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eHPCC: the future of grinding in mining?

Base metals, Bulk handling, Comminution of minerals, Environmental, Equipment maintenance, Mineral processing, Mining equipment, Mining events, Mining maintenance, Mining services, Precious metals, Sustainable mining, Water management, , , , , , , , , , , , , , , , , , , , , , , , ,

A lot has been made of the potential of high pressure grinding rolls (HPGRs) to facilitate the dry milling process many in the industry believe will help miners achieve their sustainability goals over the next few decades, but there is another novel technology ready to go that could, according to the inventor and an independent consultant, provide an even more effective alternative.

Eccentric High Pressure Centrifugal Comminution (eHPCC™) technology was conceived in 2013 and, according to inventor Linden Roper, has the potential to eliminate the inefficiencies and complexity of conventional crushing and/or tumbling mill circuits.

It complements any upstream feed source, Roper says, whether it be run of mine (ROM), primary crushed rock, or other conventional comminution streams such as tumbling mill oversize. It may also benefit downstream process requirements through selective mineral liberation, which is feasible as the ore is comminuted upon itself (autogenously) in the high pressure zone via synchronous rotating components. Significant product stream enrichment/depletion has been observed and reported, too.

As IM goes to press on its annual comminution and crushing feature for the April 2021 issue – and Dr Mike Daniel, an independent consultant engaged by Roper to review and critique the technology’s development, prepares a paper for MEI Conferences’ Comminution ’21 event – now was the right time to find out more.

IM: Considering the Comminution ’21 abstract draws parallels with HPGRs, can you clarify the similarities and differences between eHPCC and HPGR technology?

MD & LR: These are the similarities:

  • Both offer confined-bed high-pressure compression comminution, which results in micro fractures at grain boundaries;
  • Both have evidence of preferential liberation and separation of mineral grains from gangue grains at grain boundaries; and
  • Both have an autogenous protective layer formed on the compression roll surfaces between sintered tungsten carbide studs.

These are the differences:

  • eHPCC facilitates multiple cycles of comminution, fluidisation and classification within its grinding chamber, retaining oversize particles until the target product size is attained. The HPGR is a single pass technology dependent on separate materials handling and classification/screening equipment to recycle oversize particles for further comminution (in the event subsequent stages of comminution are not used);
  • Micro factures around grain boundaries and compacted flake product that are created within HPGRs need to be de-agglomerated with downstream processing either within materials handling or wet screening. In some instances, compacted flake may be processed in a downstream ball mill, whereas, in eHPCC, preferential mineral liberation is perfected by subsequent continuous cycles within the grinding chamber until mineral liberation is achieved within a bi-modal target size (minerals and gangue). The bi-modal effect differs from ore type to ore type and the natural size of the minerals of interest;
  • The preferential liberation of mineral grains from gangue grains generally occurs at significantly different grain sizes, respectively, due to the inherent difference in progeny hardness. eHPCC retains the larger, harder grains, hence ensuring thorough stripping/cleaning of other grain surfaces by shear and attrition forces;
  • eHPCC tolerates rounded tramp metal within its grinding chamber, however does not tolerate high quantities of sharp, fragmented tramp metal that create a non-compressible, non-free-flowing bridge between roll surfaces, which risks the damage of liner surfaces;
  • The coarse fraction ‘edge effect’ common in HPGR geometry is not an issue with eHPCC. In fact, the top zone of the eHPCC grinding chamber is presumed to be an additional portion of the primary classification zone within the grinding chamber. The oversize particles from the internal classification process are retained for subsequent comminution;
  • The maximum size of feed particle (f100) entering the eHPCC is not limited to roll geometry as is the case with HPGRs (typically 50-70 mm). eHPCC f100 is limited to feed spout diameter (for free flow) and dependent of machine size ie eHPCC-2, -5, -8 and -13 are anticipated to have f100 60 mm, 150 mm, 240 mm and 390 mm, respectively. The gap between rolling surfaces is greater than the respective f100; and
  • eHPCC technology shows scientifically significant product stream enrichment.

IM: What operating and capital cost benefits do you envisage when compared with typical HPGR installations?

MD & LR: Both operating and capital cost benefits of the eHPCC relative to HPGR technology are due to the eHPCC not requiring the pre-crushing and downstream classification equipment required by HPGRs.

The eHPCC operating cost benefits are associated with eliminating maintenance consumables, downtime, reliability issues and energy consumption associated with the equivalent HPGR downstream equipment listed above.

The eHPCC capital cost benefits are associated with eliminating the real estate (footprint) and all engineering procurement and construction management costs associated with the equivalent HPGR upstream/downstream equipment listed above. eHPCC flowsheets are likely to be installed as multiple ‘one-stop’ units that maintain high circuit availability due to ongoing cyclic preventative maintenance.

IM: Where has the design for the eHPCC technology come from?

LR: It was invented in early 2013 by me. I then pioneered proof-of-concept, prototyping, design and development, culminating in operational trials in a Kazakhstan gold mine in 2020. A commercial-grade detailed design-for-manufacture has since been undertaken by a senior team of heavy industry mechanical machine designers and engineers.

IM: In your conference abstract, I note that the eHPCC technology has been tested at both laboratory and semi-industrial scale with working prototypes. Can you clarify what throughputs and material characteristics you are talking about here?

LR: The first iteration of the technology, eHPCC-1, was tested at the laboratory scale from 2013-2015. This proof-of-concept machine successfully received and processed magnetite concentrate, copper-nickel sulphide ore, alkaline granite, marble and a wolfram clay ore dried in ambient conditions. The typical throughput was between 200-400 kg/h depending on the feed size, particle-size-reduction-ratios (dependent of grain size) and target product size. The feed size was limited to a maximum of 25 mm to ensure free flow of feed spout.

Alkaline granite: eHPCC-2 coarse product (left) and fine product (right)

MD & LR: From 2016-2020, we moved onto the semi-industrial scale testing with the eHPCC-2 (two times scaled up from eHPCC-1). This was designed for research and development (R&D) and tested on magnetite concentrate, alkaline granite, and hard underground quartz/gold ore. The throughput capabilities depended on the geo-metallurgical and geo-mechanical properties of feed material, such as particle size, strength, progeny (grain) size and particle size-reduction-ratios (subject to confined bed high pressure compression). Larger-scale machines are yet to be tested against traditional ‘Bond Theory’ norms.

The eHPCC, irrespective of the outcomes, should be evaluated on its ability to effectively liberate minerals of interest in a way that no other comminution device can do. The maximum feed size, f100, at the gold mine trials was limited to 50 mm to ensure free flow through the feed spout. R&D culminated in pilot-scale operational trials at the Akbakai gold mine (Kazakhstan), owned by JSC AK Altynalmas, in 2020, where SAG mill rejects of hard underground quartz/gold ore were processed. The mutual intent and purpose of the tests was to observe and define wear characteristics of the eHPCC grinding chamber liners (roll surfaces). These operational trials involved 80% of the feed size being less than 17 mm and a variety of targeted product sizes whereby 80% was less than 1 mm, 2 mm, 2.85 mm and 4.8 mm. The throughput ranged from 1-5 t/h based on the size.

IM: What throughputs and material characteristics will be set for the full-scale solution?

LR: There will be a select number of standard eHPCC sizes. Relative to the original eHPCC-1, the following scale-up factors are envisaged: -2, -3, -5, -8, and -13. These are geometrical linear scale-up factors; the actual volumetric capacity is a cube of this factor, with adjustments for centripetal acceleration. Currently -13 times seems to be the maximum feasible size of the present detailed design philosophy, but there are no foreseeable limitations in terms of feed materials with exception to moist clay. Clay was successfully processed after drying the feed in ambient temperatures during testing. Further testing of moist clays blended with other materials that can absorb the moisture as they comminute would be desirable.

IM: Other HPGRs can also be equipped with air classification technology to create dry comminution circuits. What is the difference between the type of attrition and air classification option you are offering with the eHPCC?

MD & LR: Two modes of comminution occur in the particle bed of eHPCC repetitively and simultaneously. First, confined bed pressure compression breakage occurs at a macro level that promotes shear/compression forces greater than the mineral grain boundaries. Second, Mohr-Coulomb Failure Criteria (shear/attrition) that completes the separation of micro fractures on subsequent cycles takes place.

The nip angle between the rotating components of eHPCC technology never exceed 5°. During the decompression and fluidisation portion of the cycle, the softer species – which are now much smaller – are swept out of the fluidised particle bed against centrifugal and gravitational forces by process air. The larger species, influenced by centripetal acceleration, concentrate at the outer diametric and lower limits of the conical rotating grinding chamber, continuing to work on each other during each subsequent compression phase.

HPGRs are limited to one single-pass comminution event, requiring downstream external classification and subsequent recycling/reprocessing of their oversize and/or flake product.

IM: How will it improve the mineral liberation and separation efficiency compared with other grinding solutions that combine both?

MD: eHPCC technology could compete with the Vertical Roller Mill and Horomill, however, eHPCC is likely to be more compact with high intensity breakage events contained within the all-inclusive system of breakage, classification and removal of products.

IM: When was it most recently tested and over what timeframe?

LR: The eHPCC-2 pilot plant was mobilised, setup and commissioned in March 2020, but its operation was suspended until June 2020 due to COVID-19 quarantine restrictions and a need to cater to abnormal amounts of ball fragments in the feed, the latter of which pushed the treatment of tramp metal to the extreme. The machine operated for the months of June and July using liners constructed of plasma transferred arc welded (PTAW) tungsten carbide (TC) overlay. During this period, a total of 795 t was processed at various targeted product sizes, with, overall, an average throughput of 3 t/h (nominally 265 operating hours) processed.

Side view of pilot system including feed hopper and weigh-scale feeder (right), feed conveyor (middle foreground), control and auxiliaries (middle background), eHPCC-2 (left foreground), dust bag-house (left background) and product conveyor and stockpile (not shown left background)
Front-end loader filling feed hopper with SAG mill rejects f80 18 mm

The PTAW-TC overlay was deemed unsustainable as it was consumed rapidly and demanded continuous rebuilding due to the high pressure intensive abrasive wear on the convex cone. The pilot plant operation was mostly suspended during the month of August while an alternative tungsten carbide studded liner, analogous to HPGR studded rolls, was manufactured for simulating a trial of this studded liner philosophy. The studded liner philosophy was operated in the eHPCC-2 in Kazakhstan for sufficiently long enough to ascertain the creation of the autogenous protective wear layer of rock between the studs, with the simulation trial deemed a success. The design philosophy shall be adapted on the commercial-grade eHPCC.

eHPCC-2 TungStud™ as-new (left) high-pressure-air-cleaned (middle) and brushed (right)

The pilot plant was demobilised from the Akbakai site laydown area on September 10, 2020, to release the area for construction of a non-related plant expansion. The operational experiences of the pilot plant at Akbakai provided valuable knowledge and experience pertaining to mechanical inertia dynamics and design for eliminating fatigue within eHPCC components.

IM: Aside from the test work on trommel oversize at the Kazakhstan gold mine, where else have you tested the technology?

LR: eHPCC has no other operational experiences so far. Investment and collaboration from the industry to progress the commercialisation of eHPCC is invited. The commercial-grade eHPCC-2.2 is designed and ready for manufacture.

IM: Is the technology more suited to projects where multiple streams can be produced (fines, coarse piles, etc)?

LR: eHPCC is configurable to meet the demands and liberality of a diverse spectrum of feed materials and the potential downstream extractive processes are complementary to eHPCC product streams. Therefore, it would be incorrect to categorise it as more suitable in any one niche; it is configurable, on a case-by-case basis, to meet the liberality of the specific progeny of the feed.

IM: What energy use benefits do you anticipate by creating a one-step comminution and classification process over the more conventional two-step process?

MD & LR: The energy saving benefits include:

  • Elimination of tumbling mill grinding media consumption;
  • Elimination of the liberal wastage of randomly directed attrition and/or impact events that indiscriminately reduce the size of any/all particles (gangue or precious mineral) with the conventional tumbling mill; and
  • Elimination of energy consumption of the materials handling systems between the various stages of comminution and classification, be it dry belt conveying, vibrating screens, classifiers, cyclone feed pumps, cyclones and their respective recirculating loads that can be upward of 300% of fresh feed.

IM: Do you anticipate more interest in this solution from certain regions? For instance, is it likely to appeal more to those locations that are suffering from water shortages (Australia, South America)?

MD & LR: We suspect the initial commercialisation growth market to be from base metals producers seeking to expand or retire existing aged/tired comminution classification capacity, followed by industry acknowledgement of the technology’s potential to shift the financial indicators of other potential undeveloped projects into more positive territory. This latter development could see the technology integrated into new projects.

In general, the technology will appeal to those companies looking for more efficient dry comminution processes. This is because it offers a pathway to rejection of gangue at larger particle sizes, early stream enrichment/depletion and minimal overgrinding that creates unnecessary silt, which, in turn, hinders or disrupts the integrity of downstream metallurgical extraction kinetics, and/or materials handling rheology, and/or tailings storage and management.

LR: There are a number of rhetorical questions the industry needs to be asking: why do we participate in the manufacture and consumption of grinding media considering the holistic end-to-end energy and mass balance of this (it’s crazy; really why?)? Why do we grind wet? What are the barriers preventing transition from philosophising over energy efficiency, sustainability etc and actually executing change? Who is up for a renaissance of bravely pioneering disruptive comminution and classification technology in the spirit of our pioneering forefathers?

The more these questions are asked, the more likely the industry will find the solutions it needs to achieve its future goals.

Dr Mike Daniel’s talk on eHPCC technology will be one of the presentations at the upcoming Comminution ’21 conference on April 19-22, 2021. For more information on the event, head to https://mei.eventsair.com/comminution-21/ International Mining is a media sponsor of the event

Vuzix Smart Glasses keep Rio global teams connected at Oyu Tolgoi Underground

Base metals, Communications in mining, IoT, Mineral project development, Mining services, Mining software, Precious metals, , , , , , , , ,

Rio Tinto has deployed Vuzix Smart Glasses at the Oyu Tolgoi copper-gold mine in Mongolia to continue progressing the development of the underground project in the face of travel restrictions tied to COVID-19.

Vuzik, a supplier of smart glasses and augmented reality technology and products, says the company is using its smart glasses to enable technical experts from all over the world to work with local teams on the underground project.

Rio, in its 2020 Annual Report, said it had been increasing its use of drones and mine pit cameras, and introduced video headsets (including smart glasses) to conduct visual inspections of tailings facilities and equipment while complying with travel restrictions and physical distance requirements.

“Vuzix Smart Glasses usage continues to expand across an ever-widening array of industry verticals,” Paul Travers, Vuzix President and Chief Executive Officer, said. “Companies like Rio Tinto, which is a global leader in its field, continue to provide validation of the value and effectiveness of our products in real world situations.”

Anglo’s Quellaveco to receive the coarse particle recovery treatment

Automation, Base metals, Comminution of minerals, Environmental, Mineral processing, Mineral project development, Sustainable mining, Water management, , , , , , , , , , , , , , ,

Anglo American has approved the construction of a coarse particle recovery (CPR) plant at its in-development Quellaveco copper project in Peru.

The announcement came within the company’s 2020 financial results, which showed Anglo generated underlying EBITDA of $9.8 billion and a profit attributable to equity shareholders of $2.1 billion for the year.

CPR, Anglo says, is one of many significant breakthrough technology initiatives that has the potential to increase throughput and productivity, while simultaneously reducing environmental footprint, through rejection of coarse gangue (near-worthless waste material), dry stacking of sand waste, minimising the production of traditional tailings and reducing overall water consumption.

The CPR plant signoff at Quellaveco follows a full-scale demo plant installation at the company’s El Soldado mine in Chile – which is ramping up to full capacity by mid-2021 – and the decision to construct a full-scale system at the Mogalakwena North PGM concentrator in South Africa.

The El Soldado plant used the HydroFloat™ CPR technology from Eriez’s Flotation Division. Here, a single 5 m diameter HydroFloat cell, the largest in the world, treats 100% of mill throughput, with the objective of proving the waste rejection process at full scale.

Anglo said of the Quellaveco CPR plant: “This breakthrough technology will initially allow retreatment of coarse particles from flotation tailings to improve recoveries by circa-3% on average over the life of the mine. This investment will also enable future throughput expansion which will bring a reduction in energy and water consumption per unit of production.”

The capital expenditure of the CPR project is around $130 million, with commissioning of the new plant expected in 2022. DRA Global previously carried out a feasibility study for the CPR plant at Quellaveco.

In terms of Quellaveco project progress, Anglo said today that, despite the COVID-19-related slowdown, first production was still expected in 2022. This was, in part, due to the excellent progress achieved prior to the national lockdown, and based on optimised construction and commissioning plans, Anglo said.

Key activities in 2021 include the start of pre-stripping, which will see the first greenfield use of automated hauling technology in Peru; progressing construction of the primary crusher and ore transport conveyor tunnel to the plant; completion of the 95 km freshwater pipeline that will deliver water from the water source area to the Quellaveco site; completing installation of the shells and motors for both milling lines; and completion of the tailings starter dam.

The mine, owned 60% by Anglo and 40% by Mitsubishi Corp, comes with a production blueprint of 300,000 t/y over the first 10 years of the mine.

From compliance to commitment: a key opportunity for the global mining industry

Automation, Communications in mining, IoT, Mining events, Mining people, Mining safety, Mining software, , , , , ,

In the lead up to the AusIMM Underground Operators Conference in March, Roy Slack, immediate past President of the Canadian Institute of Mining, Metallurgy and Petroleum (CIM) and Underground Operators keynote speaker, has shared his insights on the future of underground mining and the positive impact technology can have on safety.

With 35 years of global experience in mine construction, design and development, Slack is passionate about securing the mining industry’s place as a global leader for change.

“Our industry is on a journey from compliance to commitment,” he said. “From a state where we strive to just meet regulatory requirements, to a place where we meet and far surpass those requirements – not because we are legally required to do so, but because it is a moral imperative.”

Slack discusses how young professionals have an exciting opportunity to build the future of underground mining.

“Today’s youth are entering the industry, or have the opportunity to enter our industry, at a time of great change,” he said. “Change in technology, change in how we deal with people, change in the overall business model that is mining.”

As the mining industry rapidly transforms with new technologies and exciting innovations, Slack believes the whole sector needs to get on board with a fresh way of thinking.

“We need people that thrive on change, that embrace and know what to do with it.”

After such a challenging year, Slack is confident in the resiliency of the mining industry.

“What we continue to see during this pandemic is our industry recognised as an essential service, and mining companies taking the lead when it comes to establishing protocols to protect their people from the virus,” he said.

The industry’s reaction to COVID-19 displayed its agility in adjusting to circumstances, Slack says.

“Productivity did not suffer, and employees were able to better deal with work and home needs.”

Slack has been active in numerous safety initiatives over the years, as well as being appointed to the Province of Ontario’s first Prevention Council, advising the government on workplace safety. He also chairs the CIM Safety Committee.

He says new technologies will create a real sense of support and safety in the workplace for all professionals.

“I am excited about the huge potential of emerging technologies to make our workplaces not just safer, but safe,” he said. “Technology has always been an important part of safety, but the more recent applications of the technology available to us add a whole new perspective on our journey to zero injuries.”

Slack looks forward to the positive and safer benefits technology can create for on-site workers, with the pandemic in some cases speeding up the implementation of automation, remote operations and more.

Ultimately, Slack sees best practice in safety as a three-part equation: “Process, culture and technology; together protecting our people and ultimately achieving a safe workplace,” he said.

AusIMM’s Underground Operators Conference will be held from March 15-17, 2021, via a hybrid format, which offers an opportunity for delegates to attend face-to-face in Perth, Australia or online.

Find out more at https://www.ausimm.com/conferences-and-events/underground-operators

International Mining is a media sponsor of the event

Primero completes WHIMS project at Fortescue’s Christmas Creek iron ore op

Comminution of minerals, Mine operation news, Mineral processing, Mining services, Steel and iron ore, , , , , , , , , ,

Primero Group says it has completed the construction of a Wet High Intensity Magnetic Separation (WHIMS) processing plant at Fortescue Metals Group’s Christmas Creek iron ore mine in Western Australia.

The plant is expected to improve product grade and mass recovery from the desands unit at the Christmas Creek Ore Process Facility #2.

The flowsheet is based on a simple and robust configuration, where wet screen undersize at a nominal -1 mm is treated in open circuit through a low intensity magnetic stage, followed by a vertical WHIMS stage to produce a concentrate stream and a tailings stream, which can be integrated with the existing process and auxiliary equipment. The vertical WHIMS project entails the redirection of the wet screen undersize stream from the existing scrubbing circuit to feed the brownfield magnetic separation plant.

“We can proudly say that despite the impacts of COVID-19 and the fast-tracked nature of the project, the plant was successfully delivered and commissioned in less than 12 months – meeting all safety and project key performance indicators,” the company said.

Primero put the project’s success down partly to the “enhanced opportunity for collaboration early contractor involvement (ECI) provides”.

It added: “A flexible approach to project development that ensures the needs of all project stakeholders can be met prior to detailed design and implementation in a lump sum engineering procurement and construction (EPC) environment. This constructive, relationship-based contracting continued throughout construction, commissioning and now operation – demonstrating the power of the ECI contracting model when coupled with Primero’s unique, vertically integrated EPC capability.”

IMDEX excited by structural changes in mining industry

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IMDEX has heralded what it says is long-term structural change in the mining industry, as it reported a strong start to the first half of its financial year.

Delivering the company’s half-year results, IMDEX Chief Executive Officer, Paul House, revealed a robust balance sheet with a net cash position of A$47 million ($36 million) in the six months ending December 31, 2020, up 84% on the same time last year.

The company reported EBITDA of A$33.1 million, up 6% on the same time last year and 43% on the second half of 2020, on revenue of A$124.3 million, down 3% on the same time last year, but up 13% on the second half of 2020.
House said the balance sheet strength enabled the company to accelerate targeted research and development in line with demand, and leverage opportunities for growth through acquisitions.

He said IMDEX continued to navigate the impact of COVID-19 on its global operations and had responded to increasing demand for remote working technologies and software, upgrading IMDEXHUB™ and releasing new ioGAS 7.3™ geochemistry data analysis software.

The company has a record number of gyro-related technologies on rent and reached a milestone with a record number of instruments on rent for December and January, it said.

“While the opportunity ahead of us is exciting, we remain watchful and ready,” House said. “We are watchful of the current risks posed by COVID and ready to meet the increasing demand for mining technologies.

“This confluence of risk and opportunities is accelerating long-term structural change in the mining industry.”

House said activity increased in most regions, most notably Canada, the US and West Africa, boosted by strong industry fundamentals.

“Our global reach and unrivalled product offering mean we can grow in all market conditions,” House added.

IMDEX said the positive outlook for mining technology was being driven by investment in metals tied to decarbonisation such as aluminium, cobalt, copper, nickel and lithium; mining’s essential role in the global economic recovery; and the minerals industry embracing new technologies.

The overall industry drivers are being reflected in increased exploration budgets, the company added.

IMDEX also reported in these results that it had signed a joint development agreement with a Tier 1 mining company to accelerate one of its key “rock knowledge sensor” technologies for commercial use. It also has a joint development agreement to accelerate its drilling optimisation tool IMDEX MAGHAMMER™ for commercial use, with ground trials under that agreement having started.

Yancoal’s Moult to talk up METS supplier relationships at Austmine 2021

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The Austmine 2021: Harnessing Intelligence Mining Innovation Conference & Exhibition is set to open the stage to a host of high-calibre guest speakers, including Yancoal’s recently appointed CEO, David Moult.

Moult, who took on the role of CEO at Yancoal in March 2020 as COVID-19 entered Australia’s shores, has successfully navigated Yancoal through a tumultuous year, the event organisers said.

“Disruption is not new to the coal industry, though it was during the pandemic that the company’s innovation, resilience and ability to rapidly adapt came to the forefront,” they said.

Moult said the coal industry has been through many cycles for different reasons, which is what makes the industry competitive, entrepreneurial, responsive and resilient.

“Of course, no one could have anticipated the extent and impact of the COVID-19 pandemic this year, and the ramifications are far-reaching and ongoing,” Moult said. “At Yancoal, the way to survive the level of volatility the pandemic created was to be at the right end of the cost curve. Our portfolio of low-cost assets and a good workforce also gave our company the strength to survive, and it will continue to do so in the future.”

Despite a year of turmoil which has seen some companies fold, Yancoal is well positioned for ongoing growth, the event organisers said.

Moult said: “We will continue obtaining acquisitions – though with a focus on value not volume accretion. We will also expand and extend our existing projects – such as the Moolarben and Mount Thorley Warkworth mines where we’ve already identified additional production capacity.”

Yancoal’s values of Innovation, People, Safety, Integrity and Excellence, has been a standout in the heart of its people and business as the year has unfolded, Moult says.

“Whether it was working from home or installing thermal imaging to monitor worker health at mine sites, everyone worked together to implement work practices and measures to mitigate COVID related risks.

“It was through the ideas of our people that Yancoal was able to drive innovation, satisfy customers and create value for shareholders. It was a direct result of their work that we experienced minimal disruption to our operations and succeeded to meet our operational targets.

“With everyone’s efforts, by September we had achieved a reduction in our unit cost to A$60 ($46) a tonne and still made our financial targets. That’s an impressive result at a time when inflation was stagnant and some parts of the industry were at a standstill.”

Yancoal employs 4,000 workers across its 11 sites in regional areas across Queensland, Western Australia and New South Wales.

“These regions are home to our employees, our suppliers and service providers, as well as their families and friends,” Moult said. “It is critical that these communities thrive and are provided every possible opportunity to reach their full potential.

“Our mandate of safety, security and wellbeing is not only about our people on site – it extends to their families and the communities in which they belong.”

Yancoal has invested A$1.6 million into 177 local initiatives in 2019 to support the local communities in which it operates, the event organisers said. It has continuously explored new ways of undertaking routine processes to improve efficiency and safety on the modern mine site.

“At our Moolarben Underground Mine, in New South Wales, we elevated levels of automation for longwall mining as well as established new continuous miner, coal clearance, pumping and conveyor systems. At Cameby Downs Mine in Queensland, we trialled the automation of dozer-push operations.”

Moult also attributes Yancoal’s success in 2020 to its relationships with mining, equipment, technology and services (METS) suppliers, and he has some advice for new suppliers entering the marketplace.

“Premium METS suppliers are collaborative, flexible and innovative,” Moult explains. “During the pandemic, our suppliers exhibited a ‘no surprises’ mindset. This approach allowed us to work together closely to address supply challenges as they arose.

“For new METS suppliers it’s a valuable learning to consider when talking to decision makers. Suppliers need to clearly set out their value proposition and how they offer efficiency and cost perspectives that practically align to how a company does business, whether that’s in procurement or in another area.”

Last year alone, Yancoal assets produced 52.1 Mt of saleable coal for international markets.

Moult said: “Coal is a vital part of a robust energy mix and essential for developing economies. While the percentage share of coal in the mix may lessen as new energy sources reach a maturity in the marketplace, the demand and volume of coal will remain strong across the globe.”

Moult will be speaking at the Austmine 2021: Harnessing Intelligence Mining Innovation Conference and Exhibition, which will take place from May 25-27, 2021, at the Perth Convention and Exhibition Centre, in Western Australia.

Held every two years, the Austmine Conference features more than 50 mining innovation and technology experts across a two-day conference program and interactive pre-conference workshops. The event includes a series of educational and networking opportunities, including a trade exhibition featuring live demonstrations, the collaborative Ideas Exchange, Meet the Miners and the Austmine Industry Leaders’ Dinner and Awards.

For more information visit: www.austmineconference.com.au

International Mining is a media sponsor of Austmine 2021

MST Global on the rise of remote operating centres in mining

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The spread of COVID-19 has seen renewed interest in remote operating centres (ROCs) and how they can be better managed to maximise efficiencies and reduce the number of personnel required on a mine site at a time, according to MST Global.

Rio Tinto was one of the early adopters of ROCs, introducing the world’s first fully autonomous haul trucks at its Pilbara iron ore operations in 2008 followed by the launch of an automated hub in Perth, Western Australia, in June 2010, which controlled its rail systems, infrastructure facilities and port operations, 1,500 km away from site.

In July 2013, BHP followed suit, opening an automated ROC in Perth for its seven Pilbara mines. Today, all the major players globally have introduced similar ROCs to their operations.

“As an underground mining technology provider, it has been an exciting time to be a part of the industry as we develop hardware and software solutions that help our mining partners through this digital transition,” MST Global said.

In a recent report, McKinsey & Company confirmed MST’s observations, citing, in the middle of the COVID-19 pandemic, mining executives had shown a greater interest in ROCs to unlock further value for their operations.

“As mining companies seek to mitigate the impact of the COVID-19 pandemic and act to safeguard employees, some have started to relocate around 15-20% of their on-site workforce by setting up ‘control towers’ to facilitate remote working (especially for non-frontline roles like subject-matter experts),” McKinsey & Company stated.

“This is helping the industry develop more resilient, responsive and flexible operating models suited to an increasingly uncertain environment.”

MST Global says it has seen this first-hand, with many existing and new clients reaching out to the mining tech provider to assist in streamlining their operations, and looking at ways to effectively increase remote work capabilities.

MST Global CEO, Haydn Roberts, said the discussion has also centred on the transition to a smart mine, where systems and processes in place on site work together to unlock greater value for ROCs.

“COVID has really focused our minds on the importance of having enough bandwidth underground and adopting IoT and digitalisation strategies so we can have a smart mine where our sensors and video cameras are connected, and we can operate in a remote way,” Roberts said.

“Remote operation centres have become really key because of all those things, so that’s driving the change.”

The challenges

Mining companies are admittedly still in the early stages of their digital transformation, continuously looking at ways to improve to deliver on objectives.

McKinsey & Company said: “Some companies have implemented cloud-based systems that aggregate site data into a single data lake that can be accessed, analysed, and visualised for decision support, creating a ‘room of screens’; other companies manage and actively control plant automation systems, fleet management systems, and remote-controlled machines from the ROC.

“The most sophisticated companies manage all these functions on a larger geographic scale, covering the value chain from end to end, optimising post-processed ore logistics and port facilities used by multiple mine sites within a region, with regional parts and supply warehouses monitored across multiple assets for supply-chain optimisation.”

McKinsey said while the technology adoption was “the easy part”, its research revealed a common challenge: “insufficient emphasis on and investment in developing a robust change-management strategy and subsequent implementation.”

It highlighted the importance for leaders to set clear expectations of bottom-line impacts from ROCs to measure value and the need for a new decision-making structure to allow ROCs to reach their full potential.

“Without a new mandate, a new way of working, and a new decision-making structure, the ROC staff will struggle to capture the frontline team’s attention,” the report stated. “And, although the ROC is implemented and functional, it never reaches full potential for value. Without a conscious focus on organisation, a ROC can be counterproductive, creating redundant organisational structures.”

It added careful consideration must also be given to data and systems reliability, location of primary physical storage infrastructure, back-up systems and having a robust cybersecurity approach to protect ROCs from potential threats.

“These decisions can impact connectivity, bandwidth, and latency, each of which must be sufficient to enable the ROC to effectively control on-site operations in real-time: for example, adjustment of plant processing parameters or remote control of mobile equipment and process optimisation tools, such as machine-learning algorithms,” it stated.

“With the right technology foundation, the ROC can function as the analytical centre of excellence, setting data standards, creating and updating analytical optimisation models, building analytics capability and driving partnerships to co-develop solutions aligned with the new planning process for optimising site-level profit. Such actions can move the organisation toward new ways of thinking about hierarchy, decision rights, and ways of working.”

Digitalisation: what this means for jobs

There was also the issue of jobs, and how transitioning to autonomous operations and ROCs will impact workers on site.

MST Global’s Roberts said from his experience, so far with ROCs, this wasn’t something the industry should be too concerned about.

“I know some people talk about a fear that we’re going to take people out of mining and people will lose jobs,” he said. “I actually see the exact opposite of that. I think it is going to bring more people together in more meaningful work, more productive relationships.

“We’ll focus on things that will bring a new lease of life to mines. Yes, we will remove people out of harm’s way and perhaps machines, but the amount of upside there is to actually work with these solutions, from AI to big data analysis to automating and adopting more smart sensors, this is going to create a more interesting future for a lot of people.

“Mining is not going away. We obviously have to adapt it and change it to these new technologies and solutions that we have available. The people that we’re bringing into this industry expect that.”

MST Global concluded: “At MST Global, we are proud to be helping our mining partners globally embrace the transition to the smart mine and ROCs – no matter where they are at in their journey – through our leading software and hardware solutions.

“Our brand-new software platform HELIX helps underground miners create a complete digital ecosystem underground, connecting all their hardware and third-party integrations into one single platform that provides real-time data anywhere, anytime, on-site or thousands of kilometres away in a ROC.”

Nutrien increases use of Triax’s Proximity Trace tech to curb COVID-19 spread

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Nutrien says it is expanded its use of proximity monitoring and contact tracing technology, Proximity Trace™ from Triax Technologies, to its potash mines in Saskatchewan, Canada, as it looks to continue tracking and combatting the spread of COVID-19.

More than 8,000 employees are using the technology to date, with an additional 6,500 expected to be part of the expansion in the coming months, representing 65% of Nutrien’s global employee base.

At the start of the pandemic, Nutrien was deemed an essential service in its core markets for its role in supporting the agriculture industry. To help mitigate the spread of the virus, Nutrien partnered with Triax to help its workers maintain a minimum of 6 ft (close to 2 m) of physical distancing and automatically capture data about their interactions with co-workers, as part of its COVID-19 protocols.

Originally deployed last July at Nutrien’s nitrogen and phosphate sites in the US, Proximity Trace is now being rolled out at Nutrien’s potash mines in Saskatchewan and at corporate offices in Colorado, Illinois, Alberta and Saskatchewan, it said.

Nutrien EVP & Chief Information Officer, Brent Poohkay, said: “In the early days of the pandemic, global health authorities called upon the private sector to step up and do our part to help flatten the curve and slow the spread of COVID-19. Nutrien developed a playbook that articulates a strategy and a plan for handling the virus, and the Triax system has been valuable in keeping our essential workers safe to help ensure a health crisis doesn’t become a food crisis.

“Now we are expanding the playbook as we redefine the future of work with safety and integrity at the forefront.”

Proximity Trace tags are attached to workers’ clothing or hard hats and produce an audio and visual alert to those who come within 6 ft of one another. These wearable sensors also automatically log data for leaders to quickly perform contact tracing if a positive case arises, thereby preventing further spread at the site and reassuring those who are not at risk, Nutrien explains.

“Since it pinpoints the individuals who may have been exposed, the solution also helps Nutrien minimise operational shutdowns and reduces the risk of associated costs and product delivery delays,” it said.

Dr Tarek Sardana, one of the medical experts who’s been advising Nutrien’s executive leadership team regarding COVID-19 responses and protocols, said: “At the workplace, if you maintain proper physical distancing, then your risk of spreading the virus is very low. I encourage people to think of themselves as if they’re living within six-foot bubbles, and if no one penetrates the bubbles, it’s harder for the virus to spread.”

Robert Costantini, CEO of Triax Technologies, said: “We’re honoured that Nutrien has included our Proximity Trace technology as an essential part of its COVID-19 health and safety playbook. Nutrien’s commitment to worker safety through physical distancing and contact tracing was prioritised early on by their management and their focus on this issue has been exemplary. We’re pleased that our wearable sensors can play a critical role in enabling these protocols to create a safer environment.”

Since the implementation of the Triax technology, Nutrien has been able to safely support as many as 1,700 employees and contractors at a time at its nitrogen and phosphate sites. The physical distancing alerts have reduced the number of close contacts, positive cases and quarantines. Additionally, the automated data system has improved the efficiency and accuracy of contact tracing, it said.

“As Nutrien explores how to safely return more employees who have been working remotely to the workplace, the Triax technology will support additional prevention and protection across Nutrien’s North American footprint,” the company concluded.

Robotics on its way to the exploration industry, QR’s Scott says

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Mining has entered a robotics boom as developers take substantial strides in artificial intelligence (AI), use of drones, and data capture and analysis technology that will deliver safety improvements and better managed mines, Queensland Robotics Executive Chairman, Andrew Scott, says.

Speaking at the IMDEX Xploration Technology Symposium, he said that with the development of autonomous haulage and drilling technology, the mining industry had moved through a “trough of disillusionment” around robotics and was rapidly accelerating towards the “plateau of productivity”.

The two-day online conference brought together experts in mining innovation and exploration industries to discuss the latest in new technologies, tools and advanced analytics.

Scott said acceptance of new technologies had been aided by restrictions caused by the COVID-19 pandemic, with the development of some digital transformation projects planned for the next three to five years being executed in three months.

“COVID is a significant accelerator and robotics is no exception,” he said.

Capital was available to fund new and emerging projects and was another clear indicator of a robotics boom, which Scott said would undoubtedly mean more jobs not less.

“There’s a lot of work that’s underway right now to really bring to the forefront a lot of automation and robotics to deal with enhanced data capture and execution of exploration programs and also within the mining environment,” he said in an interview ahead of the symposium.

“In the mining environment, we’ve seen the proliferation of automation in the form of autonomous haulage and autonomous driving, but now we’re seeing all the other ancillary services that are requiring automation and robotic solutions to take people out of danger but also to enable a highly efficient and productive system.

“We’re starting to see some of those capabilities move across into exploration, including the ability to deploy smart sensors in the field robotically, the collection of samples, and the analytical processing of those samples.”

He told the symposium the increase in robotics was aided by a reduction in sensor and computational costs, and, with more tools and technology available, there was increased adoption and acceptance.

“Robots are helping with the dirty, dull and dangerous, and distance challenges,” he said. “Applying robotics can definitely remove people from harm’s way. It can also augment what they are able to achieve by being able to explore in environments where until now we’ve been limited.”

This included in Australia, with areas subject to extreme heat, the high altitudes of the Andes, and subsea exploration.

“Robotics is surfing the wave of AI,” he said. “There’s a huge amount of development and growth in this area. We’ve gone past the AI winter, as they call it, and the acceleration of tools, and the ease of use of those tools is becoming a critical enabler.

“My prediction is that we’re going to see more and more solutions where they’re highly engineered highly capable, robust, highly configurable and easy to use.”