Tag Archives: Sandvik Mining and Rock Solutions

Sandvik to boost battery output with higher-capacity systems, standardised processes

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Sandvik’s higher-capacity batteries – ones that could eliminate one battery swap every shift in some mining applications – will soon start to be installed across the company’s line of battery-electric vehicles, according to Brian Huff, Vice President of New Technologies for the Load and Haul Division within Sandvik Mining and Rock Solutions.

Speaking to IM on the side lines of the OEM’s Innovation in Tunneling event in Tampere, Finland, Huff said the last of the previous generation of batteries were being manufactured in Camarillo, California, with the new generation battery packs lined up for future installations.

The company announced the introduction of these batteries for BEV loaders and trucks back in May, claiming they could deliver 36% more energy in the same envelope as the previous generation.

At that point, the company said they would be in production from the December quarter of 2023 and equipped as standard on all new Sandvik BEV loader and truck orders.

In addition to 36% longer runtime, customers can expect a lower cost per amp-hour compared with current-generation Artisan® battery packs. The increased capacity also improves charge acceptance, enabling faster downhill speeds and better efficiency.

Sandvik-Camarillo-BEV

Purpose-built for underground mining and designed and manufactured in-house by Sandvik, the new battery maintains the modularity and ruggedness of the existing pack and features significant design improvements.

Revamped housing and increased rigidity enhance structural strength, enabling the battery to better withstand shock and vibration. Laser-welded terminals provide a stronger connection with lower resistance, reducing energy loss and heat while improving efficiency and safety.

Top and bottom cooling plates improve cooling performance to slow cell degradation and extend life. Key design improvements also include better ingress protection against dust and moisture.

Brian Huff, Vice President of New Technology for the Load and Haul Division within Sandvik Mining and Rock Solutions

The next-generation LFP battery cells are fully encapsulated in a non-conductive potting material, increasing thermal conductivity and reducing the risk of overheating and short circuit. Sandvik has also redesigned its battery management system for improved reliability and function. This safety feature monitors every cell’s temperature and voltage to ensure everything is within operational range.

Huff said the new battery modules and accompanying largely automated assembly process would enable the company to significantly scale up its offering from current capacity.

“The batteries will be assembled in a much more controlled environment than before, which will inherently lead to less human error throughout the process,” he said. “Laying this foundation will enable us to scale our battery production capacity with limited additional resources.”

Camarillo will be the first to benefit from the new assembly line, yet Huff said the in-construction plant in Malaysia will also benefit from the same disciplines to maximise productive capacity from the off.

Earlier this year, Sandvik said it was establishing a new production unit in Malaysia for manufacturing underground loaders and trucks to answer growing demand for its BEVs. Equipment production was slated to begin in the December quarter of 2023 following factory upgrades and other site improvements. It was expected to have an annual manufacturing capacity of 300 loaders and trucks and 500 battery cages by 2030.

Sandvik unveils second battery-electric concept surface drill rig

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As decarbonisation efforts accelerate across the surface mining sector, Sandvik has unveiled its second battery-electric concept surface drill rig.

The battery-electric vehicle is the first in its size class, capable of drilling DTH holes up to 229 mm in diameter, and blending the autonomy of battery with the continuous endurance of power cable, Sandvik says.

Electric surface rigs have long depended solely on a tethered cable as the power source. With its second battery-electric surface concept, Sandvik says it is showcasing the latest technology advancements to push the potential of more sustainable surface drilling.

“With the industry shifting towards intelligent, autonomous and emission-free equipment, surface drill rigs need to be reinvented,” Lauri Laihanen, Vice President, R&D, Surface Drilling Division, Sandvik Mining and Rock Solutions, said. “This new concept rig elevates electric surface drilling.”

The intelligent DTH rig’s battery pack provides power for up to one hour of drilling or up to seven hours of tramming. The battery is primarily intended for tramming and drilling individual holes while the bulk of a pattern is carried out via power from its 180-m tethered cable.

“The battery means greater freedom and flexibility and more efficient use of time, as the rig can drill immediately while the cable is being set up,” Laihanen said.

Sandvik designed the cable setup to be as effortless as possible. The cable tightens itself automatically according to the direction the rig is moved and is wound on a single layer, which enables a thinner, more manageable tether, it says. An operating voltage as high as 1,000 V also helps enable a lighter cable.

While Sandvik’s latest pioneering concept introduces battery-electric operation to a larger size class DTH drill, its subsystems and technologies are all tried and tested, mine-proven and energy-efficient, according to the company.

Sandvik introduced its smaller top hammer battery-electric concept surface drill rig in May 2022, developed to support more sustainable drilling in construction applications.

“Testing of the smaller concept with our construction customers has been very successful and produced valuable feedback,” Laihanen said. “We’ve learned a lot, and now it’s time to apply these learnings to mining, which has its own unique challenges.”

Sandvik will test its latest concept drill rig in real-world surface mining environments in close collaboration with mining customers.

“We need to identify the challenges, learn from them and share the knowledge,” Laihanen said. “The shift towards more sustainable mining will change the entire operating environment, and with the learnings from our latest concept rig, we can produce more value for our customers on their decarbonisation journey. We’re excited to write the next chapter in surface drilling together.”

Sandvik recognises OEM ‘first’ with AutoMine for Underground Drills introduction

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Sandvik Mining and Rock Solutions is introducing AutoMine® for Underground Drills, a cutting-edge tele-remote solution that, it says, enables operators to remotely and simultaneously control and supervise multiple automated Sandvik underground drills, increasing efficiency, safety and overall productivity in mining operations.

With AutoMine for Underground Drills, Sandvik Mining and Rock Solutions has become the first OEM to introduce a unified traffic management system for drills, loaders and trucks, according to the company.

Jouni Koppanen, Product Line Manager, Underground Automation at Sandvik Mining and Rock Solutions, said: “Sandvik’s holistic approach to integrate drills, loaders and trucks into the AutoMine system will set a new standard for underground mining efficiency. AutoMine for Underground Drills is another milestone in our commitment to revolutionising out customers’ mining operations. This tele-remote system redefines underground drilling autonomy and safety standards.”

The new offering is available for Sandvik longhole drills (DL) series machines, offering three levels of teleremote operations: single drill, drill fleet and machine fleet. Operators have the flexibility to choose between operating from an AutoMine chair or console station, depending on which offering level best suits their operational requirements.

The AutoMine for Underground Drills teleremote system includes advanced tramming capabilities, allowing seamless control and coordination of drills, loaders and trucks operating in the same area with sophisticated traffic management, the company added.

Prioritising safety, AutoMine incorporates an enhanced Access Protector System. This safety feature is designed to prevent personnel from entering the machine area while the system is operating in automation mode or remote mode. In addition, it also has an advanced traffic management system that enables operators to easily control the traffic flow of multi-machine operations and handle complex operating situations, resulting in greater flexibility and mining output.

Sami Anttila, Product Manager, Longhole Production Drilling at Sandvik Mining and Rock Solutions, said: “We have developed this system to offer our customers a deeper integration and cooperation in between the underground drills, the loading and hauling machines and especially the AutoMine environment. This means added value through improvements in machine and fleet flexible utilisation in remote operation.”

Sandvik’s history of providing proven underground solutions with automation for loading and hauling dates back to 2004. Today, more than 1,000 underground and surface units operate worldwide at more than 100 customer sites, underlining Sandvik’s commitment to delivering reliable and innovative AutoMine solutions for mining.

Sandvik to build largest US mining facility to date in Elko, Nevada

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To better serve its mining customers in the United States, Sandvik is investing more than $50 million in the company’s largest US facility to date, in Elko, Nevada.

Construction will begin before the end of this year and the new facility is expected to open in the March quarter of 2025. It will cover 14 acres (5.67 ha) and replace the company’s existing Elko office and separate warehouse.

The $51.4 million investment includes larger warehouse and workshop facilities. The new 31,250-sq.ft (2,900-sq.m) warehouse will nearly triple the size of the existing Elko warehouse, while the workshop will grow from 17,800 sq.ft (1,650 sq.m) to 25,000 sq.ft (2,325 sq.m). The two-story facility will also include 13,800 sq.ft (1,280 sq.m) of office and training space.

Designed with circularity, waste reduction and carbon footprint top of mind, the completely new facility will include dedicated infrastructure to support battery-electric vehicles, a training centre, welding areas, a painting booth and a simulator area. The facility will accommodate the current 85 employees with additional capacity for training and growth.

Victor Tapia, Vice President, Sales Area USA, Sandvik Mining and Rock Solutions, said: “This facility will be our largest of several branches serving the US mining market. We are creating a new, modern work environment for our people and, in turn, for our customers, who operate in rapidly changing market conditions with fast-evolving technology. The new building will facilitate increased collaboration opportunities and enable us to better serve our customers for years to come.”

Sandvik secures SSAB fossil-free steel for loaders and trucks

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Sandvik Mining and Rock Solutions and SSAB have signed a letter of intent to secure fossil-free steel for use initially in the production of Sandvik’s loaders and trucks.

SSAB aims to deliver fossil-free steel to the market on a commercial scale during 2026, and the letter of intent ensures Sandvik secures its required volumes within the company’s production capacity. As a fossil-free partner to SSAB, Sandvik can also apply for early fossil-free sample deliveries of, for example, a prototype frame, loader bucket or truck box to be used in a demo or concept product.

“Sustainability is at the core of our business strategy,” Mats Eriksson (pictured on the left), President of Sandvik Mining and Rock Solutions, said. “As the market demand for fossil-free products increases in the years ahead, this partnership will enable us to offer our mining customers solutions with a drastically reduced CO2 footprint.”

Johnny Sjöström (pictured on the right), Head of SSAB Special Steels, said: “We’re excited about supporting the sustainability journey of our customers in the mining industry. Fossil-free steel has the same high quality as traditional steel but with but with hardly any environmental impact. It will help to reduce our customers’ carbon footprint and offer a competitive advantage in the market.”

SSAB delivered the first steel made of hydrogen-reduced iron in 2021. The steelmaker works with iron ore producer LKAB and energy company Vattenfall as part of the HYBRIT initiative to develop a value chain for fossil-free iron and steel production, replacing coking coal traditionally needed for iron ore-based steelmaking with fossil-free electricity and hydrogen. This process virtually eliminates carbon dioxide emissions in steel production.

Sandvik adds DD322i and DD422i development drills to Digital Driller simulator line-up

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Sandvik Mining and Rock Solutions has introduced two new virtual training simulators to its Digital Driller™ offering. The new Sandvik DD322i and Sandvik DD422i Dual Controls simulators feature the latest software and advanced training methods for underground drill operators and maintenance teams, the company says.

Digital Driller simulators offer an authentic, safer learning environment for operator training across all underground hard-rock drilling applications. The virtual training environment means operators can be trained on site with zero damage to equipment or the mine environment, and no impact on machine availability.

Tiia Pohjanlehto, Sandvik Underground Drilling Training Academy Manager, said: “With the addition of the DD322i and DD422i Dual Controls models, we’re enabling even more comprehensive operator training. We can tangibly improve efficiency, productivity and safety, as operators can be trained before the drill rig arrives, on site, or during rig maintenance.”

The new DD322i and Dual Controls simulators complement the introduction of Sandvik DD322i and DD422iE Dual Control development drills to the Sandvik underground drilling portfolio in 2022.

Both new simulators retain the classic features of Digital Driller – such as total location flexibility, easy setup, customisable training courses and group learning – and now feature upgraded software for a more sophisticated and authentic operator experience, Sandvik claims.

The Dual Controls simulator, showcased earlier this year at the CIM Convention in Montreal, replicates the unique dual drilling control panel available for Sandvik DD422i and Sandvik DD422iE rigs, and can be further customised to include either one or two control panels during training, depending on the application. Operators can experience true multi-task operations from a single control panel, including bolting, boring and meshing.

The innovative Digital Driller simulators also offer environmental and sustainability benefits, with no rock tools or fuel consumed during training, zero damage to the rig or mine and zero harm to personnel, Sandvik says.

These simulators can be used across all competency levels, from product familiarisation and basic training for novice operators, to developing and refreshing the skills of experienced operators. Trained operators receive a formal qualification in Beginner, Professional or Drill Master levels after each module has been completed, the company added.

De Beers taking major technology steppingstone at Venetia Underground

Automation, Comminution of minerals, Communications in mining, Diamond mining, Environmental, Explosives and blasting, IoT, Mine shafts and equipment, Mine ventilation, Mineral processing, Mineral project development, Mining equipment, Mining project news, Mining safety, Mining services, Mining software, Power supply for mines, Sustainable mining, Water management, , , , , , , , , , , , , , , , , ,

Making the transition from an open pit mine that has been operating successfully for 30 years to an underground operation that could become one of the most mechanised and automated in the world is not something that happens overnight.

De Beers Group embarked on the $2.3 billion underground expansion of its Venetia asset in Limpopo Province in 2012, in a move that represented the biggest single investment in South Africa’s diamond mining industry in decades.

Underground production began at the mine back in June this year, at a point when construction completion was estimated at 70%.

The introduction of autonomous mining systems performing multiple mining processes to deliver up to 6 Mt/y of kimberlite ore – for circa-4 Mct/y of diamonds – is now beginning, with a ramp-up process occurring over the next four years, according to Moses Madondo, Managing Director of De Beers Group Managed Operations.

“The technologies we are implementing – some of which are under development themselves – will be gradually phased in,” he told IM. “Where appropriate, we will take advantage of ‘proven’ technologies first to ease the change management process, before advancing to less mature technologies thereafter.

“The process should see us start operating areas of the mine in autonomous capacity by 2027.”

De Beers has engaged Sandvik Mining and Rock Solutions for its automated production machines, with the OEM delivering a 34-strong fleet made up of LHDs, ADTs, twin-boom drill rigs, roof bolters, cable bolters and production long hole drills. A further 12 units will be delivered in the future. These iSeries machines include 17- and 21-t payload LH517i and LH621i LHDs, 51-t payload TH551i ADTs, DD422i face drills, DS412i roof bolters, DS422i cable bolters and DL422i production drills.

Employee in the cab of one of the fleet of Sandvik machines

The underground mine will use sublevel caving to extract material from its K01 and K02 orebodies. Initially the ore will be hauled to surface using a combination of underground and surface haul trucks. As the operation matures, the hauling systems will transition to an automated truck loop in combination with vertical shafts for steady-state production.

Sandvik is also providing its AutoMine® system for the remote operation of loaders and trucks and its OptiMine® system for machine health monitoring, task management and location tracking.

Automation will be applied through a phased approach, beginning with manual operation and close monitoring of performance through data analytics. Automation will then gradually be introduced with the necessary training and experience in the operation and support of these technologies.

Madondo explained: “Our current fleet is made up of manually operated machines, which are optimised with automated task management. This process still requires an on-board operator, although many functions are automated.

“The next step would be autonomous machines, operated and overseen from surface, with our training centres already set up to deliver that.”

A pilot project to prepare the production team for the use of remote loading at the drawpoints and autonomous tramming to the tip is in the process of being established, with trials set for later this year and into 2024.

With sublevel cave mining, there is a risk of mud rushes and water ingress at drawpoints and remote loading will allow material to be loaded without putting operators at risk.

This pilot project will have a single loader operating under AutoMine Lite in a dedicated area on 46 Level that is isolated from other areas of the mine, with the machine controlled locally from a mobile tele-remote station just outside the autonomous operating area (ie not from surface).

An integrated operations centre on surface has been constructed and is in the final stages of commissioning.

Moses Madondo, Managing Director of De Beers Group Managed Operations

This is but a fraction of the emerging technology the company plans to employ at the mine, as Madondo highlighted.

“Of course, we will be integrating more technologies into the mix – digital mobility, data analytics, a cave management system, collision prevention, personnel alert systems, equipment location and tracking, production management through digital platforms, centralised blasting systems and digital twins,” he said. “All of these projects have people working on them to deliver our project objectives.”

For Madondo, the business case for employing such high levels of mechanisation and automation has only strengthened in the 11 years since the first shovel was placed in the ground for the underground project.

“This is a challenge with deep underground mining projects – they take a long time to develop and, in that period, technology and economics change,” he said. “It is, however, clear that mechanised mining allows you to take on these advanced technologies as the years go by.

“The investments are not just for technology’s sake. The business case must be built on our ability to improve safety and keep our people away from harm; as well as to make us more efficient and beat inflation, ensuring the margins we promised investors are realised.”

On the former, the company has partnered with Booyco Electronics on rolling out the South Africa-based company’s Level 9 – as defined by the Mining Industry Occupational Safety and Health (MOSH) organisation of South Africa – Booyco Electronics CWS850 collision prevention system at the mine.

“All of our Sandvik equipment is Level 9-enabled and we’re busy on this rollout,” Madondo said. “We’re already employing Level 7 (a system that warns pedestrians of their proximity to trackless mobile machinery) for this equipment. It’s now just a matter of getting to that new advanced level efficiently and safely.”

The company is also employing the Mobilaris Mining Intelligence platform for personnel location and situational awareness to help locate individuals in case of an emergency and notify them of incidents should they occur.

On the productivity side, the company is employing a cave management system to prevent overdrawing, Madondo says, linking the sub level caving mine plan with on-board LHD diagnostics and bucket weighing for efficiency and safety.

Process controller overseeing processing operations within the Venetia Mine

On top of OptiMine and AutoMine from Sandvik, the company is looking to integrate Howden’s Ventsim™ CONTROL system for monitoring, control and optimisation of underground mine ventilation in a ventilation on demand (VoD) application.

“We will gradually introduce VoD and Ventsim CONTROL as it allows us to 1) optimise the use of air and ventilation; and 2) retain the right condition and hygiene levels in the areas of the active mine,” Madondo said.

In an automated mining scenario, Ventsim CONTROL could potentially start ventilating an area of the mine in line with the expected arrival of the autonomous equipment, optimising the process and environment, and, as a result, reducing energy use.

Reaching the pinnacle

Also part of that discussion is decarbonisation – an area the company has already made significant progress on with its move underground.

“Transitioning from surface to underground has reset the energy balance,” Madondo said. “This has seen the site become far less reliant on energy from fossil fuel sources, with the big trucks and loaders from the pit replaced with smaller underground equipment and more electrical infrastructure.

“We predict by that, by 2030, 85% of all energy consumed will be electrical and only 6% will be diesel. That is a significant shift from the open-pit operation where nearly 85% of all energy consumed was from diesel.”

The company’s broader electrification work is currently in the review stage, but Madondo did provide some insight into the focus areas.

“We are looking at battery LHDs and trucks; we will consider trolley assist hauling loops and tethered electrical loading in some of the areas too,” he said. “It is all part of a progressive shift that will be integrated with the sourcing of renewable power for the mine.”

De Beers itself has set targets to become carbon neutral across its operations by 2030, Venetia Underground included.

The first electrification project the company is likely to embark on is a battery-electric retrofit of one of its light duty vehicles, Madondo said, explaining that this technology is relatively mature and comes with less infrastructure requirements due to the ability to charge the machines on surface.

“Our wider electrification plans are being influenced by the maturity of the technology; it may be more beneficial to wait until the adoption rate and learnings increase before we commit,” he added.

Even with the planned integration of such advanced technology at Venetia Underground, Madondo says De Beers still has some way to go to achieve the FutureSmart Mining innovation-led approach to sustainable mining that its parent company, Anglo American, advocates for.

“The pinnacle of De Beers mining expertise will probably be realised when we get to rollout our Diamond FutureSmart Mining, which ultimately is a mine design that we can use to develop future mines that make mining safer, more efficient, more sustainable and with a smaller environmental footprint,” he said.

“Of course, Venetia is certainly a steppingstone to that, but we will hopefully apply the learnings from Venetia for Jwaneng Underground (in Botswana) in the not-too-distant future. That could represent a different, more technologically advanced proposition where all processes are setup to benefit from the latest innovations.”

He concluded: “This will ensure we help create a healthy environment, that we catalyse thriving communities, and that we build trust as a corporate leader. We are shaping a future that creates shared value for all our stakeholders.”

Brauteseth Blasting continues expansion into South Africa with support of Sandvik drill rigs

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Based near Port Shepstone on the KwaZulu-Natal south coast, Brauteseth Blasting’s success has evolved into a national footprint – and beyond – with multiple drill rig acquisitions from Sandvik Mining and Rock Solutions bolstering its production capacity across South Africa and multiple industries, including mining.

In fact, remarks Sandvik Mining and Rock Solutions Account Manager Andre Blom, Brauteseth Blasting has acquired units from every Sandvik boom drill range in a single year.

“This included Leopard™ DI550 and Leopard DI650 down-the-hole (DTH) drill rigs from our Leopard range, the Pantera™ DP1500i and the Ranger™ DX800 and Ranger DX900i surface top hammer drill rigs,” Blom says. The two companies have built a strong partnership since 2005, when the first Sandvik rig was acquired by Brauteseth Blasting.

Brauteseth Blasting began mainly in the civil engineering sector and in quarrying, but has now moved decisively into surface mining as well. Clive Brauteseth, Managing Director since 1989, points to the geographic expansion now beyond KwaZulu-Natal and the Eastern Cape – into Limpopo, Mpumalanga, the Northern Cape and beyond South Africa into Zambia.

By this year, the number of Sandvik drill rigs acquired by the company over the years has reached almost 50, and more acquisitions are in the pipeline by the end of the year, Brauteseth says.

“We have built a strong relationship with Sandvik over my 35 years with the company,” he says. “We have some of the best equipment in the market, and keep it well maintained and up to date; this means continual investment in replacing plant regularly.”

He notes that the quality and performance of Sandvik drill rigs gives Brauteseth Blasting the uptime and reliability that its projects demand, backed up by the experience and skills of its stable and committed teams. The ongoing upskilling also ensures the latest technology investments are put to the most productive use in the field – to deliver the bottom-line results that keep customers loyal, it says.

Of Brauteseth Blasting’s acquisitions during 2021 into 2022, the Leopard range is designed for high capacity production drilling in medium-sized to large open-pit mining operations, while the Ranger DX800 and Ranger DX900i drill rigs serve mainly the construction and small mining sectors. In between, the Pantera DP1500i rig is a ‘cross over’ for applications in quarries and smaller open-pit mines.

With the experience of almost two decades of running Sandvik drills, Brauteseth believes Sandvik Mining and Rock Solutions has the edge in this market. This is important for the way that his company embraces new technology to help keep it a step ahead.

“When there is new equipment in the market, we are always interested in what it can do for our fleet capability and our customers,” Brauteseth says. “I really value Sandvik’s continuous innovation, and the way they listen to customers when pursuing those developments.”

Blom highlights the unique partnership between the companies, where Sandvik Mining and Rock Solutions provides solid OEM support to enable Brauteseth Blasting to remain self-sufficient operationally and technically. More drill rig acquisitions are in the pipeline for 2023, as the company’s growth trend only gathers strength.

Northern Star bolsters Sandvik fleet with Toro trucks and loaders, plus DD422i jumbo

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Australia-based gold miner Northern Star Resources has selected Sandvik Mining and Rock Solutions to supply 32 new pieces of mobile equipment for its Australian operations.

Northern Star operates several open-pit and underground mines across three gold production centres: Kalgoorlie and Yandal in Western Australia, and Pogo in Alaska, USA. The company will bolster its Sandvik fleet with 17 Toro™ TH663i underground trucks, 10 Toro LH621i underground loaders, four Toro LH517i underground loaders and a Sandvik DD422i development jumbo with dual control.

Loader and truck deliveries are planned to begin in September quarter 2023 and continue into June quarter 2025. The drill is scheduled to be delivered in the June quarter of 2024.

“This commitment underscores the partnership between Northern Star and Sandvik and reflects trust in our advanced, intelligent technology that helps make our customers more productive, more profitable and more sustainable,” Wayne Scrivens, Vice President, Sales Area Australia and New Zealand, Sandvik Mining and Rock Solutions, said.

The Toro TH663i trucks each have a 63 t carrying capacity and low overall equipment weight for high ramp speeds, Sandvik says. They come with Operator Speed Assist as a standard feature to automatically limit the top speed of the vehicle during level and downhill driving. The truck’s low weight, efficient engine technology and fast ramp speeds result in low fuel consumption per hauled tonne and overall reduction of CO2 emissions, according to the OEM.

The 17 t Toro LH517i loaders, Sandvik says, provide superior hydraulic power for fast bucket filling. A powerful drivetrain enables high-speed tramming and increased productivity, while long-life components, specifically developed for the rough underground environment, contribute to low cost per tonne.

The 21 t Toro LH621i loaders are engineered for rapid mine development and large-scale underground production. With superior hydraulic power for fast bucket filling and drivetrain power for high ramp speeds, this loader can quickly clear tunnel headings for rapid advance rates, according to the company.

Eldorado testing LTE-backed Newtrax ventilation on demand solution at Olympias

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Eldorado Gold has confirmed it is testing Newtrax’s environmental monitoring platform and ventilation on demand (VoD) solution at the Olympias mine in Greece.

Mine ventilation represents the single largest electrical load at the Olympias mine and, in response to the EU energy crisis and Eldorado’s own Energy and Carbon Management System, the company has been aggressively advancing VoD implementation at the Greek operation.

The benefits associated with VoD include:

  • Targeted air circulation and improved air quality as the working environment is upgraded as fresh air is distributed through the mine in a manner that ensures workers’ health and safety;
  • Right-sizing fans to provide the required volumetric flow rates (from a static to a dynamic and intelligent air supply leading to a reduction of the total required airflow within a mine);
  • Improving energy efficiency and power consumption – by reducing the total airflow, energy can be saved in disproportionately high amounts due to the cubic relationship between volume flow and fan power; and
  • Enabling the production and development activities at the lower levels of the mine.

To obtain the immediate benefits of VoD, the Olympias mine operations team implemented a manual solution during 2022, where the team adjusts ventilation fan operations each day based on the daily mine plan. As part of this, variable speed drives were applied to many of the fans to allow air flow adjustments to meet operational needs with minimum electricity consumption. This process is being carried out via the control room on surface, with a SCADA system used to disconnect fans that are not planned to be used during the day.

This transition saw ventilation fan consumption decrease from about 620 kWh/mth of electricity consumption per kW of installed fan capacity to about 377 kWh/mth of electricity consumption per kW of fan capacity, representing a 40% decrease in energy consumption, according to Simon Hille, SVP, Technical Services and Operations. At the end of 2022, the mine had 3.1 MW of installed ventilation capacity.

“This 40% reduction represents about 9,051 MWh/y of electricity savings and about 3,800 t/y of GHG emission reductions (utilising the updated emissions factor of 0.42 t CO2e/MWh),” he told IM.

While manual VoD has been very effective, automated VoD will further decrease energy consumption and eliminate the many worker hours required to implement VoD on a daily basis, according to Hille.

This is where the company brought in Newtrax, part of Sandvik Mining and Rock Solutions, to implement an automated VoD system.

The Olympias mine will be the first Newtrax installation utilising LTE as the communications medium versus low frequency radio (leaky feeder) utilised previously, according to Eldorado. LTE was installed in August 2022 with the help of Cosmote.

The automated platform will also leverage data from the existing Micromine fleet management system and RFID-based employee location tags provided by Newtrax. Ventilation will then be provided by surface fans with higher ventilation capacities.

Olympias already uses Accutron Technology to monitor air flow velocity and Trolex technology to monitor mine air quality, according to Hille.

In addition to the VoD benefits, the Newtrax technology will improve mine safety (mine evacuation and rescue) as well as improve productivity by allowing mine supervision to have a better understanding of resource locations for improved decision making, the company says.

“Technology and connectivity are the key parameters for VoD to operate effectively,” Hille said. “Automated employee and equipment geo-location is necessary as it helps adjust ventilation delivery to different areas by effectively shutting down entire areas and thus reducing the overall ventilation demands. This requires smooth connectivity with the LTE across the mine site.”

Last month, Newtrax installed five Bluetooth low energy (BLE) devices on select mobile machinery to test system connectivity. Once troubleshooting is complete and communication is established between the underground fans and Newtrax BLE devices, full-sized implementation will be considered with equipment procurement, installation and commissioning to be done by end of Q1 (March quarter) 2024.

On top of this, Eldorado Gold is evaluating non-diesel powered equipment for all new equipment purchases and, in some cases, as an alternative to equipment rebuilds.

“The mine ventilation benefits of equipment electrification are included in the evaluation of that equipment,” Hille said.