Tag Archives: mine maintenance

Advancing maintenance in underground mining through digitalisation and automation

Automation, Equipment maintenance, IoT, Mining equipment, Mining maintenance, Mining services, Sustainable mining, , , ,

Underground mining, essential for global raw material supply, and here especially for the majority of critical raw materials, faces significant challenges, including worker safety, operational efficiency and environmental sustainability, Christel Füllenbach and Professor Helmut Mischo*, write.

Traditionally, maintenance strategies in this sector relied heavily on manual inspections and time-based preventive maintenance schedules. However, these conventional approaches have often proven labour-intensive, costly and insufficient in predicting or preventing equipment failures effectively. Recent advancements in digitalisation and automation – specifically through condition monitoring, predictive maintenance and automated inspections – are now offering transformative potential for maintenance strategies in underground mining, addressing core industry challenges.

Limitations of traditional maintenance in mining

For decades, underground mining maintenance depended on manual inspections and predetermined maintenance schedules, with equipment servicing occurring at fixed intervals regardless of its actual condition. While useful, these time-based preventive measures are inherently limited, often leading to unnecessary maintenance tasks or, conversely, to unexpected equipment failures. For example, skilled personnel conduct regular checks based on experience and judgment, which can lead to inconsistencies and the potential for missed early warnings of equipment issues (Kruczek, P., et al., 2019, p. 459 ff.). Moreover, traditional maintenance is resource-intensive, involving substantial manual labour in hazardous underground environments, which increases safety risks and operational costs (Salami, O., B., et al., 2023, p. 617 ff.).

Digitalisation and automation: Transforming maintenance strategies

During the last 15 years, the continuous shift toward digitalised and automated solutions in maintenance marks a fundamental evolution in underground mining. Condition monitoring, predictive maintenance and automated inspection systems each bring specific advantages in enhancing operational efficiency and reliability.

The implementation of condition monitoring enables real-time data collection on equipment parameters, including temperature, vibration and pressure, via sensor networks. By analyzsng this data, mining operators can determine the precise maintenance needs of machinery, rather than relying on inflexible schedules. Case studies indicate that condition monitoring reduces unexpected downtime significantly; for instance, in one South African underground mine, implementing this approach led to a 30% reduction in downtime, offering clear benefits for reliable, uninterrupted operations (Aqueveque, P. et al., 2021, p. 17365 ff.; Rihi, A., et al., p. 2483 ff.).

Building on this, predictive maintenance applies advanced machine-learning algorithms to forecast machinery failures before they occur, effectively shifting maintenance from a reactive to a proactive stance. By anticipating equipment issues, predictive maintenance reduces the need for emergency repairs and limits personnel exposure in high-risk zones. Studies have shown that predictive maintenance can reduce machinery downtime by up to 20%, while also improving safety standards (Putha, S., 2022, p. 160 ff.). In one notable instance, a mining operation utilising predictive maintenance algorithms experienced a significant drop in operational disruptions, illustrating the potential of data-driven maintenance in high-stakes environments like underground mining (Dayo-Olupona, O., 2023, p. 12 ff.).

As one of the most recent developments, automated inspection systems, including drones and robotics, offer further advancements by conducting inspections in hazardous or hard-to-reach areas without requiring direct human involvement. Drones, equipped with high-resolution cameras and other sensors, perform routine inspections with exceptional speed and accuracy, contributing to reduced inspection times and enhanced data precision. A mining company, for instance, achieved a 50% reduction in inspection time after deploying drones for regular equipment checks, thus underscoring both the efficiency and safety improvements achievable with automation (Weyers, E., 2021, S. 55 ff.).

Benefits and sustainability of digitalised maintenance strategies

The implementation of digitalised and automated maintenance strategies offer distinct advantages across safety, efficiency and sustainability metrics. Enhanced safety is one of the primary outcomes, as digital and automated tools reduce the need for personnel to conduct inspections in hazardous areas, lowering accident rates associated with traditional manual checks. Efficiency gains are equally significant; with precise maintenance scheduling enabled by data analytics, companies minimise unnecessary downtime and maximise machinery lifespan. Furthermore, this approach contributes to cost reductions, as predictive and condition-based maintenance reduce both emergency repair costs and the long-term expenses of equipment replacement (Jasiulewicz-Kaczmarek, M., 2019, p. 91 ff.).

From a sustainability perspective, automated and predictive maintenance models contribute directly to resource conservation. The reduction in maintenance frequency and improved operational efficiency lower energy consumption and material waste, aligning with circular economy principles. Automated inspections and predictive models foster an eco-friendlier mining operation by reducing carbon emissions and minimising waste outputs, which is increasingly critical for an industry under pressure to meet stringent environmental standards (Firoozi, A., et al., 2024, p. 2 ff.).

Current R&D and outlook

Current research in underground mining maintenance is focused on refining digital and automated solutions to enhance predictive accuracy and operational efficiency. Advances in machine learning are boosting predictive maintenance models, allowing improved anticipation of equipment failures by analysing large, complex data sets, such as vibration and acoustic signals (Chimunhu, P., et al., 2024, p. 30 ff.). Additionally, IoT-enabled sensors are becoming more resilient and effective in extreme underground conditions, facilitating real-time equipment monitoring and environmental data collection (Wu, Y., et al., 2019, p. 9 ff..).

Robotics also continues to improve automated inspection capabilities, with drones and autonomous vehicles now better equipped for navigating hazardous underground areas. Future developments are likely to see fully-autonomous drones that can perform inspections without operator intervention, significantly reducing human risk exposure (Zhang, R., et al-. 2023, p. 2460 ff.).

Looking forward, emerging innovations may lead to self-diagnosing and even self-correcting systems that will enable continuous operation with minimal manual maintenance. Collaboration between mining companies, technology providers and academia is also advancing universal digital standards, supporting broader adoption of automated maintenance technologies worldwide (Suhail A.H., et al., 2024, p. 150 ff.).

The integration of digitalised and automated maintenance strategies represents a critical evolution in underground mining, enhancing safety, operational efficiency and sustainability. These technologies allow mining companies to optimise their maintenance practices, reducing operational risks and improving equipment longevity while minimising environmental impacts. As digital and automated solutions continue to evolve, their transformative impact on underground mining will likely deepen, setting new industry standards for safety, productivity and environmental responsibility.

*Christel Füllenbach is Global Operations Manager at Epiroc; and Professor Helmut Mischo is from TU Bergakademie Freiberg’s Institute of Mining Engineering and Special Civil Engineering

Aqueveque, P., Radrigan, L., Pastene, F., Morales, A. S., & Guerra, E. (2021). Data-Driven Condition Monitoring of Mining Mobile Machinery in Non-Stationary Operations Using Wireless Accelerometer Sensor Modules. IEEE Access, 9, 17365-17381. https://doi.org/10.1109/ACCESS.2021.3051583.

Chimunhu P, Topal E, Asad MWA, Faradonbeh RS, Ajak AD. (2024). The future of underground mine planning in the era of machine learning: Opportunities for engineering robustness and flexibility. Mining Technology.

Dayo-Olupona, O., Genc, B., Celik, T., & Bada, S. (2023). Adoptable approaches to predictive maintenance in mining industry: An overview. Resources Policy, 86(Part A), 104291. ISSN 0301-4207. https://doi.org/10.1016/j.resourpol.2023.104291.

Firoozi, A. A., Tshambane, M., Firoozi, A. A., & Sheikh, S. M. (2024). Strategic load management: Enhancing eco-efficiency in mining operations through automated technologies. Results in Engineering, 24, 102890. ISSN 2590-1230. https://doi.org/10.1016/j.rineng.2024.102890.

Jasiulewicz-Kaczmarek, M., & Gola, A. (2019). Maintenance 4.0 Technologies for Sustainable Manufacturing – an Overview. IFAC-PapersOnLine, 52(10), 91-96. ISSN 2405-8963. https://doi.org/10.1016/j.ifacol.2019.10.005.

Kruczek, P., et al. (2019). Predictive Maintenance of Mining Machines Using Advanced Data Analysis System Based on the Cloud Technology. In Widzyk-Capehart, E., Hekmat, A., & Singhal, R. (eds), Proceedings of the 27th International Symposium on Mine Planning and Equipment Selection – MPES 2018. Springer, Cham. https://doi.org/10.1007/978-3-319-99220-4_38.

Putha, S. (2022). AI-Driven Predictive Maintenance for Smart Manufacturing: Enhancing Equipment Reliability and Reducing Downtime. Journal of Deep Learning in Genomic Data Analysis, 2(1), 160–203. Accessed Nov. 11, 2024. https://thelifescience.org/index.php/jdlgda/.

Rihi, A., Baïna, S., Mhada, F.-Z., Elbachari, E., Tagemouati, H., Guerboub, M., & Benzakour, I. (2022). Predictive maintenance in mining industry: grinding mill case study. Procedia Computer Science, 207, 2483-2492. ISSN 1877-0509. https://doi.org/10.1016/j.procs.2022.09.306.

Salami, O. B., Xu, G., Kumar, A. R., & Pushparaj, R. I. (2023). Underground mining fire hazards and the optimization of emergency evacuation strategies (EES): The issues, existing methodology and limitations, and way forward. Process Safety and Environmental Protection, 177, 617-634. ISSN 0957-5820. https://doi.org/10.1016/j.psep.2023.07.012.

Suhail, A.,H., Guangul, M., Nazeer, A. (2024). Advanced System Diagnostics Tools: Innovations and Applications. IntechOpen. doi: 10.5772/intechopen.114378.

Weyers, E. (2021). The use of drones to improve downtime management on South African mines [University of Johannesburg]. https://ujcontent.uj.ac.za/esploro/outputs/graduate/The-use-of-drones-to-improve/9918409407691#file-0.

Wu, Y., Chen, M., Wang, K., and Fu, G. (2019) “A dynamic information platform for underground coal mine safety based on internet of things,” Safety Science, vol. 113, pp. 9-18, https://doi.org/10.1016/j.ssci.2018.11.003.

Zhang, R., Hao, G., Zhang, K., & Li, Z. (2023). Unmanned aerial vehicle navigation in underground structure inspection: A review. Geological Journal, 58(6), 2454–2472. https://doi.org/10.1002/gj.4763

Delta Dunia spinoff and University of Queensland to help drive mining innovation, sustainability

Careers in mining, Environmental, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, Sustainable mining, , , , ,

PT Bukit Teknologi Digital (BTech), a subsidiary and the research and development (R&D) arm of PT Delta Dunia Makmur Tbk (Delta Dunia Group), has signed a research services agreement with The University of Queensland (UQ) to drive innovation and sustainability in the mining sector.

This collaboration synergises BTech’s advanced mining analytics with UQ’s world-class research capabilities, closely aligning with Delta Dunia Group’s focus on technology as a core growth lever, Delta Dunia says. Together, the research is strategically positioned to significantly enhance operational excellence and sustainability within Delta Dunia Group.

This joint research will focus on developing a robust framework for Asset Health Indicators that accurately determine the Remaining Useful Life (RUL) of critical equipment components. Insights into component and asset health is crucial to effective maintenance, extending component lifecycle sustainably and optimising fleet management.

To address the challenges of unplanned downtime and costly repairs in mining operations of the Delta Dunia Group, this research will  conduct an in-depth analysis using data analytics, machine learning-based failure detection, component health indexing with key parameters, and the optimization of RUL and component lifetime.

Endang Veronica, President Director at BTech (pictured on the left), said: “We are excited to partner with The University of Queensland, one of the leading universities in Australia known for its world-class research expertise. As a growing mining technology company, we are committed to investing in various innovations that enhance our end-to-end, cutting-edge solutions for our clients. This collaboration with UQ marks a milestone in our journey towards technological excellence in mining. By integrating pioneering research with our operational expertise,
we are setting new industry standards for reliability and sustainability.”

Since its spin-off in 2023, BTech has collaborated with the operating companies of Delta Dunia Group in Indonesia and Australia through a comprehensive suite of initiatives across asset management, safety, health and environment (SHE), people management and mine engineering. BTech’s strength lies in using tailored analytics to optimise operational excellence and enhance sustainability performance, it says.

Professor Sue Harrison (pictured on the right), Executive Dean of the Faculty of Engineering Architecture and Information Technology at UQ, stated, “We are thrilled to establish this important collaboration with an Indonesian company, especially in the mining sector. This partnership marks a significant step for The University of Queensland in fostering global innovation. Advancing predictive maintenance is critical in optimising mining operations, and we are excited to partner with BTech in this research, which has the potential to drive new industry milestones.

“Together, we aim to deliver solutions that enhance equipment reliability while driving sustainable practices in the mining sector.”

UQ is one of Australia’s top research-intensive universities, with an emphasis on high-quality, interdisciplinary global collaboration with public and private organizations. The School of Mechanical and Mining Engineering at UQ offers extensive expertise in mining-related research, particularly in RUL and predictive maintenance. Its research spans systems simulation, sensing technologies, strategic and tactical planning of mining systems, which support advancements in asset reliability and operational efficiency.

The partnership between BTech and UQ highlights Delta Dunia Group’s commitment to deepening connections with Australia, extending beyond business operations to collaborative R&D projects centered on sustainable practices and innovative advancements, it says. On  September 20, 2024, the group signed an Umbrella Agreement with UQ designed to benefit stakeholders in Indonesia and Australia  significantly. This agreement underpins research initiatives across all Delta Dunia Group subsidiaries, driving advancements in sustainable mining practices, workforce innovation and the integration of cutting-edge technologies.

Rio Tinto to extend use of Palantir Technologies’ AI-based solutions

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Palantir Technologies Inc has renewed its multi-year enterprise agreement with Rio Tinto, extending the pair’s pact for an additional four years and securing Rio Tinto’s ongoing access to the Palantir Artificial intelligence Platform (AIP).

As an early adopter of Palantir Foundry (Foundry), Rio Tinto has already primed its operational landscape for the deployment of AI through the creation of a robust digital twin (or Ontology), Palantir says. Via the Ontology, AIP will enable Rio Tinto to build, test, and validate AI use cases at an accelerated pace and deploy them to production safely.

These AI use cases will follow and augment critical operational workflows Rio Tinto conducts in Foundry today. From managing plant operations to monitoring geotechnical risk to coordinating dozens of unmanned trains carrying iron ore, Foundry is enabling Rio Tinto to make well-informed decisions and take appropriate actions based on a single, unified source of truth, it added.

Bold Bataar, Rio Tinto’s Chief Commercial Officer, said: “Foundry has helped to transform the parts of our business where it has been applied. In our most high-stakes environments, we are empowering our people to find better ways of working, to improve how we operate our assets, increase performance and to innovate. The Foundry Ontology has made our structured data accessible, and AIP is doing the same for our unstructured data while enabling us to attack with pace problems previously deemed too complex.”

For network specialists and train controllers in the RTIO Operations Centre, in Western Australia, Foundry provides a view of rail operations, assembled from real-time data from hundreds of equipment units and systems in the value chain. With the Ontology providing a unified view of all assets, network specialists coordinate the haulage of iron ore by 53 driverless trains, each with 240 wagons, across the Pilbara rail network. They can optimise, collaborate on and execute complex routing decisions to balance production targets and maintenance needs. As a result, both railway throughput and safety have been improved.

In Mongolia, Foundry equips Rio Tinto with a dynamic understanding of geotechnical risk at Oyu Tolgoi, one of the world’s deepest and largest block cave mines. The mine’s challenging conditions require advanced risk management and constant surveillance to ensure safe production. The Ontology Rio Tinto has configured in Foundry integrates data from thousands of sensors across the mine and serves as a single source of information for cave health, instrumentation and risk, according to the company. This represents a new paradigm for block cave mining and has enabled various adjacent workflow innovations which will be further expanded through Palantir AIP.

Ted Mabrey, Palantir’s Head of Commercial, said: “We have high expectations for Rio Tinto’s utilisation of Palantir’s AIP based on what they have already achieved with Foundry and their ambition for secure use of AI. The Ontology created by Rio Tinto’s team in Foundry over the past three years enables fast deployment of AI solutions to some of Rio Tinto’s most pressing challenges and ensures best and safe operator practice in areas like risk identification, asset management, and supply chain order and fulfilment processes.”

Mill relining system major RME celebrates 20 years in South America

Automation, Comminution of minerals, Equipment maintenance, Mineral processing, Mining equipment, Mining services, , , ,

OEM RUSSELL MINERAL EQUIPMENT (RME) is celebrating its 20th anniversary in South America, highlighting its ongoing deep connection and commitment to the region.

RME says it is seizing the milestone to express its gratitude to the team members, customers and suppliers who made RME the region’s most trusted OEM of mill relining technologies.

RME’s history in South America dates to 1996 with the export of the first RUSSELL Mill Relining Machine (MRM) to the region. With a steady stream of technology installations in the years that followed, RME established a direct presence in the region in 2004 to better serve its growing customer base.

Today, RME has five dedicated RME Regional Service Centres in Latin America and its equipment operates on 77 Latin American mine sites across Argentina, Bolivia, Brazil, Chile, Colombia, Dominican Republic, Mexico, Panama and Peru.

RME Founder, Executive Chairman and Chief Engineer, Dr John Russell, described South America as a cornerstone of RME’s operations.

Dr Russell said: “From the arrival of the first RUSSELL MRM on the continent in 1996, the opening of our regional service centre in Chile in 2004, and the opening of offices in Peru and Brazil in 2021 and 2022, respectively, RME has invested, and continues to invest in building our capacity and customer delivery capabilities in the region.

“Latin America is home to some of RME’s oldest and most loyal customers, with well-maintained RUSSELL MRMs routinely exceeding 20 years of field operation. An unwavering dedication to precision engineering and quality manufacturing ensures our mill relining systems perform optimally, translating to a lower total cost of ownership and higher return on investment for our customers across Latin America and beyond.

“With more than 100 RME employees in Latin America, the region is also home to RME’s largest cohort of specialised local technical staff, outside Australia. We are committed to transferring our knowledge and skills to benefit career development of local employees, as well as their families and communities, while ultimately improving the safety of our customers’ reline crews and mill relining productivity. As we celebrate 20 years in South America, and also approach 40 years since RME was founded, we look to the future and remain deeply committed to expanding our business in Latin America.”

The first commercial adoption of THUNDERBOLT SKYWAY, RME’s technology that roboticises the operation of THUNDERBOLT Recoilless Hammer for safer and faster worn liner knock-in, was in Panama.

Securing this initial site in 2019 was an important step in commercialising RME’s advanced relining methods and technologies. Not only did the company gain valuable insights for its innovation program, but this installation demonstrated to industry that it’s possible to eliminate fatal risk and move workers out of the line of fire during mill relining operations, RME says.

Dr Russell said: “RME’s Latin American customers have been early adopters of products from our world-first, award-winning RME Advanced Technology Mill Relining System that ultimately allows mill operators to relocate crews to work outside the mill during liner exchange and achieve step-change improvements in safety and relining speed.

“Thanks to their safety leadership, over 30 relines globally, utilising various products from the RME Advanced Technology Mill Relining System, have demonstrated the system’s broad applicability to diverse mine sites, especially in Latin America which operates some of the world’s largest mills, long-life mines and high-altitude sites.

“The region continues to work at the forefront of advanced safety and automation technology adoption with growing interest and investment in the world’s best safety technologies.”

Movex Innovation to showcase line of ultra-compact mini loaders at MINExpo

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Movex Innovation is set to showcase its line of ultra-compact electric, remote-controlled mini loaders, designed to tackle spillage and blockages in a range of applications, at MINExpo 2024, in Las Vegas, next month.

Material spillage continually challenges mine worldwide and poses significant operational and safety concerns. Traditional clean-up methods, such as manual shovelling and water hoses, are labour-intensive, hazardous and inefficient. They often lead to extended downtimes, increased operational costs and elevated risks to worker safety.

This is where the MINIDOZER 27” and MINIDOZER 48” ultra-compact mini loaders for mines and quarries come in.

Movex Innovation’s MINIDOZERs offer a transformative solution, the company says. Engineered for maximum efficiency and safety, these mini loaders can be used while conveyor systems are running, with the compact size allowing operations to access the hardest-to-reach areas.

The mini loaders require no certifications to operate and work perfectly in extreme heat and cold, according to the company, which says it offers comprehensive support and training. They also offer impressive battery life in any temperature conditions, according to the company.

MINExpo 2024 is due to run from September 24 to September 26 at the Las Vegas Convention Center

Tru-Trac continuing to troubleshoot conveyor belt issues for mining operators

Bulk handling, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, , , , , ,

With belt misalignment remaining the biggest headache for conveyor system operators across a variety of bulk material handling industries, Tru-Trac says it has evolved from this valuable niche into a full service conveyor solutions business.

Having patented and commercialised its belt tracker back in 1996, Tru-Trac has leveraged its engineering expertise and market knowledge into a comprehensive range of conveyor solutions – with a global sales and installation network. There remains, however, a ‘magic’ at the core of the business which, it says, continues to surprise customers: its deep understanding and expertise of belt misalignment solutions – belt trackers.

Shaun Blumberg, COO of Tru-Trac Rollers, highlights the serious disruption that belt misalignment on a conveyor can cause. The impact includes spillage, belt edge damage, structural harm, increased power consumption and increased labour costs. Ultimately, this leads to lost production, higher operating costs and even safety hazards.

From its local manufacturing base in South Africa, Tru-Trac has grown to serve markets nationwide and abroad – including some of the most sizeable equipment in operation. One of the world’s largest stacker reclaimers, which serves the coal sector in Germany, also experienced a Tru-Trac moment, according to Jonathan Rogoff, CEO of Tru-Trac.

“They were having significant challenges with belt misalignment – and told us they never had a belt tracker last more than a week,” Rogoff explains. “When we presented our proposed solution, they were sceptical – thinking we were either over-confident or naive.”

Leveraging decades of application data and its in-house engineering expertise, Tru-Trac enhanced its heavy-duty dual-return tracker into an extra heavy-duty (EXHD) model specifically tailored for this customer’s needs.

“This was a demanding application with the 2,300-mm-wide belt running at 9.6 m/s – close to the speed of some of the fastest belts in the world,” Rogoff says. “A year later, our product was still working well, leading the customer to standardise on this Tru-Trac solution.”

Closer to home, a mining company in Rustenburg recently had its production halted for two days after successive failures of numerous belt tracking products. After a site visit to assess the situation, Tru-Trac returned the following day with two of its belt trackers – to replace the five installed competitor products.

“Within 20 seconds, the belt centralised and the problem was solved,” Rogoff says. “Initially, our customer could not believe what he was seeing and was convinced the old problem would return when material was loaded. However, the belt remained true under full load, as we had predicted.”

Blumberg points out that there has been significant growth in the business over recent years, and the company has expanded its local manufacturing to punch above its weight on the global stage. In fact, within the industry, the brand has become synonymous with its product, to the extent that professionals often refer to any conveyor belt trackers as ‘Tru-Trackers’, the company claims.

After the success of its tracking solutions, it made sense to leverage its brand and expertise by diversifying into complementary conveyor solutions. Through its existing partnerships with international conveyor distributors, Tru-Trac began importing well recognised brands to augment its range. This includes belt scrapers and skirting rubbers as well as impact beds.

“This led to us building our own service teams to provide installation and maintenance support for customers, as we were now dealing with equipment that needed servicing,” Rogoff says. “The beauty of our belt trackers is that they are essentially ‘fit and forget’ solutions that need very little attention during their lifecycle.”

Today, there are about 50 Tru-Trac service teams working across South Africa and into the rest of Africa, to support customers. With this growth came an expansion of in-house sales teams, who work from branches in the main mining regions in South Africa and Africa

“This gave us more control over our own destiny allowing us to develop skilled customer-centric teams to service customers as a complete provider of mechanical solutions and services on conveyor systems,” Rogoff says.

Tru-Trac also now supplies its conveyor solutions to over 80 countries globally, including almost every mining country. At its facility in Centurion, near Pretoria, there are now over 100 employees on the manufacturing side alone.

The company’s in-house engineering and R&D capabilities have significantly expanded, with the size of its R&D department increasing fivefold over the past two years. This growth has enhanced Tru-Trac’s engineering and design capabilities, which include custom design and rapid prototyping, showcasing the company’s commitment to innovation and tailored conveyor system solutions.

Rogoff concluded: “One of the rewarding parts of our work is that we provide conveyor solutions that really do deliver what customers require. We still regularly have customers whose jaws drop in disbelief when we solve challenges which they have unsuccessfully been grappling with for years.”

Bradken aims for South America mill liner expansion with Funtec facility acquisition

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Bradken, a wholly owned subsidiary of Hitachi Construction Machinery Co., Ltd, has purchased the land, buildings and some facilities necessary for a foundry from Fundacion Technologica S.A. (Funtec), a manufacturer of steel castings for mining sites in Peru.

Bradken says it aims to rapidly supply products and further expand its mill liner business to respond to the vigorous demand in South America, with a focus on Peru and Chile where hard rock is mined in abundance. Bradken will now complete construction of the foundry with first production of large mill liners expected in 2026.

This recent purchase was decided as part of the goal to provide products and solutions that solve customer issues at various touch points from pit to plant at mining sites.

The South American market for mill liners is the world’s largest, according to Bradken, and focuses on hard rock. Chile and Peru, in particular, have a high concentration of copper and gold mines which account for more than 80% of the demand for large mill liners in the South American region, it said.

Currently, Bradken imports mill liners for the South American market from India and Canada. However, producing mill liners locally in Peru will build a speedy product supply system and improve the ability to meet the needs of customers, including providing a pathway to recycle spent liners, delivering a more sustainable mining process.

The foundry purchased from Funtec is located in Chilca, some 70 km south of the capital city of Lima, Peru. Since this foundry is located in an industrial park, has many of the main plant items on site and already has permission for plant operation, typical approval and construction times can be accelerated, according to the company.

Furthermore, due to the ability to procure power based on hydroelectric power generation utilising Peru’s water resources, the new plant is expected to reduce annual CO2 emissions during plant operation by approximately 95% compared with the use of typical electrical energy by maximising the usage of hydroelectric power, according to studies from Bradken.

This purchase marks the first large-scale investment project in South America in the independent business undertaken in the Americas by the Hitachi Construction Machinery Group since March 2022. In the future, the group will consider using the Peru foundry targeted for investment at this time as a depot for storing Hitachi Construction Machinery mining parts and plans to leverage it as a South American mining market base for the Hitachi Construction Machinery Group.

Dingo predictive maintenance solution cuts equipment downtime at Eldorado Lamaque

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Dingo Software is helping Eldorado Gold’s Lamaque mine in Quebec, Canada, optimise maintenance and reliability practices through leveraging the company’s predictive and condition-based maintenance solutions.

The Lamaque mine faced the dual challenge of controlling capital costs and lowering all-in sustaining costs while also navigating the complexities of the global supply chain. With a current life of mine of 10 years, the mine sought to address some of these persistent challenges.

Lamaque decided to first focus on limited access to personnel with reliability skillsets, underutilisation of some of the existing digital platforms and its exposure to the global parts shortage. The team sought solutions to help control and reduce costs, extend the lifespan of major asset components and build world-class reliability expertise, Dingo says.

The site team, in collaboration with Dingo, identified opportunities to enhance equipment maintenance and reliability key performance indicators (KPIs). The chosen strategy aimed to reduce unplanned breakdowns, extend component life cycles, increase equipment availability and mitigate the impact of the global parts shortage.

Martin Pichette, Mine Operations and Maintenance Director at Lamaque Mine, said: “Partnering with Dingo allows us to leverage remotely-located condition intelligence experts from the get-go for a fraction of the normal cost to the company. This allows our few reliability experts to focus on the top issues and make important decisions to ensure our fleet availability is where it needs to be instead of having them analysing data and looking for the issues.”

Dingo also helped Lamaque acquire new sources of business intelligence with a fully documented and centralised asset health database plus integration with the ERP/CMMS, ensuring a complete maintenance and reliability context is available to support all maintenance decisions, it said.

Phase 1 of the Dingo solution involved consolidating oil sample data into a single platform for the first time at the mine. Within a short timeframe after the go-live, critical issues were identified and shared with the site team.

In the first week after go-live, the Dingo Condition Intelligence team observed a 2% fuel dilution, decreased viscosity, increased wear metal values and combustion by-products on a Caterpillar AD30 underground truck with a C15 engine with only 1,391 operating hours.

In response, the Dingo team assigned a ‘Priority 1’ action, providing work-stop level recommendations and provided site with a troubleshooting guide from their library, including recommendations to check the fuel injectors.

Not long after, the local OEM (Toromont) supporting Lamaque identified five defective fuel injectors that required urgent replacement. However, due to the ongoing global parts shortage, the mine was left with no alternative but to perform an engine oil drain on a weekly basis until the necessary parts could be procured. Once available, the injectors were replaced under warranty. This preemptive action not only prevented potential engine failure on the Cat AD30 but also restored up to 90% of the engine’s at-risk lifespan, according to Dingo.

While this proactive intervention circumvented much larger production losses had the engine been lost, it also highlights the significant risk unplanned breakdowns can have on Mean Time in Repair and associated production losses.

Dingo said: “The joint effort between the Lamaque personnel, CAT Toromont and Dingo Condition Intelligence specialists not only averted a catastrophic breakdown but also showcased the effectiveness and rapid results achievable through Dingo’s predictive maintenance solutions. The successful identification and repair of the AD30 injectors resulted in significant cost savings for everyone. In a nutshell, such a breakdown, if it had not been prevented by the team, would have generated production losses of about $65,000 per day due to equipment downtime and significant corrective maintenance cost to the OEM under warranty.

“Beyond financial value capture, this case also aligns with Eldorado Gold’s vision of ‘breaking new ground’ by implementing innovative solutions and enhancing maintenance processes, thereby ensuring the continuous growth of their high-quality business.”

After the AD30 engine save, the Lamaque maintenance team have continued to leverage Dingo to save equipment. For example: three leaking fuel injectors were found on a 45 t haul truck and a transmission was saved on a 15 t LHD; two key prime movers that would have impeded the operation from monthly production targets. Overall, working together, Dingo and Lamaque have now secured three significant equipment ‘saves’ within the first four-month period, Dingo says.

Building on these early successes, Lamaque and Dingo plan to continue to extend the project to the entire fleet, according to Dingo. Next steps will include interfacing with the mine CMMS and leveraging Dingo’s global benchmark tool to help select best practices from similar mines worldwide and to help the mine evolve towards increasingly condition-based maintenance decision making.

Dingo concluded: “This success story exemplifies how proactive maintenance strategies, coupled with innovative partnerships, can not only address immediate challenges but also pave the way for a more efficient future in the mining industry.”

Metso continues to sign up mining companies for long-term service pacts

Equipment maintenance, Mineral processing, Mining consumables, Mining equipment, Mining services, Sustainable mining, , ,

Metso says it is consolidating its strong position in delivering tailored solutions to mining and aggregate customers through the continued expansion of its Life Cycle Services (LCS) program. In 2023, Metso secured more than 110 new LCS contracts with global and regional mining companies as well as with sizeable quarries and aggregate contractors, it says.

During 2022, the company said its LCS business experienced substantial growth with more than 130 new agreements covering these applications.

Miika Tirkkonen, Senior Vice President, Integrated Service Solutions, Metso, said: “We secured more than 110 new LCS agreements worldwide. Our concentration is always focused on how we can help customers achieve their sustainability and productivity goals and exceed their performance. This growth celebrates our customer success, as we always work to best ensure customer satisfaction.”

The LCS agreements made last year are part of a portfolio of more than 500 long-term LCS agreements globally. The average duration of a contract is three years but can range from 12 months to multiple years of cooperation. The orders are booked on a phased basis, depending on the length of the agreement. More than two thirds of the orders were booked in the Minerals segment and the remaining orders were booked in the Aggregates segment.

Life Cycle Services encompass the complete range of Metso’s aftermarket portfolio, from spares and wears to advanced maintenance, remote monitoring and other expert services.

SafeGauge to continue ELW journey with launch of MultiTool Pro at IMARC

Mining events, Mining safety, Mining services, , , , , , ,

SafeGauge, which has a goal to eliminate live work (ELW) in heavy industries, such as mining, defence, construction, agriculture and oil & gas through the use of wireless/Bluetooth testing solutions, is set to unveil a new product at next week’s IMARC event, in Sydney, Australia, that, it says, promises to elevate vehicle maintenance to unprecedented levels of efficiency and effectiveness.

The MultiTool Pro allows technicians to connect to 12 SafeTest gauges simultaneously, from up to 100 m away. SafeGauge has a range of SafeTest Pressure Transducers (PT Series), Dial Indicators (DI Series) and Tachometers (TM Series), which, it says, are the go-to solutions for heavy industry applications.

The intuitive ‘plug-and-play’ touchscreen on the MultiTool Pro interface comes packed with a host of new features, including data-logging and graphing, with the ability to generate comprehensive reports that can be exported and shared via in-built cloud connectivity, according to the company.

Fit for heavy-duty applications, it comes with a rugged IP68 designed casing, with attached stylus pen.

Luke Dawson, Managing Director at SafeGauge, said: “We are thrilled to be a part of IMARC 2023 and share our latest innovations with industry professionals. SafeGauge is dedicated to transforming the landscape of heavy vehicle maintenance, and our wireless testing solutions are a testament to our commitment to safety, efficiency and innovation.”

By eliminating the need for technicians to work in close proximity to operational heavy vehicles (inside the machine footprint) through the use of such tools, SafeGauge says it ensures both the safety of technicians and the efficiency of maintenance procedures.