Tag Archives: Weir

Weir unveils NEXT Intelligent Solutions digital offering at MINExpo

Automation, IoT, Mining events, Mining software, , ,

Weir’s new digital offering, NEXT™ Intelligent Solutions, extends and expands the OEM’s current capabilities and transforms its process optimisation services into real-time digital solutions, it says.

In recent years, Weir has been focused on harnessing digital technologies to improve equipment performance, availability and product quality – overall equipment effectiveness (OEE). Having recently added artificial intelligence (AI) capabilities to its suite of digital solutions through the addition of SentianAI, Weir is now harnessing these technologies to optimise entire circuits and processes, and it is showcasing it at this week’s MINExpo 2024 event in Las Vegas.

Weir has developed digital packages for all of its market- leading solutions – pumps, cyclones, HPGRs, screens and hoses and spools – based around key customer needs: Insight, Uptime and Production.

The Insight package provides provides actionable visibility of system health and performance. It includes:

  • Condition monitoring;
  • Process monitoring;
  • Digital documentation; and
  • Maintenance monitoring.

The Uptime package is focused on extending availability using predictive condition monitoring. It includes:

  • Stage 1 – Optimisation;
    • Wear detection technology
    • Predictive maintenance
  • Stage 2 – Automation
    • Equipment adjustment automation
  • The Production package empowers users to maximise process efficiency with AI-powered optimisation. It’s a two-stage process:
    • Stage 1 – Process optimisation
    • Stage 2 – Process optimisation automation

Weir says: “Weir knows its market-leading products better than anyone, and when this expertise is combined with the latest in AI capability and the modelling of its proprietary data, it is able to make a real difference to customers. ”

Weir’s ‘all-of-mine’ capabilities on show at MINExpo 2024

Automation, Comminution of minerals, IoT, Mineral processing, Mining equipment, Power supply for mines, Sustainable mining, , , ,

Weir is showcasing its all-of-mine capabilities at this year’s MINExpo 2024, in Las Vegas, this week.

It is launching its ESCO® NEXSYS™ GET Lip System for rope shovel dippers, which lowers lip maintenance requirements, extends tooth and adapter life and, ultimately, provides miners with longer uninterrupted shovel operation.

Weir will also be unveiling its new high-capacity ENDURON® ELITE screen. It’s a double-deck banana screen, available in a range of sizes, the largest of which has a deck measuring 4.3 m x 8.5 m and weighs nearly 50 t. It’s driven by two exciters, whereas competitor machines of comparable size require three.

It will form an integral part of Weir’s commitment to deliver transformational flowsheet solutions in which traditional tumbling mills are replaced by HPGRs and vertical stirred mills, potentially reducing energy consumption by up to 40%.

Weir’s booth will feature the Digital Hub, which will highlight Weir’s digital offering – MOTION METRICS® and Weir’s new digital brand, NEXTTM Intelligent Solutions.

The new MOTION METRICS ShovelMetrics™ Gen 3 Payload monitoring solution is designed to optimise truck loading and improve haulage efficiency by reducing both underloading and overloading. And as part of Weir’s commitment to service its customers even in the most remote locations, MOTION METRICS systems now support connectivity via Starlink, enabling reliable data transmission anywhere in the world.

NEXT™ Intelligent Solutions extend and expand Weir’s current capabilities and transforms its process optimisation services into real-time digital solutions. Weir has developed digital packages for all of its market- leading solutions – pumps, cyclones, HPGRs, screens and hoses and spools – based around key customer needs: Insight, Uptime and Production.

The Digital Hub will use monitors to create a remote operation centre, allowing attendees to experience the same digital platforms and interfaces that Weir utilises to support its customers.

Attendees will also have an opportunity to experience an interactive scale P&H 41000XPC shovel model demonstration of MOTION METRICS ShovelMetrics™ Gen 3, as well as a ShovelMetrics model control station, featuring the same touch screen monitor and controller used by operators.

Weir experts from its digital, extraction, processing, comminution, tailings, and flowsheet solutions teams will be available at the booth to continue the conversation about how Weir is partnering with customers to accelerate sustainable mining.

Jon Stanton, Chief Executive Officer of Weir said: “MINExpo is a wonderful event and a great opportunity to catch up with our customers and colleagues. We’ve been doing a lot of work to expand our portfolio of innovative, end-to-end solutions to help our customers produce the metals and minerals required to transition to a low carbon economy and it’s exciting to be able to show that off at the world’s largest mining show.

“It is clear the world needs more metals and minerals but there is a recognition in the industry that we need to mine them more sustainably than we have in the past. That means using less energy, using water wisely and generating less waste. And Weir – with our world-class engineering, advanced materials science and intelligent automation – is at the forefront of helping miners do that.”

Weir to supply Enduron HPGR for De Grey Mining’s Hemi gold project

Comminution of minerals, Mineral processing, Mining equipment, Precious metals, , , , , , , ,

Weir has been awarded the contract to supply a large ø2.4m x 2.25 m Enduron® HPGR (high-pressure grinding rolls) for De Grey Mining’s flagship Hemi gold project in the Pilbara of Western Australia.

Hemi has a mineral estimate of 10.5 Moz and at full capacity, the processing plant will have a nameplate throughput of 10 Mt/y.

Peter Holmes, Project Director of De Grey Mining, said: “De Grey Mining is pleased to partner with Weir on one of its key long lead items for its Hemi Gold Project and appreciates Weir having a local service facility to provide the required support to our site and the region.”

Bjorn Dierx, Global Product Manager for Enduron HPGRs, said: “Our partnership with De Grey Mining further expands our footprint in sustainable comminution. Our proven track record of developing highly engineered solutions for the industry, together with our capability to partner with our customers to bring projects to life, ensures that De Grey Mining will be in good hands to achieve its productivity, sustainability and project execution targets.

“The Hemi gold project will benefit from Weir’s state-of-the-art Enduron HPGR technology, which delivers operational flexibility, grinding efficiency and equipment availability. Importantly, Enduron HPGRs also provide significant improvements versus traditional tumbling mill technology with energy savings of up to 40% and in turn, a lower carbon footprint. This will be the fifth, similar-sized Enduron HPGR in the Pilbara region alone, which is a testament to its credibility in high capacity, hard-rock grinding.”

Weir recently opened its Port Hedland Service Centre, strategically located to support its customers in the Pilbara region in Western Australia. The centre features facilities for Enduron® HPGR servicing, including tyre roller assembly, and will allow De Grey Mining to benefit from product training in close proximity to the mine site.

Kristen Walsh, Regional Managing Director of Weir’s Minerals Division, said: “This win further underscores Weir’s commitment to making mining more sustainable and demonstrates the substantial opportunity that can be made to CO2 emissions reduction when choosing an energy-efficient technology in a large greenfield project.”

Weir’s ore characterisation work shifts gears to value generation loop

Base metals, Comminution of minerals, Environmental, Mineral processing, Mining equipment, Mining services, Steel and iron ore, Sustainable mining, , , , , , , , , , , , , , , , , ,

Chris Carpenter, VP of Technology for Weir ESCO®, is on a crusade to educate the mining industry on the importance of orebody knowledge.

As an executive with more than 35 years of experience and 40 patents to his name, he has heard numerous stories about “sub-optimal operational decisions” being made at mine sites due to a lack of information.

Through an ore characterisation project under development within several teams at Weir, Carpenter shared the company is focused on developing cost-effective solutions to provide this information in real time.

He is, however, aware that the mining sector, as a whole, needs convincing.

“I can tell you that many of our customers do not yet acknowledge the full value of what we are looking to provide the sector,” he told IM.

This is changing, with industry studies on the correlation between poor orebody knowledge and negative financial impacts and risks in the mine development process coming to light – IMDEX, the Mineral Deposit Research Unit and the Bradshaw Research Institute for Minerals and Mining at the University of British Columbia and Ideon Technologies are, for instance, currently engaged on such a study.

In announcing the study, IMDEX Chief Geoscientist, Dave Lawie, hit on a similar theme to Carpenter: “For the mining industry to adopt this technology, it must have clear evidence of the financial impacts and risks of poor or no orebody knowledge and a way of assessing the most efficient methods of collecting, analysing and optimising it.”

What “this technology” is remains open to debate, with many pre-concentration and ore sorting technologies continuing to sprout up among fertile innovation soil in the mining sector.

ESCO and Carpenter believe this technology – at least in a base metals and iron ore application context – has roots in Sustainable Development Technology Canada (SDTC), an arm’s-length foundation created by the Government of Canada to fund new clean technologies. Motion Metrics International Corp received SDTC funding back in 2020 for a project using the core innovations of hyperspectral imagery (HSI) sensors, 3D particle size distribution (PSD) analysis and machine-learning algorithms to control energy-intensive mining equipment, an SDTC backgrounder from 2020 explained.

Chris Carpenter, VP of Technology for Weir ESCO

Motion Metrics, in a separate announcement, said the 3.5-year project would lead to the design, development and deployment of a commercial mine-to-mill energy efficiency solution.

“Upon successful completion, mines worldwide will be able to order and deploy this solution, without changing their daily operations, to meet their sustainability targets while reducing their comminution costs,” it said.

University of British Columbia’s Norman B. Keevil Mining Engineering Department and several other organisations partnered with Motion Metrics for this project.

A lot has changed in the four years since this announcement, with Weir Group having acquired Motion Metrics International Corp and been incorporated into ESCO.

IM initially reported on developments of what Carpenter referred to as an “ore characterisation” project in 2022. At that time, this consisted of a BeltMetrics™ trial installation using a MOTION METRICS™ advanced imaging sensor for PSD analysis and a commercial, HSI sensor positioned above a conveyor that was directly after the crusher in a mine’s flowsheet.

When IM caught up with Carpenter in late July, he could report on not only progress with the BeltMetrics installation, but also a fixed-term trial of “ore characterisation” in a TruckMetrics™ installation.

“We have now run two different applications for the technology,” he said. “The belt monitoring trial continues to operate and has demonstrated the ability to predict SAG mill throughput based on the input ore characteristics. We also ran a very successful trial of bulk sorting using similar technology looking at the content of haul trucks. The trial monitored and analysed around 1,000 trucks and several were identified as low grade. Extensive lab testing continues as we evaluate mine ore samples to understand the capabilities of our approach. Based on our lab and field evaluations we are convinced the technology will allow us to quickly and accurately monitor grade, alteration, deportment and deleterious minerals.”

The BeltMetrics trial installation uses a MOTION METRICS advanced imaging sensor for PSD analysis and a commercial, HSI sensor positioned above a conveyor that is directly after the crusher in the mine’s flowsheet

“I would say our proof of concept work has really allowed us to now pick up the pace of investment and search for more development partners to further this technology.”

The TruckMetrics ore monitoring trial – carried out on 100-232 t-payload trucks – may pique interest here, but Carpenter says the initial product development path lies in the processing plant and on the conveyor.

“We are looking to, first, put more minimum viable products (MVPs) out in the market for belt-based solutions,” he said. “While our initial entry into this space was to look at bulk sorting – and we recognise this is still the ‘big target’ – [the] voice of [the] customer research has identified a huge need to provide plant-based systems for applications in managing stockpiles and feed grades.”

These MVPs are likely to be deployed on “development partner” sites with existing separation mechanisms downstream of the crusher – ie apron feeders – where diversions can be made based on the HSI and PSD data.

This same voice of the customer research highlighted the need for an in-pit system that could boost productivity, throughput and recovery ahead of the plant, yet the financial amount estimated for a commercial system based on the HSI and PSD sensor combination did not find favour.

“This has led to our own research into what we feel is a new-to-the-world application or modification of standard HSI,” Carpenter said. “We believe this will give us a competitive edge in the market.”

Illumination restrictions and uses have often been touted as the potential drawbacks of using spectral imaging in the ore sorting space, which IM understands is one of the areas of focus for Weir’s own R&D and lab-based testing.

But there are also other factors to consider ahead of a commercial Weir proposition – whether that is in the pit or plant – landing on the market.

“We don’t just want to be sensor salespeople,” Carpenter says. “The complexity and variety of applications will require a shift to specific solutions for our customers and the need to back that up with the aftermarket service our customers expect becoming their productivity partner.

“What we are proposing is more than just technology; it needs to be a solution that validates the value on a regular basis in a continuous loop.”

That same loop comes back to Carpenter’s and Lawie’s assessment of the industry need to acknowledge the value of such data ahead of adopting the technology.

“Fortunately, our ‘Mining technology for a sustainable future’ focus at Weir is allowing us to invest the money the industry needs to provide both the value generation and value acknowledgement to make such solutions viable and effective,” Carpenter concluded. “This type of work – and orebody knowledge more widely – is critical for the future of mining.”

Weir to highlight smart mining and portable crushing solutions at Electra Mining Africa

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

At this year’s Electra Mining Africa exhibition, in Johannesburg, South Africa, visitors will be attracted to the Weir stand by innovations such as the Weir Modular Wheeled Plant (WMWP), a fully mobile crushing and screening plant, as well as the latest in the company’s cutting edge digital solutions for smart mining, the OEM says.

Supporting customers to mine for a more sustainable future, Weir will showcase not only its leading range of equipment and solutions, but the digital technology to further optimise its performance and reliability.

“Our exciting Motion Metrics mine operation monitoring systems will be one of the main features at the show,” Mufaro Muzvondiwa, Process and Products Director at Weir, says. “These systems provide mines with real-time particle size analysis of material carried on shovels, loaders, conveyor belts and haul trucks – helping to avoid blockages at the crushing stage and optimise the mine-to-mill value chain.”

Using stereoscopic vision combined with artificial intelligence (AI), Motion Metrics™ cameras leverage machine learning to enhance its predictive capabilities and provide actionable insights to customers, according to Muzvondiwa.

Another highlight will be Weir’s intelligent solution which features condition monitoring technology. This is portrayed through 3D conceptualisation, showing all associated benefits including safety, savings and maintenance optimisation.

“Visitors to our stand can witness the value of real-time monitoring in enhancing plant performance and optimising uptime,” Muzvondiwa explains. “This is where Weir is supporting our customers’ ambitions to be more cost effective by driving down their total cost of ownership of equipment while driving productivity and sustainability.”

In addition to the display of its latest pumps, screens, cyclones, valves, liners and ground engaging tools, Weir will also have its recently launched mobile crushing and screening plant at its outdoor stand. With Weir’s WMWP fully mobile plant (render, pictured) mounted on an on-road trailer, the plant can be moved to site and set up within a couple of hours – as a ‘plug-and-play’ solution – Weir says.

“This innovation has already generated great excitement in the aggregates and small-scale mining sector,” Muzvondiwa says. “The design provides a fully mobile plant, making it ideal for road projects requiring aggregate crushing at various points along the route.”

Muzvondiwa highlights that Electra Mining Africa, running from September 2-6, provides a useful forum to remind visitors of Weir’s concerted focus on partnerships for sustainable mining. This includes the extensive footprint of OEM service centres and partners across Africa, ensuring technical support is always available in close proximity to mines.

“In addition to our South African presence, we are present in countries including Cote d’Ivoire, Ghana, Botswana, Namibia, Senegal, Tanzania and Zambia,” he says. “Our three manufacturing centres in South Africa also ensure high levels of local manufacture, to promote African economies and to streamline the supply chain to our customers.”

The combination of quality products and dedicated service means that Weir can be confident in the warranties and predictions it provides to customers regarding the productivity of its solutions. “This is demonstrated by our ability to enter into cost per tonne agreements with customers,” he says.

He adds that local skills development is also a priority for the company in building its service infrastructure, including its Mill Circuit University.

Weir on mining technology for a sustainable future

Automation, Environmental, Mining equipment, Power supply for mines, Sustainable mining, Water management, ,

Weir has introduced its refreshed brand – Mining technology for a sustainable future – in a move that, it says, encapsulates the company’s commitment to providing innovative end-to-end solutions that accelerate the transition to smart, efficient and sustainable mining.

The company says: “The mining industry that we serve is in a period of change – it recognises the need to scale up and clean up to deliver more of the critical metals needed for the energy transition, and produce them in a more sustainable way.

“Weir – as a united brand – is at the heart of that change, as the strategic partner that our customers can call on as they lean into their biggest challenges.”

Weir says it has changed and reshaped its business over the past few years to focus on mining technology. “We have a clear strategy and a strong purpose – to enable the sustainable and efficient delivery of the natural resources essential to create a better future for our world, ” it says, adding that this is the right time to refresh itsbrand to support that.

It added: “Our new brand represents who we are as a company, what’s important to us and what to expect from us – not only in terms of mining technology or financial returns, but from our culture, our values and our focus on creating a safe, diverse, inclusive and equitable workplace.

“Weir has over 150 years of experience of powering progress in the world’s major industries. Today our combination of deep customer insight, world-class engineering and materials science, enabled by intelligent automation, have never been more relevant as we help our customers transform, with technology to help them move less rock, use less energy, use water wisely and create less waste.

“Mining technology for a sustainable future is exactly what we do at Weir…and that puts us in a strong position to lead in the new mining era.”

It said that today marked the start of the new brand introduction with more to come over the next few months.

Weir opens new service centre in Port Hedland, Australia

Comminution of minerals, Equipment maintenance, Mining equipment, Mining services, , , , , , , ,

Weir has officially opened its new Port Hedland Service Centre, strategically located in the heart of the Pilbara region, Western Australia.

The A$28 million (US$18.6 million) state-of-the-art facility strengthens Weir’s commitment to sustainable mining and is the flagship Enduron® high pressure grinding rolls (HPGR) service centre in the region, it says.

The new facility bolsters Weir’s national network of 16 service centres and will support customers and their operations across the Pilbara region, including the Iron Bridge project which incorporates Weir redefined flowsheets – the world’s first dry comminution circuit without tumbling mills. Port Hedland serves as a critical hub for the mining and resources industry in Australia, driving economic growth and success for the important iron ore region.

The Port Hedland service centre will deliver innovative engineering solutions and expertise, enhancing operational efficiencies and advancing sustainable progress across the Pilbara’s dynamic mining landscape, Weir added.

“With best-in-class technology and support, the centre features facilities for Enduron HPGR servicing, including tyre roller assembly and Linatex® rubber lining services helping customers to extend the life of their assets,” it says.

The centre is equipped to service Weir’s broader range of products and technologies, provide engineering and maintenance support as well as critical parts storage for faster service times for customers.

Kristen Walsh, Regional Managing Director at Weir Minerals, said: “The new centre at Port Hedland will support our key customers in the region, providing Weir’s best-in-class service and expertise. The A$28 million facility demonstrates our commitment to sustainable mining and with further investment planned, we will continue to support our ambitious growth plans in the Pilbara region of Western Australia.”

The next stage of development, set for 2025, will see an expansion of the team and specialisation in the repair and overhaul of various Weir processing equipment including Warman® pumps, Cavex® hydrocyclones and Isogate® valves as well as Enduron crushers and screens.

SentianAI

Weir expands digital capability with acquisition of AI-focused SentianAI

Automation, Comminution of minerals, IoT, Mineral processing, Mining mergers and acquisitions, Mining software, Sustainable mining, , , , ,

Weir has acquired Sweden-based SentianAI in a move that, it says, will accelerate its technology roadmap and expand its digital capability to provide enhanced productivity and sustainability offerings to customers. SentianAI is a developer of artificial intelligence-based solutions that optimise performance in minerals processing. Founded in 2016, it is based in Malmö and has a team of software developers and data scientists.

The software that SentianAI develops uses advanced AI algorithms that continuously learn and adapt to the dynamic processes within a mine, providing continuous improvement and optimisation over time, Weir says. Jon Stanton, CEO of The Weir Group, said: “Digital technology has an important role in helping address the challenges of declining ore grades, production efficiency and CO2 emissions for our customers. SentianAI’s advanced software solutions complement and will bridge our Synertrex® and Motion Metrics™ technologies well. Together, these will enable us to provide holistic performance monitoring and optimisation for smart, efficient and sustainable mining.”

Earlier this year, SentianAI and Xore Analyzers formed a strategic cooperation to combine XORE’s XRF analysers, which provide real-time data on metal content, with SentianAI’s machine-learning technology, which adapts to variations in ore properties. The pact, SentianAI says, could allow mining operations to improve their recovery rates and overall efficiency.

IM interviewed SentianAI Founder and CEO Martin Rugfelt last year on its technology and approach. He said it already had a flotation project targeting increase of recovery rate but also the stabilisation of the circuit performance. It was also working on optimising a crushing and grinding circuit with the primary goal of an increase in throughput.

Martin Rugfelt, SentianAI Founder and CEO

When asked how its approach differed to other AI approaches in industry he commented: “A lot of the ‘traditional’ AI systems we see are actually AI toolkits/platforms that are sold on the basis that the customer can create AI logic that they need to solve specific problems without having to understand the detailed data science. Unfortunately, without knowledge of the underlying AI and data science, creating AI for complex systems eg control processes is very difficult. As a result, many ‘traditional’ AI systems are abandoned after purchase. Sentian has taken a different approach. Our SentianController is explicitly designed to optimise control of industrial processes, so when customers buy it, they already have the AI algorithms developed and tested for the complexity of control system optimisation. It is effectively a point solution that means you do not need a large data science team to build and run the AI solution.”

He added on the underlying technology: “SentianAI has worked for many years to select the best algorithms and refine how these algorithms work to deliver a unique AI system that has been designed to control and optimise industrial processes. This is very complex and requires some of the latest technologies in AI to be able to achieve the necessary control. We have also developed a system that can uniquely be applied in stages as data quality improves and operator confidence increases – going from making recommendations to fully autonomous control at the speed our customers want. This allows customers to build confidence before committing to fully autonomous control. We have chosen not to patent our solution as it would have exposed the technology, however, we would argue it is very unique.”

He said the system is also capable of self-adaptation, which can be achieved when you have both the right data and the right AI models. “The AI creates a dynamics model that is made from both historical and ‘live’ operational data. It can then choose the set of control parameters that deliver optimum performance towards a specific goal, eg maximum production for minimum energy usage. In comparison to traditional supervisory control systems it adapts to changes in the process. For example, if the process changes for some reason, leading to new data points, the AI incorporates these into its model, new predictions are made, and new control parameter settings are used. New goals can also be set, resulting in SentianController choosing the best control parameters to achieve those goals.”

CEEC-GlobalWaterInitiative

Weir and Agnico Eagle sign up to CEEC Global Water Initiative

Comminution of minerals, Environmental, Mineral processing, Sustainable mining, Water management, , , , , ,

CEEC International, an independent global not-for-profit committed to accelerating the adoption of eco-efficient minerals and metals production practices, has welcomed both Weir and Agnico Eagle Mines as premium sponsors and early adopters of its Global Water Initiative.

Weir, a respected provider of engineered solutions to the resources sector, shares CEEC’s mission to drive the adoption of eco-efficient practices within the industry. Its renewed support as a premium sponsor underscores the company’s dedication to advancing sustainable minerals and metals production, according to CEEC.

The support from Agnico, a major gold producer, signifies a strategic alliance and collaboration aimed at promoting sustainable mineral processing and improved understanding of water management within the resources sector, CEEC said, with the association between the two companies grounded in a shared vision to accelerate the adoption of eco-efficient practices in the resources sector.

The Global Water Initiative, officially launching at the MetPlant 2023 Conference, being held on November 5-8 in Adelaide, Australia, is a critical step towards addressing water management and risk mitigation in the resources sector. The initiative seeks to build a shared understanding, identify gaps and outline necessary actions to ensure responsible water usage within the industry.

CEEC’s mission is to facilitate knowledge sharing, cross-sector collaboration and advocacy of eco-efficient practices within the global resources sector. By disseminating research findings, analytical tools and innovative solutions, CEEC aims to reduce energy and water consumption, as well as other associated impacts in mining, processing and refining of minerals, it says.

CEEC International says it encourages industry stakeholders to join the initiative, contribute to the discussions and collectively shape a more sustainable future for water management within the resources sector.

MotionMetrics-BeltMetrics

Weir eyes game-changing energy intensity reductions with ore characterisation project

Base metals, Comminution of minerals, Environmental, IoT, Mineral processing, Mining equipment, Mining software, Sustainable mining, , , , , , , , , , , , , , , , , , ,

With an extensive footprint from the rock face all the way through to tailings, it was only a matter of time before the Weir Group decided to enter the ore sorting game.

In recent years, the company has re-focused as a pureplay mining and aggregates company that can provide value throughout the flowsheet.

The company ditched its oil & gas exposure and added to its process plant and tailings remit with the acquisition of ESCO, a front-end-focused mining technology company with leading market share in the ground engaging tool (GET) segment.

Having more recently incorporated Motion Metrics into the mix – now within the ESCO division – it is embarking on a project that could have positive ramifications throughout the wider Weir Group offering.

Motion Metrics is a developer of artificial intelligence (AI) and 3D rugged machine vision technology. Its smart, rugged cameras monitor and provide data on equipment performance, faults, payloads and rock fragmentation (read: particle size distribution (PSD)). This data is then analysed using embedded and cloud-based AI to provide real-time feedback to the mining operation.

Initially developed for GET applications, these technologies have recently been extended into a suite of products and solutions that can be applied from drill and blast through to primary processing. Motion Metrics has, in the process, built up an impressive customer base and income stream, performing well since the acquisition.

Weir has outlined a £500 million-plus ($604 million-plus) emerging digital market opportunity for the entity, with much of this hinged on rugged machine vision technology, its sophisticated digital platform and the ability to add ore sensing to its offering.

This became clear at the company’s recent Capital Markets Day during a presentation from Chris Carpenter, VP of Technology for Weir ESCO.

Sensing, not sorting

At this event, Carpenter said the company was combining Motion Metrics’ PSD capability with ore characterisation technology to explore high-value opportunities for its clients.

“Looking further out, we believe ore characterisation…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.”

Weir has outlined a £500 million-plus emerging digital market opportunity for Motion Metrics, with much of this hinged on rugged machine vision technology, its sophisticated digital platform and the ability to add ore sensing to its offering

This concept is not new. Measuring the quality of ore has been spoken of for decades and, more recently, has become a reality with the likes of MineSense, NextOre, IMA Engineering, Scantech, Malvern Panalytical and Rados International, among others, all having trialled technology or deployed commercial solutions across multiple commodities and sites.

Metso Outotec, one of Weir Minerals’ big competitors in the plant and tailings arena, has also spoken of the potential for bulk ore sorting by using its existing portfolio of material handling modules, crushing stations, mobile crushing equipment and bulk material handling solutions as the basis, while incorporating sensors from other vendors.

Weir believes it is one step ahead of its OEM counterpart in its pursuit of ore sorting, even if Carpenter is only referring to the trials currently being conducted at an unnamed copper mine as “ore characterisation” studies.

“With the acquisition of Motion Metrics, what we essentially bought was the ruggedised vision systems used in both mobile and fixed applications,” he told IM in January. “While the ore sensing piece is by no means trivial, the integrated AI capabilities and digital infrastructure that allows the data to be transported via a variety of avenues is incredibly important.

“Being able to pick up the data is one thing but being able to transport that data to the right people in a secure, accurate and timely manner is something different altogether.”

With a portfolio that includes LoaderMetrics™, BeltMetrics™, TruckMetrics™ and CrusherMetrics™, Motion Metrics and the Weir ESCO R&D team had several potential applications to start its ore characterisation journey with.

The company has settled on a BeltMetrics installation for its first trial, with Carpenter confirming the sensing solution under the microscope is currently positioned above a conveyor that is directly after the crusher in the flowsheet.

“We feel we will learn quickest over a conveyor belt, so it is really an expansion of the existing BeltMetrics solution that we will start with,” he said.

The sensing options open to Motion Metrics for this trial were also vast, with the aforementioned ore sorting vendors using the likes of X-ray Fluorescence, magnetic resonance, prompt gamma neutron activation analysis, pulsed fast thermal neutron activation, and others within their solutions.

Motion Metrics has chosen to incorporate hyperspectral imaging into its PSD mix.

Carpenter explained: “When you think about ore characterisation, we are just moving from a visual spectrum base with Motion Metrics vision-based systems to the expanded light spectrum for gathering data and making decisions. This is all being built on the established digital platform the company has.”

The company is not alone in using this type of technology. MineSense has spoken of trials using multispectral sensing technologies, while Australia-based Plotlogic has been tapping hyperspectral imaging to provide precision orebody knowledge prior to mining.

Collaborating on energy intensity reductions

Safety, scalability and flexibility were three factors taken into account with the hyperspectral imaging decision, but Carpenter was also aware of the potential limitations in using such technology.

Mines will need to be willing to make some changes and invest in alternative infrastructure to leverage the most value out of the solution the company is putting forward.

“That is where productivity partnerships that we spoke about on the Capital Markets Day are going to be really important,” he said. “It is going to be essential to collaborate with customers.”

The initial collaboration with the trial mine site looks to be extensive, stretching from the back end of December throughout 2023.

The site is already equipped with a significant amount of Weir Minerals and ESCO equipment, so the collaboration appears to have started well before this trial.

“Throughout the year, we will have the opportunity to make enhancements; starting out with an initial system that is upgraded,” Carpenter said. “By the end of the year, we should have high confidence of having something ready to commercialise. It could also be that we have other trials running concurrently with this one to extend the learnings.”

The two primary key performance indicators for the trial surround accuracy and speed, with Carpenter saying the company is targeting to at least meet the metrics competing technologies have been promoting over recent years.

“In both cases, we are well equipped to measure both and – in the initial phase – we are performing well,” Carpenter said.

“Right now, when they (the mine site) carry out an assay, they have to stop the conveyor belt, take a sample off and send it to a lab. At best, the feedback takes hours, if not days. Motion Metrics has done a really good job of building the sensors, algorithms and platforms to process the data coming from above that belt very quickly.”

There are a team of very experienced, PhD-equipped personnel currently working on this trial, monitoring the real-time results from Motion Metrics’ base in Vancouver, however there is a Weir network across the globe watching and waiting for news.

A sensor above a conveyor belt able to provide ore characterisation data is step one. Step two will most likely involve leveraging this data to provide insights as well as initiate downstream actions.

Then, there is the potential to equip these sensors for the pit on an excavator or wheel loader – which introduces many additional challenges both Motion Metrics and ESCO are aware of. Understanding exactly what is in the bank or going in the bucket will be critical to improving operational efficiencies.

These are longer-term goals that Motion Metrics, ESCO, Weir Minerals and Carpenter are cognisant of – and excited about – that may provide the true value to customers throughout the flowsheet.

“What is exciting for us is that – as may be obvious – the further upstream you can make some good decisions, the more energy you can save downstream,” he said. “As you get into some of the other processing elements in the plant, there are sustainability benefits to be had – a more efficient use of reagents to liberate the elements, a more efficient grinding setup based on ore characteristics, a reduction in water use, etc.

“The driver for this has really been sustainability and energy reduction. It is all about reducing the energy intensity associated with ore.

“We feel we are well equipped and in a good position to deliver on this and provide the industry with the step change in sustainability that it requires.”