Tag Archives: Vale

SpectraFlow NIR technology helping Vale with iron ore analysis

Comminution of minerals, Environmental, Mine operation news, Mineral processing, Mining services, Steel and iron ore, , , , ,

Vale, one of the world’s biggest iron ore producers, has approved the SpectraFlow Crossbelt Analyzer for online measurement of iron ore material at its ports and mines, the technology provider says.

After a rigorous trial that tested the stability of the hardware and measurement accuracy of the analyser, SpectraFlow Analytics is now the chosen provider for Vale’s online iron ore analysis, it says.

Vale’s Guaíba Island Terminal (TIG) is a port that receives raw material from a large number of variable iron ore sources by train and loads the material onto ships for export. Global demand, local supply and heightening climate change and sustainability pressures necessitate stricter quality assurance and control measures from the world’s largest iron ore producer, SpectraFlow says. Also, as one of the largest logistics operators in Brazil, Vale has impetus to manage train and ship loading schedules with ever smaller margins for delay. Online analysis has the potential to address all these concerns through real time chemical and mineral analysis, according to SpectraFlow, which is providing its online near infrared (NIR) technology to the company.

Minute by minute measurements for iron and other key chemical constituents from an installed Crossbelt Analyzer were compared with sample measurements by Vale’s laboratory. Accurate moisture analysis is of particularly high importance at TIG, as there is risk of ships capsizing if the moisture levels are not strictly controlled.

“Fortunately for Vale, SpectraFlow’s online measurements of moisture and all other critical chemical constituents were found to be well within the strict delta limits set by Vale’s quality control protocol,” it said. “In fact the analyser’s measurements have already been used to eliminate unplanned stoppages at TIG, helping Vale reduce downtime and deliver value timeously. Now that the technology is proven, the SpectraFlow analyzer can also be used to blend material to reach optimum grade and gangue targets at the port and even sooner in the value chain, at Vale’s mines.”

The SpectraFlow online analyser measures dry raw material composition at key points in mining, processing and refining value chains. Usually placed over a conveyor belt, or in an airslide, the analyser can measure fine deviations in the moisture, grade or gangue composition of the material in real time. By using the measurements from the analyser that are exchanged directly with the control room PLC or from SpectraFlow’s database and monitoring user interface, bulk mineral, precious metal and cement producers can create automated control loops for quality control and assurance of their final product, the company says.

SpectraFlow’s summarised benefits of its online NIR analyser are:

  • The analyser is free of any radioactive sources, neutron generators or any hazardous components. This means the SpectraFlow analyser does not require any permits or licences regarding importation, operation or maintenance. This also means that the SpectraFlow analyser is completely safe, with maintenance able to be carried out by the plant personnel;
  • Real time, short acquisition time measurements of the complete flow of material gives the customer the opportunity to provide high resolution feed forward information to downstream processing or make value-based ore sorting control decisions on the material; and
  • The Crossbelt Analyzer reduces the need for frequent belt cuts or manual sampling of the material for quality control, and instead gives the user the user large amounts of accurate composition data for real-time feedback on upstream quality delivery like ore block control and stockpile blending.

SpectraFlow says it has installed more than 75 analysers in 28 countries worldwide.

Vale makes headway on low-emission iron ore briquette development

Environmental, Mineral processing, Power supply for mines, Steel and iron ore, Sustainable mining, , , , , , , , ,

Vale says it has successfully tested a new type of iron ore briquette, adapted for the direct reduction route, which will contribute to the decarbonisation of steel production.

The new type of briquette, which will support the steel industry’s efforts to meet emission reduction targets worldwide, emits about 80% less CO2 compared with pellets in its manufacture, abating the company’s direct and indirect emissions (Scope 1 and 2). The briquette can also be used as a charge for the blast furnace (BF-BOF).

Direct reduction is one of the routes used in steel production. It is considered cleaner than the blast furnace route as it uses natural gas instead of coke – an input obtained from coking coal – and, therefore, emits less carbon and other greenhouse gases (GHG).

The production of briquette meets the trend of the steel industry to increasingly adopt the direct reduction route, Vale says. Studies show that for every tonne of steel produced in the blast furnace, two tonnes of CO2 are emitted, while in direct reduction, carbon emissions fall to 0.6-1 t.

In recent months, Vale has stepped up development of a new type of briquette for this route. So far, seven experimental tests have been carried out at plants for different clients in the Americas. The tests, known as basket tests, have involved small quantities of briquette and pellets being placed side by side in baskets, which fed the reactors.

Rogério Nogueira, Vale’s Director of Product and Business Development, said: “With the development of this new type of briquette, Vale is taking another important step in its contribution to reducing emissions from the steelmaking chain through innovation, always in close collaboration with its clients and development partners.”

In one of the tests carried out, for example, the new product outperformed pellets in metallisation, reaching a metallic iron content of around 98%, while pellets reached 95%. This result indicates that the new type of briquette can improve the productivity of steel mill clients, Vale says.

The briquette also performed well in terms of disintegration. In one of the tests, for example, around 7% of fines were generated, against 14% with the use of pellets. The smaller presence of fine particles as a result of the disintegration facilitates the passage of the gas through the reactor, increasing productivity and reducing the consumption of this fuel, which contributes to reduced carbon emissions.

The next step in the development of the direct reduction briquette is to carry out industrial tests, which should begin in June, in a reactor of a client in North America.

Announced by Vale in 2021 after about 20 years of development, the briquette is produced from the agglomeration of iron ore at low temperatures using a technological solution of binders, which gives the final product high mechanical strength. Therefore, it emits less pollutants and GHG when compared with traditional agglomeration processes (pelletisation and sintering).

The briquette can substitute any direct load (sinter, granulates and pellets) in the steel mill furnaces, according to Vale. The substitution of the sintering stage in the blast furnace route is what allows the potential reduction of GHG emissions by up to 10%. This route is the most used worldwide, while direct reduction is more common in regions with abundant natural gas at competitive prices, such as the Middle East, North America and Argentina.

To be produced, direct reduction agglomerates (briquettes and pellets) require iron ore with a higher content, approximately 67% Fe, alongside low rates of contaminants such as silica and alumina. Agglomerates for blast furnaces can be produced with ore grades lower than 65% Fe.

Vale says it is working to increase its production of high-quality iron ore and expand its capacity to concentrate ore, which also raises the iron ore grade, enabling the company to meet demand from steelmakers for these products.

The company is building two 6 Mt/y briquette plants at its Tubarão Unit in Vitória, Espírito Santo, Brazil. Start-up of the first plant is planned for the end of the first half of the year, while the second should begin operations at the end of the year.

In addition, memorandums of understanding have already been signed with more than 30 customers to study the implementation of decarbonisation solutions, including the construction of briquette plants located on the premises of some customers.

Among the agreements signed, three aim to install Mega Hubs in Middle Eastern countries (Saudi Arabia, United Arab Emirates and Oman) to produce hot-briquetted iron (HBI) to supply both local and seaborne markets, with a significant reduction in CO2 emissions. At the hubs, Vale is expected to build and operate iron ore concentration and briquetting plants, supplying the feed for the HBI plants, which will be built and operated by investors and/or customers. Vale is also studying the creation of similar hubs in Brazil.

Iron ore briquette contributes to achieving Vale’s commitment of reducing its Scope 3 net emissions by 15% by 2035. The company also seeks to reduce its absolute Scope 1 and 2 emissions by 33% by 2030 and achieve neutrality by 2050, in line with the Paris Agreement ambition to limit global warming below 2°C by the end of the century.

Antamina, Barrick, BHP, Freeport, Gold Fields, Newmont, Teck and Vale form GeoStable Tailings Consortium

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Gold Fields Limited has announced a new consortium of eight global mining companies has launched a multi-year initiative to develop and implement new technological applications for managing tailings.

The GeoStable Tailings Consortium (GSTC) comprises Antamina, Barrick, BHP, Freeport-McMoRan, Gold Fields, Newmont, Teck and Vale, with external expert support provided by Dr G Ward Wilson of the University of Alberta.

The GSTC will study options to combine various blends of tailings with waste rock to create ‘geo-stable’ landforms that are stronger and more stable than conventional tailings deposition methods and are likely to reduce process water consumption. It will undertake a range of research and development activities, including laboratory testing, field trials and data analysis, and will collaborate to promote best practices in tailings and waste management and foster a culture of continuous improvement across the mining industry.

Martin Preece, Interim CEO of Gold Fields, said: “The management of our TSFs has as its ultimate goal zero harm to people and the environment through their full life cycle. This is in line with the Global Industry Standard on Tailings Management, the new tailings storage facility (TSF) benchmark to which all members of the ICMM are committed to conform to. Having stable TSFs is a critical element of this standard.

“There is significant mining industry interest in developing geo-stable TSFs, but there is still a lack of a sound research and development including testing protocols to assess, compare and validate the performance of different technical approaches across different mineralogical and operational situations. Gold Fields is therefore a willing participant in this consortium and playing our role in becoming part of the solution.”

The new GSTC initiative builds on the work of a group formed to advance geo-waste and eco-tailings research previously pursued by Goldcorp, which was acquired by Newmont in early 2019.

Novamera concludes in-field demonstration of surgical mining, backed by Vale and OZ Minerals

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Novamera says it has completed an in-field demonstration of its surgical mining technologies, sponsored by Vale, OZ Minerals and a leading global gold producer, with the results set to be presented shortly.

The in-field demonstration, completed in late 2022, took place in Baie Verte, Newfoundland, and highlighted the technical capabilities of the proprietary guidance tool, the operational impact of real-time data in a production setting and the economic potential of surgical mining, according to Novamera.

Surgical mining, powered by Novamera’s proprietary technology, could unlock trillions in currently uneconomic narrow-vein mineral deposits to meet the increasing demand for metals, while also supporting environmental, social and governance (ESG) targets, the company says.

The Canada Mining Innovation Council (CMIC) has been steering a industry consortium of mining companies to trial Novamera’s near borehole imaging tool at various project sites, including this latest trial.

Novamera’s proprietary hardware and software seamlessly combine with conventional drilling equipment, allowing mining companies to surgically extract deposits while minimising dilution, Novamera explains. Real-time data, machine learning and production analytics drive the ‘surgical mining cycle’ to make extraction of complex, narrow-vein deposits not only viable but highly profitable. A low capital expenditure solution requiring minimal mine development, miners have a flexible, scalable mining method that can help get into ore quickly with small-scale deposits.

Working together with conventional drilling equipment and operations, the solution generates circa-95% less waste and less than half the greenhouse gas emissions of selective mining methods, according to the company. In addition, a closed loop system was created to minimise water discharge and real-time backfilling reduces environmental impact and tailings storage needs.

CMIC CEO, Carl Weatherell, said: “Novamera’s surgical mining solution supports our vision of transforming mining into a zero-waste industry. We are thrilled to be part of this new era of mining innovation that increases safety, efficiency, social licence and environmental stewardship, while providing greater financial returns for the industry.”

Dustin Angelo, CEO of Novamera, said: “The industry needs innovative new solutions. Consortiums and the participation of industry leaders like Vale and OZ Minerals are critical to enabling new technologies to enter the market. Using technology, we can now unlock thousands of smaller-scale deposits and zones within existing mines that were previously uneconomic, allowing the industry to quickly add to production – meeting the rapidly growing global demand for metals.”

Vale, Epiroc planning for automation shift with battery-electric loaders at Creighton

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The industry has been told continuously that there are plenty of synergies between automation and electrification when it comes to loading and haulage, yet the hard evidence of this complementary nature has not yet surfaced. That could be about to change if a trial at Vale’s Creighton mine in Sudbury, Ontario, proves successful.

Vale has been a key electrification partner for mining OEMs and service providers, testing out a whole host of battery-electric equipment from light utility vehicles to 42-t-payload trucks at its deep mines in Sudbury. This builds on its experience of running diesel-electric Kiruna trucks since the mid-1990s at the Coleman mine (also in Sudbury).

The miner has also commenced trials on surface with battery-electric trucks and is set to commence trolley assist operations at its massive Carajas iron ore mining complex in Minas Gerais, Brazil, later this year.

The variety of testing the company has carried out – in terms of the types of mining operations, vehicle setups, charging methods and electrical infrastructure – means it can be considered an electrification pioneer.

Now, it is looking to combine this experience with its knowledge of autonomous loading operations – again an area of the technology space it is considered a leader in.

In partnership with Epiroc, a battery-electric and automation project is in the planning stages at Vale’s Creighton underground mine.

The two companies commissioned four Epiroc ST14 Battery Scooptram and two MT42 Battery trucks at the operation in preparation for the deepening of the mine in the December quarter of 2022. Full-scale operation is ramping up with a first charging bay already commissioned and new ones coming in the next months, a Vale spokesperson told IM.

“The next steps will be to leverage the autonomous capability of those battery-electric scoops to enable operations between shifts depending on the application at the mine,” the spokesperson said.

Vale has previously said it will transition to an all-electric fleet at Creighton as part of its plans to develop the orebody down to circa-3km below surface.

Vale produces commercial-quality iron ore pellets without coal

Coal technology, Environmental, Mineral processing, Mining industry recognition, Steel and iron ore, Sustainable mining, , , , , , , , ,

Vale has announced that for the first time it has managed to produce commercial-quality iron ore pellets on an industrial scale without using anthracite coal.

In a test carried out in a pellet plant in Vargem Grande, Minas Gerais, Vale replaced 100% of the fossil fuel with biocarbon to fire the pellets (small balls of iron ore used to make steel). Biocarbon is a renewable, zero-emission product obtained by carbonising biomass, it explained.

The announcement comes on the same day as National Climate Change Awareness Day in Brazil.

Anthracite coal accounts for around 50% of carbon dioxide emissions in pellet production, which is Vale’s most carbon-intensive process in terms of direct company emissions. Today, pelletising accounts for 30% of Vale’s total Scope 1 emissions.

The test began by replacing 50% of the coal with biocarbon, before gradually increasing up to 100%. In total, approximately 50,000 t of pellets were produced, of which 15,000 t were produced using 100% certified biocarbon.

According to Engineer, Rodrigo Boyer, who led the initiative, using biocarbon just in the Vargem Grande pellet plant will cut annual carbon dioxide emissions by roughly 350,000 t, equivalent to the annual emissions of approximately 75,400 small one-litre cars.

“More tests will be carried out in 2023, of longer duration, to thoroughly evaluate the process,” he explains. “Only after this stage will we be able to generate information for the development of the necessary engineering work aimed at the definitive implementation of this project.”

Vale’s Executive Manager for Decarbonisation projects, Rodrigo Araújo, says that the test is another major step in the company’s journey, and in line with its commitment to reach net zero Scope 1 and 2 carbon emissions by 2050.

“In the case of pelletising, the use of biocarbon is our main initiative, due to the fact that there is great potential for biomass production in Brazil,” he says.

Vale is investing between $4 billion and $6 billion to reduce its direct and indirect emissions by 33% by 2030, in accordance with the Paris Agreement, and with the aim of reaching net zero in 2050. Furthermore, by 2035, the company is committed to reducing its Scope 3 emissions, related to its value chain (ie suppliers and clients), by 15%.

Rodrigo Lauria, Vale’s Executive Manager for Climate Change, said: “The climate agenda is a priority for Vale. For example, since 2020 the company has adopted an internal carbon price of $50/t of CO2 equivalent when assessing capital allocation in new projects.”

To achieve these goals, the company has been investing in low-carbon technologies, such as the use of 72-t payload electric trucks, already in operation in Indonesia and Minas Gerais, and around 50 items of underground electric mining equipment in Canada.

When it comes to Vale’s advances in Scope 2 emissions, the startup of the Sol do Cerrado solar plant in Jaíba in Minas Gerais stands out. This is one of the biggest solar farms in Brazil, with the capacity to generate enough power to supply a city of around 30,000 residents.

In relation to Scope 3 emissions, Vale has already partnered with more than 30 steelmaking clients, representing around 50% of the company’s emissions. In 2021, the company also launched “green briquettes”, a product made up of iron ore and high-tech binders, allowing clients to cut their greenhouse gas emissions in steel production by up to 10%. Vale is converting two pellet plants in Vitória to produce these green briquettes. The initial production capacity is approximately 6 Mt/y. In all, $182 million will be invested in these two plants, which will start up by the end of this year.

Vale has also entered into agreements in Saudi Arabia, the UAE and Oman to create “mega hubs” to make hot briquetted iron (HBI) and high-quality steel products using green briquettes. The production of HBI using natural gas, as planned in the mega-hub project, will emit approximately 60% less carbon compared with traditional steel furnaces that use coke and coal. In the future, the replacement of natural gas with hydrogen and the use of renewable energy could eliminate CO2 emissions.

In shipping, Vale’s emissions are also deemed as Scope 3 considerations, as it does not have its own fleets. Tests are being carried out on ships equipped with rotor sails and air lubrication technology. The goal is to reduce emissions by up to 8% through low-carbon propulsion technology, using wind as energy.

Vale partners with MIRARCO on bioleaching, bioremediation processing project

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Vale Energy Transition Metals, a leading global supplier of nickel, copper, cobalt and platinum group metals, says it is moving to accelerate commercial recovery of critical minerals from mine waste in partnership with the Mining Innovation, Rehabilitation, and Applied Research
Corporation (MIRARCO) at Laurentian University, in Canada.

As part of efforts to reduce mine waste and capture additional value from mined material, Vale has committed C$875,000 ($635,769) over five years to MIRARCO to support a new industrial research chair program in biomining and bioremediation. The announcement was made during the Prospectors & Developers Association of Canada 2023 Convention, in Toronto, Canada.

The industrial research chair program, led by Dr Nadia Mykytczuk (pictured in the centre), will develop, pilot and work towards commercialising bioleaching and bioremediation processes including efforts to recover nickel and cobalt from low-grade pyrrhotite tailings and other waste.

Luke Mahony, Chief Technical Officer at Vale Energy Transition Metals (pictured second from left), said: “This builds on our extensive R&D history and proven track record of lab-to-plant process development and represents a significant opportunity for waste-stream reprocessing here in Ontario. We see this as a triple-win, with potential to reduce liabilities, accelerate commercial recovery of critical minerals and capture additional value from mined material.”

The Government of Ontario will also contribute C$750,000 through the Northern Ontario Heritage Fund Corp. to support this industrial research chair program.

Greg Rickford, Minister of Northern Development (pictured second from right), said: “The new and improved Northern Ontario Heritage Fund Corporation is supporting innovative solutions in the resource extraction sector that will change the way we see mining traditionally. By partnering with Vale and Laurentian University, we are committing to Made in Ontario solutions that will reduce mine waste and enhance value for materials already involved in the mining process.”

Dr Mykytczuk, President and CEO of MIRARCO, said: “This funding and collaboration will accelerate the development of new tools to help us extract value from wastes, producing the metals we need in an environmentally sustainable way.”

Vale Energy Transition Metals is one of the world’s largest producers of high-quality nickel and an important producer of copper and responsibly sourced cobalt. With headquarters in Toronto, Canada, and operations in Newfoundland & Labrador, Ontario, Manitoba, Indonesia and Brazil, the business delivers critical building blocks for a cleaner, greener future.

MIRARCO Mining Innovation is in its 25th year and has been a leader in the development of innovative solutions in response to the needs of the mining industry. Located in Sudbury, Ontario, MIRARCO works collaboratively with industry, private sector, government, academia, and community stakeholders, building fit for purpose teams to effectively deploy knowledge, technology, and sustainable practices across the mining life cycle.

BluVeinXL: aiming for benchmark status in the haulage fleet electrification game

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Since being named one of eight winning ideas selected to progress to the next stage of the Charge On™ Innovation Challenge in 2022, BluVeinXL has done more than most, assembling a consortium of major mining partners focused on accelerating BluVein’s standardised dynamic charging technology to decarbonise the mining sector.

Late last year, Austmine, which manages the BluVeinXL project, welcomed Rio Tinto, OZ Minerals, BHP, Newcrest Mining, Evolution Mining and Freeport-McMoRan to the consortium of funding members to fast-track the BluVein technology. It has since welcomed Vale to the consortium.

These companies have backed the vision of BluVein, a joint venture between Olitek (Australia) and Evias (Sweden), to dynamically power mixed-OEM haul fleets while in motion, enabling smaller on-board battery packs, faster vehicle haulage speeds up ramp, grid load balancing, elimination of static fast charging, maximum fleet availability and – most importantly – the complete elimination of diesel.

These consortium partners are focused on delivering BluVein’s fleet electrification solution to Technology Readiness Level (TRL) 6 with a minimal viable product (MVP) demonstration, ahead of full commercial deployment of the technology.

BluVeinXL leverages much of what was developed for BluVein1, the primarily underground solution using the BluVein Rail™ slotted power rail system and the on-vehicle BluVein Hammer™ to simultaneously charge and power mining fleets ‘on the go’. The Rail is an enclosed electrified e-rail system mounted above or beside mining vehicles while the Hammer connects the electric vehicle to the Rail.

In underground scenarios, BluVein’s technology completely removes the need for battery swapping or static fast charging while allowing the use of smaller, lighter and lower cost batteries in continuous and high-duty applications, according to the company.

In open-pit operations, BluVeinXL will be similarly transformative, offering a next-generation alternative to what BluVein refers to as “the cumbersome, inflexible and expensive conventional catenary wire trolley systems that are currently hampering mines from fully decarbonising their haulage operations”.

To get the latest on the BluVeinXL open-pit electrification solution, IM caught up with James Oliver, CEO of BluVein.

IM: Now you have the founding consortium members confirmed for BluVeinXL, where do you go from here? Are you currently engaged with major OEMs on creating a standard design that can fit on any truck?

JO: Seven consortium members is just the start, and we will be announcing additional members very soon. We greatly value our members as it is ensuring we get ‘voice of industry’ and the key technical requirements during this critical stage. One of the major benefits our members see in BluVein is our standardisation, meaning our technology can be used with mixed-OEM fleets, mixed machine types and can even be used to make alternative clean fuel use more efficient and cost effective.

We are currently working with two to three major fleet OEMs and progressing agreements related to integration and demonstration of the BluVeinXL technology. We are confident we will be able to demonstrate with at least one OEM as the MVP, and hopefully more during the current project. Once we agree with each OEM the agreed interface point, then the BluVeinXL integration with the various fleet types becomes quite simple. To do this our technical team works closely with the OEMs on all aspects of the integration including Hammer, Rail and the control systems. By standardising with our various OEM fleet partners, we are delivering on what the mining customers are demanding – a truly standardised dynamic charging system.

James Oliver, CEO of BluVein

IM: How are you managing to engage OEMs that are also providing their own trolley assist applications that, they believe, may be suitable for similar haul truck propulsion setups to BluVeinXL?

JO: BluVein’s safe and proven electrification technology is based on over a decade of research and development undertaken for electric highways by our joint venture partner Evias. We are confident in our system’s ability to deliver high power transfer whilst also delivering on the safety and robustness requirements demanded by mining customers. Critically, the high-power transfer characteristics of BluVein’s slotted rail system enables simultaneous on-ramp hauling and charging of multiple closely spaced mining haul vehicles. This is a game-changing capability and of high interest to our mining partners. The conventional catenary wire-based trolley systems have limitations on power delivery capacity, earthing and other critical safety elements, and, therefore, are not as favoured by miners.

We do, however, see benefits of OEMs trialling a range of different mine electrification approaches, as long as we can all agree on a common vehicle connection point, specifically at the dynamic charge interface. This will ensure the end customer is able to select the best solution for their individual sites. We understand that BluVein will not be everything to everyone, but for the applications it does suit, we are confident it will be a true game changer over conventional catenary and static fast charging options for haul truck fleets.

We hope to be able to demonstrate BluVeinXL side by side with a catenary wire system to showcase the competitive advantages BluVeinXL has – that is higher power transfer; safer, easier to install, use and relocate; and overall lower cost. Ultimately it will be up to the customer to choose based on the performance of the system and we think this will stack up in BluVeinXL’s favour.

IM: Can you expand on how your system alleviates the requirements on haul road conditions that typically comes with the current generation of trolley assist technology? Do you see your Rail and Hammer technology being able to work in any conditions (the Arctic included)?

JO: Part of our current package of work is to understand with our mining partners what these extremes are to ensure we are developing a solution that has minimal up-stream and down-stream impact on operations. The vision is to have a deployable solution that suits all climates and terrains.

Our core technology partner, Evias, has spent over a decade developing BluVein’s core technology to function effectively in icy and muddy conditions. By building on these learnings, we are confident that BluVeinXL will work in the vast majority of terrains and climates experienced in mining – from the hot and humid Pilbara region of Australia to the coldest parts of northern Canada.

It is BluVein’s safe slotted e-rail technology that enables it to be located near to the ground to the side of haul roads. Our Hammer and Arm is being designed to cater for the full range of haul road conditions, thereby reducing the burden on mines to maintain haul road conditions to perfection as is required with conventional overhead wire catenary systems.

Our consortium members have very good geographic spread to help us understand and test in these conditions. Part of our current work is to clearly understand from our mining partners what these environmental extremes are to ensure our solution will function effectively in all operations.

IM: Has your work to this point indicated how small the on-board batteries could be in a typical open-pit scenario for 220-t-payload trucks?

JO: We have taken a technology-agnostic approach to what on-board power and storage system we are supplying; our current focus is getting enough energy onto the vehicle as efficiently and safely as possible to power drive motors and charge smaller batteries if and when available. While we cannot reveal exactly how much smaller we can make the batteries, early studies show the batteries can be reduced as much as 60% when coupled with dynamic charge that has enough capacity to power the drive and charge the battery.

BluVein1 for underground and quarries can provide up to 3 MW of power sufficient for up to 100-t payload vehicles

IM: So what payloads do you think you could be providing this solution for?

JO: The BluVein Rail and Hammer design is completely scalable. BluVein1 for underground and quarries can provide up to 3 MW of power sufficient for up to 100-t payload vehicles. The BluVeinXL system can offer in the range of 4-7 MW, sufficient for up to 250-t payload vehicles. Our engineering team plan to use BluVein1 and BluVeinXL as stepping stones for an eventual introduction of a BluVein solution suited to ultraclass fleets with 9-12 MW of capacity sufficient for up to 350-400 t payloads.

IM: Where are you with your field trials on this solution? Do you expect these to commence this year?

JO: The targeted ‘wheels on track’ for BluVein1 is 2023, followed closely in 2024 with the BluVeinXL MVP demonstration. Right now I cannot reveal too much but there are some exciting partnerships being progressed to achieve this.

In terms of field trials, our ideal setup – and I think one the industry really wants – is a single site where all key mine electrification technologies can be tested out side-by-side. There are some very positive conversations going on between all three parties – the solution OEMs, truck OEMs and mining companies – on this front, which is exciting for BluVeinXL.

As has been said many times, there is no ‘silver bullet’ when it comes to mine decarbonisation. We know that BluVein’s dynamic charging solutions will tick a lot of boxes, but not all. So, it’s great if we can work together to ensure we cover any gaps. There is just too much at stake to try and go it alone.

IM: Anything else to add on the subject of electrification and dynamic charging?

JO: One question we have been asked is does BluVein’s Hammer and Rail technology only support dynamic charging? While power transfer while in motion is our obvious advantage, our system is basically an automated IP2X-rated power connection that can transfer more than 4 MW of energy. Could we use this for automated static fast charging also? Our answer to that is absolutely.

Shell Consortium previews Charge On haul truck electrification solution

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Shell has become the latest Charge On Innovation Challenge winner to unveil details about its electric haul truck charging solution, outlining how its consortium of partners intend to combine an end-to-end and interoperable electrification system that reduces emissions without compromising on efficiency or safety, while aiming to be cost competitive versus diesel-powered operation.

The Charge On Innovation Challenge was launched in 2021 and invited vendors and technology innovators from around the world and across industries to collaborate with the mining industry to present novel electric truck charging solutions. The challenge received interest from over 350 companies across 19 industries, with more than 80 companies submitting expressions of interest. Twenty-one companies were then invited to present a detailed pitch of their solution, with the final eight – which included the Shell Consortium – chosen to progress from these 21.

The global challenge, launched by BHP, Rio Tinto and Vale, sought to accelerate commercialisation of effective solutions for charging large electric haul trucks while simultaneously demonstrating there is an emerging market for these solutions in mining.

The Charge On Innovation Challenge requested international solution providers to put forward charging concepts that are:

  • Designed with safety as the number one priority, using inherent defensive design and future-proof principles;
  • Able to supply a battery for 220-t payload electric haul trucks;
  • Capable of supplying 400 kW hours of electricity to a truck during each haul cycle;
  • Able to provide battery charging, or both propulsion and battery charging;
  • Cost effective, minimising complexity without reducing productivity; and
  • Interoperable, allowing different haul truck manufacturers to utilise the same charging infrastructure.

On a media call this week, Shell highlighted how its consortium of nine partners was working on a solution that could not only meet this brief, but also provide a commercial offering to electrify mining and other industries.

Skeleton, Microvast, Stäubli, Carnegie Robotics, Heliox, Spirae, Alliance Automation, Worley and Shell have come together to introduce Shell’s mining electrification solutions for off-road vehicles. This consists of:

  • Power provisioning and microgrids, with the aim to provide a consistent and reliable supply of renewable power in a safe and stable manner;
  • Ultra-fast charging whereby an approximate 90-second charge via flexible, hardwearing and resilient, on-site, ultrafast charge-points can provide assets with continuous operation of some 20-30 minutes depending on the haulage profile; and
  • In-vehicle energy storage: through a combination of advanced battery and capacitor technologies that aim to deliver long lifetimes, ultra-fast charging and high performance.

Some of the key components of the power provision and energy management solution come from Alliance Automation, a multi-disciplined industrial automation and electrical engineering company; Spirae, a technology company that develops solutions for integrating renewable and distributed energy resources within microgrids and power systems for economic optimisation, resiliency enhancement and decarbonisation; Worley, an engineering company that provides project delivery and consulting services to the resources and energy sectors, and complex process industries; and Shell Energy, which provides innovative, reliable and cleaner energy solutions through a portfolio of gas, power, environmental products and energy efficiency offers to businesses and residential customers.

The ultra-fast charging element involves solutions from Carnegie Robotics, a provider of rugged sensors, autonomy software and platforms for defence, agriculture, mining, marine, warehouse and energy applications; Heliox, a leader in fast charging systems within public transport, e-trucks, marine, mining and port equipment; and Stäubli, a global industrial and mechatronic solution provider with four dedicated divisions: electrical connectors, fluid connectors, robotics and textile.

Finally, Skeleton, a global technology leader in fast energy storage for automotive, transportation, grid and industrial applications, and Microvast, a leader in the design, development and manufacture of battery solutions for mobile and stationary applications, are in charge of the in-vehicle energy storage side of things.

As a result of this collaboration, mining operators, Shell says, are set to benefit from an integrated electrification solution that:

  • Is end-to-end, covering the full journey of the electron from generation to delivery in the drivetrain;
  • Is interoperable between different original equipment manufacturer make and models, giving mining operators greater flexibility;
  • Is modular in design to allow mining customers the opportunity to tailor solutions to their specific needs; and
  • Reduces emissions without compromising on operational efficiency or safety.

Sebastian Pohlmann, Skeleton Technologies’ Vice President Automotive & Business Development, revealed more details about the plans for the in-vehicle energy storage part of the equation, confirming that the fast energy storage solution set to be fitted on these 220-t payload haul trucks would leverage its SuperBattery.

The SuperBattery, Pohlmann said, offers a 100 times faster charging option compared with standard lithium-ion batteries, while also being free of cobalt, nickel, graphite and copper materials. He also mentioned that a SuperBattery-equipped haul truck could, in the right situation, offer higher utilisation than its diesel-powered equivalent.

The SuperBattery is due to start production in 2024, with Pohlmann saying the battery lined up for a prototype system as part of the Shell Consortium would weigh in at just over 12 tonnes. He also highlighted the potential for other applications in mining outside of 220 t haul trucks with this platform.

The ultra-fast charging solution that the consortium partners were working on assumed a peak power delivery of 24 MW, Pohlmann said, explaining that the charge points would be positioned around areas where haul trucks normally come to a stop – during dumping or loading, for instance – meaning charging would not interrupt the haul cycle and ensure high utilisation of the truck at all times.

With such a high power draw envisaged by the partners, Grischa Sauerberg, Vice President, Sectoral Decarbonisation & Innovation at Shell, explained that a stationary power element – renewable energy and battery storage – may also be provided if the grid power available cannot support such a peak draw.

The commercial offering from the partners is expected in 2025, however Sauerberg confirmed a pilot solution was set to be tested at a Shell facility in Hamburg, Germany, next year, followed by final field trials at selected mine sites in 2024.

XCMG 72-t battery-electric trucks start up at Vale operations

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Vale says it has become the first major mining company to test 100% electric 72-tonne trucks, with the trial of the XCMG Mining Machinery Co. Ltd vehicles at its Brazil and Indonesia operations.

The trial of the vehicles represent another step in the electrification of the company’s assets, it said, which is part of its wider plans to operate with net zero carbon emissions by 2050.

The first electric trucks to be used by a global mining company, tested at Água Limpa, in Minas Gerais, and Sorowako, in Indonesia, emit no CO2, replacing diesel with electricity from renewable sources. They also reduce noise, which minimises the impacts on the communities that live near the operations.

The equipment was produced by XCMG Mining Machinery Co. Ltd., a subsidiary of Xuzhou Construction Machinery Group Co. Ltd, the largest machine manufacturer in China.

Last year, Vale signed an MoU with XCMG Construction Machinery Limited, a subsidiary of XCMG, for the potential supply of mining and infrastructure equipment, including zero-emission and autonomous equipment.

The 72-t electric off-highway trucks, model XDR80TE, are part of the Vale PowerShift program. Their batteries are able to store 525 kWh, allowing them to operate for up to 36 cycles along the established route, just over a day of operations, without the need to stop and recharge, and with the possibility of regenerating energy during descents, reducing the use of mechanical brakes, maintenance work and vibration, in addition to providing more operational comfort to drivers. The machine has temperature control technology, which allows it to adapt to high temperature, humidity and rainy working conditions, and to perform even in extremely cold, high altitude and harsh weather conditions.

Alexandre Pereira, Executive Vice President of Global Business Solutions at Vale, said: “To us, this partnership with XCMG is another important step in our long-term relationship with China and towards more sustainable mining. Our goal is to expand, together with global partners, the development and co-creation of technologies that respect the environment and zero out emissions.”

Dr. Hanson Liu, the Vice President of XCMG Machinery and General Manager of XCMG Import & Export Co., said: “XCMG and Vale have reached a consensus on the green development concept of dedicating to low-carbon mining and realising net zero emissions. The delivery of XCMG’s latest pure electric mining truck, XDR80TE, at this time is a manifestation of the joint efforts of both parties on promoting global environmental protection as well as green and sustainable economic development.”

Currently, emissions from off-highway trucks running on diesel represent bout 9% of Vale’s total scope 1 and 2 emissions.

The Powershift program was created by Vale with the aim of replacing fossil fuels with clean sources in its operations. The program is promoting innovative solutions to electrify the company’s mines and railroads. In addition to the 100% electric truck, Vale’s strategy for the electrification of assets also includes the operation of battery-powered locomotives in the yards of the ports of Tubarão, in Vitória, and Ponta da Madeira, in São Luís. In Canada, the Powershift program has also led to tests with electrical equipment in underground mines – there are currently about 40 that are currently operational.

Vale’s operational equipment electrification strategy also includes a partnership with its peers BHP and Rio Tinto. Last year, the three companies, along with 17 other mining companies, launched the Charge On Innovation Challenge, a global open innovation challenge with the goal of finding innovative solutions to accelerate the safe charging of batteries for future electric off-highway trucks.