Tag Archives: Newmont Goldcorp

ICMM looks to align mining industry on cleaner, safer vehicles

When the International Council on Mining and Metals (ICMM) launched its Innovation for Cleaner, Safer Vehicles (ICSV) program just over a year ago, some industry participants may not have realised how much progress could be made so quickly by taking a collaborative approach.

The ICMM has proven influential across the mining industry since its foundation in 2002 in areas such as corporate and social governance, environmental responsibility, and stakeholder relations, yet it has rarely, until this point, engaged directly as an industry group with original equipment manufacturers (OEMs) and service providers.

Close to 12 months after being established, it’s clear to see the program and the council itself has been successful in bridging a divide.

It has been able to corral a significant portion of the mining and mining OEM market players into a major industry discussion on core focus areas set to dominate the sector for the next two decades.

Now 27 of the world’s leading mining companies and 16 of the best-known truck and mining equipment suppliers are collaborating in a non-competitive space “to accelerate the development of a new generation of mining vehicles that will make vehicles cleaner and safer,” the ICMM says.

The ICSV program was created to address three of the most critical safety, health and environment performance issues in the ICMM’s mission towards zero harm and decarbonisation. Achieving this goal would involve the industry introducing and adopting the next generation of equipment to respond to the challenges.

More specifically, the program aims to:

  • Introduce greenhouse gas emission-free surface mining vehicles by 2040;
  • Minimise the operational impact of diesel exhaust by 2025; and
  • Make collision avoidance technology (capable of eliminating vehicle related collisions) available to mining companies by 2025.

In all three, it seeks to address the industry’s innovation challenge of ‘who motivates who’ or the chicken and egg analogy, according to Sarah Bell, Director, Health, Safety and Product Stewardship for the ICMM.

“You can imagine a mining company saying, ‘we can’t adopt technology that doesn’t yet exist’ or an OEM saying, ‘we can’t invest in development because we’re getting mixed market signals’. This is, of course, why this program has been set up in the way it has,” she told IM. “Bringing both the mining company and OEMs together, they have been able to work through these normal innovation challenges and align on defining the direction of travel and critical complexity to be solved for each of the ambitions set.”

High-level participation

The list of companies the ICMM has been able to involve in this program is impressive.

It is being guided by a CEO advisory group of six; three from the mining community – Andrew Mackenzie (CEO, BHP), Mark Cutifani (CEO, Anglo American) and Nick Holland (CEO, Gold Fields) – and three from the mining equipment supply side – Denise Johnson (Group President of Resource Industries at Caterpillar), Max Moriyama (President of the Mining Business Division at Komatsu) and Henrik Ager (President of Sandvik Mining and Rock Technology).

On the mining company front, ICMM membership makes up around 30% of the total metal market share, with some 46% in copper, 27% in gold and 42% in iron ore. Participating OEMs and third-party technology providers, meanwhile, include the three majors above, plus Cummins, Epiroc, Wabtec Corporation (formerly GE), Hexagon Mining, Hitachi Construction Machinery, Liebherr, MacLean Engineering, MTU, Modular Mining Systems, PBE Group, Nerospec, Future Digital Communication and Miller Technology.

Bell says the high-level participation builds the “widespread confidence” needed to accelerate investment in these three key areas”, while the ICMM’s focus on the leadership side of the technology integration equation and change management has proven “absolutely key”.

She clarified: “This collaboration operates under anti-competition and anti-trust rules. Our role is to convene the parties, motivate action and promote solutions.”

The program offers a “safe space for the OEMs and members to work openly in a non-competitive environment”, she added, explaining that the aim is not to come up with “preferred technologies”, but define the “functional and operational pathways required to meet the ambitions set”.

Vehicle interaction (VI)

Some of the ambitions look easier to achieve than others.

For instance, collision avoidance and proximity detection technology has made huge strides in the last decade, with the ICMM arguing its 2025 target is like a “sprint”, compared with the “10,000 m race” that is minimising DPM underground by 2025 and the longer-term aim to introduce GHG-free surface mining vehicles by 2040.

“There are regulations that require implementation of collision avoidance and proximity detection technology by the end of 2020 in South Africa,” Bell said. This will undoubtedly provide a catalyst for further developments to speed up.

The ICSV program is also leveraging the work of the Earth Moving Equipment Safety Round Table (EMESRT) in its development of fundamental functional/performance requirements for operators and technology providers.

These requirements were updated and released by EMESRT in September and are known as ‘PR5A’.

Credit: Hexagon Mining

Bell delved into some detail about these requirements:

“The EMERST requirements are designed around a nine-level system that seeks to eliminate material unwanted scenarios such as – equipment to person, equipment to equipment, equipment to environment and loss of control,” she said.

“The fundamental change with this newly released set of functional requirements by EMESRT is that the mining industry users have defined the functional needs for levels 7-9 (operator awareness, advisory controls, and intervention controls). That stronger level of collaboration hasn’t necessarily been there.”

EMESRT and its guidelines have been given an expanded global platform through the ICMM’s ICSV, with the program, this year, providing the convening environment for users and technology providers to help finalise these updated requirements, according to Bell.

With all of this already in place, one could be forgiven for thinking the majority of the hard work involved with achieving the 2025 goal is done, but the working group focused on VI knows that while OEMs continue to retrofit third-party vehicle collision and avoidance systems to their machines the job is not complete.

“Let’s think about the seatbelt analogy: you don’t give buyers of vehicles a choice as to whether they want a seatbelt in their car; it just comes with the car,” Bell said.

“At the moment, by design, vehicles don’t always have this collision and avoidance systems built in, therefore there is a big opportunity for collaboration between OEMs and third-party technology providers.”

Underground DPM goals

“The DPM working group have recognised that, in the case of the DPM ambition, ‘the future is already here, it’s just unevenly distributed’,” Bell said.

“Bringing together the OEMs and the mining companies this year through the ICSV program has enabled the group to explore the variety of existing solutions out there today,” she added.

These existing solutions include higher-tier engines, battery-electric equipment, tethered electric machinery, fuel cell-equipped machines for narrow vein mining and solutions to remove DPMs and other emissions from the environment like Johnson Matthey’s CRT system.

And, there are numerous examples from North America – Newmont Goldcorp at Borden, and Glencore and Vale in Sudbury – South America – Codelco at El Teniente Underground – and Europe – Agnico Eagle Mines at Kittilä (Finland, pictured) – to draw from.

Bell also mentioned some examples from Australia where regulatory changes have seen miners apply existing technology and carry out changes in their work plans and maintenance practices to minimise DPM emissions.

Haulage and loading flexibility, battery charging and mine design have all come under the spotlight since these new generation of ‘green’ machines have emerged, so achieving the 2025 goal the ICSV stated is by no means a foregone conclusion.

“There remains more work to do in achieving diesel-free vehicles underground,” Bell said.

The interested parties are aware of this and the program’s DPM maturity framework is helping miners and OEMs plot a course to reaching the target, she explained.

“The DPM maturity framework promotes existing solutions available today that would enable a mining operation to reduce their DPM emissions to a level that would meet the ambition level (shown as Level 4 – transition to zero),” she said.

These frameworks are useful for starting a “change conversation”, Bell said, explaining that mining companies can assess within their organisations where they currently sit on the five-level chart and discuss internally how to move up the levels to meet their goals.

These same frameworks look beyond minimising “the operational impact” of DPM emissions underground, with Bell explaining that Level 5 of the maturity framework involves “non-DPM emitting vehicles”.

GHG-free surface mining vehicles

Even further in the distance is the longer-term target of introducing greenhouse gas emission-free surface mining vehicles by 2040.

This ambition, more than any other, is less clearly defined in terms of technological solutions across the industry.

While battery-electric solutions look like having the goods to reach DPM-free status underground with expected developments in battery technology and charging, the jury is still out on if they can create a GHG-free large-scale open-pit mining environment.

The world’s largest battery-electric haul truck – eMining’s 63-t payload eDumper (pictured) – may have proven its worth at a Ciments Vigier-owned quarry in Switzerland, but the world’s largest open-pit mines require a solution on another scale altogether.

As Bell said: “There is a lot of work to do to develop batteries at scale for surface fleet that suit the different operating conditions.

“That’s a key point because that lends itself to the fact that we don’t want one solution; we will need multiple solutions. We don’t want to stifle innovation; we want to encourage it.”

ICMM member Anglo American has hinted that hydrogen power could be one solution, and the miner is looking to show this next year with the development of its hydrogen-powered 300-t payload haul truck.

There has also been in the last 18-24 months a mini renaissance of trolley assist projects that, ABB’s Gunnar Hammarström told IM recently, could, in the future, work in tandem with battery-powered solutions to provide a GHG-free solution.

The ability for industry to pilot and validate technology options like this “within the boundaries of anti-competition” is crucial for its later adoption in the industry, Bell said.

She said a key enabler of industry decarbonisation is access to cost competitive clean electricity, which would indicate that regions like South America and the Nordic countries could be of interest in the short and medium term for deploying pilot projects.

It is this goal where the industry R&D spend could potentially ramp up; something the ICMM and the ICSV is aware of.

“For the OEMs and mining companies to effectively minimise capital expenditure, optimise R&D expenditure and reduce the change management required by the industry, there needs to be a careful balance of encouraging innovation of solutions, whilst managing the number of plausible outcomes,” Bell said.

In terms of encouraging the development of these outcomes, carbon pricing mechanisms could provide some positive industry momentum. Vale recently acknowledged that it would apply an internal carbon tax/price of $50/t when analysing its future projects, so one would expect other companies to be factoring in such charges to their future mine developments.

Industry-wide GHG emission caps could also provide a catalyst. In countries such as Chile – where up to 80% of emissions can come from haul trucks, according to ICMM Senior Programme Officer, Verónica Martinez – carbon emission reduction legislation could really have an impact on technology developments.

Forward motion

While 2019 was a year when the three working groups – made up of close to 50 representatives in each work stream – outlined known barriers or opportunities that might either slow down or accelerate technology developments, 2020 will be the year that regional workshops convened to “encourage first adopters and fast followers” to move these three ambitions forward take place, Bell said.

A knowledge hub containing the previously spoken of maturity frameworks (delivered for all three groups) will allow the wider industry outside of the ICMM membership to gain a better understanding of how the miner-OEM-service provider collaboration is working.

Bell said the ICMM already has a number of members testing these group frameworks on an informal self-assessment basis to understand “how they are being received at an asset level and feedback insights to the group in an effort to understand how we may portray an industry representative picture of where we are today”.

Such strategies bode well for achieving these goals into the future and, potentially, changing the dynamic that has existed between end users and suppliers in the mining sector for decades.

Bell said: “The feedback that we got from OEMs is that mining companies had completely different objectives, but they have now greater confidence that we are aligned on the direction of travel towards the ambitions set.”

Howden’s Eleonore ventilation on demand solution wins award

Newmont Goldcorp’s Eleonore gold mine was recently awarded the “Eureka Prize” from Écotech Québec, for a ventilation on demand solution that reflects the Quebec mine’s strive towards leveraging clean technologies.

Nearly 250 stakeholders in the cleantech ecosystem were present at the event.

Éléonore produced some 360,000 oz of gold in 2018 from the underground Roberto deposit. Ore is mined from four horizons using sill and stope techniques, then processed onsite using a conventional circuit that includes crushing, grinding, gravity, flotation and cyanidation.

The award received was for the Ventilation on Demand (VOD) system from Howden VentSimTM CONTROL implemented in the Newmont Goldcorp – Eleonore mine. The benefits of this solution are the energy efficiency and air treatment, according to Howden.

“Newmont Goldcorp – Eleonore is proud to recognise the teamwork that has enabled a project such as VOD to continually improve our energy efficiency performance, while maintaining the health and safety of our workers,” Sophie Bergeron, Executive Director Newmont Goldcorp – Eleonore, says.

To date, there has been a 43% reduction in mine heating costs, a drop of 56% in underground ventilation electricity costs and a remarkable 73% decrease in the cost of surface ventilation electricity, as detailed in the full case study, Howden said.

”While these figures are impressive, the full potential savings will grow even greater when the mine reaches full capacity,” Howden added.

Newmont Goldcorp delivers the hat-trick with Ahafo mill expansion

Newmont Goldcorp has announced that the Ahafo mill expansion in Ghana achieved commercial production, on schedule and within budget for around $175 million.

Combined with the Subika Underground operation, which was successfully completed in November 2018, the mill expansion is expected to increase Ahafo’s average annual gold production to between 550,000-650,000 oz/y through 2024, while lowering life-of-mine processing costs.

“The Ahafo mill expansion represents our third profitable project delivered on schedule and within budget in 2019, along with the Tanami power project in Australia and the Borden mine in Canada,” said Tom Palmer, President and Chief Executive Officer. “The mill expansion is expected to generate an internal rate of return of more than 20% at a $1,200 gold price, while also extending profitable production at Ahafo through at least 2029.”

Features and benefits of the mill expansion include:

  • Increasing mill capacity at Ahafo by more than 50% to nearly 10 Mt/y with the addition of a crusher, grinding mill and leach tanks to the circuit;
  • Adding annual gold production of 75,000 to 100,000 oz/y for the first five full years beginning in 2020;
  • Accelerating efficient processing of ore from stockpiles and the Subika underground mine, as well as harder, lower-grade ore from Ahafo’s existing pits; and
  • Supporting profitable development of Ahafo’s highly prospective underground resources, which continue to demonstrate considerable upside.

Ahafo is expected to deliver record production this year – with improved costs – driven by higher grades from the Subika open pit, a full year of mining from the Subika underground mine and the completion of the Ahafo mill expansion.

Commercial production began at Ahafo in 2006, and, in 2018, the operation sold 436,000 oz of gold at all-in sustaining costs of $864 per ounce.

Eldorado Gold weighing BEVs, vertical haulage tech for Lamaque expansion

With production at the Lamaque gold mine, in Quebec, Canada, now in full swing, Eldorado Gold is looking at a potential expansion underground that could involve the use of battery-electric vehicles, or vertical haulage with conveyors, according to Chief Operating Officer Paul Skayman.

Speaking to IM last week, Skayman said the company, following the declaration of commercial production at Lamaque earlier this year, was in the process of working on a preliminary economic assessment (PEA) to expand Lamaque. This study will evaluate increasing throughput from an average of some 1,800 t/d to 2,500 tpd, with a resultant boost in annual average production to 170,000 oz, from close to 130,000 oz.

The expansion PEA is expected to be completed by the end of year and, subject to the results, a prefeasibility study on the expansion will begin, due for completion in the second half of 2020.

While the expansion is over a year away, Skayman said the deepening of the mine could see the company look at the potential for either battery-powered haulage or vertical haulage with conveyors. This would see the mine install a decline to access the orebody, as opposed to sinking a shaft.

Skayman said the provincial government offered incentives to employ such technologies at mine, while power was relatively inexpensive, “so, we are in the right place to be looking at this”. Indeed, Agnico Eagle Mines has employed a Rail-Veyor system at its Goldex mine in Quebec, while MacLean Engineering has delivered at least one battery-powered unit to an underground gold operation in the province.

Eldorado is not currently running any battery-powered units, instead, waiting for the technology to mature to a point where machines can run for a whole shift and the charging infrastructure has been proven, according to Skayman. He said the company was watching projects such as the recently opened Borden mine in Ontario to see where miners were pushing the “technology envelope” in the electrification arena.

Eldorado has other underground operations across the globe, but Skayman said Lamaque was the prime candidate for the use of battery-powered equipment.

“[This technology] is probably more likely to be used at Lamaque than our operations in Europe; Lamaque is a vertical stacked set of lenses and the deeper sections we know of go down to 1,500 m,” he said. “We’re nowhere near that in Turkey at Efemçukuru, which is relatively mature. We eventually get down to deeper sections at Olympias, but nothing like the depth at Lamaque.”

Newmont Goldcorp’s ‘all-electric’ Borden mine reaches new milestone

Close to a week after cutting the ribbon on its Borden mine, near Chapleau, Ontario, Newmont Goldcorp has achieved commercial production safely, on schedule and within budget at the ‘all-electric’ mine.

The mine features state-of-the-art health and safety controls, digital mining technologies and processes, and low-carbon energy vehicles – the latter provided by the likes of Sandvik and MacLean Engineering.

Tom Palmer, Newmont Goldcorp President and Chief Executive Officer, said: “Consistent project delivery and disciplined operational execution remain cornerstones of our business and are central to creating long-term shareholder value. Borden joins the next generation of Newmont Goldcorp mines and leverages our leading land position to anchor this new gold district in Ontario.”

At 1,000 sq.km, Borden’s land package represents additional exploration upside as the deposit remains open at depth in a favorable mining jurisdiction, according to the miner. Ore from Borden is processed at the existing mill at Porcupine, in Timmins, profitably extending operations at the gold mining complex.

In recognition of Borden’s contribution to the future of safe and sustainable mining, the Canadian and Ontario governments each granted C$5 million ($3.8 million) towards electrification of the mine.

 

AusGroup subsidiary to work on Newmont Goldcorp’s Boddington gold mine

AusGroup’s MAS Australasia subsidiary has been awarded a five year contract to carry out maintenance at Newmont Goldcorp’s Boddington gold mine in Western Australia.

MAS will use the existing local presence and infrastructure it has in the southwest Of Western Australia and provide specialist mechanical, scaffolding and rope access maintenance services to the mine, AusGroup said.

Additionally, the scope requires MAS to provide a range of trade-qualified technicians to support Newmont Goldcorp’s mechanical maintenance and general shutdown services over the contract term.

Shane Kimpton, CEO and Managing Director, said: “This contract cements MAS’ reputation as a bespoke maintenance services provider to a diverse portfolio of customers.

“Our value proposition and service offering extends beyond LNG and construction projects and this is an excellent example of where MAS can bring innovation and significant value.”

Boddington produced 709,000 oz of gold for Newmont Goldcorp last year and is currently undergoing a stripping campaign in the South Pit in order to reach higher-grade ore.

El Nino arrives early for Premier, Nevada Gold Mines

Premier Gold Mines says processing of ore has commenced from the El Nino gold mine at the joint venture South Arturo mine, in Nevada, USA.

South Arturo is located in the Carlin Trend, and is a joint venture between Premier (40%) and Nevada Gold Mines (60%), a joint venture company owned by Barrick Gold and Newmont-Goldcorp with Barrick as the operator.

The El Nino mine was developed on-time and on-budget, with ore now being processed ahead of schedule, according to Premier Gold. Production is expected to ramp up in the second half of 2019, with a first gold bar pour having been held on September 26.

Premier said attributable gold production is estimated to meet the high end of its 5,000-10,000 oz guidance for the year and it expects that, owing to the high-grade ore at El Nino, South Arturo will have a positive effect on cash flow for the company.

Ewan Downie, President and CEO of Premier, said: “We are excited to once again realise the benefits of South Arturo, increasing the company’s production profile with an anticipated reduction in overall operating costs. Premier continues to benefit from the stellar performance of our partner, Nevada Gold, and its demonstrated ability to consistently execute on schedule.”

In the second half of 2019, surface and underground drilling will resume in an effort to continue delineating and expanding mineralisation at El Nino. El Nino is a high-grade underground deposit situated down plunge of the Phase 2 pit, where mining was concluded in 2017. Pre-stripping of the Phase 1 open-pit project, a second mine being constructed at South Arturo, is ongoing with a target of production in the second half of 2020. Work is also continuing to optimise heap leach material with a potential future decision to proceed with the development of a heap leach facility on the property, the company said.

Surface haulage automation is being tested out at South Arturo, where ASI Mining has successfully completed a proof of concept (POC) utilising five haulage units “that have delivered over 5.5 Mt faster than any other similar POC in the industry”, Barrick Gold said last month.

Newmont Goldcorp wins mining gold again for ESG practices

Newmont Goldcorp has made it onto the Dow Jones Sustainability World Index (DJSI) for the 12th consecutive year, also being named the top global gold mining company.

Newmont, which added Goldcorp to its mining mix earlier this year, was the first gold company named to the index in 2007. It was recognised for its leading environmental, social and governance (ESG) performance as the Metals and Mining sector leader by the index for a fourth year in a row in 2018.

Tom Palmer, President of Newmont Goldcorp, said: “Leading ESG performance not only helps us manage risk and create value for our stakeholders, it is also an indicator that our business is well-managed and positioned for long-term success.

“It is thanks to our employees’ strong commitment to our values that we are able to consistently demonstrate leading sustainability performance in our sector. While we are honoured to be included again on the DJSI, we recognise there is always room for improvement and will continue working to drive our performance to higher levels.”

DJSI evaluates companies based on a corporate sustainability assessment (CSA) conducted by Swiss-based RobecoSAM, a sustainability asset management, analysis and investment firm. The CSA evaluates 20 financially material sustainability criteria across economic, environmental and social dimensions.

Newmont Goldcorp said: “The DJSI’s results provide comparable and actionable data that allows investors to integrate ESG factors into their investment decisions, while identifying those companies that are well-positioned to address current and future sustainability-driven challenges and opportunities.”

The company said it ranked in the 100th percentile for leading performance in the following areas:

  • Economic: corporate governance, risk and crisis management, and materiality;
  • Environmental: management of water-related risks; and
  • Social: Labour practices, corporate citizenship, and talent attraction and retention.

Manjit Jus, Head of ESG Ratings, RobecoSAM, said: “We congratulate Newmont Goldcorp for being included in the DJSI World and the DJSI North America indices. The SAM Corporate Sustainability Assessment has again raised the bar in identifying those companies best-positioned to address future sustainability challenges and opportunities.”

World Gold Council formalises ESG standards for miners

The World Gold Council (WGC), the market development organisation for the gold industry, has announced the launch of its Responsible Gold Mining Principles.

The principles are a framework that set out expectations for consumers, investors and the downstream gold supply chain as to what constitutes responsible gold mining, the WGC said.

Working with the world’s leading gold mining companies – the WGC’s members – the council has set out the principles it believes address key environmental, social and governance (ESG) issues for the gold mining sector.

The principles focus on 10 key areas. Under the governance section, this includes ethical conduct, “understanding our impacts” and the supply chain. Social concerns include safety and health, human rights and conflict, labour rights and working with communities. The remaining three in the environmental bracket are environmental stewardship, biodiversity, and water, energy and climate change.

It is the World Gold Council’s aim that the Responsible Gold Mining Principles become a credible and widely recognised framework through which gold mining companies can provide confidence that their gold has been produced responsibly, the WGC said, acknowledging that ESG considerations are becoming increasingly important to consumers.

Companies implementing the Responsible Gold Mining Principles will be required to obtain external assurance from a third party, independent assurance provider. This will provide further confidence to purchasers of gold that the gold they buy is responsibly mined and sourced, it said.

Gary Goldberg, CEO of Newmont Goldcorp, who oversaw this initiative on behalf of the Board of the World Gold Council, said: “Adherence to strong ESG principles should be a key part of any responsible gold mining business and, as such, the members of the World Gold Council have collaborated, along with key industry stakeholders, to develop the Responsible Gold Mining Principles.

“Given the Members’ sustained focus on improving ESG performance, the formalisation of the Responsible Gold Mining Principles is a natural evolution of our daily working practices. It is my hope that these principles will be widely adopted, not only by member companies, but by the industry more broadly.”

Terry Heymann, Chief Financial Officer of the WGC, said it was the council’s aim that the principles reinforce trust in gold and the gold mining industry.

“Consumers, investors and the downstream gold supply chain will be able to know, with confidence, that their gold has been responsibly sourced,” he said. “The principles incorporate feedback from more than 200 organisations and individuals over two rounds of consultation and are designed to support the efficient operation of the gold market.”

Orica turns wireless blasting dream into a reality at Europe’s deepest mine

In Europe’s first demonstration of wireless blasting, Orica has enabled First Quantum Minerals’ (FQM) Pyhäsalmi underground mine in Finland to recover ore it previously thought inaccessible.

Orica’s WebGen™ 100, the first truly wireless rock blasting system, has been used in trials at the zinc-copper-pyrite mine since September 2018, with FQM, to date, carrying out five blasts.

Since the invention of the safety fuse by William Bickford in 1831, there has been three revolutions in blast initiation methods – electric detonators (1930s), shock tube (1980s) and electronics (~2000s). Every new initiation method development has increased the safety, precision and possibilities of initiating blasts.

The new Safety Integrity Level 3 certified WebGen system could end up being the fourth revolution in this line-up, Orica believes.

Still in its infancy with, as of August, more than 250 blasts fired using wireless initiation, the WebGen technology has already led to the development of several new mining techniques such as Temporary Rib Pillar (TRP), Temporary Uppers Retreat Pillar, Reverse Throw Retreat, Longitudinal Transverse Retreat and Pre-Loaded Retreat that would not be viable or possible without wireless blasting technology.

WebGen comprises the following components:

  • WebGen primer and accessories – including the high explosive Pentex™ W booster, i-kon™ plugin electronic detonator, the Disposable Receiver (DRX) and the encoder controller;
  • Transmission system – including transmitter, antenna and transmitter controller; and
  • Code Management Computer (CMC) – including the unique global blast and arm codes.

The system achieves wireless blasting through very low frequency magnetic induction (MI) signals communicated to the in-hole primer, with the special site-specific group ID, arm and firing codes embedded in the MI signals. The system eliminates the lead wires of conventional initiation systems, thereby also eliminating the ‘hook-up’ process at the blastholes.

The operation works as follows: The i-kon plugin detonator plugs into the DRX, energising the device and initiating a self-test. After passing the self-test, the device can be encoded with the blast code and the delay timing. The booster is attached after encoding the device. At this stage the WebGen primer is ready to be placed into the blasthole.

The transmitter controller – a magnetic induction system connected to an antenna – sends the arming signal to the transmitter. Once the arming process is successful the firing window is presented to the blaster.

The CMC is the data hub of the system and supplies the identification and firing codes as well as the mine specific codes. Orica explained: “It culminates in the ready to fire file for transmission.”

Game changer

With the elimination of lead wires, it is possible to pre-charge a full stope (eg sub-level caving mining method) and fire every ring when required without sending personnel back to the dangerous brow area to connect lead lines, Orica says. “Misfires related to damaged wires are eliminated and primers can be fired regardless of any dislocations of blasthole and/or charge.”

The Ernest Henry mine, in north-eastern Australia, engaged Orica in 2016 to perform a demonstration of sub-level caving using WebGen. The mine wanted to reduce the time spent by personnel at the brow of the cave. With the use of WebGen they were successful in pre-loading the stope production rings and eliminating the need to return to the brow for hooking up.

At Newmont Goldcorp’s Musselwhite mine, productivity and ore recovery were the main drivers for looking into wireless blasting. Together with Orica, Musselwhite developed the TRP mining method where a temporary pillar is used to withhold backfill while the second mass blast (i-kon electronic detonators) of the stope is mucked out.

Orica explained: “Once the stope is mucked out, the TRP is fired remotely and the ore can be recovered.”

With this method the mine established a 93% reduction in dilution, increase in mucking of 27% and a two-week saving in time per stope, the company said.

FQM – Pyhäsalmi

In March 2018, a team of Orica Technical Services Engineers commenced preparations and planning for the first wireless demonstration in Europe with the FQM Pyhäsalmi mine, in Finland, the deepest mine in the continent.

At the time, the mine was scheduled to close in September 2019; most of the stopes had been mined out and the remaining stopes and pillars were becoming increasingly challenging to mine. Orica said: “Pyhäsalmi had developed a system to mine the stranded pillars, but this was incurring considerable time and costs. Pyhäsalmi mine acknowledged that WebGen 100 could be a solution for the problems in retrieving remaining ore in difficult areas.”

As a first stop, the Orica team of blasting specialists had to assess if the WebGen system would successfully function in Pyhäsalmi mine. “Before firing the WebGen shot it was important to investigate if the system would work in the mine and what the maximum signal reach would be for both the quad loop and cable loop antenna,” the company said.

Signal strength testing provides positive confirmation of coded signals being received through the mine and also validates if there are any parts of the mine where the system has a reduced range.

A smaller antenna and a larger antenna were tested.

Pyhäsalmi experiences occasional sulphur dust explosions and, therefore, personnel are not allowed to be underground while blasting, Orica said. As a result, blasting takes place at the end of the shift after the shift explosives supervisor checks everyone has vacated the mine.

Initial signal testing with the smaller antenna validated the system was working with a range of at least 200 m. Further signal testing was performed using the larger antenna.

It was validated the system could send and receive signals from the production level to the furthest stope, which was 450 m away, Orica said.

After assessing the MI signal test results, it was decided it would be more convenient to use the smaller antenna.

In September 2018, the EMEA WebGen team returned to Pyhäsalmi mine for the first wireless blast in Europe. The final three rings of stope 18b10-11 on Level 1,175 were selected for the demonstration blast.

On September 4, 2018, at 22:00, the first wireless blast in Europe was fired without any issue.

Since the introduction of wireless blasting, Pyhäsalmi mine has fired a total of five blasts in challenging areas.

For one of the wireless blasts, a stope would not be accessible after the first blast, but, as the stope could be pre-loaded with wireless detonators, the mine could blast and produce 4,000 t of extra ore that otherwise would have been sterilised.

Katja Sahala, Mine Planning Engineer, FQM Pyhäsalmi mine, said she saw the WebGen wireless system as helping operations in several applications such as when ore needs to be left behind to support pillars, or where there is weak rock, or fill and selective mining is required.

She said: “In uphole charging, you need to work close or even below an open face during drilling and blasting. If it’s possible to drill and charge an entire stope before the first hole is fired, then safety will surely be improved.”

Orica said wireless blasting is a new and exciting technology that eliminates the use of cumbersome and complex wiring hook-ups while having the accuracy of an electronic detonator. It has already enabled safer work methods and mining techniques that increase recovery, productivity and efficiency, according to the company.

It concluded: “Many technical and regulatory challenges will be faced by wireless blasting, but it is a fundamental step in the automation of the explosives charging and blasting process. With the first WebGen blasts at FQM Pyhäsalmi mine, wireless blasting is no longer a dream in Europe, but a reality.”