Tag Archives: Electrification

Liebherr advances Zero Emission Program with help of ABB, ENGIE

Liebherr, on the back of an increased industry focus on GHG emissions reduction, has announced at MINExpo 2021 that it is accelerating the implementation of its existing low carbon solutions and triggered future projects to offer completely fossil fuel free mining equipment options.

While much of this development will occur in house, the company has confirmed it is partnering with ABB on trolley assist infrastructure and ENGIE on integrating different renewable energy solutions into loading, hauling and dozing processes.

Liebherr Mining’s strategy to reduce GHG emissions will mainly focus on the operational phase of its machinery, as studies showed that more than 90% of GHG emissions over the complete lifecycle of the equipment occurred during this phase.

Liebherr Mining’s Zero Emission Program, which was established to develop these future solutions, is well aligned with the values of the Liebherr Group as an independent and responsible, family-owned company, it says.

The Liebherr Group has existing in-house core competencies, across all 13 product segments, in electrification, batteries, internal combustion engines, injection systems and alternative renewable fuels. Building from this experience, the Zero Emission Program has clear targets and a roadmap to achieve low carbon solutions for the full range of off-highway trucks and excavators in 2022, and fossil fuel free solutions for the majority of applications by 2030.

The Zero Emission Program strives to deliver long-term sustainable products and services, providing different options centred on environmental sustainability, safety, cost, flexibility and maintainability. Modularisation, along with an energy-type agnostic approach to drivetrains, are key elements in Liebherr Mining’s strategy, easing the transition for customers with the possibility to retrofit modules.

2022 target: Liebherr’s low carbon emission technology

Liebherr Mining has developed and offered electrification solutions for many years and is now about to finalise all initiatives to achieve its first 2022 target to offer low carbon emission solutions for its complete digging and hauling range.

The technologies, including the haul truck Trolley Assist System and electric excavator range, are consistently achieving proven results in the field to lower carbon emissions, according to the company. The newly introduced in-built Liebherr Power Efficiency control system has also shown excellent results since field operation began in 2019, the company says.

Trolley Assist System for Liebherr haul trucks

With the T 264 trolley components production-ready in 2022, all Liebherr trucks will be available with Trolley Assist System, providing a low emission solution for customers.

The Liebherr Trolley Assist System is, the company says, an effective first step on the road to zero emission mine sites of the future. Using an overhead pantograph or trolley bars to connect the electric-drive system to the electrical network, the Trolley Assist System offers increased truck fleet productivity, or reduction in fleet size, while maintaining yearly production when compared with standard trucks. A significant reduction of diesel fuel consumption is also made possible with the Trolley Assist System along with a reduction of the truck fleet CO2 emissions. However, this of course depends on the percentage of renewable energy content in the grid supplied power.

Oliver Weiss, Executive Vice President R&D, Engineering and Manufacturing, Liebherr-Mining Equipment SAS, outlined some of the company’s trolley assist operations at MINExpo 2021 today

Liebherr delivers proven field experience with 39 T 284 units fitted with the Trolley Assist System currently in operation on two different sites, with more to be commissioned in 2022. Liebherr is also the first company to run a 100 t truck under trolley, with a fleet of T 236 trucks running on a 5 km trolley line in Austria at the Erzberg mine – the longest trolley line in the world, according to Liebherr.

‘The largest range of electric excavators’

The Liebherr Group has over 30 years of experience in electric driven machines for earthmoving, material handling and mining applications. Today, Liebherr Mining says it is the OEM offering the largest range of electric driven excavators on the market. Ranging from 130 t to 800 t, the R 9150, R 9200, R 9250, R 9350, R 9400, and R 9800 are all available as electric drive versions. The electric drive R 9600 will soon be available.

Liebherr electric excavators are existing and already proven solutions helping customers to build future sustainable mine sites, it says. Focusing on reliability, maintainability and maximum safety, Liebherr’s engineering teams strive for solutions requiring minimum change to existing energy infrastructure and operational behaviour on customer sites. Thanks to 70% of parts commonality with diesel versions, Liebherr also offers complete retrofit options for existing machines.

To offer better machine mobility and safety for the workforce on site, Liebherr has developed a cable reel option for all electric drive excavators either in backhoe or face shovel. The cable reel is completely autonomous and has a capacity of up to 300 m depending on the excavator type. Furthermore, Liebherr proposes an operational concept for excavators with cable reel in backhoe application, particularly in double benching operations.

Liebherr Power Efficiency

Liebherr says it is continuously improving and upgrading its standard machines to enable the transition to emission reductions. Liebherr Power Efficiency (LPE) is the most recent built-in technology upgrade making this productivity and sustainability contribution.

Starting with Generation 7, all Liebherr mining excavators will be equipped with LPE as standard. This specific engine and hydraulic management system drastically reduces fuel consumption by up to 20%.

The system:

  • Adapts piloting processes according to operator requirements;
  • Electronically controls pressure and oil flow;
  • Has increased efficiency of the control valves and the new Liebherr pumps;
  • Has a fully integrated engine control system;
  • Reduces hydraulic losses and load profile of the engine for increased component lifetime; and
  • Reduces energy consumption without impact on the machine performance.

Based on research and development, Liebherr is able to provide size-equivalent machinery with higher production rates and less fuel consumption.

“In fact, the combination of LPE together with the improved productivity of the R 9600, has shown 29% less fuel consumption per tonne of produced material over a one-year production study, compared to its predecessor, the R 996B,” Liebherr says. “Expressed in fuel efficiency, tonnes per litre, this corresponds to a 40% better utilisation of the fuel.”

These efficiencies allow Liebherr excavators to set new benchmarks in its respective classes and are a very important enablers for any kind of future drive train, as they significantly reduce the effort for cable handling or refuelling and storage of alternative fuels, the company says.

Pathway to zero emission solutions

As second step, Liebherr is now targeting to offer completely fossil fuel free mining equipment for hauling, digging and dozing by 2030. This development will take into consideration the GHG emissions over equipment’s full lifecycle, as well as the overall well-to-wheel energy ecosystem. The company is also taking into account the operational mining process conditions that influence the right energy type choice.

Liebherr will develop three drivetrain options to achieve near zero emissions for its off-highway trucks: battery power module, internal combustion engines powered by renewable fuels, and H2 fuel cell-battery power module.

Drivetrain electrification through battery combined with trolley assist is already underway, according to the company.

Despite some challenges, Liebherr sees also an opportunity that the propulsion energy can be provided by using hydrogen fuel cell-battery hybrids.

Research and development for internal combustion engines operating with renewable-based alternative fuels is progressing very well within the Liebherr Group, with Hydrogenated Vegetable Oil (HVO) as an approved fuel for machines powered by Liebherr engines as a first step.

Hydrogen combustion engines are also currently being tested in Liebherr’s factory in Switzerland. The methanol combustion process has been developed for large displacement engines and is ready to move towards serial engine industrialisation based on market demand, according to the company. Additionally, the ammonia combustion process is under investigation, with Liebherr seeing high potential in the usage of ammonia for heavy mobile, high energy demanding machines and gensets.

Liebherr mining excavators and dozers will also both have the option to be powered by internal combustion engines running on alternative fuels, along with the already existing electric drive version for excavators.

To achieve near zero emissions for the mining dozer and excavator, it is also crucial to use the most efficient drive system to reduce fuel consumption. The Liebherr hydrostatic drive system already achieves up to 20% improved fuel efficiency compared with mechanical competitor products, it says.

Despite this, Liebherr is currently in the process of comparing efficiency of an electric drive on a dozer prototype with hydrostatic drive efficiency. Given Liebherr’s expertise in both hydrostatic and electric AC drive systems, the company says it is in the best position to choose the most appropriate option for the best drive system for the near zero emission solution.

To accelerate the process and ensure the best solutions will be offered, Liebherr is partnering with industry experts for its Zero Emission Program.

ABB, a leader in power and automation technologies, develops state-of-the-art technology and equipment for overall electrification of mine sites and supports Liebherr’s customers and the company with a particular focus on trolley assist infrastructure deployment.

ENGIE, a renewable hydrogen, low-carbon energy and services company, will jointly with Liebherr evaluate the different renewable energy solutions, in particular renewable hydrogen and hydrogen-derived fuels, for loading, hauling and dozing processes. This cooperation ensures that an integrated well-to-wheel approach is basis to define the best solutions for the mining industry, Liebherr says.

With concept studies nearly finalised for trolley-battery hybrid, and ammonia and methanol for internal combustion engines, Liebherr expects to undertake field validation from 2024-2026, followed by the integration of proven fossil fuel free solutions from 2026-2030 into the entire range of mining machines.

Nordic Iron Ore enlists the help of ABB to ‘future proof’ Blötberget project

Nordic Iron Ore says it has appointed ABB to scope process control and management systems for a “future-proof and fully-digitalised mining operation” at the Blötberget iron ore mine project, in Sweden.

ABB, in this context, has provided mine design consultancy and recommended scope of supply for the opening of the old Blötberget mine near Ludvika in the Dalarna region of Sweden.

The Blötberget iron ore mine is expected to be operational in 2024. Iron ore was mined until 1979 when it was closed due to low iron ore prices. Nordic Iron Ore was formed in 2008 with the main aims of resuming mining operations in Blötberget and Håksberg and conducting exploration of the expansion potential of the Väsman field, together forming the Ludvika Mines, in southern Dalarna.

ABB’s recommendation addresses automation, digital and electrification for long-term, safe, sustainable and efficient mining operations at the site. ABB analysed a detailed feasibility study by Nordic Iron Ore and made significant advancement on the definitions and scope of supply of the automation and electrification aspects of the mine, it said. ABB also looked at electrical infrastructure requirements for the Blötberget mine, including surface and underground containers, switchgears and transformers.

Lennart Eliasson, Managing Director of Nordic Iron Ore, said in the latest press release: “Mining and the support industries are a significant part of the Swedish economy, with some of the most advanced and efficient mining operations anywhere in the world. There are many challenges when opening a new mine. We want to draw on the strong technology knowledge that exists in Sweden to open a mine with low environmental impact and footprint and that is also competitive and safe. The early involvement from ABB, which has a track record of working with innovative mines in Sweden, ensures that the construction, design and planning for the development of the mine can take a significant step forward and with improved costs and benefits forecast accuracy.”

Just last month, Nordic Iron Ore’s Technical and Marketing Advisor, Paul Marsden, told IM that there was potential for leveraging the technology learnings on projects such as LKAB’s Kiruna and Konsuln mines, Boliden’s underground operations and Lundin Mining’s Zinkgruvan operation to make Blötberget “future ready”.

He added: “We cannot automate and electrify it all from the off, but we can lay the groundwork to eventually automate and electrify just about everything in the mine.”

Björn Jonsson, Hub Manager, Process Industries, ABB, said: “ABB can provide assistance at an early stage in mine development for electrification and automation and routinely collaborates with mining companies from initial feasibility studies through to full deployment. Swedish mines are already benefiting from ABB solutions, using ABB Ability™ System 800xA distributed control system and the integrated ABB Ability™ Ventilation Optimizer.”

Nordic Iron Ore and ABB will continue the development of the project and have recently signed a memorandum of understanding for further collaboration at Blötberget.

Charge On Innovation Challenge sparks more miner interest

The organisers of the Charge On Innovation Challenge have reported an overwhelming response to the preliminary phase, which closed on July 31, with 21 mining companies joining as patrons, over 350 companies from across 19 industries registering their interest as vendors, and more than 80 organisations submitting expressions of interest (EOI).

The challenge, a global competition, is expected to drive technology innovators across all industries to develop new concepts and solutions for large-scale haul truck electrification systems aimed at significantly cutting emissions from surface mining. It also aims to demonstrate an emerging market for charging solutions in mining, accelerate commercialisation of solutions and integrate innovations from other industries into the mining sector.

BHP, Rio Tinto, and Vale, facilitated by Austmine, launched the Charge On Innovation Challenge in May of this year, initiating the EOI process on May 18. Since the initial launch, Roy Hill, Teck, Boliden, Thiess, Antofagasta Minerals, Codelco, Freeport McMoRan, Gold Fields and Yancoal came forward as patrons by early July.

The latest release has highlighted another nine miners to join as patrons. This includes Barrick Gold, CITIC Pacific Mining, Evolution Mining, Harmony Gold, Mineral Resources Ltd, Newcrest Mining, OZ Minerals, South32 and Syncrude.

The patrons, supported by Austmine, will assess the proposals over the next month and select a shortlist of vendors who will then formally pitch their challenge solutions.

At least one of these proposals has come from ABB, which confirmed earlier this month that it had submitted its ideas for the challenge using its mine electrification, traction and battery system eand charging infrastructure expertise.

At the end of the pitch phase, the challenge patrons will look to select the most desirable charging concepts identified as having broad industry appeal and application, as well as providing a standard geometry that enables chargers to service trucks from different manufacturers. The first concepts could be ready for site trials in the next few years, according to the organisers.

BHP’s Charge On Innovation Challenge Project Lead, Scott Davis, said: “The Charge On Innovation Challenge is a great example of the current collaborative work being done by the mining industry in seeking solutions to decarbonise mining fleets. The challenge received interest from companies based in over 20 countries, showing the truly global reach of the opportunity to help reduce haul truck emissions.”

John Mulcahy, Rio Tinto’s lead for the Charge On Innovation Challenge, said: “Twenty-one mining companies, all focused on lowering carbon emissions, have joined as patrons. Together we’re encouraging technology innovators to help us introduce large-scale haul truck electrification solutions. The sooner we bring these technologies to market, the sooner we can introduce them to our fleet, and reduce emissions.”

Vale’s Charge On Innovation Challenge Project lead, Mauricio Duarte, said: “We are very happy with the results of the first phase of the project. It´s still early to talk about the success of the challenge, but it is clear that the industry has reached a new level: we worked together on a common sustainability agenda and we will work collectively to reach our goals, gaining safety and speed on our way to low carbon mining.”

Ferrexpo to decide on trolley assist-backed haulage project by year-end

Ferrexpo’s decarbonisation and electrification plans in Ukraine are continuing to accelerate, with the company confirming it will make a decision by the end of the year on the selection of a provider for the installation of pantograph network to enable trolley assist haulage at the group’s iron ore mines.

The iron ore pellet producer previously said it was embarking on scoping studies investigating trolley assist technology at its Poltava mine in Ukraine, as part of its plans to reduce both C1 costs and Scope 1 carbon emissions.

In its first half interim results, Ferrexpo said the installation of the network of overhead power cables will enable haul trucks to ascend from the group’s open-pit mines using electricity rather than diesel fuel.

“This technology is expected to provide a significant reduction in each truck’s diesel consumption whilst driving up haul ramps, which will directly reduce the group’s Scope 1 emissions footprint per tonne,” it explained.

In the first half of the year, the group achieved a 6% reduction, year-to-date, in Scope 1 and 2 emissions combined. Following upgrade work on its pelletiser in this period, the group expects production volumes to increase in the second half of the year and, as a result, lower the group’s CO2e footprint on a per tonne basis.

Alongside the company’s latest electrification plans, Ferrexpo also updated investors and interested parties on its progress deploying autonomous haul trucks at the Yeristovo iron ore mine. These were the first large-scale haul trucks to be deployed in Europe when they were introduced in 2020 as part of an agreement with Epiroc and ASI Mining.

Ferrexpo said it now has five Cat 793D haul trucks operating in production areas in autonomous mode, with the conversion of the group’s remaining 793Ds planned as this project advances.

“Fleet automation represents a significant advancement in modern mining techniques, removing individuals from potentially hazardous production areas, whilst also providing benefits in terms of productivity and maintenance,” it said.

Highlights from the company’s first half results included a 74% year-on-year rise in revenues, to $1.35 billion, reflecting positive market conditions and investments in increasing pellet quality. It also increased its underlying EBITDA by 147% ($868 million) compared with the first half of 2020.

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 drilling, bolting, electrification innovations set for MINExpo 2021

Epiroc’s MINExpo 2021 line-up is set to include a variety of innovative and productive offerings including its latest Pit Viper blasthole drill rig, its recently launched Boomer underground drill, new rock bolters and a host of aftermarket products geared to mine electrification.

Making its MINExpo debut in Las Vegas, September 13-15, will be the Epiroc Pit Viper 291 (pictured above). This rig is designed to tackle larger diameter drilling in soft-to-medium ground conditions in both rotary and DTH drilling. The new addition to the Pit Viper range is capable of 171-311 mm diameter holes with a 16.76 m clean hole single pass with the drill bit above the table. It is also available with an 18 m option.

The Pit Viper 291 offers more than 100 different options to configure the rig to a client’s specifications. With Epiroc’s Rig Control System (RCS), the Pit Viper 291 can be configured with scalable automation features, including fully-autonomous drilling, the company said.

The new generation SmartROC D65 XLF will also be highlighted. This rig is packed with smart features such as automated drilling and rod handling, and is equipped with an intelligent fuel-saving system that reduces fuel consumption by 20% compared with the FlexiROC D65 drill rig, according to the company. It is available in three feed beam sizes to carry 5-, 6- or 8-m pipes, and has the capacity to drill down to a depth of 56 m.

The smaller SmartROC T45 will also be discussed. This tophammer surface drill rig for quarrying boosts productivity, reduces fuel costs and offers smart options and features such as Hole Navigation System, AutoPos and ROC Manager.

Epiroc’s Boomer M20 with battery option, launched earlier this year, will also receive the MINExpo 2021 treatment.

With protected hydraulics, sensors and cables, the new Boomer M20 is the next generation in underground mining, the company says. The world’s first face drill rig with internal hydraulics, the Boomer M20 is designed to minimise unplanned stops and maximise uptime and performance even in the toughest conditions.

High precision and performance are ensured with on-board automation features, tele-remote capabilities and digital drill plans to provide higher reliability and quality of the full drill cycle. The Boomer M20 comes with a battery-electric driveline option where, with the on-board charger, charging automatically happens while connected to the grid for drilling.

The Boltec M10 and E10 bolting rigs also come with a battery driveline option.

This next-generation rock reinforcement rig is available in two versions – the Boltec M10 and E10 – with the Boltec E10 showcased at MINExpo 2021. Designed for increased productivity and quality bolt installation, the rigs feature a new operator control panel, reduced noise levels, better visibility and improved operator ergonomics, according to the company.

The Boltec M10 and E10 can handle different types of bolts, mesh and installation methods, as well as optional battery-electric driveline or diesel hydraulic, radial and face bolting capabilities and extension drilling capability. Optional tele-remote operation is available, as well as single bolt auto installation with self-drilling anchor bolts in combination with pumpable resin.

Epiroc will be exhibiting several products from its tools range including the COP 57P, a versatile DTH hammer range. It is based on a modular design platform unique in today’s market, according to the company. The customisable hammer is available in 19 variants specific to mining, quarrying, water well drilling and geotechnical drilling.

To highlight Epiroc’s commitment to continued customer support, it will showcase several aftermarket products at MINExpo 2021.

Electrification solutions from Epiroc support mining customers in their transition to battery-electric vehicles, with several products and services in the battery field:

  • The Epiroc battery system is designed with modularity and safety in mind, ensuring each individual part of the battery can be monitored and controlled separately;
  • Batteries as a Service eliminates the risks of owning batteries and the solution provides all the benefits of electrical power;
  • Battery conversion kits from Epiroc will speed up the switch from diesel-powered equipment to battery-electric vehicles;
  • The electrification offering from Epiroc also includes a wide range of charging products; and
  • With the recent acquisition of Meglab, Epiroc has strengthened its capacity to provide customers with the infrastructure required as mines transition to BEV.

Apart from the electrification offering, Epiroc will display service products, upgrades and programs, including the COP MD20 hydraulic rock drill and programs in the areas of “Remanufacturing and Live Work Elimination”.

During MINExpo 2021, Epiroc will showcase automation and information management solutions as part of its 6th Sense capabilities. 6th Sense is Epiroc’s answer to the mining and construction industries need for digitalisation as an enabler for safety and productivity gains.

OceanaGold and Beca come up with decarbonisation pathway for Macraes

OceanaGold has enlisted the help of independent advisory, design and engineering consultancy Beca to reduce emissions at its Macraes gold mine in Central Otago, New Zealand.

Beca developed an Energy Transition Acceleration (ETA) study to provides a pathway to a greener future at the mine, which produced over 172,000 oz/y of gold and employs more than 600 people. Macraes is New Zealand’s largest mine.

“As participants in the New Zealand government’s ETA program, OceanaGold are focused on reducing their greenhouse gas (GHG) emissions at their Macraes site to not only improve the sustainability of their product, but also reduce their energy costs,” Beca said.

“That’s where Beca entered the picture. As program partners with the ETA, our industrial sustainability and engineering teams worked closely with OceanaGold management to develop an Energy Transition Accelerator study that identified a practical emissions reduction pathway for their business.”

The Macraes operation consists of a large-scale surface mine, an underground mine, and an adjacent process plant inclusive of an autoclave for pressure oxidation of the ore. Its annualised gold production is split approximately 75% to open-pit production and about 25% underground production.

Key opportunities for reducing the GHG emissions include harnessing waste heat recovery; fuel switching; solar lighting towers; electric elution hot water heating; battery-powered electric haulage trucks; and electrification of excavators.

“Taken together, these practical abatement measures can reduce emissions from the Macraes gold mine by a substantial 37%, whilst additional measures – such as the use of renewable energy sources on site – could increase this figure to 59%,” Beca said.

With the study now complete, Beca says it is ready to support OceanaGold in implementing the identified recommendations over coming years – with some of these options also applicable to its Waihi mine on the North Island of New Zealand.

Interact Analysis forecasts slow haul truck electrification uptake in open-pit mining

The electric revolution looks to be well and truly underway in the mining space, with underground mines of all sizes planning, trialling, or ordering various battery-electric machines to help them decarbonise their operations. Yet, the latest report on the off-highway vehicle market from Interact Analysis has indicated the transition above ground will take a little longer than many anticipated.

Homing in specifically on the 85-t-plus global hauler/dump truck market – broadly applicable to the medium-large construction space and the small-large open-pit mining sector – the market research firm laid out estimates for the annual number of new truck deliveries to 2029.

The surprising aspect of this research was the continued dominance of internal combustion engine (ICE) vehicle deliveries over this time frame.

The team at Interact Analysis expected the adoption rate/market share to go from 100% in 2020 – when 1,330 new vehicles were delivered – to 96.2% in 2029 – when it expected 1,716 units to be delivered.

The growth is slightly extreme in this comparison, but is partially accounted for by a drop off in deliveries in 2020 due to the effects of COVID-19. For reference, in 2019, 2,065 units were delivered.

Included within the ICE stats are biofuel vehicles, which have been gaining prominence in the mining space as miners realise they can both reduce diesel costs and emissions by incorporating biofuels into their operating mix.

Over the same time frame – 2020-2029 – the analysts see “hybrid” trucks commanding zero percent market share, with no sales.

Fully-electric trucks fare better, moving from zero deliveries in 2020 to two in 2021, five in 2022, six in 2023; to 72 in 2028 and 67 in 2029. The fully-electric adoption rate moves from 0% in 2020 to 3.8% in 2029.

Among these new fully-electric dump trucks is an XCMG EDF531 90 t battery-electric truck that was on show at the Bauma China show late last year (pictured below).

Jan Zhang, Senior Research Director at Interact Analysis, based in China, said this dump truck has already been delivered to a customer.

“In fact, quite a few dump fully-electric trucks below 100 t have already been used in China (in Guangdong),” she told IM. “Many of these have payloads of below 60 t, but a few are 90 t, and are in trial runs, and a few have also been exported to New Zealand, using the LiFePO4 battery from CATL.”

There has been much talk about hydrogen haul trucks taking hold in the mining space. This has been catalysed by Anglo American’s plans to test a 291 t fuel cell electric vehicle, a conversion to hydrogen fuel cell and lithium battery operation of a diesel-powered Komatsu 930E, at the Mogalakwena platinum mine in South Africa. If successful, these tests could lead to a rollout of 40 FCEVs across the global miner’s operations, it says.

Despite this, Interact Analysis’ research has no plus-85 t payload hydrogen trucks included in its forecasts to 2029.

Alastair Hayfield, Senior Research Director at Interact Analysis, based in the UK, explains: “Our statistics only look at new builds and not retrofits. My understanding is that the Anglo American vehicles would be retrofit (although there is limited detail at this point).

“Should some be new build, then we would update our forecast accordingly once we have better visibility.”

It’s worth asking the question: what about hydrogen trucks in mining beyond 2029?

Zhang said: “At present, mining trucks are mainly used in medium and large-scale coal and metal mines, and the use scenario is mainly for downhill heavy payload applications. That is to say where mineral resources are situated in a high up location, and it is necessary to load them from the mountain to the conveyor belt or transfer vehicle (the short distance transportation path is generally 2-3 km).”

She said mining truck electrification is mainly driven by two factors, with the first being operational cost advantages.

Jan Zhang, Senior Research Director at Interact Analysis, based in China

“For example, a mine truck with a total weight of 90 t will cost $45,000-75,000 in standard fuel annually, whilst the cost of electricity is only a third of the cost of fuel under the same circumstances, which means that $30,000-45,000 can be saved in the annual cost, not to mention other costs which are also higher for ICE mine trucks such as repair and maintenance,” she said.

The second factor is environmental protection and policy promotion.

“In China, the ‘National Green Mine Construction Specification’, issued by the Ministry of Natural Resources, has been implemented since October 2018,” Zhang explained. “This measure will surely help to grow the market share of hydrogen trucks in China, although the overall percentage will remain small.”

The last category included in Interact Analysis’ research was “Others” in the global hauler/dump truck market for 85-t-plus vehicles.

No deliveries for this category were registered in 2020, but the company anticipates one delivery in 2021, followed by three in 2022 and five in 2023. This gets as high as eight deliveries in 2025, but, by the end of the forecast period (2029), this category still commands 0.0% of the total.

So, what trucks fit into this category?

Hayfield explained: “We’re talking about diesel-electrics that will enter service into a trolley line operation – we essentially have to make an estimate on how we think the vehicle will predominantly be used. This is analogous to what we do in our on-highway research where we have to make estimates on how class 8 trucks are used for different applications ie long haul, distribution, vocational applications.”

This is not to say there will be no trolley assist trucks coming into the mining space, but, as far as Interact Analysis is concerned, these will not be new trucks coming out of the factory destined to head onto trolley lines. They will more likely be AC drive trucks that are retrofitted later for trolley assist operation.

When consolidated, these numbers show an underlying trend.

Back in 2019, there were 2,065 truck units delivered to the market in this 85-t-plus category, but, even out to 2029, this level is not reached, according to Interact Analysis.

Alastair Hayfield, Senior Research Director at Interact Analysis, based in the UK

In 2020, total deliveries dropped to 1,330 and, in 2021, Interact Analysis sees this rising to 1,545 units. A continual rise is expected in the years following, but it only reaches 1,783 in 2029.

What about beyond this timeframe?

Hayfield answered: “You have two fundamental pressures: a growing, resource-intensive population and a need to re-use/cut consumption because of environmental and/or legislative pressure. I suspect we will continue to see the growth of new mines throughout the 2030s in developing regions, fuelling demand for new trucks. However, I suspect we will see increasing pressure in Europe and North America on sustainability and the need to re-use materials and, hence, a slowing in the opening of new mines.”

This means demand for new trucks could start to drop during the 2030s in Europe and North America, he deduced.

This is not an exhaustive look at trends in the open-pit mining dump truck market – it is more of a taster – but Interact Analysis plans a detailed, mining specific study later in 2021. Such analysis could include forecasts for the retrofit market, providing the complete picture mining industry onlookers are after.

Epiroc continues to build equipment order book in Q4

Epiroc continued to register strong demand for its equipment in the December quarter, with the mining OEM’s order intake increasing both in the underground and surface mining segments, the company reported today.

Headline numbers from the December quarter included a 1% year-on-year increase in orders received to SEK9.3 billion ($1.1 billion), a 5% drop in revenues to SEK9.8 billion, a 10% increase in operating profit to SEK2.2 billion and a higher operating margin of 22.6%, compared with 19.6% a year earlier.

In terms of its equipment, Epiroc said orders received increased 26% organically to SEK2.97 billion in the last quarter of 2020.

Speaking to IM shortly after the results were released, Helena Hedblom, Epiroc CEO, explained: “The equipment orders…were across our portfolio, and the good thing is there were not that many large orders in the quarter; it was many small- and medium-sized orders.”

This would imply the strength in equipment demand – which came from both the underground mining and open-pit mining segment – is broad across the industry, coming not just from the major miners.

This pattern was also seen in the September quarter of 2020 when the company recorded a 25% year-on-year organic increase in equipment orders in the period, with the majority of orders coming from small- to medium-sized contracts of, say, one or two pieces of equipment, Hedblom said at the time of the results release.

Looking at the wider equipment and service segment of the business – which provides rock drilling equipment, equipment for mechanical rock excavation, rock reinforcement, loading and haulage, ventilation systems, drilling equipment for exploration, water, oil and gas, as well as related spare parts and service for the mining and infrastructure industries – Epiroc said the share of orders from equipment in this segment was 43% in the December quarter. Service, meanwhile, represented 57% of the orders.

Epiroc said it expected demand, both for equipment and aftermarket, to remain stable in the near term, while cautioning: “Uncertainty, however, still remains regarding the COVID-19 development and any further related restrictions.”

In the results release, Hedblom said automation, digitalisation and electrification solutions were in high demand over the quarter, with the company connecting more and more machines over this time frame.

“We continue to win orders and we are proud of our market-leading solutions that are globally deployed and proven,” she said. “They enable increased productivity, safety and sustainability for our customers.”

When questioned about the planned acquisition of MineRP, announced late in the quarter, Hedblom said the combination of the MineRP platform with its own digital solutions would allow Epiroc to “become a better productivity partner” in a mine’s digital journey.

IM also got Hedblom’s thoughts on if there was a regional difference in the speed of uptake of ‘new technology’ in the face of the COVID-19 outbreak. She said: “I see this technology shift coming in a different light with the pandemic. Sustainability is coming in; digital tools are becoming more and more natural as we need them.

“There is maybe an acceptance that the technology is here to stay, is available and customers want to jump on this journey now. I see it across all regions, which is a bit different to how the mining industry has adopted new technologies in the past.

“We have good traction everywhere now when it comes to new technologies.”

And, on the subject of ‘new technology’ uptake, IM asked Hedblom if she saw any parallels between the evolution of automated equipment adoption in the mining sector – which started with solely new autonomous equipment purchases to improve operations and moved towards a combination of retrofits and new equipment as the technology gained traction – and how companies may look to leverage mine electrification underground.

She answered: “I think it is too early to say yet. If I look into the coming 5-10 years, conversion of existing fleet will be one way to speed up the electrification journey. That is also why we are investing and developing these types of products to allow us to offer retrofits as part of the mid-life rebuild process, for example.”

The company confirmed back in November that its battery-electric retrofit solution for diesel-powered machines is expected to launch in the March quarter of 2021.