Tag Archives: hyperspectral imaging

Weir Group marks Minerals and ESCO progress in H1 results

Base metals, Comminution of minerals, Equipment maintenance, IoT, Mining equipment, Mining finance, Mining services, Mining software, Steel and iron ore, Sustainable mining, Water management, , , , , , , , , , , , , , , , , , ,

The Weir Group has issued its half-year results to June 30, 2023, noting some significant achievements across its Minerals and ESCO divisions.

Headline numbers for the six-month period included a 19% year-on-year jump in revenues to £1.3 billion ($1.67 billion) and a 26% rise in operating profit to £212 million.

Weir Minerals continued to execute on key strategic growth initiatives, and during the first half gained market share in its core mill circuit product categories, it said.

The company said: “We converted 100% of our competitive field trials for large mill circuit pumps, and also rolled-out our latest cyclone technology.”

One highlight in the period came at a large Brazilian iron ore mine, where Weir Minerals upgraded the cyclones to its latest Cavex® 2.0 solution. The new cyclones, which are Synertrex®-enabled, have improved separation and increased mineral recovery by more than 400,000 t/y, according to the company.

Cavex 2 cyclones were launched in 2020, introducing new geometric features to offer performance unmatched by any cyclone in operation at that point, the company claimed. The advanced LIG+ design (patent pending) enables the Cavex 2 hydrocyclones to classify up to 30% more feed slurry, while occupying the same footprint as competitor hydrocyclones, according to Weir.

Weir Minerals says it also made good strategic progress in sustainable solutions during the six-month period and delivered year-on-year growth in comminution. New orders included a pebble crushing plant for a large copper mine in South America and a crushing solution for a potash mine in Canada.

The company also said it saw “very encouraging interest” from customers for its Redefined Mill Circuit, securing orders from large copper mines in South America for coarse particle flotation (CPF) pilot circuits, in partnership with Eriez.

“Through this strategic alliance, we have integrated CPF technology with our latest generation Warman® mill circuit pumps and Cavex cyclones to provide significantly improved recoveries and process efficiencies for our customers,” it said. “Once operational in the September quarter, these plants will be important reference sites for the industry.”

Around a year ago, Weir Minerals and Eriez Flotation announced a cooperative agreement to design and develop CPF systems. This allows both companies to better connect the Eriez equipment with the slurry classification and conveying expertise of Weir Minerals, according to Ricardo Garib, Division President of Weir Minerals.

Weir Minerals also launched its new, proprietary digital intelli-solutions for pumps, cyclones and high pressure grinding rolls which, coupled with its Synertrex 2.0 platform, captures critical machine health data and enables remote condition monitoring.

It concluded: “We continued to invest in research and development of our core technologies including new materials and polymers, and upgrades and range expansions for our industry leading Warman slurry pumps.”

Weir ESCO, meanwhile, reported that the number of mines using Motion Metrics™ AI-enabled vision technology increased during the first six months of the year, with new orders including a package of five ShovelMetrics™ and five LoaderMetrics™ systems to be deployed across all large mining machines at an iron ore mine in Western Australia.

“The division made excellent progress in growing market share in mining attachments, with a 37% year-on-year increase in orders,” it said. “A particular highlight included converting four cable shovel buckets from competitor products to ESCO technology for a large North American copper miner.”

The division also provided an update on trials of its proprietary ore characterisation technology, which has been leveraging the BeltMetrics™ solution from Motion Metrics positioned above a conveyor directly after the crusher in the flowsheet at an unnamed mine. As well as using the rugged vision technology Motion Metrics has previously used, the company is also incorporating hyperspectral imaging into the mix for this trial.

It reported: “Field trials of our proprietary ore characterisation technology were successfully completed during the first half. Tests enabled critical data to be collected and validated the performance of the technology in a real-world environment.”

Development has now progressed to the next phase focused on exploring “novel illumination” technologies to enhance minerals characterisation, it added.

New Motion Metrics capabilities and functions were launched during the six-month period, including an upgraded lens cleaning solution that enhances machine vision capability and improves response times.

“Other technology investments included development of a new series of mining attachments that, once launched, will expand our addressable market,” it said.

MotionMetrics-BeltMetrics

Weir eyes game-changing energy intensity reductions with ore characterisation project

Base metals, Comminution of minerals, Environmental, IoT, Mineral processing, Mining equipment, Mining software, Sustainable mining, , , , , , , , , , , , , , , , , , ,

With an extensive footprint from the rock face all the way through to tailings, it was only a matter of time before the Weir Group decided to enter the ore sorting game.

In recent years, the company has re-focused as a pureplay mining and aggregates company that can provide value throughout the flowsheet.

The company ditched its oil & gas exposure and added to its process plant and tailings remit with the acquisition of ESCO, a front-end-focused mining technology company with leading market share in the ground engaging tool (GET) segment.

Having more recently incorporated Motion Metrics into the mix – now within the ESCO division – it is embarking on a project that could have positive ramifications throughout the wider Weir Group offering.

Motion Metrics is a developer of artificial intelligence (AI) and 3D rugged machine vision technology. Its smart, rugged cameras monitor and provide data on equipment performance, faults, payloads and rock fragmentation (read: particle size distribution (PSD)). This data is then analysed using embedded and cloud-based AI to provide real-time feedback to the mining operation.

Initially developed for GET applications, these technologies have recently been extended into a suite of products and solutions that can be applied from drill and blast through to primary processing. Motion Metrics has, in the process, built up an impressive customer base and income stream, performing well since the acquisition.

Weir has outlined a £500 million-plus ($604 million-plus) emerging digital market opportunity for the entity, with much of this hinged on rugged machine vision technology, its sophisticated digital platform and the ability to add ore sensing to its offering.

This became clear at the company’s recent Capital Markets Day during a presentation from Chris Carpenter, VP of Technology for Weir ESCO.

Sensing, not sorting

At this event, Carpenter said the company was combining Motion Metrics’ PSD capability with ore characterisation technology to explore high-value opportunities for its clients.

“Looking further out, we believe ore characterisation…has the potential to transform mining by moving less rock, using less energy and creating less waste,” he said during his presentation. “Ore characterisation technology, which is underpinned by sophisticated sensing systems, captures critical data on properties and composition of rock, including rock hardness and mineral and moisture content.”

“When coupled with Motion Metrics fragmentation analysis technology, it has the potential to be a game changer, giving miners a full picture of the size and characteristics of rocks.”

Weir has outlined a £500 million-plus emerging digital market opportunity for Motion Metrics, with much of this hinged on rugged machine vision technology, its sophisticated digital platform and the ability to add ore sensing to its offering

This concept is not new. Measuring the quality of ore has been spoken of for decades and, more recently, has become a reality with the likes of MineSense, NextOre, IMA Engineering, Scantech, Malvern Panalytical and Rados International, among others, all having trialled technology or deployed commercial solutions across multiple commodities and sites.

Metso Outotec, one of Weir Minerals’ big competitors in the plant and tailings arena, has also spoken of the potential for bulk ore sorting by using its existing portfolio of material handling modules, crushing stations, mobile crushing equipment and bulk material handling solutions as the basis, while incorporating sensors from other vendors.

Weir believes it is one step ahead of its OEM counterpart in its pursuit of ore sorting, even if Carpenter is only referring to the trials currently being conducted at an unnamed copper mine as “ore characterisation” studies.

“With the acquisition of Motion Metrics, what we essentially bought was the ruggedised vision systems used in both mobile and fixed applications,” he told IM in January. “While the ore sensing piece is by no means trivial, the integrated AI capabilities and digital infrastructure that allows the data to be transported via a variety of avenues is incredibly important.

“Being able to pick up the data is one thing but being able to transport that data to the right people in a secure, accurate and timely manner is something different altogether.”

With a portfolio that includes LoaderMetrics™, BeltMetrics™, TruckMetrics™ and CrusherMetrics™, Motion Metrics and the Weir ESCO R&D team had several potential applications to start its ore characterisation journey with.

The company has settled on a BeltMetrics installation for its first trial, with Carpenter confirming the sensing solution under the microscope is currently positioned above a conveyor that is directly after the crusher in the flowsheet.

“We feel we will learn quickest over a conveyor belt, so it is really an expansion of the existing BeltMetrics solution that we will start with,” he said.

The sensing options open to Motion Metrics for this trial were also vast, with the aforementioned ore sorting vendors using the likes of X-ray Fluorescence, magnetic resonance, prompt gamma neutron activation analysis, pulsed fast thermal neutron activation, and others within their solutions.

Motion Metrics has chosen to incorporate hyperspectral imaging into its PSD mix.

Carpenter explained: “When you think about ore characterisation, we are just moving from a visual spectrum base with Motion Metrics vision-based systems to the expanded light spectrum for gathering data and making decisions. This is all being built on the established digital platform the company has.”

The company is not alone in using this type of technology. MineSense has spoken of trials using multispectral sensing technologies, while Australia-based Plotlogic has been tapping hyperspectral imaging to provide precision orebody knowledge prior to mining.

Collaborating on energy intensity reductions

Safety, scalability and flexibility were three factors taken into account with the hyperspectral imaging decision, but Carpenter was also aware of the potential limitations in using such technology.

Mines will need to be willing to make some changes and invest in alternative infrastructure to leverage the most value out of the solution the company is putting forward.

“That is where productivity partnerships that we spoke about on the Capital Markets Day are going to be really important,” he said. “It is going to be essential to collaborate with customers.”

The initial collaboration with the trial mine site looks to be extensive, stretching from the back end of December throughout 2023.

The site is already equipped with a significant amount of Weir Minerals and ESCO equipment, so the collaboration appears to have started well before this trial.

“Throughout the year, we will have the opportunity to make enhancements; starting out with an initial system that is upgraded,” Carpenter said. “By the end of the year, we should have high confidence of having something ready to commercialise. It could also be that we have other trials running concurrently with this one to extend the learnings.”

The two primary key performance indicators for the trial surround accuracy and speed, with Carpenter saying the company is targeting to at least meet the metrics competing technologies have been promoting over recent years.

“In both cases, we are well equipped to measure both and – in the initial phase – we are performing well,” Carpenter said.

“Right now, when they (the mine site) carry out an assay, they have to stop the conveyor belt, take a sample off and send it to a lab. At best, the feedback takes hours, if not days. Motion Metrics has done a really good job of building the sensors, algorithms and platforms to process the data coming from above that belt very quickly.”

There are a team of very experienced, PhD-equipped personnel currently working on this trial, monitoring the real-time results from Motion Metrics’ base in Vancouver, however there is a Weir network across the globe watching and waiting for news.

A sensor above a conveyor belt able to provide ore characterisation data is step one. Step two will most likely involve leveraging this data to provide insights as well as initiate downstream actions.

Then, there is the potential to equip these sensors for the pit on an excavator or wheel loader – which introduces many additional challenges both Motion Metrics and ESCO are aware of. Understanding exactly what is in the bank or going in the bucket will be critical to improving operational efficiencies.

These are longer-term goals that Motion Metrics, ESCO, Weir Minerals and Carpenter are cognisant of – and excited about – that may provide the true value to customers throughout the flowsheet.

“What is exciting for us is that – as may be obvious – the further upstream you can make some good decisions, the more energy you can save downstream,” he said. “As you get into some of the other processing elements in the plant, there are sustainability benefits to be had – a more efficient use of reagents to liberate the elements, a more efficient grinding setup based on ore characteristics, a reduction in water use, etc.

“The driver for this has really been sustainability and energy reduction. It is all about reducing the energy intensity associated with ore.

“We feel we are well equipped and in a good position to deliver on this and provide the industry with the step change in sustainability that it requires.”

Rio Tinto partners with Pixxel to investigate hyperspectral satellite tech capabilities

Communications in mining, IoT, Mineral exploration, Sustainable mining, , , , , , ,

Pixxel, an edge earth-imaging technology company, has announced an early adoption partnership with Rio Tinto spanning mineral exploration, active and closed mine site monitoring and ESG metrics.

Pixxel’s imaging satellites, capable of 5 m hyperspectral imaging, will help Rio Tinto assess the benefits the technology may provide in these areas, the company said. Rio will begin its assessment of the technology following the release of imagery from Pixxel’s first high-resolution satellite, set to launch early this year.

This partnership, Pixxel says, validates the potential benefits that its technology may provide to the resources sector.

“Pixxel’s high-resolution hyperspectral satellite imagery has the potential to significantly reduce costs and timelines for exploration and improve monitoring of active and closed mine sites,” the company said. “In the coming months, Pixxel plans to launch a high resolution hyperspectral satellite, which will capture 50x information compared to common multispectral satellites. Rio Tinto will be assessing the potential of Pixxel’s hyperspectral imagery to help reduce the disturbance footprint of exploration activities, monitor the operational and environmental performance of active mining operations, and monitor biodiversity and vegetation health around closed sites.”

Pixxel Co-Founder and CEO, Awais Ahmed, said: “This partnership will be pioneering in its deployment of hyperspectral satellite imagery for commercial mining operations. We’re excited to be partnering with Rio Tinto to explore the use of hyperspectral remote sensing technology across their operations at a global scale.

“Moreover, the exponential leap in image quality (50x more detail than existing multispectral satellite imagery) allows Rio Tinto the ability to assess Pixxel’s imagery for monitoring critical mining operations and make key decisions with sustainability in mind.”

Dave Andrews, Head of Exploration at Rio Tinto, added: “Rio Tinto is participating in Pixxel’s Early Adopter Program because we believe that exploration could benefit from more cost-effective and easier access to hyperspectral satellite data.”

IOC to test government-backed hyperspectral core scanning technology

Mine operation news, Mineral exploration, Mining equipment, Mining finance, Mining services, Precious metals, Steel and iron ore, , , , , , , , , ,

Advanced drill core imaging technology being developed by College of the North Atlantic (CNA) and trialled at Iron Ore Company of Canada’s (IOC) site in Labrador, Canada, has received federal and provincial government backing to the tune of C$4.5 million ($3.6 million).

The Government of Canada, together with the Province of Newfoundland and Labrador, believe the “game-changing” tech being developed by CNA “will position the region as a global leader in the mining industry”, the CNA said.

Their investments, which come on top of support from IOC and Agnico Eagle Mines, are helping advance the development of a Hyperspectral Scanning Unit (HSU) currently at IOC’s site in Labrador City conducting its first drill core scans.

The HSU, CNA says, produces high-resolution drill core images that will give mining companies a better understanding of a region’s geology. The new technology will make drill core logging more accurate, improve exploration processes and increase the potential to discover new, lucrative mineral deposits, according to the college.

Liz Kidd, President and CEO, College of the North Atlantic, said: “This state-of-the-art technology – one of the most advanced, high throughput hyperspectral drill core scanning units available globally – aligns perfectly with the college’s vision to further expand and develop its applied research and innovation arm so that we can assist industry in achieving positive, breakthrough results in the mining sector.

“We are also excited that our graduates will benefit from the training associated with the HSU that, in turn, will provide meaningful long-term benefits for the province’s future workforce and lead the way in the advancement of hyperspectral technology for the mining sector. We are proud to play a major role in this initiative.”

Chantal Lavoie, Chief Operating Officer, IOC, said the company looked forward to testing equipment at its operations in Labrador West to make IOC an even “more efficient, competitive and sustainable business for generations to come”.

Guy Gosselin, Senior Vice President of Exploration, Agnico Eagle Mines, added: “Agnico Eagle is pleased to be part of this partnership and excited with the potential it represents for our industry. The mobile HSU, developed by CNA, is breakthrough and innovative technology that will bring more robustness to data analysis in a field traditionally based on human observation, while improving its consistency and quality. Ultimately, it will lead to increased exploration and potentially more discoveries, which is key for the future of our business.”

Orbital Sidekick goes above and beyond to improve hyperspectral imaging

IoT, Mine surveying, Mining services, , , , ,

Orbital Sidekick (OSK) has announced the upcoming launch of its newest and most powerful hyperspectral imaging satellite, Aurora, which is set to expand contracts and pilot program opportunities for, among other things, sustainable mining practices.

Aurora leverages OSK’s previous experience collecting and analysing hyperspectral data to provide action-oriented insights, with a broad focus on sustainability, OSK says. The Aurora satellite will serve OSK’s customers in the energy, mining, and defence sectors, including expanding contracts and pilot program opportunities for oil and gas pipeline monitoring & methane mapping, clean energy resource exploration, sustainable mining practices and wildfire risk mitigation.

The Orbital Sidekick Aurora Satellite is a 30 kg precursor to the six 100 kg ESPA class GHOSt satellites scheduled for launch in 2022. Seattle-based launch services provider, Spaceflight, will be coordinating the launch with a total of 36 payloads onboard the SpaceX Transporter-2 rideshare mission, taking place June 25, 2021, at Cape Canaveral Air Force Base in Florida, USA.

Aurora will capture more than 450 spectral bands in the visible to shortwave infrared light spectrum (400 to 2,500 nm), OSK says, with a pixel size of approximately 30 m, making it the highest resolution commercial hyperspectral imagery available to date, the company claims.

“We’re excited to be launching Aurora to help provide consistent monitoring services across all of our clients as well as further the exploration for clean energy sources globally,” Dan Katz, CEO & Co-Founder of Orbital Sidekick, said. “Working with Astro Digital, OSK will be able to focus on the payload and extract information from our unique and proprietary hyperspectral data with the utmost precision.”