Tag Archives: locomotives

Riino zero-emission monorail haulage system receives mining company backing

Riino, a company incorporating technology influences from monorails, subway systems and the mechanised raise climber, is a step closer to bringing its zero-emission material movement concept to reality, having signed up three mining company backers for a technology scoping study, utilising a consortium approach, supported by the Canada Mining Innovation Council (CMIC).

Agnico Eagle Mines, Rio Tinto and Vale are now all part of a CMIC-backed consortium pushing the Riino project forward under CMIC’s Surface Mining Alternative Haulage project. In addition, Riino has also been successful in achieving funding as part of Canadian government backing through the Mining Innovation Commercialization Accelerator Network.

Riino is an innovative monorail haulage system targeting the reduction of the industry’s carbon emissions and achieving net-zero goals, CMIC says. It is designed to receive its power from internal, train-mounted motors as well as auxiliary on-board batteries for a complete electric and automated operation.

The Riino concept originated out of President and CEO Aaron Lambert’s experience as a contract miner in Sudbury – a role that saw him interact and engage with many different technologies.

The standard 120-t (18% grade) or 400-t payload numbers used by Riino have been influenced by existing underground or open-pit mining profiles

Lambert has been working on Riino for several years, with the initial plan to produce a system that is both capex- and opex-efficient. The headline numbers associated with this are a targeted 50-80% reduction in haulage operating costs.

As time has gone by, the zero-emission element has created a further selling point for Riino, encouraging mining companies to consider its use alongside a host of other ‘green’ haulage alternatives to the standard diesel-powered truck and shovel fleet.

All three of the mining companies attached to the ongoing scoping study have been interrogating the data and designs Lambert and his team have assembled over recent months, and are now pledging financial resources to wrap some in-depth numbers and technical data around what it will take to build a prototype to a sufficient technology readiness level.

To this point, the power requirements for Riino have been based off existing specifications for both open-pit and underground mines. The standard 120-t (18% grade) or 400-t payload numbers have also been influenced by existing underground or open-pit mining profiles.

“We’ve had great early engagement from mining companies since we started the Riino project, and the latest backing from Agnico, Rio and Vale is tangible evidence of that,” Lambert told IM.

The three mining companies and Riino are currently engaged in this four-month study, which will be concluded by the end of this year. The idea is to then engage in another staged development process that could result in a full-scale prototype being built for testing at a location in Sudbury, owned by Rainbow Concrete Industries.

Trevor Kelly, Innovation Manager at CMIC, said: “We see the scoping study as a good opportunity for the industry to look at this solution. It offers a low-cost entry point and definitive outcome to enable companies to get involved initially, quickly. As with many other CMIC projects, we work with entrepreneurs and mining companies to find the ‘sweet spot’ between what money and resources are available, matching that to a relevant technology scope.

“As a result, it gives Riino and the mining companies a view on the potential of this technology and the possible paths forward.”

Gary Molloy, Innovation Manager at CMIC, added on the scoping study: “At this stage, it is all about building confidence in your company and your product.”

Each Riino locomotive – of which there are several making up a system – has internal, train-mounted motors to offer optimal driveline power across the system. These locomotives also come with wheels that have full attachment to the rails – via load-bearing, side-attachment and under-attachment wheels – similar to that of a rollercoaster. This eliminates the potential for train derailments, according to Lambert, saving potential system damage as well as downtime.

The inclusion of a Busbar able to provide 750 V of DC power comes out of the subway and surface transit space, meanwhile.

On top of this, the system has auxiliary on-board batteries to eliminate a significant amount of electrical infrastructure such as power cables and additional sub-stations.

This makes for a system able to offer speeds of up to 80 km/h, transport material lump sizes up to -760 mm, carry 120 t on a standard 18% incline road/ramp and navigate road widths of 1.8 m.

The Riino system has auxiliary on-board batteries to eliminate a significant amount of electrical infrastructure such as power cables and additional sub-stations

Lambert concluded: “Riino’s ambitious journey to revolutionise material movement in mining has gained substantial momentum and is swiftly progressing toward realisation.

“This pivotal phase, marked by rigorous study and financial commitments, aims to propel Riino towards a prototype build, positioned for testing in Sudbury. With a scoping study drawing to a close by year-end and subsequent developmental stages on the horizon, Riino stands poised to redefine mining logistics, offering a glimpse into a greener, more efficient future.”

Wabtec to provide Fortescue locomotives with another 20 years of life

Wabtec Corporation has announced an agreement to modernise locomotives for Fortescue Metals Group, representing Wabtec’s delivery of the first fleet of modernised locomotives for an Australia-based customer.

The fleet will be transformed into AC44C6M locomotives to meet the performance requirements of Fortescue while delivering operational and environmental efficiencies, it explained.

“While we have completed more than 1,000 modernisations for customers globally, it’s a first for Australia and demonstrates Fortescue’s commitment to drive more sustainable rail operations,” Wendy McMillan, Senior Regional Vice President, South East Asia, Australia and New Zealand, said.

“By repurposing and rebuilding our locomotives, we give these heavy-haul trains another 20 years of life, while reducing the fuel consumption and maintenance, and repair and overhaul expenses by up to 20%. For Fortescue, the modernised trains will deliver up to a 55% increase in tractive effort and more than 40% increase in reliability.”

The modernised locomotives will benefit from improved performance and increased reliability with new features including a UX engine, new electrical cabinets, a new design high-efficiency radiator and radiator cab, an upgraded control system to remove obsolescence, and AC traction with individual axle control, Wabtec explained.

General Manager Hedland Operations, Mark Komene, said: “The procurement of the modernised locomotives is an important element of Fortescue’s locomotive fleet strategy. This newly modernised fleet will enable substantial long-term capital and operating costs savings, provide the latest traction and control technology, and enable future upgrades to alternative energy sources such as battery electric in support of Fortescue’s industry-leading target to be carbon neutral by 2030.”

The new AC44C6M locomotives will be rebuilt at Wabtec’s Fort Worth facility in Texas, USA, before making the journey to Western Australia over the next two years for deployment at Fortescue’s mining operations.

Wabtec’s modernisation program is a key component of the company’s effort to advance a circular economy. It updates ageing locomotives with customised solutions that range from simple changes including control system upgrades to complex restorations, such as the comprehensive transformation of an aged DC locomotive into an AC locomotive outfitted with state-of-the-art digital technology.

Fortescue, meanwhile, has progressively been looking to decarbonise its locomotive fleet, making plans to purchase two new battery-electric locomotives from Progress Rail, a Caterpillar Company, to transport its iron ore to port in Western Australia. This comes on top of trials at Fortescue Future Industries development facility in Western Australia of a locomotive operating solely on green ammonia and other green renewable fuels and technologies.

Fortescue, FFI and Progress Rail collaborate on battery-electric loco deployment

Fortescue says it is continuing to progress the decarbonisation of its locomotive fleet with the purchase of two new battery-electric locomotives from Progress Rail to transport its iron ore to port in Western Australia.

The new eight-axle locomotives will have an energy capacity of 14.5 MWh and will be manufactured at the Progress Rail facility in Sete Lagoas, Brazil.

Fortescue, in December, said it was planning to test locomotives powered solely on green ammonia and other green renewable fuels and technologies at its rail operations in 2022, with two four-stroke locomotives arriving at Fortescue Future Industries’ Hazelmere facility, in Western Australia. These locos will undergo further testing on the new fuel system, joining other two-stroke locomotives which underwent testing earlier in 2021.

Fortescue Chief Executive Officer, Elizabeth Gaines, said on the latest developments: “The purchase of these new battery-powered locomotives marks an important milestone in the decarbonisation of Fortescue’s locomotive fleet and demonstrates our commitment to achieving carbon neutrality for Scope 1 and 2 emissions by 2030, as we diversify from a pure-play iron ore producer to a green renewables and resources company.

“The new locomotives will cut our emissions while also reducing our fuel costs and our overall operational expense through lower maintenance spend.

“The acquisition builds on the work being carried out by Fortescue Future Industries’ Green Team in Hazelmere to deliver locomotives operating solely on green ammonia and other green renewable fuels and technologies.”

Fortescue is expected to take delivery of its first battery-powered locomotive in 2023.

Fortescue Future Industries (FFI) Chief Executive Officer, Julie Shuttleworth, added: “FFI is a key enabler of Fortescue’s decarbonisation strategy. Our Green Team has made outstanding progress in their mission to transform Fortescue’s trains, trucks, ships and other mobile equipment to operate on zero pollution fuels as soon as possible, and the purchase of these new battery-powered locomotives complements this work.

“Fortescue and FFI are working together to demonstrate that renewables can power the energy needs of Australia’s mining and resources sector.”

Marty Haycraft, President & CEO of Progress Rail, a Caterpillar Company, said: “We are pleased to be working with the Fortescue team to determine the application, feasibility and suitability of battery-electric technology for deployment on their railway and to manufacture two of our BE14.5BB locomotives for this important project.

“We look forward to continuing to support our global customers with innovative products and services to help them meet their sustainability goals.”

Fortescue making plans to test ‘green’ locomotives at rail operations in 2022

The decarbonisation of Fortescue Metals Group’s (Fortescue) locomotive fleet is ramping up with the arrival of two additional locomotives at Fortescue Future Industries’ (FFI) research and development facility in Perth, Western Australia.

The two four-stroke locomotives will undergo further testing on the new fuel system, joining the first two-stroke locomotive which underwent testing earlier this year.

Fortescue Chief Executive Officer, Elizabeth Gaines, said the arrival of the additional locomotives allowed FFI’s Green Team to expand their development as they focus on delivering a locomotive operating solely on green ammonia and other green renewable fuels and technologies.

“This is part of Fortescue’s ambitious target to be carbon neutral by 2030 for Scope 1 and 2 emissions,” she said. “Our target is underpinned by a pathway to decarbonisation as we focus on investing in renewable energy and eliminating the use of diesel across our mining fleets. Fortescue’s fleet of locomotives is a critical element in decarbonising our operations and, through FFI, we are investing in cutting-edge technologies to power the green mining fleet of the future.”

FFI’s Green Team have been trialling technology in hydrogen, ammonia and battery power for trains, ship engines, haul trucks and drill rigs.

Earlier this year, the team achieved the successful combustion of blended ammonia fuel in a two-stroke locomotive, marking a significant milestone in Fortescue delivering on its decarbonisation targets.

FFI Chief Executive Officer, Julie Shuttleworth, said: “FFI is a key enabler of Fortescue’s decarbonisation strategy, and it is pleasing to see such rapid progress being made by our Green Team. We are investing in research and development to transform Fortescue’s trains, trucks and ships on the road, rail and sea with zero pollution fuels as soon as possible.”

Planning is underway to deploy a demonstration locomotive in Fortescue’s rail operations in 2022.

Mader Group hits another quarterly record as it keeps expanding

Mobile and fixed plant equipment maintenance provider Mader Group has declared a stellar set of quarterly financials that included a second consecutive quarterly revenue figure.

Revenue for the three months to the end of June came in at A$86.4 million ($63.5 million), up 24% on the prior corresponding period (PCP), and up 14% on the previous quarter.

Revenue generated in Australia increased to A$77 million, up 21% on the PCP, driven by high levels of customer demand, while, in North America, quarterly revenue increased to A$6.8 million, up 45% on the PCP excluding foreign exchange movements (30% on an A$ basis).

The company said its preparations for operational delivery into Canada were now complete with customer negotiations well advanced.

Reflecting on Mader Group’s quarterly performance, Executive Director & Chief Executive Officer, Justin Nuich, said: “On the back of two consecutive quarters of record revenue growth, we close our books for the financial year with A$304 million in revenue and with a strong earnings result to follow. This is very pleasing and reflects the strength of our labour-focused business model.

“Our operations are more flexible and adaptable than ever, housing a dynamic in-house workforce of more than 1,600 skilled tradespersons deployed across nearly 400 sites globally. In all locations, we have prioritised the needs of our customers and our people, safely delivering over 3.4 million hours of specialised equipment maintenance for financial year 2021.”

During the period, the company continued to develop its internal safety systems to ensure the health and wellbeing of a largely remote workforce. Mader prioritised the continued roll out of a bespoke in-vehicle monitoring system for its service fleet, seeing considerable improvement in driver behaviour over the quarter, it said.

Mader also commenced trialling its safety-focused mobile app to its North American workforce.

The platform, which is already widely accessible to Mader employees within Australia, is designed to connect Mader employees to its digitally integrated safety processes, resources and company alerts.

Within Mader’s Australian operations, the group’s infrastructure and ancillary maintenance service lines remained a key focus in the business’ growth strategy. Continued diversification saw the company expand its ancillary service offerings.

“Moving into climate control support for mobile equipment, Mader supported a renewable energy project in a bid to convert diesel-electric haul trucks, exploration drills and locomotives into zero emissions technology,” the company said.

“Mader also worked with a local OEM to conduct off-site rebuilds for plant conveyors and mills. Revenue generated from the business’s ancillary maintenance services increased 21% vs PCP and by 12% vs PCP for its infrastructure maintenance services.”

Mader said its core service areas also gained traction during the quarter leading to the expansion of its in-field maintenance operations for heavy mobile equipment, driven by high customer demand across Australia. In Western Australia, this included growth in its Rapid Response team and “specialised equipment maintenance offerings”.

The company added: “Our disruptive business model continues to roll out into a large addressable market that has an appetite for significant additional capacity. All of our core business divisions continue to grow and our strategy of building new divisions that address new geographic locations or that provide additional trades and services is driving further growth.

“We are seeing structural advances in the Australian market as large owner-miners continue to develop multibillion-dollar resource projects, ultimately increasing the size of the maintainable mining fleet.”