Tag Archives: Konsuln

LKAB welcomes more autonomous LHDs at Kiruna ahead of electric machine arrivals

LKAB says it is now running six autonomous LHDs at its Kiruna iron ore mine, in northern Sweden, with battery-powered and cable-electric machines set to arrive at the operation later in the year.

The company has been stepping up its automation efforts at the underground mine, going from three autonomous loaders in November to five in December and, now, six as of this month.

These loaders have come from both Sandvik and Epiroc, with at least three of these being 21 t Sandvik LH621i LHDs and two being 18 t Epiroc Scooptram ST18 LHDs.

“For the time being, the loaders are diesel-powered, but battery-powered Epiroc machines and Sandvik’s larger electric loaders will be delivered this year,” the company said. “Safety and loading capacity will be tested and assessed, so that the vision of a carbon-dioxide-free LKAB can be realised.”

Magnus Lindgren, Production Manager for the remote-control centre at level 1365 in the Kiruna mine, said: “Our operators work in close collaboration with both Sandvik and Epiroc and, thereby, take part in these suppliers’ development. We test the systems and provide feedback, so we can eventually take delivery of a better product.”

LKAB conducts blasting at the mine each night. When the blasting gases have been evacuated and rock stresses have decreased, personnel can access the production area. With remote-control machines, LKAB can load, haul and dump crude ore without having to worry as much about these considerations.

Roger Lärkmo, Engineering Developer at LKAB, added: “Autonomous loading at night is optimal in terms of both safety and work environment, and from a productivity perspective. That doesn’t mean manually-operated machines are a thing of the past; it just means that we have more tools in the toolbox. Many parameters have to be taken into the equation for our loading operations to deliver an even flow of ore to the processing plants.”

This summer, the Konsuln mine will take delivery of its first battery-powered loader, the 14 t ST14 from Epiroc. Epiroc said last month it will also deliver a Minetruck MT42 Battery for use at the main Kiruna iron ore mine for production, and in the Konsuln test mine.

Preparations are now under way for the ST14 Battery’s arrival at Konsuln, from planning of the drifts where batteries will be exchanged, to risk analyses and simulations, LKAB said.

During 2021, three of Sandvik’s larger 625IE electric loaders, which have a 25-t payload capacity, will also be delivered to LKAB in Kiruna. The company took delivery of a “renewed” Sandvik LH625iE electric loader for field testing in 2020.

Lindgren said: “LKAB has been running loaders with electric power cables for more than 20 years, both manually operated and with remote control. Now we are going to test the new generation of electric loaders. These tests will begin in the autumn.”

Anita Oraha Wardi, Project Manager for autonomous, smart and carbon-dioxide-free machines at LKAB, said the company was participating in development work early on, so it can understand and influence performance, loading capacity and, not least, the safety aspects.

“We are going to test to see how battery-driven and electric loaders compare with diesel-powered machines, and how remote-control machines function in comparison with manually-operated loaders,” she said.

“One of several objectives is that operators, regardless of the make or model of the vehicle, should be able to run remote-control vehicles via the same system and in the same production area. Then, we will be approaching a world standard.”

ABB ready to demonstrate electrical and automation advances at SUM project

ABB electrification and automation knowledge and solutions are being employed at LKAB’s Sustainable Underground Mining (SUM) project, as the project partners strive towards demonstrating the possibility of developing a mine with zero carbon dioxide emissions and relative productivity increases of 50%.

The company has provided electrification, connected control and operations management systems, high-visualisation and mobile operator workplaces as part of this project, which also involves Combitech, Epiroc and Sandvik. It is now looking to connect electrical and automation systems that have so far been developed and leverage these in a demonstration workshop as part of the project’s next phase.

Devised by LKAB, the SUM project has the goal of setting a new world standard for sustainable mining at great depths. The framework outlines ambitions for zero carbon dioxide emissions, completely safe mines for humans, productivity increases of 50% and deeper mining.

ABB will continue to contribute its deep knowledge in electrification, automation and workplaces together with other suppliers to the mining industry, it said.

Test work in LKAB’s Kiruna mine, northern Sweden, as well as a virtual test mine will study the best way to build a carbon dioxide free and autonomous production system.

“Within the mine, the Konsuln orebody is used to demonstrate future workplaces in a decentralised environment with efficient use of an autonomous electrical mobile transport system in a mixed environment,” ABB said. “Real-time process information is available to all organisations involved. When combined with the wider efforts of the SUM partnership, this shows a way of bringing completely new technology solutions to market for safer, more sustainable and more efficient mining production processes.”

Jan Nyqvist, Global Product Manager for Underground Mining Automation at ABB, and one of the leaders in the project, said: “We are taking significant strides towards a vision of the future operator environment through smarter working and demonstrable results. Electrification and automation are two important factors for the mining industry to continue its rapid, but effective, modernisation. Sharing of information and data is crucial to reach substantial end goals.”

He added: “It is becoming increasingly common for suppliers to create dedicated collaboration groups to reach the best possible solutions for their customers. Collective successes and progress and the meeting of key targets for SUM, are initial evidence of the mutual benefits of collaboration.”

ABB has a relatively large team committing time to the project, with experts in digitalisation and research, as well as electrification and automation.

“ABB is integral to the next step, which is to build a demonstration workshop to connect electrical and automation systems that have so far been developed for this challenging project,” Nyqvist said. “We will, through various developed scenarios, be able to show how the systems work together.”

By 2022, the ABB electrification and automation solutions will be fully installed, and the aim is that a new standard for mining production will be displayed at the project by 2030.

Sandvik enters LKAB-led SUM project as Volvo Group departs

Sandvik has joined the Sustainable Underground Mining (SUM) project being run by LKAB at the same time as the Volvo Group has exited the Sweden-based collaboration.

The moves come as the iron ore miner looks to “further strengthen a joint endeavour towards sustainable underground mining at great depths”, it said.

To develop the digitalised, autonomous and carbon-dioxide-free mine of the future, in collaboration with other globally leading Swedish companies, LKAB initiated SUM in 2018.

After 2030, LKAB must be ready to mine iron ore deeper in the mines in Kiruna and Malmberget, in northern Sweden. For this, one of Sweden’s biggest industrial investments ever, decisions will have to be taken in the mid-2020s.

“This type of strategic collaboration project is very complex, each company contributes its specific expertise, and the partners will link together both digital systems and operations,” LKAB says. “Providing unique possibilities for SUM, the test mine, Konsuln, in Kiruna will serve as a real mine environment where technology, machines and working methods will be tested.”

Sandvik will be joining LKAB, Epiroc, ABB and Combitech in trying to achieve this goal. The Volvo Group’s earlier partnership in SUM will now take the form of other collaboration with LKAB, the miner said.

Jan Moström, President and CEO of LKAB, said: “In the coming years, LKAB must have a solution in place to be able to mine iron ore at depths approaching or exceeding 2,000 m in a cost-effective way by employing technology that is safe, autonomous, electrified, digitalised and carbon-dioxide-free.

“To enable this, collaboration with other leading industrial companies will be decisive. Sandvik’s longstanding experience of producing underground vehicle systems will complement the ongoing work in an important way.”

Stefan Widing, President and CEO Sandvik, said: “LKAB has used automated equipment from Sandvik for many years and we look forward to the opportunity to extend our collaboration and introduce new and advanced solutions that will set an industry standard.”

Epiroc and Sandvik will be relied on for battery-powered, autonomous and efficient mining equipment and related solutions that will ensure improved productivity and safety in LKAB’s mines. ABB’s role is to contribute knowledge and solutions for electrification, automation, service and maintenance. Combitech, meanwhile, will bring broad expertise and experience when it comes to connecting autonomous processes and people via so-called digital ecosystems.

LKAB says significant progress has been made on the project to date, including:

  • Successful establishment of the test mine, Konsuln, in Kiruna, where testing is carried out in a real mine environment;
  • An integration and collaboration platform, ‘LOMI’ (LKAB Open Mine Integrator) has been developed to enable an open systems architecture whereby all partners can develop modules and solutions that work together;
  • ABB has delivered ABB Ability System 800xA, the control-room console Extended Operation Workplace and a “Collaboration table” for visualising key functions and key figures in the mine, allowing the operator to monitor and control equipment in the best, most sustainable way. The ambition is that everything that is done in the test mine can be approved, planned and controlled via a project office at surface level, so that underground work can be done more efficiently;
  • Epiroc has delivered the drill rig Easer L and Scooptram ST18 LHD, both equipped for automation functionality, for the test mine, and operators and service personnel have been trained. The Easer L, commissioned in 2019, has shown good results in drilling over 50-m-long holes in the test mine, which is an important step for planning the future mine layout. For the loader, during Autumn 2020, the plan is to conduct tests with increasing complexity in terms of automation and interoperability; and
  • Combitech has delivered new solutions for systems platforms on an ongoing basis together with LKAB’s IT department. The aim is to synchronise new technology with existing systems.

In March 2020, the “Testbed for integrated, efficient and carbon-dioxide-free mining systems”, a part of SUM, received funding amounting to 207 million Swedish kronor ($23 million) from the Swedish Energy Agency.

LKAB set to test Epiroc Easer rig at Konsuln

LKAB says it is getting ready to test Epiroc’s Easer L raiseboring rig at its Konsuln test mine this month as part of the Sustainable Underground Mining (SUM) project it is taking part in.

The mobile rig is set to start work this month, with LKAB being Epiroc’s first customer in Europe to use it, according to Carlos Quinteiro, a specialist with LKAB’s Mining Engineering department.

Designed to drill opening holes in block cave, sub level caving and sub level stoping mines, the Easer L can also be used for precondition holes, paste fill tube holes and media holes. The rig works in drifts from 4.7 x 4.7 to 6 x 6 m. When drilling with a 750 mm diameter reamer, the Easer L can drill conventional holes up to 200 m and box holes and down reaming holes up to 60 m, according to Epiroc. It also has the capability to drill angled holes in any direction with a minimum range of 90°–60° from horizontal.

Quinteiro, who is also the Project Manager for the SUM subproject 1, said: “The rig can drill opening holes up to a maximum of 60 m. “We will start by test drilling 40-50 m and then evaluate the results.”

The drill rig will initially be used at level 436 in the Konsuln mine, which is the first level that has an increased sublevel height – of a total of 40 m.

“With an increased sublevel height, we have to be able to drill longer opening holes than our existing rigs can handle,” explained Quinteiro.

A number of different tests will be carried out to check LKAB’s quality and productivity requirements, the iron ore miner said. “Only after an acceptance test has been performed will a decision be made on whether Easer L can be used in production at Konsuln.”

LKAB plans for live SUM project testing at Konsuln in 2020

LKAB, one of five companies invested in the Sustainable Underground Mining project (SUM), says it is hoping to move into test mode in 2020 with a number of projects aimed at making future mines carbon dioxide-free, digitalised and autonomous.

SUM has four sub-projects that are closely interconnected. In one of the sub-projects, autonomous, smart and carbon-free vehicles will be tested in LKAB’s test mine, Konsuln, in Kiruna. This will see humans and machines work together safely, according to the company.

The Swedish miner, which is looking to set a new world standard for sustainable mining at great depths, will be helped by ABB, Epiroc, Combitech and the Volvo group in its efforts.

LKAB said: “The strength of a major partnership such as SUM is that each company can contribute with its unique expertise. Epiroc has extensive experience of machinery developed for use underground and the Volvo group of vehicles used above ground. Combitech contributes with knowledge of how different systems can be integrated with each other and ABB with management systems, ie how the communication can work.”

In sub-project 2, DP2, the focus is currently on knowledge sharing and finding a common level to start with, LKAB said. The goal is to test electrically-driven, both manual and self-steering loaders, drilling rigs and forklifts that will interact with each other, people and other vehicles operating in the mine.

Hans Engberg (pictured), LKAB’s Project Manager for DP2, said: “There are several challenges, but one of the biggest is to find smart, simple and above all safe systems for underground transport in mixed traffic. We know that autonomous machines must work together with driver-controlled vehicles in the mine. Many people think that the technology already exists, but it does not. We will be the first with this.”

Mariana Forsberg, Project Manager for the Volvo group, said the company started with a survey of LKAB’s mining operations. “Volvo needs to know what vehicles are in the mine, how and where people will move and how everything works together. From that, we will then look at what autonomous solutions can work in the rather special environment that is, after all, an underground mine.”

With autonomous machines, loading operations can be carried out done for longer periods of time without breaks, which among other things would help LKAB reach its goal of increased productivity.

LKAB is also striving for a carbon-free operation, and this is where electric vehicles with batteries are deemed to be an option in the mine. How and where batteries should be charged in a production environment is one of the many questions that sub-project 2 should provide answers to.

Niklas Fors, Epiroc’s Project Manager, said: “Based on the overall objectives of the project, we will set milestones so that we can perform real test situations in Konsuln. It is a case of making use of the knowledge that exists in our various companies in SUM and bringing some fresh thinking together, with safety as a guiding light. SUM is bigger than the sum of its parts.”

Another important issue is finding answers to how data should be communicated, so that the right information reaches the right recipients at the right time.

“For a safe and accessible working environment, vehicles should also be smart, ie able to exchange information by being connected in real time,” LKAB said. “This requires precise positioning of machines and people. How the data is to be collected and reach the right person or vehicle must be tested and evaluated.”

The ambition is that live testing will begin in the test mine in about a year. All test results should then be used as a basis for LKAB in the mid-2020s to decide how mining should look after the year 2030, when the current main levels in the mines in Malmberget and Kiruna are deemed to be mined out.

Engberg said: “Autonomous and smart machines are absolutely part of the solution to become carbon-free and increase productivity, but we will always need people in the mine. However, today’s miners will not do the same things as tomorrow’s. New technology brings new tasks, just as it always has in all development, whether it be in the mining industry or in society at large. What we are facing requires knowledge, fresh thinking and hard work. SUM is about our future.”