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RCT collaborates with Barminco on latest automation project at IGO Nova

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Today, RCT’s agnostic automation can be found at many of Barminco’s operations throughout the Goldfields region, and now there is one more to add with the completion of its most recent project at IGO’s Nova mine.

Despite the site’s existing automation infrastructure, when it came time for upgrading, RCT Automation was selected as the preferred supplier by Barminco, a subsidiary of global mining services group Perenti.

“Technology and innovation are a key focus for Barminco, and we appreciated the simplicity of the RCT Automation solution – quicker setup times and ease of use for our operators,” Darren Kwok, Head of Mining Electrification and Technology for Perenti Contract Mining, said.

The loaders are operated from the safety and comfort of Automation Centres, which have been situated both underground and on the surface of the mine.

To enhance sustainability and cost efficiency, existing cabins were repurposed, refurbished at RCT’s Kalgoorlie branch.

Kalgoorlie Branch Manager, Rick Radcliffe, said: “The cabins required sandblasting and painting before we lined them with fridge panelling and fitted them out with RCT’s state-of-art ergonomic chair and operations centre.”

In addition to providing agnostic automation, RCT was able to work with Barminco to use both the existing underground communications technology and supplement it with the RCT connect to ensure we provide the best and most cost-effective solution for the client. The team also provided extensive operator training to empower site and ensure self-sufficiency with the technology.

Kwok added: “We have a good working relationship with RCT, and this extends beyond just the service delivery and project delivery.

“Outcomes from the project have been positive and we have worked collaboratively with RCT to ensure any operational concerns raised were reviewed and their product offering improved based on our feedback.”

Radcliffe said: “When two companies have the same goal of implementing quality products into a technology focused operation, they will always be successful, and that was certainly the case at Nova.

“We are looking forward to working with Barminco over the coming months to assess the impact that the project has had.”

ABB, IGO and Perenti on collaborating for full mine electrification

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An industry panel discussion on the potential of electrifying IGO’s Cosmos underground nickel project at IMARC 2023 today highlighted the opportunities, risks and complexities associated with ‘greening’ a brownfield mining project at the moment.

Back in June, Perenti and ABB, in collaboration, were awarded an inaugural contract by IGO to undertake a study for the full underground electrification of the project, in Western Australia.

This study was to see experts from Perenti and ABB work side by side with IGO to provide a pathway for the optimum design of mine electrification at Cosmos. All aspects of electrification were to be considered in the study, including:

  • Mine design optimisation for electric operations;
  • Production and operating philosophy;
  • Fleet selection;
  • Power distribution and electrical infrastructure design;
  • Electrification system and battery management;
  • ESG and safety impact analysis; and
  • Cost modelling of both capital and operating expenditure.

At IMARC today, on the ‘Going All-Electric: Collaborating to Fully Electrify IGO’s Underground Cosmos Nickel Project’ panel discussion, chaired by Emma Jones, Innovation Management Lead, Southern Hemisphere, GHD, all three companies had representatives on stage to flesh out some of these bullet points, with the result being a fascinating discussion on implementing what is still a revolutionary concept.

The Cosmos study is split into three distinct parts with the companies currently half way through the process.

Both Chris Carr, Head of Technical Services at IGO, and Darren Kwok, Head of Mining Electrification and Technology, Perenti, admitted that the task at hand was highly complex.

Carr said the process would be much easier in a greenfield mine, with the potential ventilation and refrigeration cost reductions that would come with introducing electric machines likely to “pay” for the new equipment required.

At the same time, he acknowledged that the networks and communication would need to be improved to effectively run an all-electric mine to allow operators to know what vehicles had what state of charge and deploying these machines in the optimal way.

“This could potentially see whole sites use Wi-Fi or 5G for better data transmission,” he said. “At the same time, we would know where every vehicle is and where every vehicle is going, providing the opportunity for ‘true’ collision avoidance.”

Kwok said there was likely to be a “flow-down effect” when electrifying equipment, which would have an impact on how mines plan, schedule and operate. “We need a holistic view of a mine,” he said, explaining that “just in time” mining would not work in an all-electric operation where energy management is a key concern.

Kwok added: “We also have to link the fleet together with the rest of the operations – that is the secret sauce here.”

Mehrzad Ashnagaran, Global Product Line Manager – Electrification and Composite Plant, ABB, said any mining company looking to fully electrify their mines needed to recognise that they were working with “immature technology” that cannot meet all of their requirements.

“The design of an all-electric mine is different to the vision we originally had,” he said. “This is why we need to break the process down into manageable projects for a phased approach that can allow customers to start decarbonising now.”

This is where the company’s eMine™ approach comes in, providing a roadmap of solutions on the way to longer-term electrification goals.

“In reality, the solution we are offering today may not be the same one we offer companies in five to 10 years’ time,” he added.

There was also an engaging exchange on the risk management associated with embarking on this exercise.

Ashnagaran said, for ABB, the Cosmos study and other all-electric projects the company is working on would see its vendor agnostic and interoperable approach tested and scrutinised.

“The whole eMine philosophy, however, is that no-one can go on such a journey alone; we need to collaborate with partners,” he said.

Kwok said the study allowed the service provider to learn and understand the terms of how electrified mining can practically work.

“We, at Perenti, already understand what ‘good’ looks like [from an operating perspective]…and we also understand what change looks like at a mine site,” he said, adding that the company already has electric machine data to pull into such studies.

Carr said building ‘the electric mine’ is both a risk and an opportunity, with the mining company prepared to financially back most of the expense associated with this as it had, potentially, the most to gain from a successful outcome.

He also added a bit of wider IGO context to reinforce the point.

“At IGO, we invest A$70 million ($44.5 million) a year on exploration, putting drills into the ground,” he said. “Not all of those holes are deemed a success, but they allow us to keep building our knowledge,”

The same is true for this all-electric Cosmos study.

“Regardless of the outcome, we will learn a lot,” he said. “We are driven to be the ‘first to be first’ here; first to be second simply does not work for us.”

IMARC 2023 organisers preparing for ‘grand slam’ event

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The world’s mining and resource leaders are heading to Sydney, New South Wales, for the International Mining and Resources Conference (IMARC) from October 31 – November 2 in what has become a “grand slam” event of the industry, globally, event organisers says.

IMARC Chief Operating Officer, Anita Richards, said this year’s event was looking to be the largest ever, with over 520 speakers from global giants such as BHP, Fortescue, MMG, Gold Fields, Wesfarmers, Worley, Perenti, IGO, the US Departments of Energy and Defense and the ICMM, coming together to collaborate on themes including digital transformation and innovation; sustainability, social value, environmental resilience, people and culture; trade, investment and project opportunities; and energy transition.

She said: “The mining and resources industry is evolving rapidly to meet the growing energy demands of today while developing the minerals needed for a decarbonised economy – under unprecedented scrutiny from communities, regulators and investors.

“IMARC 2023 comes at a time when explorers and miners are diversifying portfolios to align with future demand, triggering the highest level of M&A activity across both mining and METS we have ever seen.”

This year’s conference will see the return of the IMARC NextGen Program, which will provide an opportunity for 200 NSW school children to learn about the diverse and exciting mining and resources industry.

IMARC 2023 also features:

  • A special ESG focus on creating social value;
  • An extensive look at First Nations engagement, human rights and transparency;
  • A look at best-practice mine rehabilitation;
  • A global perspectives on heritage and environmental custodianship and economic development;
  • A return of the successful Balance for Better Program which promotes equality, diversity and inclusion across all areas of the mining and resources sector.

Richards added: “Mining and resources have never been more important for sustainable economic, social and innovative development across the globe. We need more exploration and development to match surging demand for the critical minerals that are central to the global energy transition. IMARC 2023 is where the most important conversations are being held about how mining and resources can help achieve global development sustainably and equitably.

“IMARC is a key forum to address these challenges, and the global profile of the event is reflected in delegations already confirmed from India, Saudi Arabia, Ecuador, Chile, Mongolia, United States, South Korea, Japan, Germany and many more.”

At IMARC 2023 a range of new features have been added to the program. These include the Low Emission Technology Australia session to help accelerate innovation in the clean technology sector, the 4,000 sq.m IMARC Mining Pavilion with over 150 exhibitors present and the final of the Unearthed Global Innovation Games where the winners will be announced and their technology displayed.

IMARC 2023 will take place at the ICC Sydney from October 31 to November 2 and will be a celebration of what has grown into one of Australia’s biggest business events, with a record 8,500 delegates from over 120 countries, including upwards of 50 government delegations expected to attend, organisers say.

International Mining is a media sponsor of IMARC 2023 and will be in Sydney reporting on the event.

Barminco and RCT partner on ‘world first’ agnostic remote installation of Cat 2900 XE

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Barminco has enlisted the help of RCT to carry out what it believes to be the world’s first agnostic remote installation on Caterpillar’s R2900 XE diesel-electric underground loader.

The mining services company will be using the R2900 XE loader which has a diesel engine and electric driveline at the IGO-owned Spotted Quoll underground mine, in Western Australia.

Built on the platform of Caterpillar’s most popular underground loader, this new LHD – which was previewed at MINExpo 2021 in Las Vegas – features optimised lift arm and component geometry plus load-sensing hydraulics to improve breakout force by 35% over the Cat R2900G, Caterpillar claims.

RCT’s Kalgoorlie Branch Manager, Rick Radcliffe, said: “Technology and innovation are two of Barminco’s core components, so it made sense they chose RCT to carry out the installation of this automation project. We are receiving a lot of interest in this project as it is a hybrid loader which reduces fuel burn resulting in low diesel particulates, which is something companies are looking at doing to mine more sustainably in the future.”

This project is currently underway with RCT’s Kalgoorlie branch completing the installation.

The world’s first R2900 XE was delivered to Western Australia-based Westgold Resources, with the gold miner having since agreed to purchase another six of these loaders.

Think & Act Differently Cohort set to revolutionise in-situ recovery

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The Think & Act Differently (TAD) incubator, powered by BHP, has announced its support for a new cohort that has come together to develop an innovative technology roadmap for in-situ and alternative extraction options, the company says, lower the impact of mining and processing.

In collaboration with its partner, Unearthed, the TAD Cohort was curated through a venture-style selection process, which also involved selection of members from the TAD Ecosystem.

This cohort is supported and funded by BHP, Boliden, Rio Tinto, South32 and IGO, as part of the TAD Collaboration that is commited to unlocking new technologies and reimagining lower impact mining and processing to find value in overlooked resources.

The TAD Cohort comprises a diverse group of companies ready to apply new ways of thinking to in-situ recovery. It includes:

  • Auric BioRecovery: using bio recovery processes to release metal from tailings;
  • Clean & Recover: ElectroClear recovery of water from acid mine drainage;
  • Destiny Copper: Using high activation potential and chemistry to eliminate electricity requirements for plating copper;
  • Draslovka: A ‘green’ recyclable lixiviant, selective in leaching base and precious metals from host minerals (pictured in a test lab above);
  • Eden GeoPower: Rock preconditioning technology to enable in-situ solution mining;
  • Ekion: Enabling the in-situ extraction of metals using electrokinetics;
  • EnviroGold Global: Clean-technology process for metal recovery from sulphide mine tailings and smelter residues; metal recovery includes strategic, critical, base and precious metals;
  • LeadFX: Metal recovery with CO2 capture;
  • Loop Hydrometallurgy: Clean technology unlocking copper, rare earth elements and other metals from tailings and concentrates;
  • Muon Vision: Cosmic ray sensing for tailings and heap leach monitoring; and
  • Precision Periodic: Enabling industrial scale chromatography using novel filtration media to recover and concentrate elements in mining applications and treatment of wastewater.

Barminco wins extended stay at IGO’s Flying Fox nickel mine

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Perenti says its Barminco subsidiary has been awarded a nine-month contract extension at the Flying Fox mine, in Western Australia, owned and operated by IGO Ltd.

The contract extension is effective from January 1, 2023, and has a value of approximately A$30 million ($20.2 million) over the nine-month term.

Mark Norwell, Managing Director & CEO of Perenti, said: “In Australia, the labour market is still tight, and inflation and cost escalation remains stubbornly persistent, however strong and collaborative working relationships, like the relationship between IGO and Barminco, are key to the success of our business as well as the success of our clients. By working collaboratively with our clients, we continue to navigate and manage challenging macro-economic conditions.”

Paul Muller, President of Perenti Contract Mining, added: “We have a very long and proud history of operating within the Forrestania Operation and we are pleased to have delivered value and certainty at the Flying Fox mine from a greenfield development project through to a mature operating mine as it is today. We look forward to continuing our relationship with IGO, our largest client in Australia.”

IGO became the owner of the Flying Fox mine, part of the Forrestania Operation, in 2022, as part of the acquisition of Western Areas. It remains one of the highest grade nickel mines in the world. Production commenced in 2006, and the mine now operates at depths of over 1 km underground.

ZERO Automotive brings newest ZED70 Ti BEV to IGO’s Nova project

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ZERO Automotive has delivered what it refers to as an ultra-safe ZED70 Ti battery-electric converted utility vehicle, using LTO battery technology that does not suffer from thermal runaway, to Independence Group’s Nova nickel-copper-cobalt operation in Western Australia.

This is the second convered vehicle, and the first dual cab, for Barminco, the contractor at Nova.

Like the first delivery, this conversion also allows for ultra-fast charging and maintains the highest torque rating for a mining-spec battery-electric vehicle by a factor of one-and-a-half times, the company says. Site integration activities with charging infrastructure and data capture will be the focus in the coming months, with the installation of the Geotab GO9 telematic device allowing for vehicle monitoring and tracking.

This is the third vehicle delivered with METS Ignited support previously awarded to ZERO Automotive. It also forms part of the trials being undertaken by Barminco in its role as lead of the Electric Mine Consortium light and auxiliary vehicle working group, of which ZERO Automotive is also a participant.

The next conversion for Barminco will be its upgraded production platform, which will provide available torque of 267% greater than its closest competitor, and allows for faster charging, ZERO Automotive says.

Miners need to address workplace culture, diversity issues, IMARC panel says

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There has been keen focus on workplace culture and diversity on the final day of the International Mining and Resources Conference (IMARC) in Sydney, Australia.

Throughout the conference, mining leaders have acknowledged that if the industry does not act now to fix and change the culture, they will not be able to attract the staff required for the new resources boom.

Chief People Office at IGO, Sam Retallack, told the conference: “We as industry have broken the psychological contract of trust that we have with the community. We are seen as a cause of climate change, not as a solution. We are seen as an unsafe workplace for females, we are seen as inflexible with our rostering and that you must commit to FIFO work. It’s not a particularly attractive proposition for new workers.”

Danielle Martin, Director of Social Performance at ICMM, spoke to the substantial issues facing the industry as workforce skills change and evolve.

“The competition for talent will be tricky for mining because the skills in many cases are less specific to mining and are applicable across other sectors,” Martin said. “Because of the culture and perception of mining, it is a less attractive industry for many workers who could work in other industries.”

All is not lost, however. Stuart Jenner, General Manager of Capability and Culture at Gold Road Resources, reflected on the cultural issues the Australian Defence Force faced 20 years ago. Changes to workplace culture will likely lead to an increase in the recruitment of new staff and the retention of key talent as the competition for skills intensifies, he argued.

Jenner said the Defence Force “recreated its brand and aligned it with its purpose and mining needs to do the same”.

He added: “We need to be upfront, honest and transparent to establish that purpose. The Defence Force pays nowhere near what the mining industry does but because of their purpose, they have a huge amount of success in attracting talent.”

There is a realisation from the sector the industry must act now and push for the acknowledgment that these issues need to be addressed from the top down.

Gavin Wood, Chief Information Officer at Newcrest Mining, explained to the delegates at IMARC the work the company is doing to change culture with their existing workforce.

Wood said many of its existing staff grew up in mining areas and communities and the company needed to give them the skills to interact with other aspects of business and by virtue society.

“If we do not give them these skills the culture will not change,” he said.

Over the three-day conference, mining leaders from across the globe have challenged the current standard of culture within the sector and have discussed ways to make the industry safer for all.

GR Engineering bolsters EPC scope at IGO’s Cosmos nickel operations

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GR Engineering Services says it has increased the scope of work related to the engineering, procurement and construction contract with Australian Nickel Investments Pty Ltd, a wholly owned subsidiary of IGO Limited, for the upgrade of the existing nickel concentrator at the Cosmos nickel operations, in Western Australia.

The company has been awarded a variation by IGO to further increase the throughput of the nickel concentrator at the project from circa-750,000 t/y to 1.1 Mt/y. This will bring the contract sum to A$76 million ($49 million), it said.

Geoff Jones, GR Engineering Managing Director, said: “GR Engineering has a long history of working with the IGO management team and is pleased to be awarded with this variation. GR Engineering looks forward to safely and successfully completing this important project.”

IGO’s CEO, Matt Dusci, added: “IGO is pleased to be working with GR Engineering on the Cosmos project after the previous successful collaboration on Nova.”

Following the acquisition of Western Areas Limited on June 20, 2022, IGO commenced work toward developing a project optimisation strategy and plan designed to deliver higher production rates for the life of the operation and a more safe and sustainable mine plan at Cosmos. The increased plant throughput strategy was part of this.

IGO is currently developing the Odysseus underground mine at Cosmos, with plans to deliver high quality nickel concentrates into the global market.

Zero Automotive overcoming barriers with BEV conversion offering

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Zero Automotive is one of several Australia-based companies looking to supply the clean and green light utility vehicles the domestic hard-rock sector requires over the next decades to achieve crucial sustainability goals while retaining high productivity levels.

Thanks to the support of a significant copper-gold miner in Australia, its membership of the Electric Mine Consortium (EMC) and METS Ignited backing, the company finds itself in a strong position to deliver these machines against a backdrop of supply chain issues and ever-evolving safety and regulatory requirements.

“We’ve got commitments for six machines altogether and are in the process of offering our production version to the market,” Dan Taylor, Business Development Manager for Zero Automotive, says.

The first and second units are already running at OZ Minerals’ Carrapateena copper-gold mine in South Australia – Zero Automotive’s home state.

The first machine – a ZED70 Ti™ battery-electric light vehicle – was originally delivered to the mine at the back end of 2020 for testing. After successful trials, the company acquired this unit outright and, in early-2022, added a second Zero Automotive ZED70 Ti to enable its workforce to familiarise themselves with the capabilities and charging methodology that come with electric light utility vehicles.

Since then, the company has delivered a third ZED70 Ti conversion to Barminco, which is now on site at its client IGO Ltd’s Nova nickel-copper-cobalt operation in Western Australia. This vehicle is the first single cab conversion developed by Zero Automotive and will be deployed to site foremen to allow the mining contractor to gain a good understanding of its capabilities.

All three of these machines – and the three to follow – are based off battery-electric conversions of the Toyota LandCruiser 79 Series, a vehicle that has been part of the Australian mining landscape for many years.

The modular nature of the Zero Automotive platform enables its long-life battery energy system to be reused in multiple chassis, lowering the total lifecycle cost of the fleet as well as the cost of Scope 1 emissions, according to the company.

They also include dual AC-DC charging with the CCS Combo2 connection, which is becoming increasingly standardised in the mining space.

Data and feedback from the second OZ Minerals machine and the initial Barminco vehicle will be fed back into the EMC ecosystem under the Light and Auxiliary Equipment Working Group as part of the consortium’s continual improvement and knowledge sharing remit.

The EMC said of the consortium’s ongoing light and auxiliary equipment electrification ambitions: “Converting light and auxiliary vehicles as rapidly as possible to electric is key to the industry building the broader understanding and familiarity with electric equipment and infrastructure that will accelerate adoption across all aspects of operations.”

The EMC is a growing group of over 20 mining and service companies driven by the imperative to produce zero-emission products for their customers and meet mounting investor expectations. The objective of the EMC, backed by METS Ignited, is to accelerate progress toward the zero-carbon and zero-particulate mine.

The following three machines are also expected to be deployed to EMC members, with METS Ignited agreeing to provide some A$400,000 ($297,938) of funding towards the diesel-to-battery conversion projects outside of the vehicles already delivered to OZ Minerals.

“The key thing with all of these vehicle deployments is the ZED70 Ti being able to do the job the miners need to perform safely and reliably, getting the associated charging infrastructure right and working with key stakeholders on the change management process,” Dave Mitchell, founder and CEO of Zero Automotive, says. “Operators also need to get used to the power under the hood and how to maximise the battery re-charging capabilities when going down ramp.

“As a matter of course, we train up and educate the sites about the best way to utilise these vehicles,” he said.

To this point, the two prototype vehicles already operating out at Carrapateena have shown that they can work for a typical shift without requiring a re-charge and can then utilise the battery’s AC/DC-DC fast-charge option during shift changeover to enable another user to run the machine for the following shift.

The use of LTO (Lithium Titanate Oxide) battery chemistry and a 60-kWh battery capacity has been behind this performance. This electric motor can generate continuous power of 75 kW and peak power of 134 kW, plus 358 Nm of continuous torque. These values will be increased to 100 kW, 200 kW and 520 Nm (1,200 Nm peak) for the production version.

To this point, the power dimension has often been the main metric quoted with any battery-electric machine, but Taylor pointed out that safety and regulatory considerations were often the biggest barriers to overcome in terms of getting machines operating at underground mines – a hurdle that Zero Automotive has cleared.

“We were able to successfully commission our second ZED70 Ti for OZ Minerals within two days of the machine arriving on site,” he said. “A lot of people are putting out offerings for light utility vehicles, but the required risk analysis in terms of deploying a vehicle underground has not been successfully worked through. This is rightfully a high bar to clear.

“We address any safety or regulatory considerations during our design process – not when the machine is on site – to make sure that operators can start using them quickly.”

Mitchell adds: “The user case is what we are focused on. That has allowed us to scale our offering quickly and ensure our clients can start running the machine underground as soon as they have it on site.”

Zero Automotive is expecting to deploy the other three machines on its books to the same companies (OZ Minerals and Barminco), but the final two machines of the six to be delivered will be under a revised platform to the original ZED70 Ti.

“It will be a platform that is designed from the ground up that incorporates the desired features and learnings from the first conversions, but we will simplify it to reduce complexity, weight and cost,” Mitchell said. “We’re sticking with the same battery configuration – which has proven itself in terms of power, safety and longevity – but we’re adding some auxiliary power outputs and ensuring the machine is multi-purpose.”

The latter element is tied to the company’s medium-to-long-term ambitions, which include the potential to supply battery-electric machines specific to the extended range space too.

For now, Zero Automotive is focused on getting its machines underground at hard-rock operations, ensuring operators and mining companies start realising the productivity and emission benefits that come with these zero-emission conversions.