Tag Archives: hydrogen

Chart, Howden ready to showcase a ‘ventilation and more’ offering at MINExpo

Howden’s transition into the wider Chart Industries offering is allowing it to branch into new territory; territory that it will be showcasing at MINExpo INTERNATIONAL® 2024 in Las Vegas later this month.

For over a century, Howden has supplied underground ventilation fans to every major global mining company. Today, its fully integrated ventilation air quality control approach can, it says, dramatically reduce energy usage by 50%.

Chart Industries, which Howden is now a part of following its acquisition in March 2023, says it is a leading global solutions provider to clean energy and industrial gas markets across the Nexus of Clean™ – clean power, clean water, clean food and clean industrials.

The combination between Chart and Howden is broadening business, according to Leo Botha, Director of Global Mining Sales at Chart.

“At Howden, we have traditionally focused on the underground mining sector, whereas Chart Industries has significant exposure to the surface mining industry,” he told IM.

The legacy Howden business supplies a variety of fans – main, booster and auxiliary fans – that provide versatility, economic advantages for efficiency and maintenance, low noise and outstanding aerodynamic performance. It combines this with mine cooling and mine heating systems to ensure the optimal solution for each mine site.

Underpinning this is the Ventsim® platform.

Ventsim DESIGN enables the 3D design, modelling and simulation of underground mine and tunnel ventilation systems with controls for safe and efficient operations. It originated as mining management software in 1993 and, today, ensures operations within mines and tunnels are safe and efficient through a suite of solutions.

Ventsim CONTROL is designed to reduce energy consumption, associated costs and improve energy efficiency in underground mining ventilation systems, supporting customers’ net-zero goals. The software suite uses advanced algorithms to analyse real-time data and adjust ventilation equipment to maximise energy savings while maintaining safe working conditions.

“We continue to enhance Ventsim capabilities and leverage advancement in technologies like AI,” Chart says. “We’re furthering our energy management and control tool kit and implementing a carbon calculator, building on the energy dashboards we have in place to visualise energy consumption, energy savings and, more recently, carbon emissions.”

The company can also highlight LNG and hydrogen storage, system, transport and fuelling options.

Chart provides LNG energy storage and fuel delivery solutions for natural gas power generation, on-board LNG fuel tanks for mine haul trucks and service vehicles, and related fuel station equipment. It now also offers the exact same solutions for energy and power generation using gaseous or liquid hydrogen with its onboard LH2 vehicle fuel tanks and fuel stations, LH2 storage tanks and vaporisers, H2 compressors and related supply chain equipment.

Botha says some of the early conversations with customers have already gone into specifics on how they can access some of these hydrogen solutions at their sites.

“Chart, which has a remit of ‘cleaning up’ the industries it works in, has hydrogen and LNG storage solutions that could allow these mines to reduce their carbon dioxide emissions drastically,” he said. “We’re now just looking to align on whether that may be hybrid solutions involving diesel and H2/LNG, or a single energy source.

“These solutions aren’t likely to be integrated at mine sites tomorrow, but they are commercially-available in other sectors and, in some instances, present a strong mining business case.”

In the field of carbon capture, utilisation and storage, Chart has significant knowledge of and solutions for the processes and challenges of energy-intensive, hard-to-abate industries such as mining and mineral processing.

Lastly, Chart’s water business, ChartWater™, can offer the most efficient, cost-effective, environmental solutions for contaminant removal, including antimony and arsenic, oxygenation for remediation of rivers/lakes/reservoirs, aerobic biological processes, pH control for mineral acid replacement, enhanced metal flotation and remineralisation, the company says.

Botha continued: “We look forward to continuing to offer our customers different commercial solutions and increased functionality. This, for instance, includes leasing and rental options – options that Howden customers have not previously had before becoming a part of Chart.”

Fabrum, Fortescue commission Australia’s largest liquid hydrogen plant at Christmas Creek

Australia’s largest liquid hydrogen plant at a mine site is now operational at Fortescue’s Green Energy Hub at Christmas Creek in Western Australia, according to Fabrum, a company that played a significant role in delivering an end-to-end liquid hydrogen ecosystem for the plant.

New Zealand-based Fabrum collaborated on the design, build and commissioning of the liquid hydrogen plant at Christmas Creek, which comprises a hydrogen liquefaction facility, liquid hydrogen storage and a liquid hydrogen refuelling station. Liquid hydrogen from the plant will be used to power Fortescue’s zero-emissions mining equipment prototypes including its offboard power unit and its hydrogen-powered haul truck prototype (the hydrogen-powered T 264 haul truck prototype that arrived this month). The liquid hydrogen plant can produce circa-350 kg of liquid hydrogen per day and has circa-600 kg of storage.

Christopher Boyle, Fabrum’s Executive Chair, said: “We’re delighted to be developing world-leading hydrogen technologies for our partner, Fortescue, to help the company achieve its decarbonisation goals. While others in the industry might see the decarbonisation challenge as too big, Fortescue is leading the way in adopting new technologies to enable a zero-emissions economy. Together, we’re demonstrating the future is here now – and that our liquid hydrogen production and refuelling technologies can enable industry to power operations and transport today.”

Fabrum’s liquid hydrogen production system

Dino Otranto, Fortescue Metals Chief Executive Officer, said: “Fortescue is moving at rapid speed to decarbonise and the completion of our hydrogen facility, which is the largest gaseous and liquid hydrogen plant on any mine site in Australia, is testament to our commitment to leading heavy industry in decarbonising. Hydrogen and fuels made using renewable energy will have a role to play in decarbonising mining, whether it’s in buses, heavy mining equipment such as haul trucks and excavators, or producing green iron.

“This renewable hydrogen plant is versatile, enabling us to produce gaseous and liquid hydrogen to be used to power our mining equipment prototypes, while also providing the added benefit of refuelling our fleet of coaches at Christmas Creek.”

Dr Ojas Mahapatra, Chief Executive Officer of Fabrum, added: “This is the first project we’ve collaborated on with Fortescue, an investor in Fabrum, and it highlights the great opportunities we see to help each other be successful in the future. This project also represents our entry into the mining and minerals industry to add to our work in heavy transport, aviation and other industries. It’s an exciting time for Fabrum as we continue to grow rapidly to meet increasing global demand for hydrogen production systems and other technologies.”

Europa hydrogen-powered prototype arrives at Christmas Creek as Liebherr, Fortescue eye zero emission AHS milestone

The first hydrogen-powered T 264 haul truck prototype, developed by Liebherr and Fortescue, has arrived on site at Fortescue’s Christmas Creek mine in the Pilbara region of Western Australia for testing in a real-life mining environment.

The site-based testing of this T 264 prototype, known as Europa, will take place over the coming months and will help inform Fortescue’s future fleet of zero emission haul trucks, Liebherr says.

Oliver Weiss, Executive Vice President of R&D, Engineering and Production, Liebherr-Mining Equipment SAS, said: “Liebherr and Fortescue are aligned in the belief that hydrogen and hydrogen carriers, such as ammonia, will play an important role in supporting the mine decarbonisation additional to electrification. What we learn from this hybrid truck will significantly shape and enhance our future development strategies for zero emission haulage. The integration of a Fortescue Zero battery into a Liebherr haul truck marks a huge milestone in the partnership between the two companies. It is fascinating to see how this cooperation helps to fast track our planned developments of new technology from ideas to demonstration and operation in the field.”

Europa contains a 1.6 MWh battery (developed in-house by Fortescue WAE) and 500 kW of fuel cells. The prototype can store over 380 kg of liquid hydrogen.

Dino Otranto, CEO, Fortescue Metals, added: “It’s fantastic to have our hydrogen-powered haul truck prototype now joining its battery-electric equivalent, Roadrunner, up at site.”

Once commissioned on site, Europa will be refuelled with liquid hydrogen from a gaseous and liquid hydrogen plant located at Fortescue’s Green Energy Hub at Christmas Creek.

Liebherr and Fortescue have been working together to develop zero-emission haul trucks since the collaboration was announced in 2022. Recently, the companies announced their collaboration to co-develop and validate a fully integrated Autonomous Haulage Solution.

Otranto added: “This deployment of Europa builds on our wider collaboration with Liebherr, where we are working together to develop and validate a fully integrated Autonomous Haulage Solution, which we’re aiming to be the first to operate in zero emission vehicles globally. To decarbonise mining you need a system solution, so this new operating system, which integrates a fleet management system and energy management, will be a game changer for Fortescue in reducing our carbon emissions.”

LKAB-HYBRIT

The HYBRIT initiative receives major funding for fossil-free steelmaking developments

The HYBRIT initiative has received support from the Industrial Leap (Industriklivet), Swedish Energy Agency’s program to support Swedish industry’s transition to fossil-free, with a total of SEK3.1 billion ($302 million) granted for the establishment of a first demonstration plant in Gällivare, Sweden, for the production of fossil-free sponge iron on an industrial scale.

LKAB is responsible for the construction of the planned plant and will be the main recipient of the support.

Jan Moström, President and CEO of LKAB, said: “The processing and production of fossil-free sponge iron is central to the climate and to Swedish competitiveness. We are pleased with the announcement that the state is participating and sharing the initial risk in this crucial step to industrialise the HYBRIT technology. In order to counter climate change, we need to move forward quickly, and to keep up the pace, it is important that we get all the prerequisites in place for future investment decisions.”

Hybrit Development AB (HDAB), owned by LKAB, SSAB and Vattenfall, had originally applied for SEK4.9 billion in support from Industriklivet for the next step in the development of the HYBRIT initiative. On October 31, 2023, HDAB and LKAB submitted a supplementary application stating that LKAB will be responsible for the construction of the planned demonstration plant and will also be the main recipient of the requested support. At the same time, the amount of aid applied for was reduced to SEK3.7 billion.

The demonstration project is one of 35 projects from 12 EU countries that are part of the Hy2Use IPCEI integrated project. IPCEI stands for Important Projects of Common European Interest and enables EU Member States to provide government support to priority initiatives with a strategic common European interest.

Robert Andrén, Director General of the Swedish Energy Agency, said: “The future competitiveness of Swedish industry lies largely in becoming fully fossil-free. Therefore, the investments made in Industriklivet are of great importance, not only for the sake of the climate and the environment, but also for the supply of skills and employment in both new and old industrial locations in our country. The decision we are now taking is the largest financial decision made so far in this work and it is an important one.”

Although the HYBRIT technology has been tested and proven successful, it has not yet been fully used on a large scale. The support now granted is intended to be used to get past the initial stage, from pilot to industrial production, with a first demonstration plant planned at LKAB’s industrial area in Gällivare. This is in line with the development of the HYBRIT cooperation and the aim of developing a fossil-free value chain for iron and steel production with fossil-free electricity and hydrogen.

The plan for the demonstration plant is to produce over 1.3 Mt/y of sponge iron, volumes intended for SSAB’s transition. With sponge iron produced with hydrogen instead of coal, carbon dioxide emissions in the steel industry can be largely eliminated by replacing coal-fired blast furnaces with electric arc furnaces, the initiative says.

Martin Pei, EVP and CTO, SSAB, said: “We welcome the decision as an important signal of the potential of the green transition for Swedish competitiveness. We have started the transition of SSAB’s steel production in the Nordic region, which will reduce carbon dioxide emissions in Sweden and Finland by ten and seven percent respectively in around 2030. The HYBRIT technology has made us global pioneers in fossil-free steel production and we look forward to scaling up our pilot deliveries of fossil-free steel to commercial levels. Today’s announcement is therefore important for our strategy going forward.”

The electricity demand for the demonstration plant with HYBRIT technology is estimated at about 5 TWh/y at full operation and is primarily for large-scale production of fossil-free hydrogen needed for the direct reduction process.

Andreas Regnell, SVP Head of Strategic Development at Vattenfall, said: “This is gratifying news, for the climate, but also for Sweden’s future competitiveness. Cooperation on the entire fossil-free value chain for fossil-free steel has proved successful. This and access to competitive fossil-free electricity is and will be crucial to the success of the transition. Sweden already has a fossil-free electricity system, and thus has an advantage over most other countries in the world, but now we need to ensure that we expand the supply of fossil-free electricity and hydrogen in line with the needs of industry. Vattenfall is investing in fossil-free electricity production, transmission and development of flexible technologies, such as hydrogen storage, to contribute to continued competitive energy supply.”

The owner companies in HYBRIT have accounted for approximately 75% of the financing for the technology development. SSAB, LKAB and Vattenfall have together invested one third each, a total of about SEK1.7 billion in a feasibility study for the pilot phase, implementation of the pilot and a feasibility study for the demonstration phase. HYBRIT has previously been granted more than SEK520 million in state aid.

LKAB has begun transitioning its mining and processing operations with the goal of making all products and processes carbon-free by 2045 – a step-by-step transition for sponge iron production that will reduce carbon dioxide emissions from customers around the world by 40-50 Mt/y, equivalent to Sweden’s entire annual greenhouse gas emissions. In May 2023, LKAB submitted an application for the environmental permit necessary to begin the transition.

Moström added: “This is a huge opportunity for Sweden and for the climate. Our high-quality iron ore combined with good access to fossil-free energy gives us unique conditions compared to other countries to establish a sustainable and competitive value chain for the fossil-free iron and steel production of the future. Now it is important that we as a society take advantage of these benefits and build competitiveness while attacking emissions.”

The planned construction of the demonstration plant builds on the positive results achieved in the HYBRIT initiative, where the pilot operations in Luleå continue to play an important role in the development of the technology, the companies say. The jointly owned research and development company Hybrit Development AB will continue to develop the technology with the aim of eventually licensing it to licensees outside the current circle of owners.

Orica and Mitsubishi Heavy Industries team up to tackle decarbonisation

Mitsubishi Heavy Industries (MHI) and Orica have signed a Memorandum of Understanding (MoU) to explore potential opportunities for collaboration on emission-reduction initiatives, aligned with Orica and MHI’s shared decarbonisation ambitions.

The collaboration will leverage MHI’s reputation for manufacturing excellence and innovation, as well as Orica’s existing presence and emerging opportunities in the global renewable hydrogen and ammonia markets, the companies say.

The collaboration covers various areas of mutual interest, including:

  • Exploring technology deployment opportunities for renewable hydrogen and renewable ammonia production near Orica’s facilities in Newcastle and Gladstone, Australia;
  • Creating demand opportunities for renewable hydrogen and renewable ammonia in the power generation, maritime, industrial and agricultural industries;
  • Investigating activities to further reduce emissions from Orica’s existing operations.

Orica says it is building a strong pathway towards achieving net zero emissions by latest 2050, while positioning the business for a lower carbon world. Orica’s continued partnerships and investment in decarbonisation and the production of renewable hydrogen and renewable ammonia will support Orica’s sustainability goals and also support the individual goals of existing and future customers, including in key Asian growth markets such as Japan.

Orica Chief Development and Sustainability Officer, Andrew Stewart, said: “We are delighted to partner with MHI, a company that shares our vision and commitment to a more sustainable future. This collaboration signals another step towards building Orica’s climate resilience and opportunities to support further growth while supporting our customers to achieve their ESG goals. We look forward to working with MHI to explore potential emissions reduction opportunities for our organisations and our customers.”

On the signing of the MoU, Dr Hitoshi Kaguchi, Senior Executive Vice President at MHI responsible for energy transition and the expansion of growth fields, said: “It is a great honour to be able to collaborate with Orica, a leader in decarbonising hard to abate industry and developing low carbon fuel value chain in Australia. We are looking forward to contributing to Orica’s net zero ambition through our reliable technology in the future.”

Fortescue-ChristmasCreek

Fortescue Board approves ‘green pit to product’ hydrogen-based iron ore project

Fortescue Metals Group has approved an investment of up $50 million to construct a Green Iron Trial Commercial Plant at Christmas Creek, with annual production of more than 1,500 t.

The plant, in Western Australia, will use the existing green hydrogen infrastructure at Christmas Creek to lower the overall capital requirement and demonstrate a green pit to product supply chain, the company said. Construction will commence following a work program and is subject to receiving the relevant approvals. First production of green iron is targeted in 2025.

The pilot’s technology options will support both magnetite and hematite ores, with Fortescue recognising the importance of taking steps to support the reduction of its Scope 3 emissions.

Fortescue said: “The project represents a significant milestone in Fortescue’s green iron journey, where the company has been examining various hydrogen-based pathways to produce green iron, while also developing a low-temperature, electrochemical process at its Perth R&D facility.”

The term “green iron”, in this instance, refers to the end product resulting from processing iron ore into iron, without the use of fossil fuels, and instead using renewable energy.

Alongside this investment, the company also confirmed two other green energy projects – namely an 80 MW electrolyser and liquefaction facility in Arizona able to produce up to 11,000 t/y of liquid green hydrogen (the Phoenix Hydrogen Hub) and a 50MW green hydrogen project using Fortescue’s own electrolyser technology (the Gladstone PEM50 project).

Cat-C13

Caterpillar looks at hydrogen-hybrid power options for C13D engine platform

Caterpillar has launched a three-year program to demonstrate an advanced hydrogen-hybrid power solution built on its new Cat® C13D engine platform.

Starting in the March quarter of 2024, Caterpillar will develop a transient-capable system for off-highway applications. The project will demonstrate how state-of-the-art control systems and electric-hybrid components can help hydrogen-fuelled engines meet or exceed the power density and transient performance of traditional diesel engines.

Caterpillar will serve as the prime contractor on the project, providing engine research and development as well as system integration. As the project progresses, other industry and academic collaborators will be brought into the program to provide additional specialist expertise. The initiative will be delivered at Caterpillar facilities in Chillicothe, Illinois, and San Antonio, Texas.

With research commencing in 2024, the project is supported and partially funded by the U.S. Department of Energy’s (DOE) Vehicle Technologies Office (VTO) through the Office of Energy Efficiency and Renewable Energy (EERE). It is included among 45 projects across 18 states and Washington, D.C., receiving funding to advance research, development, demonstration and deployment in several areas critical to reducing greenhouse gas (GHG) emissions in the transportation sector.

The hydrogen-hybrid power demonstration project is the latest in a series of initiatives that builds upon Caterpillar’s 35 years of enterprise experience in hydrogen fuels.

“Every off-highway application has its own unique duty cycles, lifecycle demands and performance expectations, and this complexity is driving the development of a wide range of power solutions for the energy transition,” Steve Ferguson, Senior Vice President Caterpillar Industrial Power Systems, said. “One size does not fit all, which is why we’ve engineered flexibility into the C13D engine to serve as our platform of the future.”

Caterpillar’s hydrogen-hybrid demonstration project leverages the performance, packaging and fuel flexibility engineered into the new 13-litre Cat C13D engine platform – an engine that is currently used on the company’s 15-t-payload R1700 loader.

Unveiled at the CONEXPO-CON/AGG 2023 construction exhibition in March, diesel-powered versions of the Cat C13D engine offer eight power ratings from 456 to 690 hp (340 to 515 kW) with up to 3,200 Nm of peak torque. It provides up to a 20% increase in power and up to 25% more low-speed torque over the previous generation of Cat diesel engines in its power class.

The inline, six-cylinder Cat C13D enables the use of renewable liquid fuels such as 100% HVO, B100 Distilled Biodiesel, and even up to B100 Standard Biodiesel by working with the local Cat dealer, the company says. In addition to using hydrogen, its core architecture is designed for the future development of spark-ignited natural-gas capabilities.

Available for early OEM pilots in 2025 and scheduled for production in 2026, the Cat C13D engine is targeted for a wide range of off-highway equipment, including rock crushers, material-handling equipment and large industrial pumps.

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

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

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

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

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

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

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

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

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

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

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

dynaCERT

dynaCERT proprietary HydraGEN technology destined for South America miner

dynaCERT Inc’s dealer, H2 Tek LP, has put in more purchase orders to dynaCERT for its proprietary HydraGEN™ technology, with a total of 161 units to be fulfilled in 2023, destined for one of its mining customers with operations in South America.

These orders follow positive results of several pilot projects as previously announced by dynaCERT, whereby H2 Tek had advised dynaCERT that the company’s HydraGEN Technology had been installed at certain mining operations in Chile, Peru, Brazil, Argentina and Australia by H2 Tek. These installations were pilot projects to test the numerous benefits and impacts of dynaCERT’s HydraGEN Technology on mining equipment with the intent that successful pilot projects can result in the adoption of the technology to be used for mining equipment and mining fleet applications.

Following the completion of such pilot projects, H2 Tek has indicated to dynaCERT that it has reported very compelling results to such mining and resource companies involved in pilot projects which evaluated dynaCERT’s HydraGEN Technology, including its customer for these purchase orders.

Joao Araujo, Vice President of Global Operations and Partner of H2 Tek, says: “Our customer is a major mining operator in South America. The HydraGEN solution fits perfectly with its commitment to improve its performance with the use of clean energy, in reducing greenhouse gas emissions in operations and in the value chain. This project is just the first step for us to support our client’s ESG objectives.”

HydraGEN is a carbon emissions reduction device for all types and sizes of diesel engines. dynaCERT says: “As part of the growing global hydrogen economy, our patented technology creates hydrogen and oxygen on-demand through a unique electrolysis system and supplies these gases through the air intake to enhance combustion, resulting in lower carbon emissions and greater fuel efficiency.”

dynaCERT said recently that Codelco had been using the technology on board Komatsu 930E trucks at its Radomiro Tomic mine site, in Chile, to reduce GHG emissions and fuel savings.

David Van Klaveren, VP Global Sales/Partner of H2 Tek and Araujo, stated: “Certain large mining vehicles can consume more than 1 million litres of fuel per year, which, with assumed fuel and emission reductions of an assumed 10%, could offset up to 270 t of CO2e per year. We look forward to playing an important role in helping mine operators achieve their carbon emission reduction targets.”

Jim Payne, President & CEO of dynaCERT, added: “We are pleased to support H2 Tek’s mining and resource customers as committed users of our proprietary HydraGEN Technology. The growth of international acceptance of our HydraGEN Technology products, which are designed to reduce fuel consumption and reduce carbon emissions in diesel internal combustion engines, encourages our company to continue to actively foster greenhouse gas emission reductions on a global basis.”

Terrafame leveraging Kelluu hydrogen-powered airship mine monitoring solution

Terrafame, a responsible battery chemicals producer for electric vehicles, has selected Finland-based airship development company Kelluu to provide accurate and geo-referenced terrain data for continuous monitoring of its 60 sq.km industrial site.

The aerial monitoring has been done mainly using satellites or helicopters, battery-powered drones, or land-based surveys.

Kelluu develops long-distance, self-flying and hydrogen-powered airship concepts mounted with several spectral cameras, sensors and scanners that can gather real-time data on terrain, vegetation and infrastructure. It then processes the data to create an accurate 3D digital twin of the environment, enabling Terrafame in this instance to monitor and forecast dynamic changes at the industrial site and optimise its infrastructure maintenance and production processes, and further strengthen the environmental safety of the site, Kelluu says.

Aki Ullgren, Senior Geotechnical Engineer at Terrafame, said: “The combination of high-resolution RGB, multispectral and Flir images, combined with the same 3D mesh, is a fascinating tool, especially in heap leaching and open-pit slope stability modelling. We’re happy to welcome Kelluu to the group of monitoring services we use to promote safety and efficiency at our Terrafame site.”

Kelluu’s airships are highly efficient, emitting 99.5% less CO2 emissions than traditional aerial monitoring, and frequently cover mission times of over 12 hours, the company claims. The airships are effectively operational in sub-zero temperatures.

Kelluu says its facility in Finland is the only airship factory and product development laboratory in northern Europe.

Janne Hietala, CEO of Kelluu, said: “It is truly mesmerising to see the Kelluu’s airships in the air at Terrafame. We felt a strong connection with Terrafame’s commitment to positively impacting the world by reducing emissions of electromobility. What Terrafame does for mobility, we do it for aviation. Together, we provide increased safety using Kelluu’s breakthrough intelligent airship technology.”

Terrafame has one of the world’s largest production lines for chemicals used in electric car batteries on its industrial site in Finland. The plant can produce nickel sulphate for around 1 million electric cars per year, it claims. The carbon footprint of the nickel sulphate produced by Terrafame is among the smallest in the industry.

As Terraframe produces hydrogen onsite and the airships are powered by hydrogen, Kelluu has built a ground base for its airships on Terrafame’s industrial site. Kelluu will autonomously transfer its airship from its current base in Joensuu, Finland, to Terrafame’s base in Sotkamo.

In addition to Kelluu, Terrafame has multiple other partners helping to monitor its site and develop its operations and occupational and environmental safety.