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British Gypsum set to expand Komatsu Joy lithium-ion battery fleet at Barrow mine

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British Gypsum’s Barrow-upon-Soar gypsum mine in the UK, part of Saint-Gobain, is looking to expand its use of Joy battery haulers following the initial deployment of two lithium-ion haulers from Komatsu, IM heard during a technical session at the SME MineXchange Conference and Expo, in Phoenix, Arizona, recently.

“The operation has been running two of these 18 short ton (16.4 t) payload battery haulers, BH18ACs, for just over nine months, with the units replacing 16 short ton diesel DBT ‘Ram Car’ vehicles,” Jerry Davis, Principal Engineer at Komatsu, said during his presentation ‘Case Study on the benefits of implementing the lithium-ion battery powered haulage in underground mining’.

“Komatsu has manufactured 820 battery haulers to date (the majority being with lead-acid batteries), with 15 of these lithium-ion battery versions,” Davis said. “This is set to expand to 29 lithium-ion battery units in the near term.”

Two of these lithium-ion haulers are now at the Barrow-upon-Soar mine. These are capable of mining seams of 1.45 m and represent some of the first lithium-ion battery models of their kind to have been delivered in the UK. British Gypsum said previously that it would replace a third diesel hauler with a battery-powered unit this year.

The BH18AC is the first lithium-ion battery hauler in soft-rock mining in Europe and, Komatsu Mining says, is designed to boost productivity with 75% faster charge time, and much lower maintenance versus traditional lead acid technology. “Brushless AC-traction motors drive each front wheel independently and are designed to deliver maximum torque,” the company says. “Your operators enjoy excellent steering, smooth operation and strong performance on steep inclines. Regenerative braking enhances control on descents. When conditions require extra traction, operators can hold down a button on the joystick to engage the trailer wheels for all-wheel-drive.”

The Joy lithium-ion battery charging option is capable of approximately two hours from discharged to full charge with no cool down period needed. At the Barrow-upon-Soar mine, it is currently using the haulers with a battery swapping mechanism.

At the Barrow-upon-Soar mine, British Gypsum is currently using the haulers with a battery swapping mechanism

The two new haulers have been tested on surface and underground in the room and pillar gypsum operation. They have been in commercial operation since mid-2023.

Davis said the operation was still awaiting feedback on operating cost and productivity comparisons, but the two vehicles had already achieved vehicle availability of approximately 100% (compared with the diesel-equivalent circa-70%). The Joy battery haulers had also averaged a 6-m advancement in 12 loads, compared with the diesel-equivalent’s 16 loads.

“In addition to the third unit, the mine operator is also considering replacing its existing cable-tethered loaders with battery haulers”, Davis added.

For Komatsu, meanwhile, the company is looking to continue product specific development within its Komatsu Mine Analysis Platform to aid asset management, productivity improvement solutions, operational support, application engineering, product development and warning systems.

Sakatti-FutureSmart Mining

Anglo American highlights next FutureSmart Mining advances at Woodsmith, Sakatti

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Anglo American has provided its latest sustainability performance update, highlighting a number of technological advancements the company is looking to take at its in-development Woodsmith polyhalite mine in the UK and its exploration asset, Sakatti, in Finland.

Anglo American says it has an integrated approach to sustainability in project development, helping secure its ability to deliver responsible long-term growth in future-enabling metals and minerals.

The company is moving towards its goal of carbon neutral operations by 2040, evolving its pathways as it progresses, learns and as technologies develop.

At the end of 2022, its Scope 1 and 2 emissions were 21% below the peak levels of 2019 – a significant reduction that, Anglo American says, reflects its transition to 100% renewable electricity supply across its South America operations, with Australia to follow in 2025.

In southern Africa, it is working in partnership with EDF Renewables to build a 3-5 GW renewable energy ecosystem of wind and solar generation capacity, designed to tackle its largest remaining source of Scope 2 emissions and support energy reliability and grid resilience while catalysing broad socio-economic opportunities.

While Scope 3 emissions reduction is largely dependent on the decarbonisation of Anglo American’s value chains and the steel industry, in particular, it is progressing towards its ambition to halve these emissions by 2040.

Tom McCulley, CEO of Anglo American’s Crop Nutrients business, provided several references to Quellaveco, Anglo American’s most technologically-advanced mine that uses automation, a remote operations centre and high levels of digitalisation, when looking at its FutureSmart Mining™ plans at Woodsmith, a 5 Mt/y operation that could ramp up to 13 Mt/y.

McCulley, who also led development of Quellaveco, said Woodsmith will be developed as a benchmark for sustainable mining. This includes plans for the mine to be a low carbon, low water and low waste operation, with no tailings generation and with a minimum impact design.

“We hope this can show a way of how mining can be done in the future,” McCulley said of this approach at Woodsmith.

When it comes to Sakatti, Alison Atkinson, Projects & Development Director, said the development could end up being “our next greenfield project”.

The project is a rich multi-metal deposit with not only copper, nickel and cobalt resources, but also platinum, palladium, gold and silver.

“High concentrations of metal combined with consistency of the mineralisation between the boreholes make Sakatti a unique deposit,” Anglo American says of the project. Its resources are estimated to be sufficient for mining operations to last more than 20 years.

Atkinson said Sakatti is being designed as the next generation of FutureSmart Mining, building on what it has learned from Quellaveco and Woodsmith, particularly when it comes to ensuring there is minimal surface footprint and “using technology and innovations to deliver even better sustainability outcomes”.

She added: “Sakatti is set to be a remotely operated, low carbon-underground mine with an electric mining fleet using technology and mining methods that will create zero waste and enable high degrees of water recycling, contributing to a sustainable supply of critical minerals.”

The company also sees the potential to use sorting technologies for coarse particle rejection and material recovery opportunities.

South Crofty pre-con, ore sorting test work implies improved project economics, Cornish Metals says

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Cornish Metals Inc has received results back from TOMRA Sorting GmbH that indicate X-ray Transmission (XRT) sensor-based sorting could be a viable option for its South Crofty tin project in the UK.

The feasibility study on South Crofty, a iconic former producing copper and tin mine with first documented production history dating back to 1592, is advancing on schedule with a substantial amount of the study completed, Cornish Metals said. The mine was the last tin operation in Cornwall to close in 1998.

Metallurgical test work and heavy liquid separation (HLS) pre-concentration test work provided “excellent results”, the company said.

Conducted on samples from the 2023 metallurgical drill program across five mineralised zones (No. 4 Lode, No. 8 Lode, Roskear B/D Lodes, North Pool Zone and Dolcoath South), it represented the majority of the potential production areas in the first six years of the proposed mine life, according to Cornish Metals.

The XRT work came back with a 55% mass rejection and less than 3% metal loss (-50 mm – +15 mm size fraction), while the HLS testing saw a 50% mass rejection and lesss than 5% metal loss (-15 mm – +0.85 mm size fraction).

The XRT ore sorter test work of bulk composite samples was completed by TOMRA Sorting GmbH, with the HLS test work of bulk composite samples completed by Wardell Armstrong International.

Cornish Metals said: “The test work results confirm the upgrading potential of South Crofty mineralisation and enables continuation of the process design optimisation work to reduce the size of the mineral processing plant and materially lower capital costs, operating costs and environmental footprint.”

Richard Williams, CEO and Director of Cornish Metals, said the company expected the mineralisation at South Crofty to respond well to XRT ore sorting, but these results exceeded “our most optimistic expectations”.

He added: “We expect this result will have a positive effect on the project economics, allowing for lower power consumption and a smaller process plant and therefore lower capital and operating costs.”

In addition to ore sorting test work, the following feasibility study components have also been completed:

  • Headframe structural modelling and refurbishment;
  • Schedule and costing for the refurbishment and recommissioning of New Cooks Kitchen and New Roskear shafts;
  • Televiewer investigations and geotechnical rock testing to confirm known historical structural and rock mass property data;
  • Conceptual numerical modelling of the proposed underground mining methods and stope designs. Back analysis supports historical operating data. Ground conditions and excavation stability are expected to be very good;
  • Phase 1 of the metallurgical testwork program (mineralogy, physical competency, characterisation and gravity response test work). The gravity response results are very good and confirm previous operational results;
  • Concept engineering on paste backfill options and sighter test work; and
  • Ground investigations for the new mineral processing plant.

The following dtudy components are currently underway:

  • Mineral processing plant design, layout and capital cost study, incorporating the results of the metallurgical test work program reported today and potential future throughput expansions;
  • Underground mine design and optimisation using the latest South Crofty resource estimate published in September 2023;
  • A mine ventilation study, underground infrastructure design and hoisting analysis;
  • A feasibility study-level engineering design for the paste backfill plant;
  • Hydrogeology, environmental, social, marketing and closure studies; and
  • AMC Mining Consultants has been appointed to independently review and compile the feasibility study with initial gap analysis and site visits completed.

Volvo CE welcomes Indonesia delegation to Motherwell rigid hauler facility

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The Volvo Construction Equipment (Volvo CE) factory in Motherwell, UK, recently hosted a group of visitors from Indonesia who toured the facilities and the R60 rigid dump truck (RDT) on show.

The event, led by Volvo CE’s Erwin Budi, Head of Key Accounts for Indonesia, and Luciano Suetugo, Head of Product Marketing for Haulers and Loaders in Region Asia, saw a delegation of Volvo CE representatives, dealers, and customers from Indonesia travel to Scotland to visit the Volvo CE rigid hauler factory and get some personalised experience of the new R60.

Hendro Sugito, Aftermarket Director at Indotruck Utama, the Volvo CE dealer for Indonesia, joined them. Two customers were also in attendance, both of whom already operate a fleet of Volvo RDT machines: M Yunus Anis, Operational Director at Hasnur Riung Sinergi, and Edi Suryadi, COO at Prima Sarana Gemilang, which currently operates 35 units of R60D machines and is in search of replacement units to upgrade its non-Volvo fleet, according to the OEM.

The trip started with a manufacturing plant tour and inspected the R60 on the test pad. On day two, there was a visit to a nearby job site to see an R60 in action, and had a chance to enjoy the smooth ride of the R60. Following this, both dealer and customer representatives traveled back to Indonesia, while Budi and Suetugo enjoyed two days of intensive product training on the R60. For this, they were joined by Volvo CE colleagues from Region Europe, Region North America and Region Latin America.

Budi said: “Our customers and dealers found the trip highly valuable. There have been many updates and investments at our rigid hauler factory and it was good for everyone to see those. We strengthened our relationships and boosted our knowledge of the R60, so it was a very worthwhile trip. The R60 has great potential in Indonesia and offers many advances over the previous R60D, including a new engine, transmission, and suspension.

“We can’t wait to welcome the first units into our country.”

The R60E, the successor of the R60D, introduces a range of new features and design improvements, setting a new standard of reliable and high-performing rigid haulers, according to Volvo CE. The model boasts a more powerful engine, delivering increased power and torque for tackling demanding tasks. The new generation transmission shift control ensures smoother and more precise shifting, while the updated adaptive control of the retarder system enhances braking efficiency, the company says. The operator environment has also been upgraded with a modern control panel, offering intuitive access to functions along with overall improved ride comfort.

(Pictured left to right: M Yunus Anis, Paul Douglas, Hendro Sugito, Drew Watson, Johncraig Savage, Craig Shaw, James Gibson, Edi Suryadi, Nick Love and Luciano Suetugo in front of the new R60)

WAE to open new facility in Oxfordshire focused on zero-emission, off-road solutions

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Fortescue Future Industries says it is significantly expanding its battery and electric powertrain production operations in the UK with the announcement of an additional state-of-the-art facility in Oxfordshire.

Fortescue Chairman, Andrew Forrest, said the expansion is part of Fortescue’s commitment to grow its British presence through the recent integration of British manufacturers WAE (formerly Williams Advanced Engineering).

“With Fortescue’s investment, British engineering will be at the cutting edge of the green energy economy with WAE’s battery systems providing world leading technology to the entire global industrial sector,” Dr Forrest said.

Following entry-into-force of the Australia-UK Free Trade Agreement, Fortescue will open a new state-of-the-art site in Banbury, Oxfordshire, significantly expanding its UK manufacturing capability, supplying advanced batteries and electric powertrains globally.

The new location will be focused on production of a wide range of zero-emission products for the off-road sector including trucks and trains. It will form part of a new global business aimed at driving decarbonisation in all fields of economic activity, while building sovereign capabilities in emerging technology.

The factory will cover over 13,500 sq.m in total and employ over 120 highly-skilled engineers, technicians, apprentices and graduates, with recruitment for the industrialisation program starting now, FFI said.

The integration follows Fortescue gearing up to meet growing global demand for the development, manufacture and supply of advanced electrification technology solutions to the off-highway sector.

The new Banbury facility will operate alongside Fortescue’s other Oxfordshire facilities including the Kidlington factory, which will open later this year. The Banbury site will be a purpose-built facility focusing primarily on manufacturing of heavy industry, electric/zero-emission powertrain systems. It will offer automated assembly for battery modules and packs, assembly of power conversion and power systems, as well as truck and train production support.

The first prototype build is targeted for July/August 2023 with the first mining haul truck module due for completion in August 2023.

The site will officially open in 2024 and will create job opportunities across all levels, including apprentices and graduates, acting as showcases for a future rollout by WAE of further global high-tech manufacturing hubs.

Carlton Power aims to supply Imerys and Sibelco with green hydrogen

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Carlton Power says it has signed partnership agreements for the Langage Green Hydrogen project to supply hydrogen fuel to two international mining and materials companies: Imerys and Sibelco.

Both companies have clay mining operations within 8 km miles of the Langage site. Sibeclo’s Cornwood operation and Imerys’ Lee Moor operation both produce kaolin, mainly for the brick ceramics and tiles industries.

These agreements follow last month’s announcement that the Langage Green Hydrogen project in Devon, England, had been shortlisted by the UK Government for financial suppor.

Both Sibelco and Imerys plan to cut their greenhouse gas emissions over the next decade, and the transition away from fossil fuels to hydrogen is an important lever in their sustainability strategies. Carlton’s 10 MW hydrogen hub project at Langage, earmarked to enter operation in 2025, will help the two companies achieve their sustainability goals, Carlton Power says.

Ben Uphill, Director Operations at Sibelco, said: “The hydrogen scheme at Langage fits well with our drive to use greener fuel alternatives. With our site only a few kilometres away from the proposed hydrogen production facility, it seems an ideal concept to be involved with, and it’s good to hear greener energy being produced locally, securing energy supply. China Clay has been mined in the area for hundreds of years, and Sibelco plan to be in the area for many years to come.”

Mark Hewson, UK Hub Director at Imerys Minerals, said: “Imerys will reduce its greenhouse gas emissions by 42% by 2030, from the base-year of 2021. Our UK operations are committed to carbon emission reduction and one of the important strands of our strategy is the use of hydrogen to replace natural gas in our calcining operations. As such, the partnership agreement with Carlton Power in their Langage project is very important and will facilitate our transition from natural gas and consequently the reduction in our carbon emissions.”

Eric Adams, Hydrogen Projects Director at Carlton Power said: “We are delighted that Sibelco and Imerys, both major mining companies with operations across Devon and Cornwall, will work with Carlton Power to enable Langage to supply green hydrogen to their operations. Their move gives a strong and positive signal to other high-energy users in the West Country to make the switch. Following the development of our initial 10 MW project at Langage, we hope to increase its capacity to allow more companies – in industry, manufacturing and transport – to decarbonise their operations.”

The green hydrogen produced at Langage Green Energy will be supplied by an underground pipeline to Cornwood (Sibelco, pictured) and Lee Moor (Imerys Minerals).

Subject to reaching final agreements on the Langage project with the UK Government and a financial investment decision, Carlton Power is aiming to start construction onsite before the end of the year. Langage secured planning consent from South Hams Council in 2022.

Anglo American continues SBR-led shaft sinking progress at Woodsmith

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While Anglo American continues with its detailed technical review of the Woodsmith polyhalite project in the UK, shaft sinking activities at the asset continue to progress, the company confirmed in an investor update today.

The project was acquired by Anglo American in 2020 with the purchase of Sirius Minerals. Since then, Anglo American has been working on refining the development pathway and overall production potential of the asset.

In an investor presentation today, the company outlined physical progress on the site, explaining that shaft sinking for the circa-1.6-km deep service shaft had progressed to the circa-265-m level. It also said the mineral transport shaft, which it is working on with Redpath Group as sinking contractor, had reached the circa-230-m level of a planned 321-m depth.

Regarding horizontal development, it added that the 37-km mineral transport tunnel – which will connect to the mineral transport shaft – had reached the 20-km development mark with tunnel boring machine technology.

The Woodsmith project overview includes the sinking of production and service shafts with 6.75-m diameters – having depths of 1,594 m and 1,565 m, respectively – and the 37-km-long concrete-lined tunnel containing a conveyor belt, which transports the polyhalite ore from Woodsmith mine, near Whitby, to the Mineral Handling Facility, on Teesside, for processing and shipping.

Both the service shaft and production shaft at Woodsmith are being sunk using Herrenknecht’s Shaft Boring Roadheader technology, which has previously featured on the Jansen potash project in Saskatchewan, Canada, where it excavated two 8-11 m diameter blind shafts down to circa-1,000-m-depth and the Slavkaliy-owned Nezhinsky potash project, where it ended up breaking shaft sinking records under the guidance of contractor Redpath Deilmann on a project to sink two 8-m diameter shafts (one to 750-m depth and one to 697-m depth).

The first cut for the service shaft was made in July 2021, with Anglo American and Redpath Deilmann – which is now leading the sinking project as shaft sinking contractor – restarting sinking activities on this shaft earlier this year.

In the same investor presentation issued today, Anglo American said it planned to start sinking in the production shaft in the March quarter of 2023.

While the ongoing review takes place, Anglo American confirmed it had approved $800 million of capital expenditure for Woodsmith next year, focused on shaft sinking and other critical infrastructure as part of its phased approach to the asset.

Stephen Pearce, Finance Director of Anglo American, said on Woodsmith: “As we have said for some time, we are improving the project’s configuration to ensure we realise the full commercial value over the expected multi-decade asset life. This will extend the development schedule and the capital budget, compared to what was anticipated prior to our ownership, and so potentially impact our carrying value of Woodsmith for accounting purposes at the year end.

“Looking ahead, we are even more positive today about the prospects for Woodsmith and its potential to become a high margin, major contributor to our diversified product portfolio given the outstanding nature of the resource and the premium pricing upside we expect to realise for Poly4 – the highly effective, low carbon fertiliser we will produce.”

EPC-UK’s rock-on-ground services team heading to Hemerdon tungsten-tin project

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EPC-UK says its full rock-on-ground services will soon begin work at the Hemerdon tungsten-tin deposit in Devon, England, as part of a new contract it has secured.

The company’s work will begin in 2023 and will enable operator, Tungsten West Ltd, to benefit from EPC-UK’s skilled level of drilling and blasting expertise as it sustainably extracts specific critical minerals, it says.

The reopened Hemerdon mine comprises the world’s third largest tungsten mineral resource, with a recently-released mining plan envisaging restarting production during the first half of next year.

In terms of mining, Hemerdon will aim to process 2.1 Mt of ore in year one, 2.6 Mt in year two, before ramping up to steady-state production of 3.5 Mt throughput in year three. This targets WO3 in concentrate production of 2,200 t, 3,000 t, 3,900 t, and tin in concentrate production of 320 t, 430 t and 600 t in years 1, 2, and 3 respectively.

In advance of EPC-UK’s rock-on-ground service commencement on site, it has agreed a program of early investment in the Tungsten West project, which has allowed us to fully understand the operation’s requirements and meet the project’s needs, including, among other things, the use of the latest equipment.

This will see the company deliver new Epiroc drilling rigs fitted with autosampler capabilities for drill returns.

Explosive supply to site will also benefit from EPC-UK’s latest smart truck technology supported by the full Vertex software package, which can incorporate drone gathered data and GPS capabilities to refine and improve blast performance, assess against incremental changes in design and subsequently optimise results for customers, the company says.

In terms of digital services, EPC-UK plans to use its digital techniques and engineering expertise, together with subsequent blasting operations, to enable the most efficient ore extraction to realise the most value possible, it said.

Ben Coppock, General Manager Blasting and Explosives at EPC-UK, explained: “We’re keenly anticipating our delivery start date at Hemerdon and look forward to realising results from our joint agenda with customer, Tungsten West. Our business ethos, commitment to safety and levels of expertise are aligned, and we will work successfully and sustainably to meet our mutual greener goals.”

James McFarlane, Managing Director of Tungsten West, said: “Tungsten West has full confidence in EPC-UK as a drilling and blasting rock-on-ground provider. The preparations the team has already put in place in advance of contract work commencing is impressive and demonstrates complete customer focus and a commitment to achieving leaner operations. The reopening of the Hemerdon Mine and its promise to bring sustainable economic activity back to the area is a significant development and we anticipate the results that EPC-UK and Tungsten West will deliver.”

Worley receives PM & EPCM work at Anglo American’s Woodsmith mine

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Engineering firm Worley has been awarded a contract for program management services and engineering, procurement and construction management (EPCM) to support Anglo American’s Woodsmith project in the UK, the mining company has confirmed.

Worley, in tandem with other contractors, is being tasked with delivering a polyhalite mine for its client Anglo American.

The project includes the sinking of production and service shafts with 6.75-m diameters – having depths of 1,594 m and 1,565 m, respectively – and a 37-km-long concrete-lined tunnel containing a conveyor belt, which transports the polyhalite ore from Woodsmith mine, near Whitby, to the Mineral Handling Facility, on Teesside, for processing and shipping.

In Anglo American’s half-year results, released earlier this year, the company outlined that major critical path components had continued to progress to its updated plan at Woodsmith.

“[Our] ongoing technical review confirmed there are several improvements to modify design to bring it up to Anglo American’s safety and operating integrity standards and optimise value for the long term,” it said.

The company acquired Woodsmith when it took over Sirius Minerals in 2020.

Tungsten West makes EPCM progress at Hemerdon as TOMRA XRT ore sorters hit the road

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Tungsten West has named Fairport Engineering Limited as its engineering, procurement and construction management (EPCM) contractor at the Hemerdon tungsten-tin project, in the UK, as well as confirmed it was soon expecting to receive seven X-ray Transmission (XRT) sensor-based ore sorters from TOMRA.

Since successfully listing on the AIM Market of the London Stock Exchange, Tungsten West has been advancing the development of Hemerdon, which is one of the most advanced mining projects in England and is expected to be a key future global supplier of tungsten and tin.

Hemerdon is, Tungsten West says, the third largest tungsten resource globally, as well as being a previously producing mine that was operational from 2015-2018. Tungsten West purchased the Hemerdon Mine in 2019, and has since completed a bankable feasibility study that demonstrated an extensive reserve of approximately 63.3 Mt at 0.18% W and 0.03% Sn, as well as 37.4 Mt of saleable aggregate material. The company estimates that the life of mine is currently 18.5 years with the opportunity to extend this through future investment.

On top of the ore sorters, Tungsten West said the rest of the long-lead items had been ordered and were scheduled for delivery within the company’s timetable. It plans to recommence mining this year.

The upgrade and refurbishment of the existing processing plant at Hemerdon is centred around the optimisation of the existing concentrator circuit as well as the introduction of a new crushing and screening circuit that will then feed into a new XRT ore sorting stage. These upgrades will streamline processing, minimise plant downtime and improve recovery rates, according to the company.

After significant test work, Tungsten West engaged TOMRA to supply the seven units that are required to treat the run of mine throughput. This consists of six duty and one standby units. Orders and deposits for these units were placed in 2021 and the units have now been delivered to the UK and await final transfer to Hemerdon where they will be installed in the front end of the processing plant.

On top of this, six new screens and 11 vibrating pan feeders have been ordered from Vibramech of South Africa at fixed prices. These will replace the existing large screens, which caused the low frequency issues, and were a key contributor to plant downtime under Wolf Minerals – the previous owner of Hemerdon. Delivery is expected in the June quarter of 2022.

Max Denning, Tungsten West CEO, said: “We are extremely pleased with progress at site, particularly the onboarding of Fairport Engineering to undertake the detailed design and construction of the project. We are looking forward to working with Fairport as we move towards restarting full production at Hemerdon, with a substantially improved processing route, through the introduction of XRT ore sorting and upgraded processing equipment. The company has assembled a strong projects and operations team, and we remain confident in our progress.”