Tag Archives: digitalisation

Bosch Rexroth opens up BODAS software use, lays groundwork for off-highway automation

Bosch Rexroth says it is opening up its mobile electronics software, BODAS, to all manufacturers and partners as part of a move to help OEMs speed up the launch of new machines and functions.

The company plans to offer manufacturers of off-highway machines free access to the entire standard portfolio of BODAS software for controlling mobile machines, with the company set to highlight this at the upcoming Bauma 2022 event in Munich, Germany, in October. Via the digital myBODAS platform, OEMs can download validated software packages for a range of applications, free of charge, in order to test them and adapt them to suit their own requirements.

Proven modules within the platform minimise the time, investment risks and costs involved, with the service only billed via a payment model based on credits if the software is used during series production. This makes it easy to use, flexible and transparent, Bosch Rexroth says.

“Whether it be hydraulic control, automation, connectivity or electrification – software plays a central role in the highly dynamic off-highway market,” the company says. “In order to achieve success with their mobile machines, OEMs must reduce the development time in a cost-effective manner while reducing functional and financial risks.”

Following registration and confirmation of the terms and conditions of use, the individual modules in the BODAS application software (AS), such as the eDA for the drivetrain, are then available. The modules are developed in accordance with current standards and already meet functional safety requirements, the company says. As a result, Bosch Rexroth helps manufacturers of any size to cope with increasing complexity in vehicle development, to compensate for a lack of know-how or resources and to update or expand their offering more quickly, it added.

“This way, the OEMs’ software developers can concentrate on selected customer values and speed up the launch of new functions and machines,” the company said. “They can also scale their own offering more quickly with software modules validated for Rexroth hardware.”

The open ecosystem of BODAS is being expanded all the time with standardised, extensively documented modules. myBODAS, thus, offers a toolkit for various control tasks involving mobile machines which is always up to date, the company explains. The growing need for automation solutions and the rapidly increasing number of assistance functions such as payload estimation, position sensing or surround sensing also make the system an attractive proposition.

Related to this, the company will present an integrated portfolio for the needs-based automation of off-highway machines, such as excavators, wheel loaders and telehandlers, at Bauma 2022.

The assistance functions cover advanced sensor systems and intuitive operating devices, including driver assistance functions for more efficient working and even virtual walls and emergency braking assistants for greater work safety. Ready-to-use software modules help to reduce the integration time into existing and future vehicle architectures and speed up their market launch, the company says. And, as a hardware platform for higher automation levels, Bosch Rexroth will announce a microprocessor-based, ROS2-compatible robotic control unit.

The automation portfolio presented at Bauma 2022 will be based on the BODAS platform for hardware, software and telematics.

The current range of assistance functions for productive and safe working processes includes easier levelling, load capacity measurement during handling operations, electronic vibration damping and various motion control systems for wheel loaders and telehandlers. Virtual walls and virtual rotary limiting systems protect the immediate surroundings by preventing the machine from accidentally leaving the safe working area. A number of functions can be adapted for other sectors, for example for tractor front loaders.

A ground-breaking HMI concept provides an intuitive user experience, the company says. This is based on ergonomic Sense+ joysticks with multi-dimensional optical and haptic feedback as well as high-resolution, high-contrast and glove-operable BODAS displays with easy-to-record visualisations for the relevant assistance functions.

The BODAS ecosystem also includes telematic modules for remote updates over the air, software remote maintenance and interfaces for transferring the wide range of operating data generated by the automation functions to ERP systems and their digital processes.

The new sensor systems for ultrasound, radar and inertial measuring systems form the basis for numerous other automation functions by recognising objects in the surroundings and recording the position of the kinematic systems with respect to each other via acceleration. There are plans to add extra functions and sensors such as LiDAR on a step-by-step basis, the company says.

For object recognition and terrain mapping, Bosch Rexroth is working with Bosch to develop a ROS2-compatible perception stack. On this basis, Bosch Rexroth plans to offer complete function packages in the future – from sensor integration and object recognition to machine intervention.

The new control platform is currently being developed, with prototypes for pilot projects available from the middle of 2023.

DMT devises four-step toolbox to help small- and medium-sized miners go digital

DMT GROUP, the global engineering and consultancy group, is launching a new Digital Transformation Office (DTO) to, it says, strengthen its support for small- and medium-sized mining businesses needing to introduce digitalisation across their people, operations, processes and sustainability obligations.

According to BCG’s Digital Acceleration Index, the metals and mining sector is around 30-40% less digitally mature than comparable industries – such as automotive or chemical. SME mining companies are increasingly required to meet the same compliance obligations around health and safety, ESG and operational inefficiencies as more financially secure mining majors, the accurate reporting of which is reliant on digital tools.

To bridge this ‘digital divide’, DMT is expanding its digital portfolio of consultancy and engineering services. From owners to operators and investors, DMT says it will support SME clients to design or implement a digital transformation roadmap, from exploration and operational phases, up to mine closure, rehabilitation and subsequent site use.

The company said: “Digitalisation is leading to meaningful operational improvements across the mining sector, and enabling companies to maintain resilience amid new challenges and secure future competitiveness. DMT will provide full-service support through a four-step toolbox: digital readiness assessment, roadmap creation, digital process engineering and implementation supervision.”

The four-step strategy provides a comprehensive analysis of a customer’s digital capabilities and priorities, and outlines a clear roadmap for implementation so that they can drive transparency and efficiency across their operations, reduce costs, and ultimately improve their operations, according to the company.

Vassilis Roubos, Head of DMT GROUP Consulting Services, said: “COVID-19 has accelerated digitalisation and automation across a number of sectors. Mining is well poised to benefit from greater use of digital tools, as an industry which demands improved productivity, sustainability, competitiveness, transparency and safety. Digital mining will continue to evolve through tools, methodology and knowledge over the next 10 years, but the changes we are already seeing in digitalisation, automation and technology are making the scope of our role more complex and more dynamic. We are excited to be further extending our mining capabilities in line with the changing demands of our clients, and are pleased to now assume the role as our clients’ digital transformation office.”

DMT will support either as the consultant for use case specific tasks or as a companion alongside the entire digital transformation journey, customising bespoke packages of third-party solutions for clients technology shifts, it explained. Alternatively, DMT can provide its services to meet any specifics the client may need.

EU competition, collaboration and connections helping Epiroc solve mining challenges

Epiroc’s start-up mentality is enabling it to continue to solve the mining industry’s biggest challenges, but it is not doing this alone, according to Katarina Öquist, R&D Manager of Technology and Innovation in the Underground Division.

Speaking ahead of her appearance at the EIT Raw Materials Summit 2022 in Berlin, Germany – taking place on May 23-25 – Öquist said access to other industry partners, academic institutes and start-ups through initiatives like EIT Raw Materials continues to help the company overcome challenges the sector throws at it.

“Specifically on the EIT Raw Materials project, there is the possibility to take in young start-ups and academic institutes, which can prove key when considering the ‘kicks‘ the funding can provide such companies and initiatives,” she said. “It is important for these young technology companies to have a connection to applications, being able to test out concepts and ideas in a real-world environment with companies like Epiroc, and, at the same time, introduce new thinking into industries such as mining.”

This wide scope of participation is increasingly required when considering the future direction of the mining industry, according to Öquist.

Katarina Öquist, R&D Manager of Technology and Innovation in Epiroc’s Underground Division

“If you look at the mining industry, and the part I am in with Epiroc, we are experiencing the biggest technology shift ever,” she said. “We are looking at electrification, autonomy and digitalisation all at the same time. All of these have interdependencies and connections in between, which make it quite complicated.

“When I started in the start-up sector some 15 years ago, you often were looking to solve one problem, but, today, you are not offering the sole solution; you must interact with a much bigger technology ecosystem.

“For this, collaboration is very important.”

In this regard, EIT Raw Materials and European Union Commission funding are more important than ever, ensuring all stakeholders are connected and focused on coming up with workable solutions for industry to achieve their lofty ambitions.

While not tied to EIT Raw Materials, the NEXGEN SIMS project is a good example to highlight here.

NEXGEN SIMS builds on the EU-sponsored SIMS (Sustainable Intelligent Mining Systems) project, which aimed to demonstrate new technology and solutions for the mining industry. Running from 2017 to 2020, the SIMS project resulted in, among other things, the Epiroc line of battery-powered mining machines.

NEXGEN SIMS, meanwhile, is a consortium of 13 partners collaborating in an EU-sponsored project to develop autonomous, carbon-neutral, sustainable mining solutions, building on the SIMS success. The partners are Epiroc Rock Drills, AFRY – ÅF Digital Solutions, Agnico Eagle Finland, Boliden Mineral, Ericsson, KGHM Cuprum, KGHM Polska Miedź, K+S Minerals and Agriculture, Luleå University of Technology (LTU), LTU Business, Mobilaris MCE, OZ Minerals and RWTH Aachen University. The project, led by Epiroc, has a budget of €16 million ($16.8 million) and will run from May 2021 to April 2024.

“In the case of NEXGEN SIMS, it is built on a known partnership including new partners,” Öquist said. “After being involved with the majority of these partners since SIMS, we build from a high level of trust, which increases the possibility of success, especially concerning integration.

“Europe, in general, is very good in facilitating these type of collaborative projects that involve all segments of the innovation ecosystem – start-ups, industry partners and academics.”

According to Öquist, the NEXGEN SIMS project remains on track, with the integrations between electrification, automation and digitalisation likely to hold the most exciting outcomes for the wider mining industry.

For its part, Epiroc is also helping accelerate the development of start-ups of its own, taking stakes/interests in key technology providers and allowing them access to its much larger network.

ASI Mining, FVT Research and Mining TAG represent just a few examples here.

Öquist expanded on this with a reference to Mobilaris MCE, a company Epiroc acquired outright just last year, after five years of holding a 34% stake.

“They (Mobilaris MCE) started off in 1999 as a start-up from the telecoms business,” she said. “Due to them being in the northern part of Sweden, they tagged onto the mines and we ended up acquiring a minority interest in them.

“In the five years since, they have had a nice journey under the guise of Epiroc. They represent a local small start-up growing by going under the wings of a much larger industry partner.”

Epiroc, too, has benefitted from this collaboration, with Mobilaris MCE’s situational awareness technology recently becoming a key part of the OEM’s 6th Sense digital solution.

Not all OEMs would be willing to facilitate the growth of other companies in such a way, but Öquist, who has only been in her role with Epiroc for two years, puts this down to the company‘s unique culture.

“We call ourselves a 150-year-old start-up,” she said. “Regardless of how big we grow, that mindset remains – if someone highlights a problem, we set out to solve it through both internal and external collaboration.”

MacLean’s van Koppen on affecting industry change

MacLean Engineering has been a fast mover when it comes to leveraging battery-electric equipment, having announced an EV Series platform back in September 2016 and rolled out electrified machinery across its production support offering in the five-and-a-half-years since.

A family-owned company with roots in Canada’s mining technology heartland – Sudbury – MacLean is continuing to innovate with new solutions that leverage not only electrification, but the latest in automation and digitalisation too.

IM spoke to Maarten van Koppen, VP Product Management, ahead of his presentation at The Electric Mine 2022, in Stockholm, Sweden, to find out how these three industry trends are converging in line with the company’s Application Intelligence philosophy.

IM: As a mine engineer with experience integrating both battery-electric and autonomous equipment into mining operations (at the Borden operation, among others), what new perspectives have you brought to MacLean since you joined in 2020?

MvK: It’s a little atypical for a mining engineer from a mining company to join an OEM. Mine engineering graduates do join OEMs, but the typical route is to head there straight from school.

In terms of electrification and automation, the perspective that I brought to MacLean was an acute awareness of what is ‘on the other side of the fence’. Having that knowledge has slightly changed the way we interact with customers.

I made a point of preparing material for consultants and study managers that could be very useful in preparing tradeoff studies and inspiring more discussion. We now have an overview for consultants that lists the budgetary prices – based on an ‘average’ MacLean vehicle – for both electric and diesel equipment in an apples-to-apples comparison. We also have crude cost models that can be customised with different energy prices, labour rates and a couple of other key drivers. That really helps consultants with these early tradeoff studies.

Having been a study manager at Borden, I can appreciate what it takes to make consultants and study managers’ lives easier. We are now getting positive feedback from industry that speaks to that.

The good news for me and MacLean was that there was a solid team with Stuart, Anthony and others already doing this work. They understood what the industry was looking for and our key strengths as an OEM.

Since coming in, I have also taken over the static simulations for our EV Series offering. A lot of customers still have range anxiety and I have been able to help with that by customising these simulations for their own sites factoring in, for example, their ramp grades, lengths, etc. Through those simulations, you can outline different scenarios and explain the opportunity charging philosophy in a way that is specific to their operation.

And, finally, MacLean was already on this track, but I reiterated that our battery rental arrangements were very simple and needed to remain so. It is typically just a fixed rate, single number per month. Other OEMs use other arrangements that are a little more complicated, but my experience is that, in terms of forecasting and budgeting, these systems can become onerous to administer and difficult to model out accurately without encountering a bias around expected machine utilisation rates.

IM: At the same time, what was it that attracted you to a company like MacLean?

MvK: First and foremost, my dad, until he retired, was a heavy-duty mechanic who was promoted up the ladder in the company he worked for. This was primarily in the Port of Rotterdam where he helped maintain the big forklifts that operate there – these can be quite complicated from an operational point of view. In that regard, I have always had an affinity and interest in equipment, something that has carried through to my siblings, all of whom are involved in engineering.

Second, joining a family-owned company with three generations of MacLeans involved is a sign of long-term commitment. That was also very attractive.

On a slightly different note, I felt that joining an OEM would allow me to affect the greatest amount of change across the industry. In my role, I get to talk to customers all over the world with a wide range of projects, enabling me to explain where electric machines might make most sense for them in terms of generating increased shareholder value, improved working conditions for employees, etc. That also had a bearing on my decision to join MacLean.

Then, of course, there was an opportunity to embark on a steep learning curve – learning about powertrains, drive trains and all the mechanical and electric bits and pieces that go into our machines. It has been very rewarding so far.

Maarten van Koppen, MacLean Engineering’s VP Product Management

IM: Have you been surprised by the industry take-up of these new solutions since joining MacLean? What trends have supported this acceleration in demand?

MvK: That’s an interesting question. Taking it back a little further, when I started off at Borden, I expected the industry adoption to be quite rapid – perhaps more so than it has been.

We were on a good track in 2019, but the pandemic caused a brief interruption. I think a lot of operations took that time to re-evaluate certain choices or projects.

We were very busy with consultants on tradeoff studies in the early days of the pandemic – that never really stopped – and we’re starting to see these studies result in fleet orders.

The other thing that went under the radar with the pandemic is, in 2020, all the big mining companies made massive commitments to carbon reductions. Part of that is now starting to trickle through with quotes and interest.

For companies that have aggressive targets for 2030, this is impacting fleet decisions today. If you buy a machine now, it will most likely last for 15 years or more, so you are effectively deciding today about what machines you will be operating in 2037.

IM: MacLean initially announced an equipment electrification plan all the way back in September 2016 at MINExpo, selling your first EV Series machine that year. Since then, you have accrued in excess of 100,000 operating hours on these machines. When evaluating this data, what has surprised you in terms of operating performance, industry acceptance, cost outcomes, etc?

MvK: We have a lot of experience with all our BEV equipment, which is spread out across the offering. We have, through this experience, confirmed operating performance and proven the increased speed of these machines going up-ramp. For instance, with the new batteries we are using on 17% ramps, providing the road conditions are OK, you can drive up that ramp at 15 km/h with an empty battery-electric boom truck. You are looking at 8 km/h with a diesel-powered boom truck, so the speed difference is quite significant.

We have also carried out some very targeted trials, one of which was with a customer in British Columbia, Canada, last summer, where we captured those carbon savings with a bit more detail.

In that trial, we recorded 315 hours on the machine over the course of three months. If you had used a diesel machine over those hours, it would have consumed about 5,000 litres of diesel, generating about 18 t of carbon. With the grid being as clean as it is in BC, the carbon emissions from powering up the machine were about 100 times lower than pure diesel – about 130 kg in total.

Even when we do the back calculation using conventional diesel generation to power up these electric machines, it is still three times cleaner than a machine with a diesel engine.

The one thing we still need to do at our test facility in Sudbury is to confirm what heat savings we can achieve when using BEVs compared with diesel vehicles. We know from other work in the industry that we should see an order of magnitude lower heat emissions, and we are looking at building on our own in-house simulations with real-world test data.

IM: Has this data and feedback influenced your EV Series product line developments over this timeframe? What new products/concepts have come to light on the back of analysing this data?

MvK: Absolutely. Our on-board chargers, for instance, now come from a different supplier that offers better performance, a lower price point and an improved tolerance to less-than-ideal power infrastructure. If you have more robust electronics on these batteries, it is always likely to be better suited to more underground mines.

We have also been able to simplify the drivetrain by removing the transfer case for some of our lighter machines such as the shotcrete sprayer.

As well, we have some exciting changes coming up with the offering of a CCS-2-type off-board charger receptacle. For all-electric mines where off-board chargers are required to power other equipment, such as trucks and loaders, we figured it would make sense for our equipment to be compatible. This means we can charge machines with up to 250 kW of power, provided the off-board charger can push that kind of energy. As for on-board charging, we hit a practical limit to our maximum 100 kW charging capacity. Most mine grids have a limit of about 150 kW on their 400-1,000 V AC mine grids to accommodate jumbos, so we have to stay within that limit. Depending on customer needs, we can configure the charging solution to what makes sense for their project or operation.

MacLean, on the charging front, is also working with the BluVein consortium out of Australia to explore overhead battery charging. While primarily focused on haul trucks, this type of charging solution could be a good fit for our battery-electric grader. Graders typically work on ramps – where this charging infrastructure would be located – and, out of all the machines in our portfolio, a grader is the one machine that should not stop moving in ideal circumstances. The overhead charger matches the application in that regard.

We don’t blanket everything with one solution at MacLean – there is a niche for every solution when it comes to batteries and charging. Yet, knowing and understanding what the application is provides us the opportunity to configure a better product for the customer. That type of Application Intelligence is at our core.

Where this ties back to our battery-electric vehicle experience is in the importance of the ramp quality in these types of operations. In every haulage operation, you know the smoother the ramp, the faster you can tram and the more efficient it is for the overall mine. Yet, the added benefit that comes with battery-electric machines is the regeneration opportunities presented with a smoother ramp. That is why we felt it was necessary to come up with a product like this.

IM: On-board, opportunity charging with a standardised battery capacity has been the order of day for the majority of machines you have deployed in mining to this point. Is this blueprint changing for the next generation EV Series in line with the different applications?

MvK: We’re open to evaluating just about everything, but the one thing we are married to is the idea of the battery staying on our vehicle. This makes sense for the type of equipment we make and the applications we serve. Outside of that, we’re pretty flexible.

On top of the CCS 2-type charger coming out in 2022, we have a chiller for active cooling available to allow BEVs to work at higher ambient temperatures. That is currently on a boom truck in South Africa. As you can imagine, it is easier to test a chiller in a South African summer than a Canadian winter. We think we can operate those machines effectively up to 50°C ambient temperature and possibly more.

The battery supplier change is very big for us and we now have a roadmap to improve performance where we can more easily switch between battery products with that one supplier, taking advantage of future improvements.

It is interesting times as that whole battery-electric vehicle component field is changing so much with the world going greener in general terms. The more components we can pick from that are meant for mobile industrial uses, the better we can configure our machines. The one thing I don’t think people realise is that mining equipment manufacturers are way too small to mandate customised components on a machine. We are at the mercy of what components are available on the market.

Those technology improvements will also hopefully put some downward pressure on costs when all the supply chain interruptions settle down.

IM: Where is the industry’s level of maturity with battery-electric solutions? Have many of the initial barriers to entry (upfront cost, worries over range, etc) been overcome?

MvK: I think there is still a bit of a ‘sticker shock’ when people see the quotation for a BEV, which is common among the OEMs. Yet, people are now looking beyond the initial capital cost, taking into consideration the cost savings that can be realised over the lifetime of the machine.

What I find interesting is how capital markets are now playing a role.

For example, underground coal miners, on top of the regulatory pressures they are facing, are now finding it very difficult to attract capital for their operations. The flipside is true when we think about some junior companies out of Canada that have announced plans to go carbon neutral and fully electric – they have been able to attract capital from investors that would typically steer away from mining. This is especially true when they are looking to mine ‘battery minerals’.

There is still a level of scepticism and hesitancy, but customers that have trialled BEVs generally realise the need to go all-electric. I do expect with the regulatory changes in certain jurisdictions where we do a lot of business, there will be more enquiries. If it becomes a tradeoff between going all-electric or spending a tonne of money on upgrading your ventilation infrastructure to abide by regulations, the battery-electric vehicle value proposition for existing operations will become a lot clearer.

“Knowing and understanding what the application is provides us the opportunity to configure a better product for the customer,” van Koppen says. Pictured is the battery-powered TM3 concrete transmixer

IM: In terms of technology development, MacLean has also been developing automation and digitalisation solutions. How do you see all three – electrification, automation and digitalisation – complementing each other?

MvK: The combination of electrification and digitisation is a good match. A lot of our telemetry developments came from the BEV side where we needed those diagnostics; these are now carrying over to the diesel side. Also, integrating automation and digitisation makes a lot of sense for a lot of the same reasons that you need the data to automate operations.

A lot of the engineering challenges will be around automation and electrification working together, and how you get energy into the machine. Driving, stopping and controlling the machine is not a problem – it is actually probably easier on an electric machine – it is how to get energy into it. The consortium we are in with BluVein is one solution, but I don’t think it is the ‘only’ solution. There are others on the market, but they currently come with a price point that makes them prohibitive.

IM: I know you have partnered with universities and colleges on the robotics side of things in recent years. What’s the latest on these developments?

MvK: A lot of the collaboration, to this point, has focused on boom movements. We are starting to automate boom movements as we think it will have applications in not just oversize management with water cannons, blockholers, or secondary ore reduction drills, but shotcrete and explosives loading too.

We are also partnering on several other things with universities and colleges on tech development. One of the things that comes to mind is the Robobolter we are working on right now. Here we are looking to put a robotic arm on the deck of our tried and proven Omnia bolter platform to take the operator out of the environment.

Customers have been telling us for a while that, due to the travel times, heat or seismic exposure, they would like to see the operator further removed from the face when it comes to bolting operations. At the same time, we wanted to make sure this solution had all the strengths of our proven platform bolter – being able to load up for an entire round, provide multiple types of support without extensive retooling, etc. We’re looking to introduce that product in 2023.

Like many of our new products coming out, these vehicles will primarily be designed around battery-electric operation, with a diesel option. That is a shift in thinking – designing for electric with a diesel consideration, instead of the other way around. The grader is the exception to that as we had to make the first one in diesel form. But, when we look at our new explosives rig coming out next year, that is primarily designed as an electric machine, which we will make available in diesel as well.

IM: Is the Robobolter likely to be your most advanced machine in terms of automation, digitalisation and electrification when it comes out in 2023?

MvK: I think the Robobolter, at launch, will be our most advanced machine, but there is increased internal competition within MacLean to reach new benchmarks across our offering. That competition is good for the business and the industry.

It’s refreshing and encouraging that the MacLean ownership is big on growth in both product lines and the territories which we operate in. We also want to disrupt the sector in the niches we operate in, having full support in terms of innovating and coming up with new products.

On top of that, as it is family-owned company, you can make decisions that best suit our customers. For example, our ownership will not allow us to sell machines we cannot support in the field.  This philosophy has somewhat saved our bacon with the supply chain pressures the industry is experiencing of late, ensuring we have enough spares to supply new machines as well as service those in the field.

Maarten van Koppen will be presenting ‘Electric, automated and digitally-connected: the MacLean machine pipeline’ at The Electric Mine 2022 conference in Stockholm, Sweden, on February 17-18, 2022. For more information on the event, click here.

Hindustan Zinc accelerates growth plans as it partners with industry leaders

Hindustan Zinc Ltd (HZL), a Vedanta Group Company and the world’s second largest integrated producer of zinc and lead, is in acceleration mode, embarking on aggressive expansion and collaboration plans with technology and innovation partners from across the globe.

One of the first mining companies to commit to going “Net Zero” by 2050, it has a strong focus on ESG reinforced by plans to deploy battery-electric vehicles, tap into more solar and wind power potential and recycle waste heat from its captive power plants. Such ambitions are being delivered with up to $1 billion of finance in the next five years to “go green” and, by 2025, achieve focused sustainability goals.

At the same time as it is looking to become an ESG leader, it is boosting its mine and metal production by leveraging “smart mining” and an extensive resource and reserve base.

IM put some questions to Arun Misra, Hindustan Zinc CEO, to find out how the company intends to deliver on its lofty ambitions.

IM: HZL’s 2021 financial year to March 31, 2021, was characterised by record production volumes and profitability; how were you able to achieve such results given the COVID-19-affected constraints on your operations?

AM: The uncertainty has evolved continuously. If I give you an example, we started the year with the uncertainty of COVID only; that is people getting infected leading to absenteeism. It was so contagious, it spread so fast, half of our workforce were down. So, that struck us heavily, but, nevertheless, because we had experience of last year, and this time there was no lockdown of industry, we were able to figure out how to manage and we did manage well, compared to last year’s same quarter, which was also COVID-affected. We had introduced various measures to change the way of working to ensure a safer working environment for the employees. We also got our workforce vaccinated along with their families to further minimise the risks associated with the pandemic.

Hindustan Zinc CEO, Arun Misra, says Hindustan Zinc has been at the forefront of ensuring personal health, be it of its employees or local communities

Furthermore, the automation and digitalisation efforts at Hindustan Zinc are equipped to better withstand these testing times while ensuring quick revival to a normal level of operations.

IM: During the height of the pandemic, HZL – like other socially responsible mining companies – supported communities within or close by to its operations. Can you highlight some of the actions you took over this period and what impact they had?

AM: We at Hindustan Zinc have been at the forefront of ensuring personal health, be it of our employees or local communities. We have gone beyond and extended our support to the state of Rajasthan and the nation at large by contributing significantly to the PM Cares Fund and Rajasthan Chief Minister Relief Fund.

To meet the requirement of oxygen during the second wave of the pandemic, we had set up an oxygen bottling plant at our Dariba unit (Rajsamand district) in a record time of five days and had supplied over 14,000 cylinders of medical oxygen. We even arranged 500 oxygen concentrators to be imported and distributed for use across the state.

We had provided an insulated vaccine van to the Udaipur district medical health office to support a smooth vaccination drive and extended support to the local health administrations, by disinfecting villages by spraying and fumigating with sodium hypochlorite solution and providing medical gear like masks, sanitisers and PPE to local communities.

We even constructed an 8,000 sq.m air-conditioning dome hospital, based on German technology, which has a capacity of 100 beds – including 20 ICU beds – to accommodate patients and provide them with essential COVID treatment and medical facilities.

IM: ESG is obviously a major focus area for HZL, as these examples illustrate. Where specifically are you investing in your mining, power and smelting operations to make them more environmentally friendly?

AM: As a COP26 business leader, we have always been active in tackling the repercussions of climate change and have a strong focus on reducing carbon emissions. We are pioneers in India, declaring our ambition to convert all our mining equipment to battery-operated electric vehicles and will invest $1 billion over the next five years to make our mining operations environmentally friendly.

We are continuously expanding our renewable power of 274 MW of wind and 40 MW of solar under our greenhouse gas reduction goals by converting 50% of our total power to renewable forms in the next five years. We are among the only two metal and mining companies globally – and among four Indian companies – to be part of the coveted CDP (Carbon Disclosure Project) ‘A List’ 2020.

Furthermore, we have even published our first Task Force on Climate-related Financial Disclosure (TCFD) Report this year and have also joined the Taskforce on Nature-related Financial Disclosures (TNFD) forum to understand nature-related risks and opportunities and accelerate the transition towards a nature-positive and carbon-neutral future.

We have set Sustainability Development Goals to 2025 for ourselves where we are aiming towards sustainable operations for a greener tomorrow.

Hindustan Zinc has embarked on a major growth push at its mining operations with six ongoing expansion projects that will see over 100 km of tunnels developed for underground infrastructure and ore access

IM: At the same time as this, HZL has embarked on a major growth push at your mining operations with six ongoing expansion projects that will see over 100 km of tunnels developed for underground infrastructure and ore access. How are you able to balance your sustainable expansion plans with pledges to reduce your overall footprint?

AM: We strive for operational excellence and cost efficiencies and continue to stay on the growth track while being equally cognisant of our environmental, social and governance commitments, as well as our sustainability goals. We are leveraging more digitalisation and automation than we ever have, as well as engaging with technology leaders to do ‘more with less’.

The SmartDrive equipment we plan to use enables higher productivity, lower operating costs and, most importantly, zero local emissions, featuring in-built energy recuperation technology to make the most of regenerative braking energy during downhill driving and deceleration.

Being a power-intensive business, our key focus is always on reducing dependence on non-renewable sources of energy and enhancing our renewable power base.

IM: How important has it been to partner with like-minded technology and solution providers to ensure you meet these ambitious goals? Can you provide some examples here?

AM: We always look for partners who align with our philosophy of running sustainable operations to achieve company goals. We don’t need one-off solutions from companies to meet our targets; we need companies that will engage throughout our medium- and long-term projects and provide an element of customisation that factors in the realities of operating in our underground mines. We look for global partners to work with us where we exchange ideas, insights and knowledge with them in our growth journey.

We believe in providing opportunities to our business partners to leverage collaboration on technology, innovation and digitalisation, for long-term value creation and mutual growth.

To support our expansion plan, it is crucial for Hindustan Zinc to collaborate with mine development and operation partners who share a similar vision to ours, which is to leverage cutting-edge technology to create a positive impact on the entire mining fraternity. We are currently working with companies like Sandvik, Epiroc, Normet, Barminco, RCT, Siemens, etc as our global partners. We have engaged with them to provide end-to-end solutions rather than sourcing a specific supply or service.

Hindustan Zinc has given an equal platform for women engineers in its mining operations, appointing India’s first female underground mine manager in 2021

IM: You have already stated a goal of 1.5 Mt/y of zinc production in the upcoming years and extending your lead as India’s largest integrated zinc-lead producer; what is your vision for the company to 2030 and beyond?

AM: We are excited about our next phase of expansion to take mining capacity from 1.2 Mt per annum to 1.35 Mt/a. We will surely cross 1 Mt and we should be above our guidance if we achieve the desired run rates in our third and fourth quarters.

While our growth plans are a key part of the company’s future, we are also focused on becoming the leading zinc-lead-silver producer from an environmental, social and governance point of view. Our DJSI Ranking of being among the Top 5 companies in the metal and mining sector is testament to this. We are already winning significant awards for our ESG and CSR efforts, and expect this recognition to continue and grow as we head towards mapping out our 2025 sustainability goals.

Also, the mining value chain is changing across the globe and more consumers are becoming aware of the origins of the products they buy and the emissions that come with their production.

To collaborate with Hindustan Zinc on its green growth mission, email [email protected]

Nerospec SK digital mine survey highlights industry opportunities and skills gaps

The concept of ‘the digital mine’ has been around for several years, however a recent survey conducted by Nerospec SK indicates the underground mining sector is much closer to the beginning of its digitalisation journey than the end.

The ‘How Digital Is Your Mine?’ survey from Nerospec SK, a company focused on a suite of digital and automation solutions for the sector, focused on six key themes and messages in its report, which was based on replies from 43 participants from across the global mining sector.

The first theme indicated that digitalisation was continuing to grow, with more than 70% of participants expecting increased investments in projects going forward.

This expected growth was influenced by the second theme: ‘digitalisation pays off’. The survey highlighted three quarters of the projects pursued to digitalise operations had been deemed successful, and 70% of them had come with a return on investment of less than three years.

To this point, mine safety has been the biggest beneficiary, according to the survey, with some 64% of participants agreeing that digitalisation projects had positively impacted operational safety. This has been seen with the likes of proximity detection, collision avoidance and vehicle intervention systems underground, preventing collisions between people, machinery and mine infrastructure.

The added transparency that comes with these digitalisation endeavours was expected to translate into productivity gains down the line, according to survey participants.

“Knowing what the machines have been doing during their shifts and, with that, identifying systematic improvement opportunities is the real game changer, enabling the sector to unleash the next frontier of operations improvements,” Nerospec SK said.

One of the biggest hurdles to achieving these gains is the availability of data communication networks, more than half of survey participants pointed out. “As regular wireless communication equipment is not effective underground, this is still a hurdle that many mines have not tackled,” Nerospec SK said, explaining that new solutions such as LTE and the like were only just becoming available.

At the same time, survey participants (68%) highlighted that the “simplicity of digital solutions” as well as the “technology readiness” for underground mining applications were major challenges associated with leveraging more digitalisation projects. “This indicates that the industry is not yet convinced of the availability of robust underground mining proven solutions that can be installed and maintained with the available mining personnel,” Nerospec SK said.

Of the most promising digital technologies available to the underground mining sector, automation of machinery was highlighted, being named the biggest single game-changing technology innovation with the greatest business value contribution by 38% of participants. This surprised the survey analyst team given electrification, ventilation on demand and connectivity have been highlighted as transformative in other similar industry polls.

The last theme centred on digital training and the industry-wide need for obtaining local mine and service crews with updated knowledge on new digital technologies. Around 35% of survey participants highlighted the digital readiness of service and maintenance personnel when asked the question: ‘What skills developments are required to become ready for the digital mine?’

“Finally, in terms of people qualification the survey participants are not so worried about the underlying fundamental software development, data analytics, or automation capabilities of developers,” Nerospec SK said. “The greatest need is seen in getting the local mine and service crews ready to work with the new digital technologies.”

Siemens looks at the future of mining in Africa as it launches SIDRIVE IQ

Siemens has launched its SIDRIVE IQ industrial IoT monitoring solution for drive systems at its Virtual Smart Mining Forum, seeking to showcase how the solution can increase drive uptime to improve mine site productivity.

The SIDRIVE IQ Suite has a powerful dashboard to minimise unplanned downtime with automated failure notifications, improve data transparency with easy access to recent and historical data, and troubleshoot faults.

The Virtual Smart Mining Forum the company is using to launch SIDRIVE IQ will explore new trends and the impact of technology on the African mining sector.

Taking place from August 3-5, the event brings together the mining community, industry experts, decision makers, thought leaders, technology providers, consumers, users, engineers and designers to discuss topics affecting the mining industry, with all participants exploring ways in which technology can drive effective change in the sector, Siemens says.

“COVID-19 has prevented the industry from having progressive conversations about how to move the mining sector forward,” Tim Walwyn – Head of Mineral Solutions, Siemens Southern and Eastern Africa, said. “This three-day event is an opportunity for us to bring the mining community together to reignite the dialogue and share knowledge to help us sustainably transform the future of mining in Africa. As a partner to African mines, our electrification, automation and digitalisation portfolio offers a combination of deep understanding of the mining industry with state-of-the-art technologies.”

Sabine Dall’Omo, Siemens CEO for Southern and Eastern Africa, says: “Our main objective with this event was to initiate a forum for knowledge transfer to the industry and raise awareness of the opportunities created by technology. We’re excited to bring this collaborative forum, where we can showcase the latest technological innovations for the industry and explore their effects on the African mining landscape.”

Siemens has invited various South African universities and will introduce them to Mendix, a low-code rapid application development platform that enables users to build and continuously improve mobile and web applications at scale. During the forum, Siemens will launch a hackathon using the Mendix platform.

As part of the company’s commitment to enterprise and supplier development, Siemens will also provide 10 industrious SMMEs that deliver solutions and services to the mining industry a chance to showcase their companies and expertise in a separate virtual showroom.

Dall’Omo said: “The future of mining and the transformation of the mining industry depends highly on staying abreast of advancing technology and industry trends. It also depends on the sustainable development of new enterprises, collaborations, and ongoing conversations among relevant stakeholders in the public and private sector and educational institutions. Now is the time to contribute to small business growth, promote job creation and develop critical job skills required for the transformation in the mining industry.”

Jeffrey Dawes looks forward to a sustainability-focused MINExpo 2021

As the world’s largest mining event, MINExpo INTERNATIONAL is used as an industry barometer for the health of the sector. While this year’s event will be a little different given the impacts of COVID-19, the anticipation continues to build for an in-person gathering that will highlight the biggest and best mining has to offer.

Ahead of this year’s event, sponsored by the National Mining Association (NMA) and due to take place on September 13-15, in Las Vegas, IM put some questions to Jeffrey Dawes, MINExpo INTERNATIONAL 2021 Chair. Dawes is also VP of Komatsu’s Global Mining Business Division and President and CEO of Milwaukee-based Komatsu Mining Corp.

IM: How will this MINExpo be different to previous editions? How are companies planning to ‘open up’ their exhibits and presentations to the widest audience possible considering COVID may restrict some of the in-person international attendance seen in previous years?

JD: MINExpo offers the mining industry the unique opportunity to experience, in person, the newest mining equipment and talk directly with the technical experts behind the most innovative technology and solutions. NMA has done a great job adapting plans this year as COVID restrictions have evolved, so they were prepared for a very different experience if need be, but fortunately it looks like we will be able to have a fairly normal show experience, albeit from a North American perspective – we will be missing some of our international friends who cannot join this year’s event. Part of what has always made our industry great is a strong sense of community, so it will be great to be able to get together in person after such a long time.

To accommodate our friends and colleagues who won’t be able to make the show in person, exhibitors this year have plans to utilise the latest in virtual technology to showcase what will be at the show. Exhibitors will also be able to upload product information, videos and other materials to the online directory, which will be available and open to anyone for a year after the show. Finally, the Opening Session will be live streamed.

Jeffrey Dawes, MINExpo International 2021 Chair

IM: What will be the big innovation themes at the event and what do these themes say about the future direction of the mining industry? 

JD: Digitalisation, electrification and automation will be the big innovation themes this year. Full enterprise optimisation can only be achieved by connecting tasks, processes, systems and people across the value chain. Solutions that leverage digitalisation, electrification and automation are the key to that full enterprise optimisation. They also play a crucial role in creating sustainable systems that support society’s growing needs in the most environmentally responsible ways.

IM: In a general sense, what positive impacts do you think COVID has had on the mining sector’s innovation/technology uptake? Has it accelerated the rate of innovation through necessity (remote working, increased HS&E considerations, shift to cloud-based network infrastructure, etc)? Is this likely to shine through at MINExpo in terms of what companies are showcasing and talking about?

JD: COVID really gave the mining industry a chance to reflect on its goals and take a deeper look at the tools now available to help it reach those goals. I think it also helped us gain a better understanding of the importance of aligning our business objectives – to extract the minerals needed by society – with society’s need for us to do that in the most sustainable, efficient and least intrusive ways possible. I’m certain that the products and solutions presented by the exhibitors at MINExpo this year will centre on the innovations and technology available now and in the near-term future that will help mines meet both their own and society’s needs.

IM: How do you see Komatsu’s contribution shaping/influencing the event? Are your solutions likely to be the ‘talk of the show’?

JD: We think so, yes. This year at MINExpo, Komatsu will focus on the power of smart technology and connected systems, the freedom of interoperability on an open platform, and the equipment and solutions that will help our industry move forward toward a more sustainable future. I’m particularly looking forward to sharing our newest haulage concepts, which are designed to help meet our customers’ needs for autonomy and the drive toward zero emissions. We’re also excited to give attendees their first in-person look at our newest surface blasthole drill, with 122,000 lb (55,338 kg) of pull-down force, the ZR122. Also, our newly branded WE1850 Gen3 wheel loader with switched-reluctance hybrid drive technology, with a bucket capacity of 60 tons (54 t), and our latest offerings for underground hard-rock and soft-rock operations.

Ultimately, at Komatsu we believe in providing our customers with the technology, solutions and flexible support they need for the lifecycle of their equipment and mining operations. Our customers need a reliable partner they can trust with whom to invest for the future of mining. We aim to be that partner.

IM: Aside from being a topic of discussion on the stands and in the conference rooms, how will sustainability be on show at MINExpo? Will this be the most ‘sustainable’ MINExpo yet in terms of organisation, emissions, etc?

JD: Mining has always been an essential part of keeping modern society moving forward. As we say, if it’s not grown, it’s mined. As an industry we have to focus on how to evolve to continue to meet those needs sustainably. The mining industry is already finding new ways to extract the minerals needed to meet the requirements of the world’s more energy conscious and environmentally friendly future. I am sure that many of the exhibits at this year’s show will showcase those new sustainability-focused solutions.

IM: Are you able to provide any preliminary expectations of attendee numbers?

JD: Varying country restrictions – and the US’ own restrictions – are obviously making this a year unlike any other, placing unusual limitations on attendance. However, we were pleased to have nearly 90% of our 2020 planned exhibitors re-book for this year and new exhibitors are booking space every day. We’re looking forward to welcoming representatives from 32 countries as both exhibitors and attendees. We hope to see even more attendees register as vaccination rates continue to rise, case numbers fall and an increasing number of countries lift travel restrictions as evidenced by recent changes in Canada.

International Mining is a media sponsor of MINExpo INTERNATIONAL 2021

Epiroc prepared for more order records after strong Q2

Record orders received, high revenue growth and improved profitability were all part of Epiroc’s June quarter financial results as the OEM also made significant headway on its diesel-to-battery-electric retrofit plan to help electrify the mining sector.

Orders received increased 37% to a record high of SEK11.07 billion ($1.27 billion). This corresponds to 45% organic growth compared with the June quarter of 2020, the company said, noting that the 2020 three-month period was significantly impacted by the COVID-19 pandemic.

Within this, equipment had the highest organic order growth of 76%, supported by a few large orders, such as an underground mining equipment order from Mexican contractor CoMinVi for use at several mines throughout the country.

The aftermarket also had a strong development, with organic growth of 26% for service and 42% for Tools & Attachments, Epiroc noted.

On the electrification front, Epiroc also highlighted that the June quarter had seen the company win several orders for battery-electric equipment, including one from Ivanplats for the Platreef project in South Africa, while receiving the first orders for its diesel-to-battery retrofit solution. The latter is starting with the conversion of diesel ST1030 loaders to battery-electric versions.

Revenues increased 15% to SEK9.733 billion in the June quarter, while operating profit and operating margin rose 54% and 22.4% to SEK2.182 billion and 22.4%, respectively.

The period was also characterised by several acquisitions, including the purchase of Australia-based Kinetic Logging Services, Canada-based 3D-P, and South Africa-based MineRP. Chile-based Mining TAG and Meglab, based in Canada, also came into the Epiroc fold in earlier July.

Speaking to IM just after the results came out, Helena Hedblom, Epiroc President and CEO, said the company had seen the automation, digitalisation and electrification trends observed across industry accelerate in these regions, among others, since the emergence of COVID-19.

“We see that different regions are ahead in terms of different capabilities,” she said. “We have seen a lot around digitalisation and automation in Australia, and, in Canada, when it comes to electrification, there are a lot of things happening. South Africa is strong when it comes to software and, on top of that, there are some regional players serving the sector like Mining TAG.

“We, as Epiroc, can come with our global footprint and help these regional players go abroad and roll out the technology on a global level.”

These acquisitions have seen the company’s staffing contingent swell in the last year. At the end of June, Epiroc said it had 14,569 employees across the globe, compared with 13,967 a year earlier, tied mainly to these acquisitions. Indeed, the three companies acquired during the June quarter came with 430 employees in total.

At the end of 2019, prior to the global onset of the pandemic, Epiroc had 14,268 employees on its books.

While Hedblom acknowledged much of the staffing increase was on the back of acquisitions, she did say the company was ramping-up additional workforce in “manufacturing, in supply chain and in service”.

And looking back to the rationalisation carried out across the company during the height of COVID-19 worries – which saw a notice of termination provided to 425 employees in Sweden and the consolidation of the manufacturing of exploration drilling tools in Canada – Hedblom said the company had since repositioned itself for the type of growth it was now experiencing.

“When we did the correction last year, we addressed a lot related to, mainly, admin and back office. With these acquisitions coming on board, of course, the majority of employees are technology-related people…software developers and service people to manage the technology out in the field.”

And, lastly, when it comes to the capacity to keeping up with record orders, Hedblom said: “We have a very flexible manufacturing setup where we do the final assembly, in house, and a lot of the pre-assembly is done by some external suppliers. That is how we are – and have always – managed swings in order volumes.

“We can also add more capacity if needed in our assembly lines. We are not regionally limited there; being able to use the different facilities we have in both the US and Sweden, in addition to China and India. We can balance that demand between the sites.”

Epiroc Canada launches RAC Teams, Control Tower to aid mining’s digital transformation

Epiroc Canada, adapting to changing technological trends in the mining sector, has introduced Regional Application Center (RAC) teams to, it says, assist in the industry’s new digital transformation.

“Across the board, mining projects are continually pushing for increased production while prioritising safety,” the company said. “With this in mind, Epiroc has assembled specialised automation and digitalisation support systems in strategic locations across the globe to help improve customer processes and boost productivity.”

The result, Epiroc says, is a heightened level of production that keeps workers out of danger zones on site while providing enhanced strategic direction for customers. Interoperability improvements have reduced variability and allow project planners to move towards their targets with renewed confidence.

Martin Champagne, Application Center Manager at Epiroc Canada, said: “Our RAC team gives new perspectives on achieving efficiency for the organisations we partner with. The team itself utilises members from a wide range of disciplines; from data analysts and project engineers to network specialists, software developers, IT specialists and digital product managers – the support system is always available when customers need it.”

Epiroc’s Canadian Customer Center has successfully applied this technology since the late 1990s, when the RCS Rocket Boomers with advanced boom controls and autodrill features were first introduced. In 2005, Canadian operations implemented one of the first Epiroc Scooptram Radio Remote Controls using long-range Bluetooth technology; 2009 for the first fleet of semi-autonomous Epiroc Scooptram implementations; 2012 for the first fleet of Pit Viper 235s with tele-remote systems; and 2019 for the first SmartROC D65 autonomous drill.

With Epiroc’s 6th Sense offering, the shift towards automation, digitalisation and interoperability is already underway, and the Regional Application Centers work collaboratively with many industry partners across the globe to achieve their goals, Epiroc said.

It added: “While working together with customers, Epiroc has initiated the move from machine autonomy to process autonomy, which consists of automating a complete process and allowing different kinds of equipment to communicate with each other effectively.”

To help support these functions, a newly renovated Control Tower located at Epiroc’s Lively, Ontario facility now acts as a home base for the RAC team, who are continually collecting data and developing innovative techniques to improve performance.

“Customers utilising this service for their projects can now turn their focus to other areas of the business with the knowledge that Epiroc’s team of experts are carefully monitoring progress on site and offering solutions in real time,” Epiroc concluded.