Tag Archives: Weir Group

Weir expands ESCO GET capacity with new foundry in China

Equipment maintenance, Mining consumables, Mining equipment, Mining services, , , , , ,

The Weir Group has officially opened its new foundry in Xuzhou, China, expanding capacity for the manufacture of ESCO® ground engaging tools (GET) in line with continued growth opportunities.

The foundry, which is part of Weir’s ESCO global foundry network, celebrated the breaking of ground back in July 2022.

The opening ceremony, hosted by Weir’s CEO, Jon Stanton, was attended by a Senior Leadership Team from Xuzhou Hi-Tech Industry Zone and other members of Weir and its ESCO division from China and across the globe.

Occupying a 16.5-acre (6.7-ha) site in Xuzhou’s High-Tech Industrial Zone, the new foundry features the very latest technology and equipment, incorporating high levels of automation, the company says. These enable Weir to optimise capacity and enhance its foundry processes, improving efficiency and further reducing cost of manufacture, aligned with the goals of Weir’s Performance Excellence transformation program. The company added: “It strengthens our global foundry network, ensuring we remain highly responsive to customers’ needs.”

The new foundry represents a $60 million investment and will replace the existing foundry that is located close by. Staying in Xuzhou allows Weir to, it says, capitalise on its culture of continuous improvement and sustainability, resulting in consistently high performance in process control, safety, employee engagement and on-time delivery.

The new foundry has been designed to produce a wider range of our proprietary GET products, including larger sized components, enabling the manufacture of more product types in a more cost-effective way, according to Weir. It expands the company’s foundry capacity in China by over 30% and provides additional flexibility across its global network to best serve customers around the world.

Stanton said: “The opening of our new foundry in Xuzhou is a significant strategic milestone for Weir. I’d like to congratulate our project team in Xuzhou who have designed and built what we expect to be the safest, most efficient, most sustainable, most advanced foundry within our global network. I’d also like to thank our partners throughout the Xuzhou Government for their time and experience to help deliver this important project.

“This investment demonstrates our commitment to long-term presence and economic contribution in Xuzhou, ensuring Weir drives further efficiency and sustainability in our operations while supporting our continued growth as supplier of premium mining GET technology to customers worldwide.”

Weir Group highlights energy, emission reduction opportunities in comminution study

Comminution of minerals, Environmental, Mining equipment, Mining events, Mining services, Power supply for mines, Sustainable mining, Water management, , , , , , , , ,

The Weir Group has completed a comprehensive study that highlights a significant opportunity to reduce energy use and emissions in comminution by leveraging three alternative technology combinations.

The study, presented by Paula Cousins, Chief Strategy and Sustainability Officer at Weir, during a COP28 panel discussion hosted by the Ministry of Economy, Trade and Industry of Japan and moderated by the World Business Council for Sustainable Development (WBCSD), showed that replacing conventional technology with innovative new solutions can cut energy use by 40% while also avoiding 50% of CO2e emissions.

Weir’s study focuses on comminution – the crushing process that turns big rocks into tiny particles to expose the entrapped mineral so that it can be extracted later in the mining process. Comminution is the most energy intensive stage of a typical mine site process. It is already electrified and is responsible for at least one-third of an average mine’s energy use and CO2e emissions1 and globally consumes around 3% of the world’s electrical power, according to studies.

The study is the first to use WBCSD’s Avoided Emissions Guidance to study mining processes and the avoided emissions results have been independently assured by SLR Consulting Limited, Weir says. Three of Weir’s technology combinations were evaluated against a conventional comminution circuit design for an archetypal mine processing 15 Mt/y of copper ore in Chile. All three of the technology combinations are shown to yield sizeable benefits versus the traditional circuit.

In the optimal combination, the comminution process consumes around 40% less energy and can avoid up to 50% of CO2e emissions. Importantly, there is no trade off elsewhere, as the redefined process uses less water too, according to the study.

Each circuit is based on a ‘rock to recovery’ system boundary – reducing rock direct from the mine to a size that enables the mineral to be recovered. The four configurations are:

  • Conventional comminution circuit based on a Semi-Autogenous Grinding (SAG) mill and ball mill (SABC circuit);
  • Weir High Pressure Grinding Roller (HPGR) replacing the SAG mill at the initial grinding stage (2C HPGR BM);
  • HPGR, plus vertical stirred mill (VSM) replacing the ball mill (2C HPGR VSM); and
  • Addition of a coarse particle flotation (CPF) unit (2C HPGR VSM and CPF).

These assessments focus on the use-phase of the life-cycle only; other life-cycle phases have been excluded because previously studies have shown these to be immaterially small across all comparisons (<1% of energy and emissions impact). Assessments have been made using a “year-on-year” timeframe approach. Comparative impacts have been assessed only in terms of energy use, grinding media consumption, and associated emissions, since other environmental trade-offs were deemed immaterial for comparison.

Given its energy intensity, the decarbonisation opportunities in comminution are huge, with the basic comminution process not having changed significantly for many decades, Weir says.

The company is collaborating with customers and other partners to redefine the process, developing innovative combinations of proven technologies to make significant improvements to efficiency and environmental performance.

Cousins said: “The need for technology solutions in mining is compelling – the world needs more transition metals to achieve net zero, but the mining industry needs to extract these using significantly less energy and water.

“By adopting a systems-based approach to technology collaborations, we can help the mining industry scale up and clean up at the same time.”

 

Weir Group marks Minerals and ESCO progress in H1 results

Base metals, Comminution of minerals, Equipment maintenance, IoT, Mining equipment, Mining finance, Mining services, Mining software, Steel and iron ore, Sustainable mining, Water management, , , , , , , , , , , , , , , , , , ,

The Weir Group has issued its half-year results to June 30, 2023, noting some significant achievements across its Minerals and ESCO divisions.

Headline numbers for the six-month period included a 19% year-on-year jump in revenues to £1.3 billion ($1.67 billion) and a 26% rise in operating profit to £212 million.

Weir Minerals continued to execute on key strategic growth initiatives, and during the first half gained market share in its core mill circuit product categories, it said.

The company said: “We converted 100% of our competitive field trials for large mill circuit pumps, and also rolled-out our latest cyclone technology.”

One highlight in the period came at a large Brazilian iron ore mine, where Weir Minerals upgraded the cyclones to its latest Cavex® 2.0 solution. The new cyclones, which are Synertrex®-enabled, have improved separation and increased mineral recovery by more than 400,000 t/y, according to the company.

Cavex 2 cyclones were launched in 2020, introducing new geometric features to offer performance unmatched by any cyclone in operation at that point, the company claimed. The advanced LIG+ design (patent pending) enables the Cavex 2 hydrocyclones to classify up to 30% more feed slurry, while occupying the same footprint as competitor hydrocyclones, according to Weir.

Weir Minerals says it also made good strategic progress in sustainable solutions during the six-month period and delivered year-on-year growth in comminution. New orders included a pebble crushing plant for a large copper mine in South America and a crushing solution for a potash mine in Canada.

The company also said it saw “very encouraging interest” from customers for its Redefined Mill Circuit, securing orders from large copper mines in South America for coarse particle flotation (CPF) pilot circuits, in partnership with Eriez.

“Through this strategic alliance, we have integrated CPF technology with our latest generation Warman® mill circuit pumps and Cavex cyclones to provide significantly improved recoveries and process efficiencies for our customers,” it said. “Once operational in the September quarter, these plants will be important reference sites for the industry.”

Around a year ago, Weir Minerals and Eriez Flotation announced a cooperative agreement to design and develop CPF systems. This allows both companies to better connect the Eriez equipment with the slurry classification and conveying expertise of Weir Minerals, according to Ricardo Garib, Division President of Weir Minerals.

Weir Minerals also launched its new, proprietary digital intelli-solutions for pumps, cyclones and high pressure grinding rolls which, coupled with its Synertrex 2.0 platform, captures critical machine health data and enables remote condition monitoring.

It concluded: “We continued to invest in research and development of our core technologies including new materials and polymers, and upgrades and range expansions for our industry leading Warman slurry pumps.”

Weir ESCO, meanwhile, reported that the number of mines using Motion Metrics™ AI-enabled vision technology increased during the first six months of the year, with new orders including a package of five ShovelMetrics™ and five LoaderMetrics™ systems to be deployed across all large mining machines at an iron ore mine in Western Australia.

“The division made excellent progress in growing market share in mining attachments, with a 37% year-on-year increase in orders,” it said. “A particular highlight included converting four cable shovel buckets from competitor products to ESCO technology for a large North American copper miner.”

The division also provided an update on trials of its proprietary ore characterisation technology, which has been leveraging the BeltMetrics™ solution from Motion Metrics positioned above a conveyor directly after the crusher in the flowsheet at an unnamed mine. As well as using the rugged vision technology Motion Metrics has previously used, the company is also incorporating hyperspectral imaging into the mix for this trial.

It reported: “Field trials of our proprietary ore characterisation technology were successfully completed during the first half. Tests enabled critical data to be collected and validated the performance of the technology in a real-world environment.”

Development has now progressed to the next phase focused on exploring “novel illumination” technologies to enhance minerals characterisation, it added.

New Motion Metrics capabilities and functions were launched during the six-month period, including an upgraded lens cleaning solution that enhances machine vision capability and improves response times.

“Other technology investments included development of a new series of mining attachments that, once launched, will expand our addressable market,” it said.

Brownfield expansions and sustainable mining projects boost Weir Group Q1 orders

Base metals, Comminution of minerals, Environmental, Mining equipment, Mining finance, Mining services, Sustainable mining, Water management, , , , , , , , ,

Weir Group continued to benefit from relatively high commodity prices, tightness in physical inventories of metals and minerals, and strong end market demand for commodities in the March quarter, registering a 22% boost in original equipment order growth in the three-month period.

The company said brownfield activity and sustainability projects were behind this leap in orders.

“Customers are ordering Weir solutions to debottleneck, expand and improve the sustainability of existing mines, while also increasingly engaging on new sustainability driven technologies, such as our redefined mill circuit and the Motion Metrics digital offering,” the company said in its results.

Weir Group’s “redefined mill circuit” encompasses Weir Minerals’ Enduron® high pressure grinding rolls, along with the additions of technologies from Eriez and Swiss Tower Mills (STM) Minerals, which are part of specific partnerships. These solutions are enabling it to redefine the mining mill circuit so customers can use less energy, use water wisely and create less waste during minerals processing, it says.

Weir Minerals recently announced the completion of the STM Minerals AG vertical stirred mill commissioning at the Weir Technology Hub in the Netherland. Regarding Eriez, the combination of pumps, cyclones, classification equipment, and other mill circuit products supplied by Weir Minerals, along with Eriez’s HydroFloat, StackCell®, columns and sparging systems, allows owners to take advantage of well-matched equipment designed and tested as a system, Weir says. This makes Weir a natural fit for contributing to Coarse Particle Flotation flowsheets, it added.

In terms of the Weir’s outlook, it said in its March quarter results: “The business is executing well and conditions in our mining markets are positive. High levels of activity and demand for our aftermarket spares and brownfield original equipment solutions are driving order book growth. Our guidance for 2023 is reiterated and we expect to deliver growth in constant currency revenue, profit and operating margin. We are on track to deliver our target of 17% operating margin in 2023, supported by operational efficiencies and early benefits from Performance Excellence.

“Further out, the long-term fundamentals for mining and our business are highly attractive, underpinned by decarbonisation, GDP growth and the transition to sustainable mining. We have a clear strategy to grow ahead of our markets, with specific growth initiatives underpinning our ambition to deliver through-cycle mid-to-high single digit percentage revenue growth.”

The Weir Group’s latest GHG emission reduction targets win SBTi approval

Environmental, Mineral processing, Mining equipment, Mining industry recognition, Sustainable mining, , , , , , , ,

The Weir Group PLC has had its new, more ambitious emissions reduction targets approved by the Science Based Targets initiative (SBTi).

The targets, announced back in July 2022, cover greenhouse gas (GHG) emissions from Weir’s own operations (Scope 1 & 2) and value chains (Scope 3).

Its SBTi approved near-term science-based emissions reduction targets are to:

  • Reduce absolute Scope 1 & 2 GHG emissions by 30% by 2030 from a 2019 base year; and
  • Reduce absolute Scope 3 GHG emissions from use of sold products by 15% within the same timeframe.

The company said: “We believe that challenging ourselves to further reduce emissions from our own operations and in our wider value chain is right for the world and for our business. We have a responsibility to minimise carbon emissions to help protect the future of the planet, aligned with our purpose to enable the sustainable and efficient delivery of the natural resources essential to create a better future for the world.”

Weir Group says it has already made good progress towards its targets, having reduced its Scope 1 & 2 GHG emissions by a cumulative 17% since 2019. In the company’s broader value chain, the overwhelming majority, 97%, of Weir Group’s Scope 1, 2 & 3 combined footprint is attributable to the use phase of its long-lifespan products and solutions on customer sites. These are, in turn, considered its customers’ Scope 1 & 2 emissions, which make for a shared goal to reduce that footprint. Weir Group says its latest technologies are already offering customers energy savings of up to 40%.

Weir’s technology and R&D roadmap is focused on five key themes, with voice of customer at its core: Move less rock; Use less energy; Use water wisely; Create less waste; and Boost with digital. Further innovation to reduce energy consumption per tonne of ore processed will help reduce emissions from mining even further.

Jon Stanton, CEO of the Weir Group, said: “The world is not moving fast enough to avoid the consequences of climate change. We know the crucial role of metals in low-carbon technologies which is why accelerated, collective action is needed to transform the way metals are mined and produced. Mining needs to scale up and clean up, and Weir’s engineered solutions have an important role to play in achieving that. The approval by SBTi of our near-term science-based greenhouse gas reductions targets reinforces our commitment to make mining smart, efficient and sustainable.”

Weir preparing to trial proprietary ore sorting tech by the end of 2022

Automation, Comminution of minerals, Explosives and blasting, IoT, Mineral processing, Mining equipment, Mining services, Mining software, Sustainable mining, Water management, , , , , , , , , , , , , ,

In the Weir Group Capital Markets Event presentation last week, Chris Carpenter revealed that the company was collaborating within its divisions on trials of ore sorting technology in an effort to move less rock at mine sites and optimise processing within the plant.

Carpenter, Vice President of Technology at Weir ESCO, said the company was combining Motion Metrics’ particle size distribution (PSD) capability with ore characterisation technology to explore “in-pit sorting” opportunities for its clients.

“Looking further out, we believe ore characterisation and in-pit ore sorting has the potential to transform mining by moving less rock, using less energy and creating less waste,” he said during his presentation. “Ore characterisation technology, which is underpinned by sophisticated sensing systems, captures critical data on properties and composition of rock, including rock hardness and mineral and moisture content.

“When coupled with Motion Metrics fragmentation analysis technology, it has the potential to be a game changer, giving miners a full picture of the size and characteristics of rocks.”

Motion Metrics, a developer of artificial intelligence (AI) and 3D rugged machine vision technology, was acquired by Weir almost a year ago, with the business incorporated into the Weir ESCO division. Its smart, rugged cameras monitor and provide data on equipment performance, faults, payloads and rock fragmentation. This data is then analysed using embedded and cloud-based AI to provide real-time feedback to the mining operation.

These technologies were initially developed for ground engaging tool applications but have recently been extended into a suite of products and solutions that can be applied from drill and blast through to primary processing.

Carpenter said the added PSD capability from Motion Metrics was expanding the company’s value presence across the mine to the processing plant, where Weir Minerals operates.

“Results from early adoption of Motion Metrics PSD solutions have been extremely encouraging,” he said. “Feedback from customers is positive; data sharing and collaboration have increased.

“Given this early progress, we are really excited about the opportunity and expect fragmentation analysis to be a key growth driver for Motion Metrics in the years to come.”

On the in-pit sorting potential, Carpenter said Weir ESCO had laboratory-validated equipment and field trials of its proprietary solution that were due to start at customer sites before the end of the year tied to these developments.

“If successful, this technology opens the door to in-pit sorting, where miners complete the first stage of crushing in the pit and analyse the outputs to make real-time decisions about which rocks have sufficient mineral content to be moved,” he said. “This is a step change from the current process, where energy is expended in transporting and processing all of the rocks, regardless of mineral content, and with significant waste generated from zero- and low-grade material.”

He concluded: “Our vision is to move less rock, moving only the rocks with sufficient mineral content and using the data that is captured on size and hardness to optimise processing. The natural evolution thereafter will be towards real-time automation control of processing equipment, ensuring the right rocks are processed in the most efficient way, using less energy and creating less waste.”

Weir and Swiss Tower Mills align on energy efficient comminution pathway

Comminution of minerals, Environmental, Mining equipment, Mining services, Sustainable mining, , , , , , , , , ,

The Weir Group has announced a new alliance with Swiss Tower Mills Minerals (STM) in which Weir will market STM’s vertical stirred grinding mills for coarse grinding applications worldwide.

Integrating vertical stirred grinding mills into Weir’s minerals processing flowsheet will provide customers substantial improvements in throughput and energy efficiency, helping them to meet their productivity and sustainability goals, Weir says.

STM’s vertical stirred grinding technology is proven for energy efficient comminution in the mining market with more than 80 units currently operating in the hard-rock mineral processing industry across the globe, according to the company. It is used within the comminution segment of the minerals processing circuit as part of a series of crushing and grinding processes that create the fine particles from which minerals can be extracted through flotation.

Comminution, as has been well documented, is one of the most energy intensive parts of the mine, accounting for 25% of the final energy consumption of an average mine site.

Weir says it is already a leader in comminution technologies, offering solutions such as Enduron® high pressure grinding rolls (HPGRs) to drive down energy consumption by around 40% for customers.

This new alliance with STM takes things to the next level, offering the mining and minerals industry a proven low energy alternative to traditional high energy consuming tumbling mills, it said. Combining and integrating these energy-efficient technologies into a single, optimised flowsheet will deliver significant reductions in energy use, driving down costs and carbon emissions.

In order to prove the most beneficial flowsheet for specific projects, STM has already supplied two vertical test mills to the Weir Minerals HPGR test facility in Venlo (Netherlands). This will put Weir and STM in the unique position to provide clients combined energy efficient grinding test work of HPGR followed by STM’s vertical stirred mill, they said.

Ricardo Garib, Weir Minerals Divisional President, said: “Weir and STM share the same vision of enabling primary resource providers to produce resources in the most sustainable manner. This is a perfect match of best-in-class technology providers. Integrating STM mills with Weir’s comminution products, which includes Enduron HPGRs and Enduron screens, will improve throughput and help bring substantial reductions in carbon emissions.

“This is a real win-win.”

Fritz Moser, STM Chairman, said “Both the HPGR and the STM vertical stirred mills provide significant energy savings compared to conventional grinding technologies. Our new supply agreement with Weir will enable us to fast track the roll out of an innovative flowsheet using STM mills in conjunction with Weir’s Enduron HPGR.”

Weir ESCO breaks ground on new foundry in China

Equipment maintenance, Mining consumables, Mining equipment, , , , , , ,

Weir ESCO has broken ground on a new foundry in China that, it says, will build capacity and support increased demand for ESCO ground engaging tools (GET), while retaining 100% of its experienced team.

Employees, dignitaries and local partners celebrated at a ground-breaking ceremony in Xuzhou, China, where Vice Mayor Gong of Xuzhou City and other elected officials, local business partners and Weir Minerals Managing Director of China, Angela Wang, were present.

The company broke ground on its new foundry in China on July 27, as the latest milestone in the future expansion of its Xuzhou site.

The project was announced in 2021, with production from the facility scheduled to start in late 2024 ahead of reaching full production in 2025.

In Weir Group’s half year results to June 30, the company noted that Weir ESCO had received a record order intake of £349 million ($426 million) for the six-month period on the back of high levels of activity in mining and infrastructure markets, plus pricing and volume growth.

Weir Group commits to more ambitious Scope 1, 2 and 3 emission goals

Bulk handling, Comminution of minerals, Environmental, Mineral processing, Mining equipment, Mining industry recognition, Sustainable mining, , , , ,

The Weir Group says it has submitted new, more ambitious Scope 1, 2 and 3 emissions reduction targets to the Science Based Targets Initiative (SBTi) for validation.

The move, which follows its commitment, in December 2021, to set SBTi targets, could see the company include absolute reductions in Scope 1 and 2 emissions of 30% and Scope 3 emissions of 15% by 2030, versus a 2019 baseline.

Weir Group explained: “The targets are more ambitious than our previous goals, set in 2020, in two ways:

  • “Switching from an intensity to an absolute emissions reduction basis will drive deeper cuts in Scope 1 and 2 emissions; and
  • “The new Scope 3 commitment adds targets for emissions in Weir’s upstream and downstream value chain for the first time.”

These new targets will make a significant contribution to decarbonising the mining industry, according to Weir. Delivering them would mean that, in 2030, an annual reduction of circa 4.2 Mt CO2e is achieved, equivalent to the annual CO2 emissions of almost 1 million petrol cars.

Weir is focused on developing engineered solutions for smarter, more efficient and sustainable mining, providing customers with new value-adding technologies for use in the most energy intensive processes in the mine, it says.

“With 97% of our total emissions falling within Scope 3, over the lifetime of our products in use, we recognise that our biggest contribution to decarbonising mining will come from delivering sustainable solutions to accompany the industry’s transition to low-carbon energy sources,” the company said.

“The mining industry is critical to the global energy transition as it extracts the raw materials needed to implement new, greener technologies. However, it is energy intensive and so has to meet this increasing demand while delivering on its own environmental commitments. Therefore, it is imperative that we actively partner with customers and others across the industry to drive the broader energy transition required.”

Jon Stanton, Weir Group CEO, said: “These new, more ambitious targets mark another important step in our strategy and strengthen our commitment to further reduce emissions from our own operations and in our wider value chain. Weir’s products and solutions already have a positive impact on the energy efficiency of our customers’ operations, but we recognise that more needs to be done. Our customers are pushing us to innovate lower carbon, more energy efficient solutions and we are stepping up to this. We continue to push boundaries at pace to develop smarter, more efficient and more sustainable solutions for the global mining industry that will enable the delivery of the natural resources essential to create a better future for the world.”

Weir ESCO takes advantage of expansion opportunities in Utah, Quebec

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Weir ESCO’s growth trajectory has continued in 2021, with the ground engaging tool (GET) major capitalising on two fast-moving expansion opportunities in western USA and eastern Canada in the March quarter.

The acquisitions represent exciting new platforms for sales and brand recognition growth in the two regions, according to the Weir subsidiary.

With one of ESCO’s largest dealers, based in the Western US, set to retire last year, Weir ESCO decided to fill the void.

The company explained: “Without the dealer to represent us, our future with a significant mining operation in the region – a mine that generates approximately 11% of annual copper production in the US – was at stake.”

The mine’s cable shovels are outfitted exclusively with ESCO GET and multiple other pieces of equipment, including hydraulic machines and front-end loaders, are also fitted with ESCO products.

The company’s teams jumped into action to secure the business, with the new Salt Lake City branch becoming operational in early January. It got right to work establishing a direct service relationship with the key customer, Rio Tinto Kennecott, and expanding market share with other mining and infrastructure companies customers in the territory, the company said.

Up north in Canada, the launch of Weir ESCO’s Quebec branch resulted from seizing a timely, high-stakes opportunity, as well, the company said.

Quebec is home to Canada’s largest operating open-pit gold mine, Canadian Malartic. The mine employs more than 2,000 workers around the clock and many pieces of equipment are outfitted with ESCO GET, according to the company.

“When changes in the local distribution channel occurred, Weir ESCO began considering how to parlay the situation into market expansion opportunities,” it said.

Weir Minerals, a division of the Weir parent company, already had an established presence in the area, presenting additional synergy opportunities.

By the end of January, Weir ESCO’s new Quebec team was on board and sharing office space with the Minerals branch (office pictured).

As in Salt Lake City, the Quebec branch will focus on growth through a direct service approach with customers, it said.

Pete Huget, Managing Director for North America, said: “This is an energising time for us as we move with more speed and agility to take advantage of market opportunities to grow the business. We are looking forward to capitalising on these opportunities to service our own customers directly. No one can service a customer like an ESCO employee.”