Tag Archives: Freeport McMoRan

Freeport-McMoRan Chino feels the ‘value add’ from MineSense ShovelSense installation

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During a Technical Session at the SME MineXchange Conference and Expo, in Phoenix, Arizona, today, a speaker from Freeport-McMoRan highlighted the value case for using MineSense’s X-ray Fluorescence-based ShovelSense® system at its Chino copper mine in New Mexico, USA.

In a presentation titled, ‘ShovelSense Bulk Ore Sorting Use Cases and Value at Freeport-McMoRan Chino Mine, New Mexico, USA,’ Maurice Sunkpal, Senior Ore Control, Freeport-McMoRan, showcased how the company’s use of ShovelSense had resulted in multiple benefits.

The company has been employing ShovelSense alongside other solutions such as Orica’s OREPro™ 3D as part of a five-year, ore control focused strategy at Chino. Chino is a highly heterogeneous copper porphyry skarn deposit where ore control is especially challenging due to the natural variability of the deposit, sparse blasthole sampling and blast movement, causing inevitable ore loss and dilution.

Chino has retrofitted its main production Komatsu P&H4100 electric rope shovel with ShovelSense to predict grades at the mine face for the purpose of bulk ore sorting, diverting mis-classified trucks to their correct destination.

Sunkpal was able to showcase the difference in the waste and ore definitions from a standard block model and that of one based on XRF data from ShovelSense (see below). This data – and the resultant diversions – in the mining of high contrast ore-waste contacts resulted in more than 10% truck diversions, yielding significant economic benefits by reducing dilution and ore loss, he said.

Block model differences: the original on the left and the ShovelSense-aided block model on the right

He also said the integraion of ShovelSense was enhancing the self-audit capabilities of ore control tools at the mine via real-time tracking of the ore control process. He added that this process had identified opportunities for further process optimisation.

Further, Chino has seen a reduction in variance from mine to mill with ShovelSense, while allowing the company to carry out selective mining with increased accuracy and confidence.

Metso-Freeport-refinery

Freeport-McMoRan books material handling order with Metso for El Paso electrorefinery

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Freeport-McMoRan has awarded Metso an order for the delivery of a state-of-the art tankhouse material handling solution to its El Paso electrorefinery in Texas, USA.

The order, which comes with a value exceeding €10 million ($10.9 million), will see Metso deliver Outotec Anode Preparation and Cathode Stripping Machines, both based on proven design, ensuring high safety and long-term reliability, the company says. Both machines use modern robotic electrode handling to, Metso says, optimise layout and material handling efficiency in the existing refinery.

Mikko Rantaharju, Vice President, Hydrometallurgy business line at Metso, said: “We are pleased to continue our collaboration with Freeport-McMoRan with this important project. We are confident that our technology will ensure high efficiency and quality of copper production in the El Paso copper electrorefinery after the modernisation. The solution will combine our long-term experience of similar equipment with modern robot technology to fulfill the material handling requirement of the existing tankhouse.”

Metso says it is a leading tankhouse technology supplier for copper refineries, with its offering covering key equipment based on proprietary technology, as well as basic engineering, digital solutions and services.

RME heralds ‘world-first’ semi-automated mill relining system deployment

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Mill relining systems manufacturer RUSSELL MINERAL EQUIPMENT (RME) has deployed what it says is the world’s first semi-automated mill relining system, delivering significant safety and commercial outcomes for its customer and the wider industry.

The reduction in mill relining risks and shutdown duration was achieved through a combination of: roboticising RME’s mature and proven technologies; compatible liner and bolt design; and strong collaboration and change management with site management and reline crews.

RME says its automated system addresses the two main phases of mill relining: worn liner removal and new liner placement, and enables the completion of these necessary maintenance processes without anyone inside the mill. This system was developed and implemented in close collaboration with some of RME’s existing customers, including PT Freeport Indonesia (PT-FI).

RME Founder, Executive Chairman and Chief Engineer, Dr John Russell, describes the new paradigm for fast, automated mill relines as the ultimate in safety and improved commercial performance for concentrators.

He said: “RME’s goal has been to enable our customers to reline mills with no one inside, providing them with remarkable safety and efficiency benefits. By eliminating human-machine interaction, we can speed up the machines and relining processes, consistently and repeatably. This advanced capability is now a reality.

“We are grateful to our customers, and to our liner and bolt technology partners, for their shared commitment to achieving these results. I would also like to recognise and thank our team at RME who has made our shared vision a reality.”

The results achieved to date can be attributed to RME’s systems engineering approach, it says. Safety inside and outside the mill was the priority and every step was carefully reviewed according to RME’s 24 Steps to Mill Relining Standard.

“We understood from our 35-plus years as an OEM that to safely automate mill relining, we would need to consider the many interdependent tasks across the entire process,” Russell added.

“The engineering result is now a tightly-integrated system of advanced modular technologies that automate manual repetitive tasks, eliminate risks and speeds-up relining.”

Consequently, RME’s automated system enables a staged implementation whereby upgrades happen within planned maintenance windows over multiple reline events. This ensures customers will not experience additional costly mill downtime scenarios.

One major advantage of RME’s semi-automated mill relining system is that its underpinning technologies are well-established and well-used by the industry, according to the company.

Dr Peter Rubie, who held the role of Chief Engineer at RME until 2019 and is a Non-Executive Director at RME, played a key role in the development of the company’s automation technologies.

“Mining can be conservative when adopting new technologies, due to economic risk,” Dr Rubie said. “For some of our customers, even one hour of downtime can cost upwards of $200,000 of production. We can avoid these impacts by automating existing proven systems. The beauty of RME’s mill relining technologies ecosystem is that the elements are modular and future-proofed. Miners of all sizes can deploy the base components and then incorporate additional automation steps at their own pace.”

The centrepiece of RME’s semi-automated mill relining system – the RUSSELL 7 Model R AutoMotion™ Mill Relining Machine (MRM) – is a highly advanced configuration of the industry’s most adopted 7-axis liner exchange machine, the RUSSELL 7 MRM.

It is complemented by THUNDERBOLT SKYWAY, a semi-automated knock-in system used on the exterior of the mill. Operational since 2020 at sites in Central America and Indonesia, SKYWAY is well-proven, the company says. This technology is now also available as a portable lift-in solution called THUNDERBOLT SKYPORT. It is another automation of RME’s established technology that increases asset utilisation by being sharable between mills onsite.

These systems, working together with INSIDEOUT™ Technology tooling and compatible liner and bolt design, can grab knocked-in worn liners off the shell or from the charge, and place new liners against the shell with millimetre precision and without personnel working inside the mill, according to the company. The securing of liners, nuts and bolts from the mill’s exterior can also now be achieved using RME BOLTBOSS.

RME has been collaborating with customers across several sites to progressively automate mill relining, including upskilling their customers’ local crews.

Analysis of historical reline shutdown data using conventional relining methods, compared with filmed data using some, but not all, of RME’s automated mill relining technology suite, reports a 65% risk reduction for activities inside the mill and 30% productivity uplift for a 38 ft SAG mill, RME says.

Following a staged implementation, PT-FI recently completed its first reline using the combination of THUNDERBOLT SKYWAY and the RUSSELL 7 Model R AutoMotion MRM. While the performance data is currently being analysed, early indications point to an even greater reduction in risk and increase in productivity than was originally targeted.

Director Metallurgy and Strategic Planning at Freeport-McMoRan, Dr John Wilmot, summed up the outcomes FCX is seeing as safer and faster mill relining at the recent SAG 2023 conference in Vancouver, Canada.

“PT-FI Indonesia has largely removed crew from inside the mill as we reline,” he said. “While there are still a few residual activities where we need to enter, such as wash-down, we’re executing relines faster and safer than before. Mill relining is no longer on the critical path.

“RME’s modular systems approach enabled us to progressively implement the technology, which meant we could quantify the safety and productivity improvements at each reline event, even as the new technology was being deployed.

“The staged implementation also provided an opportunity to create strong buy-in from our reline crew. In our experience, when the crew is part of the optimisation journey, the change program is infinitely more successful. At PT-FI Indonesia, our reline crew has now taken full ownership of the process.

“Leveraging RME’s equipment and methodologies, as well as the compatible liner and bolt designs, our crew has experienced the difference that automation can make. They’ve found it to be safer and faster, and they won’t go back to conventional methods. We’re incredibly proud of their work. By collaborating closely with all the stakeholders involved, we are engineering the risk out of mill relining.

“We believe RME’s collaborative and staged approach can serve as a model for the mineral processing industry. It is already achieving step-changes in safety and mill availability for our customers and we’re excited to see the impact it may have industry-wide.”

Dr Russell concluded: “We have now completed more than 30 real world relines using the various products of RME’s Advanced Technology suite. It gives me the confidence to present our system as the safest solution for our industry. And the data we’re seeing from the 30-plus relines, gives me the confidence to state that this system better for productivity.

“The transition to net zero requires an enormous increase in the minerals that are essential to the decarbonisation of our economies. We are delighted to be able to play a part in safely speeding up the production of those minerals. We’ve achieved these results in partnership with our customers, using the same pioneering mindset with which we’ve approached the past 35 years.”

Resourcing Tomorrow

Major miners join Resourcing Tomorrow lineup

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Representatives from the world’s largest mining companies Anglo American, BHP, Glencore, Rio Tinto and Vale have confirmed their attendance for this year’s Resourcing Tomorrow event, in London, event organisers say.

These attendees will join other leading mining companies including AngloGold Ashanti, Antofagasta Minerals, Barrick, B2 Gold, Eldorado Gold, Endeavour Mining, Freeport-McMoRan, Newmont, Sibanye-Stillwater and Teck Resources.

As Europe’s largest mining event, Resourcing Tomorrow: Accelerating the Energy Transition takes place in London on November 28-30 and is poised to be yet another agenda-setting edition for the industry, fostering collaboration and knowledge exchange among professionals in the field, event organisers say.

Resourcing Tomorrow unites all stakeholders in the mining industry, including global mining and energy companies, investors, government delegations, researchers, educators, regulators, suppliers and operators. The conference program will provide 100-plus sessions in which all of the aforementioned miners will participate, giving attendees the opportunity to engage and network with leaders and industry specialists from around the world.

The event will draw participants from more than 100 countries, including Australia, USA, UK, Canada, India, Brazil, South Africa, Ghana, Chile, Nigeria, Peru and Germany, demonstrating its international appeal and the global significance of the mining industry, organisers say.

With the increasing pace of change and emerging technologies in the mining industry, Resourcing Tomorrow will focus on the future of our industry and presents a unique opportunity for international representatives of the world’s leading resource economies to meet, find new partners, discuss current challenges, and share the latest research, technology and best practice.

International Mining is a media sponsor of Resourcing Tomorrow.

Antamina, Barrick, BHP, Freeport, Gold Fields, Newmont, Teck and Vale form GeoStable Tailings Consortium

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Gold Fields Limited has announced a new consortium of eight global mining companies has launched a multi-year initiative to develop and implement new technological applications for managing tailings.

The GeoStable Tailings Consortium (GSTC) comprises Antamina, Barrick, BHP, Freeport-McMoRan, Gold Fields, Newmont, Teck and Vale, with external expert support provided by Dr G Ward Wilson of the University of Alberta.

The GSTC will study options to combine various blends of tailings with waste rock to create ‘geo-stable’ landforms that are stronger and more stable than conventional tailings deposition methods and are likely to reduce process water consumption. It will undertake a range of research and development activities, including laboratory testing, field trials and data analysis, and will collaborate to promote best practices in tailings and waste management and foster a culture of continuous improvement across the mining industry.

Martin Preece, Interim CEO of Gold Fields, said: “The management of our TSFs has as its ultimate goal zero harm to people and the environment through their full life cycle. This is in line with the Global Industry Standard on Tailings Management, the new tailings storage facility (TSF) benchmark to which all members of the ICMM are committed to conform to. Having stable TSFs is a critical element of this standard.

“There is significant mining industry interest in developing geo-stable TSFs, but there is still a lack of a sound research and development including testing protocols to assess, compare and validate the performance of different technical approaches across different mineralogical and operational situations. Gold Fields is therefore a willing participant in this consortium and playing our role in becoming part of the solution.”

The new GSTC initiative builds on the work of a group formed to advance geo-waste and eco-tailings research previously pursued by Goldcorp, which was acquired by Newmont in early 2019.

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

Environmental, Mining equipment, Mining services, Mining software, Power supply for mines, Sustainable mining, , , , , , , , , , , , , , , , , , , , , , , ,

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

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

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

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

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

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

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

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

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

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

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

James Oliver, CEO of BluVein

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Jetti Resources to deploy catalytic leaching tech at Freeport-operated El Abra

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Jetti Resources has reached an agreement with Sociedad Contractual Minera El Abra and Freeport-McMoRan to deploy Jetti’s leaching technology at the El Abra copper mine in Chile, majority-owned and operated by Freeport.

The use of Jetti’s technology will enable El Abra to produce more copper while taking advantage of existing infrastructure and will generate strong financial returns, according to Jetti.

This is not the first Freeport installation for Jetti, with a spokesperson for the mining company recently confirming to IM it was trialling the technology through “a commercial installation” at its Bagdad mine in Arizona, USA.

Jetti’s catalytic technology will be deployed on the existing leach stockpiles at El Abra and will target over 20 MIb/y (9,072 t/y) of incremental copper cathode production after an initial ramp-up period. The project will leverage existing El Abra infrastructure including excess tankhouse capacity sufficient to process all production from Jetti’s leaching technology. Engineering work for the establishment of Jetti’s on-site catalyst facility is already well advanced, with construction expected to commence in the first half of 2023 and commissioning expected in the second half of the year, Jetti said.

El Abra is an open-pit copper mining complex with a large sulphide resource as well as an established leaching operation. In 2022, El Abra produced approximately 200 MIb of copper.

Mike Outwin, CEO and Co-Founder of Jetti Resources, said: “El Abra is Jetti’s first deployment in Chile, and we are delighted to extend our partnership with Freeport to a second site. Real momentum is building behind the deployment of Jetti’s technology as its unique technological, commercial and environmental benefits become increasingly clear. We look forward to working with Freeport to successfully unlock profitable new pounds of copper with a low carbon footprint and with reduced water consumption.”

Freeport-McMoRan adds Grasberg to Copper Mark-approved sites

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Freeport-McMoRan has achieved the Copper Mark at all 12 of its copper producing operations globally after adding its 48.76%-owned Grasberg mine, in Indonesia, to the lineup.

The Copper Mark is an assurance framework to promote responsible production practices for copper, built on the vision of improving practices across the whole industry over time. Its participants commit to fully meet the Copper Mark’s standards within two years of signing up to the assurance process and to continuously strengthen practices as these standards continue to be updated to align with increasing stakeholder expectations on environmental, social and governance (ESG) issues.

The Copper Mark seeks to promote transparency and accountability of its participants in general and especially in the case where a participating site manages complex issues that have significant environmental or social impacts. PT-FI Grasberg, the operating entity for Grasberg, owned 48.76% by Freeport and 51.24% by PT Inalum and PT Indonesia, operates a riverine tailings management system which the Copper Mark recognizes as one such issue.

In addition to the Copper Mark advances, Freeport’s two primary molybdenum sites, the Climax and Henderson operations in USA, were awarded the Molybdenum Mark.

The extensive, independent on-site assessment of PT-FI Grasberg confirmed the site’s conformance with the current Copper Mark expectations and standards, including the Interim Tailings Guidance, which requires all participants to implement the Global Industry Standard for Tailings Management, where applicable, and also specifies the expectations for riverine, ocean and lake tailings systems.

The Copper Mark is also developing additional guidance for any participating sites identified as having significant long-term environmental or social impact issues. Once finalised, PT-FI Grasberg will be required to demonstrate conformance with these additional requirements through onsite third-party assurance.

Executive Director of the Copper Mark, Michèle Brülhart, said: “We congratulate Freeport-McMoRan for achieving the Copper Mark at all of its copper operations globally and we are thrilled to see the company continue its commitment to demonstrating its responsible production practices with its two primary molybdenum sites to receiving the Molybdenum Mark.

“We recognise the significant impacts caused by the riverine tailings system at PT-FI Grasberg. During extensive discussions in 2021, the Copper Mark considered available standards and guidance on how to manage riverine, ocean and lake tailings systems. We believe it is essential to engage with copper producers operating in complex environments with a view to increase transparency and provide independently verified information on how sites prevent, minimize and remedy negative impacts.”

Freeport furthers its leading copper leaching excellence

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Among the new applications, technologies and data analytics Freeport-McMoRan is advancing as part of a plan to improve copper recovery from its leach processes in North and South America is Jetti Resources’ patented catalytic technology, the company has confirmed to IM.

In its December quarter and 2022 annual results, released late last month, the leading copper miner said it believed the leach innovation initiatives it was pursuing provided potential opportunities to produce incremental copper from its large existing leach stockpiles and lower-grade material currently classified as waste.

The company has been exploring the potential for incremental low-cost additions to its production and reserve profile for some time, saying in the latest results release that it had identified opportunities to achieve an annual run rate of 200 MIb/y (90,718 t/y) of copper through these initiatives by the end of 2023.

Freeport has a long history of copper leaching production with its Americas division, which includes assets such as Morenci and Cerro Verde, having developed and implemented industry-leading technologies for leaching of oxide ores.

The company has been pursuing internal and external initiatives to expand this leading position, focusing on traditional ores and sulphide orebodies that have been typically considered difficult to leach, like chalcopyrite.

This is where Jetti’s technology comes in.

The Colorado-based company has developed catalytic technology to allow for the efficient and effective heap and stockpile leach extraction of copper. This bolts onto existing solvent extraction/electrowinning (SX/EW) leaching plants so it can be deployed rapidly with limited capital expenditure and, because it uses no heating or grinding, has low operational costs. In addition, there are huge environmental benefits from using leaching over pyrometallurgy, according to Jetti.

A Freeport spokesperson confirmed to IM that the company was in a trial of the Jetti technology through “a commercial installation” at its Bagdad mine in Arizona, USA. This mine is one of its major leaching test hubs, with the company targeting over 3 MIb/y of incremental copper cathode production from the open-pit copper mine through this work.

Bagdad has a 77,100 t/d concentrator that produces copper and molybdenum concentrate, an SX/EW plant that can produce approximately 6 MIb/y of copper cathode from solution generated by low-grade stockpile leaching, and a pressure-leach plant to process molybdenum concentrate.

The spokesperson added: “There is potential to expand production via the treatment of additional stockpiles at Bagdad in the future based on results.”

The use of Jetti’s technology is one of several leaching initiatives the company is pursuing – some with outside vendors, some using its own technology and some with joint venture partners.

All of these are focused on not only adding low-cost production to Freeport’s large production base, but also achieving a lower carbon footprint.

Jetti, which Freeport is an investor in, has been conducting a carbon footprint study and Life Cycle Assessment (LCA) of its technology, with the LCA including analyses of typical copper mining operations without Jetti’s technology and a mining operation with Jetti’s technology installed. The LCA is being conducted in conformance with the ISO 14040/44 standard and will be critically reviewed by an independent expert.

Jetti Resources has developed catalytic technology to allow for the efficient and effective heap and stockpile leach extraction of copper

Jetti has also committed to starting to track water usage and waste at all its operations and sites, which includes the installation it has at Capstone Copper’s Pinto Valley operation, also in Arizona.

At Capstone’s operation, Jetti technology is being used extensively as part of a plan to recover up to 350 MIb of cathode copper over the next two decades from historic and new mineralised waste piles.

Teck Resources has also taken an interest in Jetti’s technology having signed an agreement for the evaluation of the solution at a number of Teck’s assets with potential copper resources outside of existing mine plans. BHP, through its BHP Ventures arm, is also an investor in Jetti.

As to Freeport’s wider leaching plans, it said it was looking to use data analytics to provide new insights to drive additional value, while new applications to retain the heat in the stockpiles were “yielding results”.

The company has assessed that it has some 38,000 MIb of contained copper in leach stockpiles deemed “unrecoverable” by traditional leach methods. Of this amount, about 50% is from the massive Morenci mine, which already has leaching production capacity of 900 MIb/y of copper.

The Komatsu AZPG: bringing unique mining concepts to life

Automation, Environmental, Equipment maintenance, IoT, Mining equipment, Mining services, Mining software, Power supply for mines, Sustainable mining, , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,

Seeing Komatsu’s Arizona Proving Grounds (AZPG) in person, it is easy to understand why the OEM is in a leading position when it comes to both surface mining automation and electrification.

The 660-acre (270-ha) facility is a living and breathing example of mining’s past, present and future; touring round, one can see 20-plus-year-old machines, the latest -5 ultra-class haul trucks and concept vehicles that will form the basis for future commercial autonomous and/or electric solutions.

These concept vehicles – at least when IM visited in November – included the company’s EVX battery proof of concept vehicle and the cabless IAHV autonomous mining truck concept.

The EVX is based off the basic 860E platform (a 254-t payload machine) and was shown off at MINExpo 2021. Prior to that, it had been testing out its all-battery power functionality at AZPG.

The IAHV, which debuted at MINExpo 2016, was developed by Komatsu as an unstaffed vehicle designed to maximise the advantages of such operation. It remains on show, with the company incorporating several learnings from this vehicle into its standard Electric Drive Trucks (EDT) and autonomous products.

Pat Singleton, Product Director, EDT, refers to AZPG as the “ultimate laboratory to be able to bring unique mining concepts to life”.

He added: “The testing we do at AZPG gives us the opportunity to reduce product development risk and take the validation process one step further before the products make it to the mine.”

The original focus at AZPG was the EDT product line, yet, as Komatsu has expanded its product offerings, more solutions continue to be tested or validated at the facility each year.

This testing is extensive, as was made obvious to IM while navigating an autonomous vehicle ‘assault course’ and hearing about new wet- and dry-disc brake trial combinations, higher speed tramming on autonomous haul trucks and more.

It is not just trucks subject to these try outs either, with hydraulic shovels, surface drill rigs, water trucks, dozers and other vehicles having a presence on site.

“If anything, the importance of AZPG has increased as technology has continued to evolve,” Singleton said. “AZPG allows for a single location to harmonise development efforts of all the Komatsu entities, providing research and development into our products.”

What’s more, the facility is located in Arizona’s renowned copper heartland.

This has been very useful for Komatsu, with Asarco’s Mission mine next door to the facility representing a real life mine site testing opportunity for solutions that have graduated from AZPG.

AZPG has 23 full-time staff, but its desk count is much higher, indicating the number of visitors and partners AZPG welcomes on a weekly basis from across the globe.

Some of these visitors include FrontRunner® autonomous haulage system (AHS) customers, who have, more recently, been invited to send operators to the facility for invaluable training ahead of planned autonomous deployments.

Anthony Cook, Vice President, Autonomous Systems, Mining Technology Solutions, told IM that this approach is enabling mining operations to leverage more of the benefits of AHS from day one of deployment, reducing the need to conduct a ‘soft start’ with the technology as operators come to terms with the transition from staffed to autonomous operations.

A representative from Komatsu’s dealer network was receiving training on the AHS system during IM’s visit, with Cook confirming another major mining customer and Komatsu distributors had sent operators to Arizona earlier in 2022 ahead of a planned deployment in 2023.

AHS developments are a key focus area for AZPG, with the on-site trucks testing out many different scenarios that customers could experience at their operations.

Software updates make up many of the ongoing FrontRunner AHS developments, but the company also continues to explore the use of more sensors and cameras on board its vehicles for obstacle detection and positioning. This is all geared towards improving visualisation, communication and safety, reducing potential false positives during operation and ultimately helping to improve productivity.

As for software upgrades to FrontRunner AHS, all developments are initially tested in a bench environment where the company can simulate the system. This may be within the former Modular Mining facility, also in Tucson, or at another one of Komatsu’s many testing hubs.

“Once it has passed virtual testing then final functional and stability testing is validated at AZPG before release to the customer,” Singleton said.

Some recent testing related to mixed fleet operations of staffed and autonomous trucks that originated in the lab to later emerge at AZPG has since led to a FrontRunner first at Anglo American’s Los Bronces mine in Chile.

The mining company only recently started its AHS deployment at the copper mine, initially going live with ten 930E-5 trucks, but Cook confirmed to IM that these vehicles are now interacting with staffed trucks in the mining environment.

“We’ve got off to a very strong start at Los Bronces, with Anglo American really embracing the technology and pushing it to its limits,” he said.

The full Los Bronces deployment could see 62 electric drive Komatsu 930E trucks running by 2024.

Those who visited MINExpo 2021 in Las Vegas will also remember the PC7000-11 shovel that was being teleremote operated live from the show, while the unit was over 600 km away at AZPG. This unit (above) is still positioned on site and the teleremote operation is continuing to be refined from inside the facility, with AutoSwing and AutoDump functions a few recent notable additions for improved operability.

Komatsu expects to replace this shovel with a backhoe version later this year, to also be teleremotely operated.

Trolley transformation

The first vehicle IM saw when driving up to AZPG was the EVX; its shiny yellow exterior providing the perfect contrast to the rich blue backdrop of the Tucson sky.

Since leaving Las Vegas in September 2021 and heading for Tucson, the company has made preparations to remove the small on-board battery which was displayed on the Komatsu stand and begin replacing it with a larger one from one of its integration partners.

The connectors for trolley were still on board and the team was awaiting final commissioning of the on-site trolley line ahead of further testing.

IM Editor Dan Gleeson (left) on site at AZPG with some of the Komatsu team

Singleton explained: “The EVX was a proof of concept to demonstrate that a large electric drive haul truck could be powered by a battery. Now that we better understand the ability of this technology to work in our EDT products, we must continue to advance the technology to drive increased performance and reduced operating costs.”

To date, Komatsu has continued with truck testing to learn how the various subsystems work with batteries while finalising its battery chemistry.

“We’ve also installed trolley infrastructure, which will allow us to conduct further testing on batteries and other alternative power sources,” Singleton said.

This infrastructure – made up of 39 poles that are ‘movable’ and ‘self-supporting’ – could support two 980E-5s running on the line at the same time.

Initially, it will support both the EVX and one 930E running in tandem.

The line itself is powered by a 9 MW substation, which Siemens and a local electrical and engineering company established.

The trolley course has been designed with a 60° corner to demonstrate to operators that this technology is for more than just straight hauls.

“This highlights the flexibility of the system and shows mining operators where the technology can already go today,” Cook said. “The concrete pillars, which can be moved with wheel loaders and other support equipment, are an indication that the trolley can ‘move with the mining’, too.”

Singleton said the next development for the EVX will focus on an increase in the battery capability and the investigation of proof of concept on a variety of static and dynamic charging options.

The trolley line will, no doubt, play a role in this testing, although it is not yet known if a single or hybrid power setup will be selected initially.

What is more certain, however, is the status of fuel cell electric vehicle (FCEV) testing on the EVX. Singleton said research into this area continues, yet a practical test where fuel cells and a battery were mounted on the chassis was some way off.

At this early stage, Singleton says the first commercial power-agnostic offering the company establishes will likely be diesel and/or diesel trolley.

He explained: “This approach delivers reduced risk to the overall portfolio by blending the power-agnostic chassis with a refined version of an existing technology (diesel engine + overhead dynamic trolley).”

“It also serves the secondary purpose of allowing battery technology the opportunity to mature from a performance perspective as we work to define overall truck fleet performance. Additionally, static and dynamic charging options (including development of an industry-standard connector) are within the scope of this product.”

And the first commercial power-agnostic truck will be in the 291 t (320 ton) class – the same size as a 930E – Singleton confirmed, adding that scalability was something being considered at every stage of the truck’s development.

“Scalability is the overall goal and is in alignment with the general power-agnostic approach to our design,” he said. “The major challenge will be the scalability of the energy storage componentry from a cost and performance standpoint. This is the primary driver behind the continued deliberate development cadence designed to give the battery technology time to mature over the intervening period before the design is finalised.”

When asked about fixed fast charging – a concept that has risen up the mine truck charging rankings of late with Charge On Innovation Challenge work from Hitachi Energy and a consortium led by Shell, respectively – Singleton referred to developments as a “two-way street” and a “work in progress”.

“Essentially those solutions need better definition and ‘mining proofing’ before we introduce them into AZPG,” he said. “Perhaps an opportunity exists to co-develop these technologies and improve speed to market but, again, this is still being defined.”

The trolley infrastructure at AZPG – made up of 39 poles that are ‘movable’ and ‘self-supporting’ – could support two 980E-5s running on the line at the same time, according to Komatsu

All this work sounds encouraging for those companies interested in adding to their ultra-size class truck fleets in the 2030s in line with industry-wide decarbonisation plans, but Komatsu customers looking to buy trucks today will be after future-proofed solutions.

Komatsu is all too aware of this and planning to provide a battery retrofit solution for its current -5 products, Singleton said.

GHG Alliance and beyond

As has been well documented, Komatsu has aligned with a core group of customers under its GHG Alliance to accelerate developments on the electric haulage front.

Rio Tinto, BHP, Codelco, Boliden, Teck, Antofagasta Minerals SA and Freeport-McMoRan are key stakeholders within the alliance and will be keen to see what testing emerges on that trolley line into 2023.

While Singleton said the communication process with these customers was still being refined, he acknowledged AZPG’s role in future developments.

“There is no question AZPG will provide a critical backdrop to accelerating our efforts and streamlining our ability to communicate and advance the development progress with our customers,” he said.

Whether the company chooses to initiate an early-learner program like the other big yellow equipment maker it competes with is yet to be seen, with Singleton saying its plans will leverage the “Komatsu approach” regardless of what the competition is doing.

What is clear is that AZPG will continue to keep Komatsu on the leading edge of mobile mining equipment technology developments.

As evidence, Cook reeled off several ongoing projects the company was engaged in, including an autonomous water truck in Australia, automated dozers in Brazil and plans to semi-automate electric blasthole drills.

Going forward, another consideration will be the ability to integrate AHS with trolley operations.

“Komatsu, as an organisation, is committed to solving our customer’s and the industry’s challenges, and we will continue to leverage AZPG and the wider Komatsu network to do this,” Cook said.