Tag Archives: decarbonisation

Gold Fields to up the renewable ante at St Ives with A$296 million investment

The Board of Gold Fields Limited has approved the go-ahead for a A$296 million ($195 million) renewables project at the St Ives mine, in Western Australia, in a move that could boost the operation’s renewable input to over 70%.

The project will comprise:

  • 42 MW of wind power delivered via seven wind turbines;
  • 35 MW of solar power delivered via 60,000 solar panels;
  • A 33 kV renewable energy hub substation; and
  • A 132 kV transmission line.

The project, the largest in the Gold Fields portfolio to date, will provide 73% of the mines electricity requirements and is planned to commence construction in May 2024 and will be operational by the end of 2025.

While previous renewables projects of this nature were built and managed by independent power producers, the St Ives project will be built by Gold Fields, the company stated.

Six out of Gold Fields’ 10 mines and projects are already powered partially by renewable electricity, and, in addition to the St Ives project, the company is studying additional renewable energy projects to meet the company’s decarbonisation commitments.

In 2023, renewable electricity accounted for 17% of electricity consumption across the Gold Fields business, compared with 13% a year earlier, leading to a 5% decline in carbon emissions during the year, the company said. Renewables provided 50% of electricity consumed at the Agnew mine in Australia and 15% of South Deep’s electricity consumption. The Cerro Corona mine in Peru is fully supplied by hydroelectricity, which is classified as 100% renewable. The Windfall project in Canada (which is a 50:50 joint venture between Gold Fields and Osisko Mining) is also supplied by hydroelectricity.

Once operational, the St Ives project will boost renewable energy in Gold Fields’ electricity mix further to approximately 24% and will contribute markedly to achieving the group’s 2030 target of reducing Scope 1 and 2 emissions by a net 30% against its 2016 baseline. St Ives itself will reduce its Scope 1 and 2 emissions by approximately 50% by 2030. Gold Fields has also committed to Net Zero by 2050.

“The St Ives renewables project is a clear and tangible signal to our stakeholders of our decarbonisation commitments,” Gold Fields CEO, Mike Fraser, said. “Investing in renewables has obvious environmental benefits, but it also provides the business with cheaper electricity and offers an enhanced level of energy supply security.”

The St Ives renewables project will reduce electricity costs to a third of the previously projected costs by 2025.

The project has received the required approvals from Traditional Owners of the land, the Environmental Protection Agency and the Western Australian Department of Energy, Mines, Industry Regulation and Safety.

Gold Fields has also advanced plans on other key renewables projects in its portfolio, which include:

  • A 11 MW expansion to the current 8 MW solar plant at its Granny Smith mine in Australia;
  • A 7.7 MW photovoltaic solar plant at the Salares Norte mine in Chile to be added to the current diesel generator sets about a year after first gold production. The project has already received the required environmental approvals; and
  • Adding up to six wind turbines to provide approximately 40 MW of power to the South Deep mine in South Africa. This project is currently in feasibility phase and awaiting final environmental approval.

Fraser added: “All our operations continue to investigate the possibility of adding further renewable electricity sources where it makes technical and economic sense to do so. We are also exploring the most capital efficient ways to fund these projects as part of our disciplined capital allocation. Gold Fields is committed to playing its part in mitigating the impact climate change is having on the world.”

The Government of Canada awards Rio Tinto’s IOC funding for decarbonisation project

The Government of Canada has awarded C$18.1 million ($13.4 million) from its Low Carbon Economy Fund to Rio Tinto’s Iron Ore Company of Canada (IOC) to support the decarbonisation of iron ore processing at its operations in Labrador West, the mining company says.

The funding will enable IOC to reduce the amount of heavy fuel oil consumed in the production of iron ore pellets and concentrate, according to Rio Tinto. The company will install an electric boiler to displace emissions from the usage of the heavy fuel oil boilers, as well as instrumentation and fuel-efficient burners to further reduce heavy fuel oil consumption from induration machines.

Over the lifetime of this project, IOC will see a cumulative reduction of about 2.2 Mt of greenhouse gas emissions.

Installation of the new equipment will begin in the June quarter of 2024 and is expected to be completed in the first half of 2025. The project will create more than 100 jobs during the construction and implementation stages in Labrador West.

IOC President and Chief Executive Officer, Mike McCann, said: “Rio Tinto IOC has a plan to decarbonise and continue producing some of the lowest carbon-intensity high-grade iron ore products in the world, right here in Canada. This project alone will eliminate approximately 9% of IOC’s greenhouse gas emissions. We look forward to collaborating with the Government of Canada and other partners towards our goal of achieving net zero emissions by 2050.”

Labrador Member of Parliament, Yvonne Jones, said: “By working with organisations across Canada, such as IOC, we can help the community save money on monthly operating costs and grow the economy, all while fighting climate change. Through the Low Carbon Economy Fund, the Government of Canada is partnering with climate leaders nationwide to cut emissions. I applaud the leadership shown by IOC for helping to keep our air clean and build resilient communities in Newfoundland and Labrador.”

The Government of Canada’s contribution represents approximately 25% of the total cost of the project, with IOC funding the remainder of the investment, Rio Tinto clarified.

Dyno Nobel, Fortescue sign tech alliance focused on drill and blast decarbonisation

Incitec Pivot Limited’s Dyno Nobel is to extend its supply relationship with Fortescue, with the two parties agreeing to a long-term extension that will see Dyno Nobel continue providing explosives technology and collaborating on key decarbonisation projects to assist Fortescue in reaching its ‘Real Zero’ goal.

A key focus of the new agreement is an innovative technology alliance. As part of this, Dyno Nobel will invest A$5 million ($3.2 million) in new technologies to support Fortescue’s decarbonisation efforts within its drill and blast process. The new agreement will apply across Fortescue’s Pilbara operations: Cloudbreak, Christmas Creek, Solomon and Eliwana. The Iron Bridge project, which Fortescue has a majority stake in, is supplied by Dyno Nobel under a separate contract the two companies announced last year.

Dyno Nobel Asia Pacific President, Greg Hayne, said: “We’re incredibly proud of our relationship with Fortescue who are at the forefront of efforts to decarbonise the mining industry. The agreement will see us ramp up our decarbonisation efforts which will include conversion of our MPU (mobile processing unit) fleet to renewable energy sources and investigating the use of lower carbon footprint, bio-fuel based explosives.

“This is about providing our customers with technology solutions that lower our carbon footprint and, in turn, theirs.”

Fortescue Metals CEO, Dino Otranto, said: “We’re looking forward to continuing our successful partnership with Dyno Nobel, which will deliver blasting services as well as provide new technologies to help us achieve our industry leading target of Real Zero emissions across our Australian iron ore operations.”

The agreement will provide Fortescue with the opportunity to benefit from Dyno Nobel’s commercialisation of a reduced GHG emissions DIFFERENTIAL ENERGY® solution, an explosives method that tailors the energy delivered to different rock layers within a blast hole and across a blast. The efficiencies generated through the use of DIFFERENTIAL ENERGY reduce both overall mining costs and emission volumes for customers, according to Dyno Nobel, with the reduced emissions solution able to reduce Scope 1 emissions by up to 25% in normal blasting circumstances.

Hayne said that since Dyno Nobel’s DIFFERENTIAL ENERGY technology was introduced to the Australian market in 2018 it has provided customers with production and environmental benefits.

“Fortescue has already seen the technology deliver value at their Iron Bridge operations, one of the first sites in Australia to fully benefit from DIFFERENTIAL ENERGY and the results have been very positive. We are now pleased to be increasing these advantages via a reduced emissions offering. It is just another example of our technology innovation happening on the ground.”

He said Dyno Nobel’s technology development aligned with Fortescue’s vision.

“We are looking forward to continuing our successful partnership with Fortescue which has evolved into finding innovative and sustainable solutions for the future by working together,” he said.

HydraGEN, Railveyor, BluVein, BEVs, hybrid vehicles being assessed by Evolution

Evolution Mining is considering the application of a number of technologies to displace diesel in its mining fleet, with its latest sustainability report highlighting several short to medium-term and longer-term solutions currently being assessed and considered by the gold-focused miner.

Evolution has set a target of reducing its Scope 1 and 2 emissions by 30% by 2030, with plans to reach net zero emissions in these two categories by 2050.

Over the course of its 2023 financial year, Evolution says it achieved an 11.2% reduction in absolute emissions compared with its FY 2020 baseline; maintained a robust direct (Scope 1) and indirect (Scope 2) accounting program, including resetting its emissions baseline; conducted a CO2 abatement cost review focusing on marginal abatement cost curves; externally validated modelling of emissions data including all input modelling; and developed and integrated internal emissions modelling tools to assess the impact of acquisitions and projects on its net zero performance and FY 2020 baseline.

It also completed an energy audit and decarbonisation roadmap for Mungari, conducted an independent audit of Scope 3 emissions, and developed and implemented its Renewable Sourcing Strategy, resulting in the Cowal (mine pictured above) power purchase agreement with AGL Energy Limited.

Evolution says the application of technologies to displace diesel in its mine fleet represents a complex decarbonisation challenge, hence the reason it is evaluating several options. It has been collaborating with partners as well as its supply and value chain partners to identify emissions reduction opportunities, including membership with the Electric Mine Consortium and Sustainability Advantage, the latter being a New South Wales Government scheme looking to accelerate the adoption of sustainable practices in the state.

Among the solutions Evolution is considering – ones it categorises as “technologically mature – are the HydraGEN carbon emissions reduction device, the all-electric Railveyor material haulage method, BluVein’s dynamic charging technology, and hybrid vehicles.

Evolution is already part of the consortium of funding members to fast-track the BluVeinXL project, looking at powering heavy-duty mining fleets with up to 250 t payloads through dynamic fast-charging technologies.

The company said in the report that it was also exploring “technologies that have high potential but have limitations at present due to their practical application within Evolution operating mines and their commercial competitiveness”. One example that comes under this category is battery-electric vehicles, which Evolution has experience of thanks to its use of both battery-electric loaders and utility vehicles at its Red Lake operations in Canada.

An asset that could potentially feature some of these technologies under consideration is the Mungari mine, in Western Australia, which is undergoing an expansion to boost output to 4.2 Mt/y, from 2 Mt/y.

In the latest report, Evolution said: “The Mungari mine expansion will result in a near-term increase in emissions due to an interim reliance upon diesel to power remote assets. However, Evolution is exploring potential opportunities to avoid diesel use and mitigate associated emissions through considerations such as hydrogen power and electrified Railveyor.”

FLANDERS-FREEDOM

The FREEDOM Drive System: FLANDERS’ approach to haul truck decarbonisation

Recognising the need for efficient and environmentally responsible haul trucks, FLANDERS has developed what it says is a game-changing innovation: the FREEDOM Drive System.

With its exceptional flexibility and OEM independence, this ground-breaking technology is poised to transform the haul truck industry, according to the company.

The FREEDOM Drive System is a modular, retrofit drive system designed to enhance the capabilities of existing haul trucks, regardless of the OEM. It is equipped to receive power input from multiple sources, including combustion engines, batteries, hybrids, trolley systems and hydrogen fuel cells. This adaptability allows mining companies to choose the most suitable and eco-friendly power source for their specific operational needs.

The key strength of the FREEDOM Drive System lies in its modularity, FLANDERS says. The system’s patent-pending design enables easy retrofitting into any OEM chassis without requiring extensive modifications or replacements. As emissions reduction technology evolves and matures, this modular approach ensures companies can continuously upgrade and adapt their haul truck fleets to meet the latest environmental standards without investing in entirely new vehicles.

The modular nature of the drive cabinet is another standout feature, allowing the system to be tailored to meet each client’s specific needs to progress at their preferred pace while effectively reducing their carbon footprint.

“This cost-effective solution allows businesses to retrofit their existing haul truck fleet with the FREEDOM Drive Cabinet, avoiding the hefty investment of acquiring brand-new vehicles,” the company says. “Furthermore, FLANDERS understands that solutions must be technically advanced and capable of withstanding the demanding conditions of mining operations. The FREEDOM Truck Drive System is designed to be miner-proof, ensuring its reliability and durability even in the harshest environments.”

In addition, the drive system also offers a complementary hybrid mechanical truck upgrade. This combines the drive system with a specially designed electric motor, with the upgrade introducing decarbonisation capabilities to mechanical haul trucks, enhancing their productivity while reducing emissions.

FLANDERS concluded: “The FLANDERS FREEDOM Drive System goes beyond a mere technical solution; it represents a comprehensive and strategic approach to haul truck decarbonisation. By enabling carbon reduction without purchasing new trucks, ensuring the reliability of mining operations, and offering a modular, customisable journey to sustainability, FLANDERS delivers an elegant and future-proof system for mining and construction companies looking to build a greener and more efficient fleet.”

Equipping mining with the tools to minimise the biodiversity cost of decarbonisation

As the race to net-zero intensifies, it is increasingly clear that the extractives industry has a crucial role to play supplying the raw minerals needed for decarbonisation. While navigating the balance between accessing new deposits and environmental sustainability is challenging, new methods of biodiversity monitoring offer a potential solution to minimise impacts on nature, Joe Huddart* says.

The race to net-zero is driving the fastest energy transition in history, and with the International Energy Agency (IEA) suggesting we will need to quadruple our mineral inputs by 2040 if we are to meet the goals of the Paris Agreement, there has been an emphasis on the need for the extractives industry to ensure they can meet this demand.

However, given that 20% of existing mines tracked by the MSCI ACWI Investable Market Index (IMI) are in biodiversity hotspots, accurately assessing and measuring the impact of existing and future mines on biodiversity and the environment is vital. The Earth’s biodiversity remains our greatest asset, not only acting as “our strongest natural defence against climate change” according to the UN, but also fundamental to our global economy. The World Economic Forum estimates that more than 50% of global GDP “is moderately or highly dependent on nature”.

Therefore, it is critical that risks to biodiversity are central to decision making in all sectors to drive a sustainable future in the race to net zero. Of course, this includes mining. A sector which has historically been seen as a driver of environmental degradation; destroying ecosystems within their immediate footprint while damaging communities and ecosystems beyond their area of influence via pollution and contamination.

However, coupling this expected sector growth with the fact that 20% of global mines tracked by the MSCI ACWI Investable Market Index (IMI) are located in biodiversity hotspots, accurately assessing and measuring the impact of mining operations on their surrounding environments is essential. The Earth’s biodiversity is our greatest asset, not only acting as “our strongest natural defence against climate change” according to the UN, but also fundamental to our global economy.

The World Economic Forum estimates that more than 50% of global GDP “is moderately or highly dependent on nature”. Therefore, it is critical that nature-based considerations are central to decision making in all sectors to drive a sustainable future in the race to net-zero. This includes mining, which has historically been seen as a driver of environmental degradation, while also posing health risks to communities and ecosystems exposed to the pollution it creates.

As biodiversity loss, externalities, material risks and dependencies on nature go mainstream, the importance of protecting biodiversity is reflected in the alphabet soup of frameworks that have been launched in recent years, including the Global Biodiversity Framework (GBF), Science Based Targets Networks (SBTN) and the recently announced Task-Force on Nature-related Financial Disclosure (TNFD). The latter being a nature equivalent to the earlier Taskforce on Carbon-related Financial Disclosures (TCFD) which is now incorporated into legal frameworks in many countries. The common goal of these frameworks and by those who have already adopted them, is to preserve biodiversity and establish the nature-positive practices necessary for a sustainable future. For business, there is a significant first-mover advantage for early adopters, as nature reporting mirrors the journey from voluntary to regulatory and compliance that carbon took. It is not just mining companies adopting these, but also financial institutions; with lenders, from institutional investors to banks, adopting these frameworks as prerequisites to mining customers accessing finance. This is similar to the earlier development banks biodiversity lender requirements, such as the IFC’s PS6 and EBRD’s PR6.

However, these biodiversity frameworks all acknowledge the complexity of reporting on nature impact. Compared with carbon emissions which are measured and widely traded as tonnes of CO2, the similar commodification of biodiversity is far more challenging. Biodiversity, loosely defined as the variety and number of plant and animal species in a given location, varies considerably across ecosystems. Developing standardised metrics that can be used to accurately measure, track, assess and report on biodiversity across ecosystems, from deserts to rainforests, to even coral reefs and the deep ocean, is therefore much more difficult.

While the frameworks provide businesses with a means to understand what they are required to monitor and how to disclose it within a standardised system, how to acquire the raw data needed to fulfil these requirements remains an elephant in the room. This is a shift away from species-specific monitoring of ‘trigger’ species – those that are particularly rare, threatened or indicators of ‘critical habitat’ – towards comprehensive, all-inclusive biodiversity baselining across taxonomic groups, from fungi to mammals, which comes with a range of issues and an expensive price tag.

“We cannot decarbonise without exploring, developing and exploiting existing and new mineral deposits, but we can minimise the impact this will have on biodiversity and nature”

To monitor species at the biological community resolution using conventional, observation-based methods is often prohibitively time-consuming, expensive and invasive or destructive. For instance, it is almost impossible to survey fishes at scale without using nets, which nearly always results in high mortality, with mortality often needed to identify collected specimens to species-level back in the laboratory. Even then, there is a very real chance many species are missed as nets will miss certain habitats and so datasets remain incomplete.

We also need to ask ourselves: if, during the limited time in which ecological teams are in the field, environmental teams can they reasonably be expected to encounter, detect and identify all the fauna and flora present in biological communities? This is challenging in some of the species-poor regions of the world, but near impossible in the richest, the biological hotspots where many mines will need to be located. Then there are the considerable health and safety risks of having such teams in the field for extended periods of time to contend with, too.

The rise of nature intelligence

Thankfully, the last few years has seen the emergence of innovations in ‘nature intelligence’ technology, such as environmental DNA (eDNA), which are equipping companies with the means to measure nature accurately and cost-efficiently on a scale never before seen.

All life on earth – from bacteria to blue whales – leaves tiny traces of DNA in its environment. eDNA technology allows us to sample the environment for these fragments of DNA to reveal a complete picture of the biodiversity of that ecosystem. eDNA surveys allow organisations to survey for and identify at-risk invasive or protected species, alongside wider biological groups, simultaneously. This establishes comprehensive biological baselines from which changes in biodiversity, good and bad, can be detected. This allows companies to link activities to impacts and so better understand biological risks, monitor progress and guide the implementation of effective management actions.

The emergence of innovations in ‘nature intelligence’ technology, such as environmental DNA, is equipping companies with the means to measure nature accurately and cost-efficiently on a scale never before seen

Combining eDNA surveying with other nature intelligence technologies that capture the complexities of nature, such as Earth observation/GIS, bioacoustics and drones, is proving a game-changer. The granular scale at which biodiversity can be repeatedly monitored and assessed is enabling companies to track, understand, report on and, above all, better manage their operations’ relationship with nature.

Moving the dial towards nature-positive in mining

As it ramps up operations while faced with increasingly sophisticated biodiversity regulations, the mining industry is in a difficult position. The Lassonde Curve, the time from discovery to commercial extraction, still takes some 16 years; closing this gap will be vital to meet decarbonisation goals. However, this should not result in the loosening of environmental standards or ‘red tape’ and so come at the expense of already beleaguered biodiversity and the environment. If anything, quite the opposite. In conjunction with nature reporting, the need to speed up mining developments should catalyse the adoption of increasingly sophisticated environmental management by the mining sector through the deployment of nature intelligence to improve the quality and scale of biodiversity data. This will not only demonstrate improved due diligence and ‘going the extra mile’ to produce better environmental impact assessments but enable regulators to make faster decisions.

Many companies, including Anglo American, Sínese and Rio Tinto have already found success using these technologies for different purposes to support their drive to nature-positivity.

For Anglo American, eDNA has transformed their biodiversity monitoring across the project cycle, and they have deployed the technology in 16 projects across 11 countries since 2020.

Warwick Mostert, Biodiversity Principal at Anglo American, believes eDNA monitoring has “huge applicability…[firstly] in the discovery and exploration phase, where knowledge is limited about the potential biodiversity risk in the area…[also] when a mine is in full operation, it will become a key part of the ongoing monitoring and evaluation in terms of biodiversity performance…[and] when we start to get to the point where an operation is coming to closure, it will allow us to make sure the work has been done and we can meet our objective of restoring an environment to better than its pre-mining state”.

The International Council on Mining and Metals (ICMM) has also noted the useful potential of the data that mining companies can generate, saying, “Mining companies can play a huge role in contributing biodiversity and environmental monitoring data in areas where such data has typically been scarce. Technologies like eDNA can also be used to unlock new pathways in democratising the collection of and access to data. More radical participation, transparency, openness and access to data is required to shift us towards a nature positive future. This should be at the core of both developing and implementing any corporate nature positive strategy.”

The mining industry has found itself at the nexus of two existential crises, climate and biodiversity. We cannot decarbonise without exploring, developing and exploiting existing and new mineral deposits, but we can minimise the impact this will have on biodiversity through nature intelligence. This will play a key part at all stages of the mining life cycle, ensuring mines can improve their management of biodiversity and that this can be reported efficiently in the incoming frameworks.

Lastly, we have to remember that mines have a lifetime, and mine closure is a vital yet historically neglected stage in the life of mine cycle. Nature intelligence can assist here to ensure mines are demonstrably rehabilitated and handed back to communities in a decent biological condition that does not constitute an ongoing risk to humans, fauna and flora, but can actually benefit local communities and ecosystems. All biodiversity impacts are environmental impacts and – given our dependency on natural systems and ecological functions – all environmental impacts are ultimately social impacts. Nature intelligence will therefore ensure we embark on a mining trajectory that improves outcomes for both nature and society.

*Joe Huddart is Subject Matter Expert and Freshwater Ecologist at NatureMetrics

Toyota Australia and BHP strengthen decarbonisation partnership

Toyota Australia and BHP have strengthened their relationship, aimed at enhancing safety and decarbonisation measures within BHP’s Australian operations. This collaboration, solidified today through the signing of a Memorandum of Understanding (MoU), represents a significant milestone in the ongoing relationship between the two industry-leading brands.

Back in 2021, Toyota Australia announced a local electric-vehicle pilot trial with BHP, with the small-scale trial involving a LandCruiser 70 Series single-cab ute that had been converted to a battery-electric vehicle by Toyota Australia’s Product Planning and Development division in Port Melbourne.

A primary objective of this latest collaboration between the two companies is to work together across safety, engineering and product development teams focused on safety in light vehicles design and future state technologies and challenges.

Furthermore, the collaboration is designed to support BHP with its objective to reduce greenhouse gas emissions by 30% by 2030. By leveraging the combined expertise of Toyota and BHP, both companies are committed to BHP achieving this important target, BHP says.

This initiative showcases both brands’ commitment to embracing solutions for lowering vehicle operation emissions.

President and CEO of Toyota Australia, Matthew Callachor, said: “BHP is a key player in Australia’s export industry, and Toyota Australia is delighted to announce this collaboration which is designed to enhance safety measures at BHP’s Australian work sites and reduce vehicle operation and other CO2 emissions on BHP sites.”

Through this MoU, BHP will gain access to the knowledge and resources of Toyota’s expert engineering teams across Australia and globally and aims to support BHP in realising its broader decarbonisation goals.

The two companies will also collaborate on a decarbonisation journey map that will look at a range of options and alternative technologies to develop a comprehensive strategy that aims to achieve agreed targets, according to BHP.

BHP President Australia, Geraldine Slattery, said: “At the heart of our efforts to decarbonise our operations is an ambition to electrify our fleet of 5,000 light vehicles in Australia. Collaborating with leading suppliers like Toyota shows our clear commitment to developing shared solutions for a safer and more sustainable future.”

BHP Group Procurement Officer, James Agar, added: “Combining our engineering expertise and resources with Toyota is a terrific example of the approach we are taking with major suppliers to develop new technologies that will improve our safety and sustainability. It’s an exciting project and there’s plenty of work to do, but we’re up for the challenge and we look forward to seeing what we can do together.”

Once completed, the capabilities developed through the partnership are expected to provide a blue-print for other organisations seeking to safely electrify their light-vehicle fleets and contribute to decarbonisation, BHP says.

Fortescue kicks off battery-electric truck testing in the Pilbara

Fortescue Metals Group has started testing a battery-electric truck at its operations in the Pilbara of Western Australia as part of its latest decarbonisation efforts.

Having floated the idea of a battery-electric haul truck some three years ago – and started a physical build process 12 months ago – the company is now testing a battery-electric converted MT4400 AC truck at its Christmas Creek iron ore operations, Fortescue confirmed last week.

WAE and Fortescue Future Industries, part of Fortescue’s newly branded Fortescue Energy division, have been spearheading developments on this truck, referred to as the “Roadrunner” (pictured). The 221-t payload vehicle is fitted with a 1.4 MWh battery from WAE. It has already been run through more than 20 hours of dynamic testing that has included, among other things, downhill recharging scenarios, Fortescue said last week.

The vehicle is thought to be the largest battery-electric haul truck running in Pilbara operating conditions.

The converted MT4400 AC is expected to be joined by a 3 MW charger prototype – developed by WAE and a third party – by the end of the year. “This will help us to understand and develop haul truck duty and charging cycles,” Mark Hutchinson, CEO of Fortescue Future Industries, said in a conference call last week.

In June, Fortescue, through WAE, announced the expansion of its battery and electric powertrain production operations in the UK with an additional state-of-the-art facility in Oxfordshire. The facility, which will open in 2024, will focus on the production of a wide range of zero emission products for the off-road sector, including trucks and trains.

Alongside these battery-electric developments, Fortescue said it will have its first “green hydrogen fuel cell haul truck” on site for similar testing next year. This truck is being delivered through the company’s partnership with Liebherr and will be based off a 240-t-payload T 264 haul truck.

In June 2022, Fortescue announced a partnership with Liebherr for the development and supply of green mining haul trucks for integration with the “zero emissions power system” technologies being developed by FFI and WAE. Under the partnership, Fortescue agreed to purchase a fleet of 120 haul trucks from Liebherr; a commitment that represents approximately 45% of the current haul truck fleet at Fortescue’s operations.

In answer to an analyst question last week, Christiaan Heyning, FFI’s Head of Decarbonisation, said: “We are…putting both battery-electric trucks as well as a fuel cell electric trucks on-site this calendar year to do extended testing to figure out the ramp-up efficiency of both battery-electric and fuel cell. We will use those insights to make the final decisions about what our fleet will be.

“As you appreciate, it’s really dependent on whole routes and, therefore, we need to do more testing before we can make up our mind.”

A 100-day “sprint” FFI project focused on converting a legacy 221-t class Terex Unit Rig MT4400 AC electric drive, diesel-powered haul truck to run on a ‘green’ hydrogen 180 kW fuel cell system and a 300 kW/h battery was previously completed and run at Fortescue’s Hazelmere facility in Western Australia.

BluVeinXL: aiming for benchmark status in the haulage fleet electrification game

Since being named one of eight winning ideas selected to progress to the next stage of the Charge On™ Innovation Challenge in 2022, BluVeinXL has done more than most, assembling a consortium of major mining partners focused on accelerating BluVein’s standardised dynamic charging technology to decarbonise the mining sector.

Late last year, Austmine, which manages the BluVeinXL project, welcomed Rio Tinto, OZ Minerals, BHP, Newcrest Mining, Evolution Mining and Freeport-McMoRan to the consortium of funding members to fast-track the BluVein technology. It has since welcomed Vale to the consortium.

These companies have backed the vision of BluVein, a joint venture between Olitek (Australia) and Evias (Sweden), to dynamically power mixed-OEM haul fleets while in motion, enabling smaller on-board battery packs, faster vehicle haulage speeds up ramp, grid load balancing, elimination of static fast charging, maximum fleet availability and – most importantly – the complete elimination of diesel.

These consortium partners are focused on delivering BluVein’s fleet electrification solution to Technology Readiness Level (TRL) 6 with a minimal viable product (MVP) demonstration, ahead of full commercial deployment of the technology.

BluVeinXL leverages much of what was developed for BluVein1, the primarily underground solution using the BluVein Rail™ slotted power rail system and the on-vehicle BluVein Hammer™ to simultaneously charge and power mining fleets ‘on the go’. The Rail is an enclosed electrified e-rail system mounted above or beside mining vehicles while the Hammer connects the electric vehicle to the Rail.

In underground scenarios, BluVein’s technology completely removes the need for battery swapping or static fast charging while allowing the use of smaller, lighter and lower cost batteries in continuous and high-duty applications, according to the company.

In open-pit operations, BluVeinXL will be similarly transformative, offering a next-generation alternative to what BluVein refers to as “the cumbersome, inflexible and expensive conventional catenary wire trolley systems that are currently hampering mines from fully decarbonising their haulage operations”.

To get the latest on the BluVeinXL open-pit electrification solution, IM caught up with James Oliver, CEO of BluVein.

IM: Now you have the founding consortium members confirmed for BluVeinXL, where do you go from here? Are you currently engaged with major OEMs on creating a standard design that can fit on any truck?

JO: Seven consortium members is just the start, and we will be announcing additional members very soon. We greatly value our members as it is ensuring we get ‘voice of industry’ and the key technical requirements during this critical stage. One of the major benefits our members see in BluVein is our standardisation, meaning our technology can be used with mixed-OEM fleets, mixed machine types and can even be used to make alternative clean fuel use more efficient and cost effective.

We are currently working with two to three major fleet OEMs and progressing agreements related to integration and demonstration of the BluVeinXL technology. We are confident we will be able to demonstrate with at least one OEM as the MVP, and hopefully more during the current project. Once we agree with each OEM the agreed interface point, then the BluVeinXL integration with the various fleet types becomes quite simple. To do this our technical team works closely with the OEMs on all aspects of the integration including Hammer, Rail and the control systems. By standardising with our various OEM fleet partners, we are delivering on what the mining customers are demanding – a truly standardised dynamic charging system.

James Oliver, CEO of BluVein

IM: How are you managing to engage OEMs that are also providing their own trolley assist applications that, they believe, may be suitable for similar haul truck propulsion setups to BluVeinXL?

JO: BluVein’s safe and proven electrification technology is based on over a decade of research and development undertaken for electric highways by our joint venture partner Evias. We are confident in our system’s ability to deliver high power transfer whilst also delivering on the safety and robustness requirements demanded by mining customers. Critically, the high-power transfer characteristics of BluVein’s slotted rail system enables simultaneous on-ramp hauling and charging of multiple closely spaced mining haul vehicles. This is a game-changing capability and of high interest to our mining partners. The conventional catenary wire-based trolley systems have limitations on power delivery capacity, earthing and other critical safety elements, and, therefore, are not as favoured by miners.

We do, however, see benefits of OEMs trialling a range of different mine electrification approaches, as long as we can all agree on a common vehicle connection point, specifically at the dynamic charge interface. This will ensure the end customer is able to select the best solution for their individual sites. We understand that BluVein will not be everything to everyone, but for the applications it does suit, we are confident it will be a true game changer over conventional catenary and static fast charging options for haul truck fleets.

We hope to be able to demonstrate BluVeinXL side by side with a catenary wire system to showcase the competitive advantages BluVeinXL has – that is higher power transfer; safer, easier to install, use and relocate; and overall lower cost. Ultimately it will be up to the customer to choose based on the performance of the system and we think this will stack up in BluVeinXL’s favour.

IM: Can you expand on how your system alleviates the requirements on haul road conditions that typically comes with the current generation of trolley assist technology? Do you see your Rail and Hammer technology being able to work in any conditions (the Arctic included)?

JO: Part of our current package of work is to understand with our mining partners what these extremes are to ensure we are developing a solution that has minimal up-stream and down-stream impact on operations. The vision is to have a deployable solution that suits all climates and terrains.

Our core technology partner, Evias, has spent over a decade developing BluVein’s core technology to function effectively in icy and muddy conditions. By building on these learnings, we are confident that BluVeinXL will work in the vast majority of terrains and climates experienced in mining – from the hot and humid Pilbara region of Australia to the coldest parts of northern Canada.

It is BluVein’s safe slotted e-rail technology that enables it to be located near to the ground to the side of haul roads. Our Hammer and Arm is being designed to cater for the full range of haul road conditions, thereby reducing the burden on mines to maintain haul road conditions to perfection as is required with conventional overhead wire catenary systems.

Our consortium members have very good geographic spread to help us understand and test in these conditions. Part of our current work is to clearly understand from our mining partners what these environmental extremes are to ensure our solution will function effectively in all operations.

IM: Has your work to this point indicated how small the on-board batteries could be in a typical open-pit scenario for 220-t-payload trucks?

JO: We have taken a technology-agnostic approach to what on-board power and storage system we are supplying; our current focus is getting enough energy onto the vehicle as efficiently and safely as possible to power drive motors and charge smaller batteries if and when available. While we cannot reveal exactly how much smaller we can make the batteries, early studies show the batteries can be reduced as much as 60% when coupled with dynamic charge that has enough capacity to power the drive and charge the battery.

BluVein1 for underground and quarries can provide up to 3 MW of power sufficient for up to 100-t payload vehicles

IM: So what payloads do you think you could be providing this solution for?

JO: The BluVein Rail and Hammer design is completely scalable. BluVein1 for underground and quarries can provide up to 3 MW of power sufficient for up to 100-t payload vehicles. The BluVeinXL system can offer in the range of 4-7 MW, sufficient for up to 250-t payload vehicles. Our engineering team plan to use BluVein1 and BluVeinXL as stepping stones for an eventual introduction of a BluVein solution suited to ultraclass fleets with 9-12 MW of capacity sufficient for up to 350-400 t payloads.

IM: Where are you with your field trials on this solution? Do you expect these to commence this year?

JO: The targeted ‘wheels on track’ for BluVein1 is 2023, followed closely in 2024 with the BluVeinXL MVP demonstration. Right now I cannot reveal too much but there are some exciting partnerships being progressed to achieve this.

In terms of field trials, our ideal setup – and I think one the industry really wants – is a single site where all key mine electrification technologies can be tested out side-by-side. There are some very positive conversations going on between all three parties – the solution OEMs, truck OEMs and mining companies – on this front, which is exciting for BluVeinXL.

As has been said many times, there is no ‘silver bullet’ when it comes to mine decarbonisation. We know that BluVein’s dynamic charging solutions will tick a lot of boxes, but not all. So, it’s great if we can work together to ensure we cover any gaps. There is just too much at stake to try and go it alone.

IM: Anything else to add on the subject of electrification and dynamic charging?

JO: One question we have been asked is does BluVein’s Hammer and Rail technology only support dynamic charging? While power transfer while in motion is our obvious advantage, our system is basically an automated IP2X-rated power connection that can transfer more than 4 MW of energy. Could we use this for automated static fast charging also? Our answer to that is absolutely.

Mineral Resources, MEVCO agree on battery-electric Toyota HiLux utility vehicle deliveries

Mineral Resources says it will be the first miner in Western Australia to take delivery of Australia-engineered battery-electric Toyota HiLux utility vehicles for its mine site operations.

The investment, it says, is a demonstration of MinRes’ commitment to decarbonise its mining operations in Western Australia, which includes two of the world’s largest hard-rock lithium mines.

MinRes placed the order with mining industry vehicle supplier and global systems integrator MEVCO, which recently announced a partnership with SEA Electric to electrify Toyota HiLux and LandCruiser utes.

From its factory in Melbourne, SEA Electric is converting the vehicles from diesel-powered engines to all-electric using its SEA-Drive power-system.

The HiLux utility vehicles purchased by MinRes will be fitted with an 88 kWh battery that provides a range of up to 380 km and can be charged up to 80% in less than one hour, according to the company. The mine site-ready electric vehicles also produce no noise, fumes, heat or vibrations.

A demonstration model arrived in Perth, Western Australia, this week and MinRes is expected to take delivery of the first batch of electric vehicles in April.

MinRes, which is committed to net zero emissions by 2050, will use the electric utility vehicles at its various mine operations across Western Australia, including at the Koolyanobbing iron ore mine in the Yilgarn.

The addition of the electric utility vehicles comes two years after MinRes took delivery of the first all-electric light truck to roll off the SEA Electric production line.

MinRes is cutting emissions at its mining operations through a variety of technologies, including plans to transition road trains at its Onslow Iron project from diesel to electric.

At the Wonmunna iron ore project in the Pilbara, a 2.1 MW solar array and battery system is also being installed that will provide 30% of the site’s energy requirements.

MinRes Chief Executive Officer, Mining Services, Mike Grey, said: “MinRes has a plan to transition to a low-carbon future and cutting our reliance on diesel is central to achieving this goal. Our MEVCO electric utes are just one of the many ways we’re driving towards net zero and an exciting step in our decarbonisation journey.

MEVCO Chief Executive Officer, Matt Cahir, added: “While many companies talk about decarbonisation, MinRes is actually doing it. Partnering with one of the leading innovators in the mining industry is testimony to the MEVCO HiLux ute.

“MinRes is a company that is at the forefront of innovation and understands how that culture attracts and keeps the best mining talent in the industry. We are excited to be part of MinRes’ decarbonisation journey.”