Immersive.

A commissioning celebration and handover was carried out by Edwin Trisnohadi, Regional Vice President Immersive Technologies Asia & Indonesia region, and Director of PT. PPA, R. Teguh Sapto Subroto. Also present at the event were Sunaryo, Head of PPA Academy, and Teddy Ramdani, Customer Support Manager of PT. United Tractors, Tbk.

Equipped with a professional-grade visual system, the PRO5 is the first mining simulator to combine stereoscopic 3D, a one-piece curved display, photo-realistic graphics and RealView™ head tracking technology, according to Immersive. It delivers realism at a level not previously seen by the mining industry, according to the company, with these advancements helping new and experienced mining equipment operators develop competencies at a rapid pace, while maintaining high levels of learning retention.

Previously, in order to improve the competence of newly graduated workers, PPA’s only option was on-iron training. This takes extra time and also has safety risks. Now, these novice “green” workers can develop psychomotor skills and learn critical behaviors in a safe, simulated environment, while also reducing fuel consumption, according to the company.

PPA is a mining contractor, which, in recent years, has recorded significant growth to become the third largest contractor in the Indonesian mining industry.

The speed of growth requires an investment in the workforce and training tools to become more effective and efficient and to prepare personnel to become mine-ready. This year, PPA is targeting an additional 100 million bank cubic metres (BCM) above last year’s 267 million BCM. In order to achieve this target, an additional 3,200-3,500 operators are needed. The company also needs an additional 1,500-2,000 mechanics. PPA targets an addition of 150 million BCM next year, with another circa-6,000 mechanics and operators needed to support this.

To onboard 6,000 workers, PPA can no longer rely on outdated training techniques.

R. Teguh Sapto Subroto said: “Simulators will help us to develop personnel at a safe and steady pace, independently of disruptions such as weather conditions. We need this technology.”

Before arriving at the decision to buy four PRO5 platforms, PPA had made an in-depth study of simulation vendors and related solutions, according to Subroto. This involved proof of concept product testing from Immersive Technologies.

“The biggest challenge in workforce development is to rapidly develop quality talent with the skills to be safe and productive,” Subroto said. “If you recruit well, you will compete with others, but skill levels may remain 30% below ideal. To produce a quality workforce, you need the right tool that make humans more efficient and effective.”

The simulators will later be managed by the PPA Academy.

Ramdani said that this latest PRO5 simulator has only been available to the market for a short period of time and PPA incorporated it rapidly because of the value it could bring. “Hopefully it can help PT. PPA in building worker competencies, especially for operators,” he said. “PPA recorded the highest growth in the industry which must be balanced with the quality of qualified workforce.”

Trisnohadi explained: “This level of realism and reliability will help companies produce quality workforces and significant return on investment. Our goal is to help PPA in obtaining a world-class workforce, which ultimately would result in greater operational efficiency.

“This PRO5 simulator is the cutting-edge product from Immersive Technologies with the latest evolution of display systems. It is a combination of seamless curve screen with stereoscopic 3D technology which provides unmatched training value and highest levels of learning.”