International Mining Engineer November 2025

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EXPLORATION

WITHOUT THE RISK Emesent’s Hovermap technology generates highly detailed 3D imaging for previously unmappable areas

NATURE’S GIFT

RETURN PROJECT

JUST ADD WATER

Microbial fuel cells clean up mining waste

A European consortium tackles e-waste recycling

A carbon-removal technology uses natural water flow

CONTENTS

Welcome This issue of International Mining Engineer will appeal to those interested in digital technologies and big data, as several stories include AI technologies, continuous monitoring, digital mapping and data.

Our cover story (page 6) explores Hovercraft by Emesent, which combines LiDAR scanning with SLAM technology to create detailed 3D maps in GPS-denied environments. Another article by ASC Sensors (page 10) details the use of continuous monitoring data to protect the structural integrity of mines from subtle earth vibrations unnoticed by humans.

The fight to make mining more sustainable is ongoing. Two pieces explore technologies that harness the power of nature to lessen the environmental blow dealt by the mining industry. In one piece, the founder and CEO of Vycarb (page 32) details the company’s waterbased carbon capture technology.

The other piece hears from Tersa Earth founder and CEO Barinder Rasode (page 16), whose microbial fuel cell technology contributes to a circular economy.

As trade wars continue, countries keep exploring how to reduce reliance on foreign critical raw materials and processing facilities.

The Return Project (page 37) analyses the e-waste recycling technology being developed in a European consortium’s efforts to break Europe’s dependence on carbon-intensive imports. An Australian-American alliance (page 22) looks at the recently-signed framework for accelerating priority projects delivered by and for the two countries, thereby reducing reliance on China.

Saskia Henn Editor

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– NOVEMBER 2025 – COVER STORY

OPERATIONS MANAGEMENT

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Exploration without the risk LiDAR scanning and SLAM technology combine to map previously unmappable areas

LOAD & HAUL

10 12 14 15

Nature's gift A Vancouver company harnesses the power of microbes in recycling

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Under the sea How AI can assist in and accelerate seabed exploration processes

Seismic sensors Continuous vibration monitoring technology protects structural integrity of mines

Better data

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Striking gold A Nevada mining company finds a potentially significant gold system

A data project supports detailed record-keeping

Autonomous Options Why automated fleets could become the norm

Hitting the hydraulics How tailored hydraulic cylinders assist in countless mining tasks

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CONTENTS

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n Australian-American A alliance What the signing of a bilateral framework on critical minerals and rare earths means

SPECIALIST EQUIPMENT

24 25 26 27

Transferring torque A new disc coupling line offers higher torque capacity

Drilling deep How hybrid impact technology trumps traditional methods

Advanced crushers A new range of jaw and cone crushers is eliminating manual intervention

Driving longevity How medium voltage variable frequency drives are prioritising precision

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Funding digital transformation A technology programme aims to accelerate digitalisation

MATERIALS HANDLING

32 34 37 40

42 44

Just add water A look at a Brooklyn-based startup’s novel carbon capture method

Preventing belt drift Why belt alignment is important and how to monitor it

The Return Project How a European consortium is tackling e-waste

Customisable conveyors How a tailored approach can optimise materials handling

Low-cost lithium The advantages of a new ion-exchange technology for lithium extraction

Steady strides How Saudi Arabia’s investment into mining resources has paid off

SKILLS ZONE

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Simulation software A look at the advantages of practicing digitally first

SHOW PREVIEW

48

Morocco International Mining Congress

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An opportunity to respond

Supporting sustainable mining

Resourcing Tomorrow

HEALTH & SAFETY

28 29

Improving safety for mining workers A 5G radio addresses the drawbacks of PMRs

An argument for self-rescuers Exploring the closed-circuit system of filter alternatives

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PUBLISHER Jerry Ramsdale EDITOR Saskia Henn shenn@setform.com CONTRIBUTING EDITOR Nicola Brittain nbrittain@setform.com DESIGN – Dan Bennett, Jill Harris HEAD OF PRODUCTION Luke Wikner production@setform.com BUSINESS MANAGERS John Abey | Darren Ringer ADVERTISEMENT EXECUTIVES Paul Maher, Iain Fletcher, Peter King, Marina Grant, John Davis e advertising@setform.com

Setform’s international magazine for mining engineers is published four times annually and distributed to senior engineers throughout the world. Other titles in the company portfolio focus on Process, Design, Transport, Oil & Gas, and Power.

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Setform Limited | 6 Brownlow Mews, London, WC1N 2LD, United Kingdom

EXPLORATION WITHOUT THE RISK Mapping the unmappable

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COVER STORY

Mines can now be mapped and monitored remotely

EXPLORATION

WITHOUT THE RISK

Emesent’s Hovermap technology generates highly detailed 3D imaging for previously unmappable areas

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COVER STORY

M

ining is an industry made up of extremes. Hazardous physical environments, risky working conditions, cavernous depths and high reward.

In 2024, the International Council on Mining and Metals (ICMM) reported 42 worker deaths, an increase from previous years.

Of the 42 deaths, which were recorded from ICMM’s 24 member companies, nearly half of them occurred underground, where lack of visibility and understanding of the pathways and rooms beneath the Earth’s surface could have contributed to the danger.

One of the most common organisational factors responsible for fatality incidents was failed risk management. Risk management involves identifying, assessing and controlling hazards to reduce the likelihood of incidents, with an emphasis on early identification and continuous monitoring.

Traditionally, early identification and continuous monitoring of hazards have been difficult to execute thoroughly, in large part due to the inaccessible nature of unexplored mining areas. However, as technology has evolved, mines can now be mapped and monitored remotely, removing workers from potential hazards.

Hovermap’s real-time visualisation extends to 360 degrees

MEET EMESENT

Australian design engineering company Emesent is leading the charge on flexible, low-risk navigation software with its autonomous (SLAM)-based LiDAR mapping technology Hovermap.

Emesent’s cofounders, Dr Stefan Hrabar and Dr Farid Kendoul, are former researchers in the Robotics and Autonomous Systems Group within CSIRO’s Data61. Their expertise in robotics, autonomy, AI, machine learning, research and data analytics helped them to found Emesent and create its Hovermap technology.

“Hovermap combines LiDAR (Light Detection and Ranging) scanning with

As technology has evolved, mines can now be mapped and monitored remotely, removing workers from potential hazards Dr Stefan Hrabar, cofounder

Dr Farid Kendoul, cofounder

SLAM (Simultaneous Localisation and Mapping) technology to create detailed 3D maps in GPS-denied environments,” explains Hrabar.

HOW DOES THE TECHNOLOGY WORK?

Hovermap’s light detection and ranging (LiDAR) technology uses a pulsed

CASE STUDY CMOC’s Northparkes block cave mine, located in NSW, Australia, was the first in the country to use the highly automated block caving method for underground mining of copper and gold since 1994.

Planned expansion underground required new intake and exhaust vent raises, which failed in the lower sections shortly after raise boring was complete.

Cage-mounted Hovermap was lowered 560m down the intake shaft, capturing detailed geotechnical data of the deformation and overbreak.

This enabled accurate data collection on the condition of the raises so they could develop remediation or contingency plans.

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COVER STORY

Both above and below ground areas can be analysed. Shadowless underground images and real-time visibility are possible through the technology’s 3D cloud points in GPSdenied areas.

The same unit that is autonomously used underground can also be deployed above ground as a dronemounted, vehicle-mounted, handheld, or backpack-mounted scanner.

Hovermap’s above ground capabilities can help to monitor infrastructure conditions, stockpile volumes, and assist with rehabilitation planning.

HOW CAN HOVERMAP HELP?

Unlike traditional surveying methods, SLAM enables the system to build a map while simultaneously tracking its own location

Hovermap can be used above or below ground

laser light to measure distances and generate highly detailed 3D point cloud data of the Earth’s surface or objects, or beyond line-of-sight.

Simultaneous localisation and mapping (SLAM) are possible with Hovermap through the emittance of laser pulses and measurement of the time it takes for the light to reflect, creating precise models of terrain, vegetation, and built environments.

“The technology operates without GPS or operator line-ofsight, enabling safe data collection in hazardous or inaccessible environments,” says Hrabar.

Instead, Hovermap uses navigation software designed by Emesent, which is an AI-powered autonomy engine called Cortex.

“Unlike traditional surveying

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methods, SLAM enables the system to build a map while simultaneously tracking its own location,” says Hrabar.

“It works reliably in the toughest environments such as tunnels, confined spaces and open areas, where other SLAM systems fail, and automatically corrects for errors in large maps.”

By combining these time-of-flight measurements with the system’s position and altitude data (often from a GPS receiver), the LiDAR system computes precise 3D coordinates.

EXPLORATION

Hovermap covers large areas quickly with its sensing range of up to 300m and more than a million points per second. The real-time visualisation extends to 360 degrees, eliminating blind spots with no light required.

Enabling quick and accurate volumetrics helps industry players to achieve improved awareness of ground and structural conditions, particularly in unstable, inaccessible or abandoned areas.

“Hovermap protects mining operations across multiple dimensions - safeguarding personnel, preventing equipment loss, minimising production downtime and associated costs, and reducing legal and compliance risk,” says Hrabar.

Hovermap allows for the quick identification of deformation and faults through rock mass. With Hovermap, operators can conduct repeat scans of chutes, ore passes and drifts, identifying potential problematic areas requiring evacuation and reinforcement before they become hazardous.

“In mining there are often environments that are not only unsafe, but completely inaccessible to humans – steep declines, high walls, large stopes, or narrow spaces where the alternatives are manual and bulky options such as long survey poles, or not possible at all,” says Hrabar.

Hovermap’s ability to investigate damage, identify hazards and improve upon historical map data can assist in informing operational plans.

It also keeps personnel from having to manually monitor these areas and putting their lives at risk.

For more information visit: www.emesent.com

asc-sensors.de

INERTIAL SENSOR SOLUTIONS

Precision Drilling:

from Mining to Geothermal Energy Drilling down several thousands of meters requires high-tech tools and equipment. Equally crucial is the appropriate sensor technology, to keep to the exact drilling path for precise results. So are shock and heat resistance to prevent strong vibrations and high temperatures from skewing measurement outcomes while drilling through the rock strata.

For the geothermal energy industry, this is enabled by ASC inertial sensor technology. Our portfolio includes high-end JAE quartz-based JA-5 and JA-25 accelerometers particularly suitable for this purpose. In addition, MEMS-based ASC OS-series accelerometers conduct accurate, stable vibration analyses on machines like hydraulic deep drilling vibrators for soil inspection and preparation, to keep them running smoothly and prevent damage.

ASC Inertial Sensors are used for:

Measurement While Drilling (MWD) Geothermal Energy Mining Seismic Monitoring Tunnel Construction

When can we convince you?

Examples of our product portfolio:

Gyroscopes

MEMS accelerometers

IMUs

Seismic accelerometers

Quartz-based accelerometers

SUCCESSFUL WORLDWIDE. AT HOME IN GERM ANY.

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SEISMIC SENSORS Recording and monitoring seismic activity is vital in mining

Continuous vibration monitoring technology from ASC Sensors is protecting the structural integrity of mines

V

ibrations affecting mines are caused in various ways. For instance, by blasting or drilling activities, construction work, industrial facilities, road or rail traffic. The resulting mechanical shocks can place considerable strain on structures, people and technical equipment.

At the same time, vibrations can impact mining shafts and quarrying and drilling sites. Tectonic movements impact them too. They are typically triggered by many subtle tremors that are not immediately noticeable but can be measured. Over time, even lowintensity vibrations can jeopardise the stability of structures and the reliable operation of equipment. Therefore, the recording and monitoring of seismic activity and resulting – or expected – changes in structural integrity play a key role in location selection,

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design measures and safe operation of mining and other industrial sites.

PROTECTING PEOPLE AND OPERATIONS

To help with both challenges, seismicgrade ASC EQ accelerometers are characterised by extremely high resolution far exceeding that of conventional analog sensors. They are based on proven MEMS technology of the capacitive operating principle. Their ability to register even the smallest amplitudes of less than one millionth of gravity (less than 1µg) enables the exact determination of the force and intensity of vibrations – whether caused by seismic activity, open-cast blasting or other work or traffic in the vicinity.

“With the ASC EQ series, we offer highly flexible inertial sensors of seismic accuracy”, says ASC Sensors senior application engineer Markus

Nowack. “Based on this precision technology, we tailor solutions to minimise risks to structures, people and equipment, and to ensure smooth, safe and productive mining operations.”

Specifically designed for the dynamics of subtle and seismic vibrations, the ASC EQ sensor series covers a wide range of vibration events, frequency ranges and amplitudes. With available measurement ranges of ±3g and ±5g, the signal-to-noise ratio (SNR) is around 113dB at a bandwidth of up to 20Hz, and around 108.5dB at up to 100Hz.

CONTINUOUS VIBRATION MONITORING For mining sites and other longterm operations associated with causing regular vibration impact on communities and people in the area, authorities often require monitoring and documentation using suitable

LOAD & HAUL

UP TO 9,500 TREMORS A DAY Earthquakes are caused by shifts in the continental plates. Quakes with a magnitude of 6.0 or above according to Richter typically attract large-scale media coverage. These occur around 20 times a year globally, with the potential to cause major destruction.

Less immediately critical, yet far more frequent are earthquakes of up to 3.0 on the Richter scale: They shake the globe up to 9,500 times daily. Most of these subtle vibrations are not noticed by humans. Regardless, critical structures suffer tremendously from this constant infliction of stress over time.

In addition to Richter, earthquakes are classified according to their intensity using the 12-point European Macroseismic Scale (EMS 1998). Intensity level VII corresponds to an average ground acceleration of around 1m/s2 (0.1g, approximately 10% of gravitational acceleration), which already causes moderate to serious damage to buildings. It is estimated that around a quarter of Earth’s total land mass is at risk of suffering earthquakes of intensity VII and above.

Based on this precision technology, we tailor solutions to minimise risks to structures, people and equipment, and to ensure smooth, safe and productive mining operations

measurement technology. Thresholds for maximum permissible vibration loads on humans and buildings are regulated by relevant norms and standards. Specific focus is placed on protecting employees exposed onsite directly or who work in sensitive locations or machinery.

Continuous monitoring of the structural integrity of buildings, mines, shafts and critical infrastructure is, therefore, of great importance, even outside known earthquake zones.

Magnitudes and intensity levels measured in the region can assist in site selection, construction designs and employee protection measures.

The ASC EQ sensor series is designed to register even the smallest vibrations

For more information visit: www.asc-sensors.de

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BETTER DATA The ICMM’s latest project aims to support reliable, robust record-keeping

T

he need for record-keeping is gaining importance alongside an overarching paradigm shift in the mining industry. A growing focus on sustainable solutions and their impact on developers, policymakers and investors has highlighted the need for standardised documentation.

“Reliable, transparent and consolidated data on the mining and metals industry is a foundational prerequisite for evidence-based policymaking, effective governance, and global progress towards sustainability targets,” says International Resource Panel co-chair Janez Potočnik.

“Only with robust data can we fully understand the sector’s environmental, social, and economic impacts, monitor progress, and ensure accountability throughout global supply chains.”

A GLOBAL DATASET

The International Council on Mining and Metals (ICMM) is attempting to fill the current information gap by creating a data system that can help to inform policy and guide the entire industry.

The first step of the multi-year initiative has been the creation of the ‘Global mining dataset: Understanding the global distribution of mining and metals facilities’ report.

The Global Mining Dataset report provides the most comprehensive publicly available overview of mines, smelters, and refineries worldwide, covering 8,508 sites. It draws from a broader internal record of 15,188 large-scale facilities producing 47 primary commodities.

The report identifies how many mines, smelters, refineries and processing plants exist worldwide, where they are located, and what they produce.

“ICMM’s foundational dataset shows that over 75% of national economies have at least some connection

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The report details which commodities are produced and where

to large-scale mining or mineral processing,” says ICMM president and CEO Rohitesh Dhawan.

“Having a global view of the location, type, commodity and footprint of these facilities is essential to inform the right public and policy debates for this critical sector. With minerals and metals at the heart of the energy transition and geopolitical shifts, robust, global, industry-wide data has never been more critical.”

The report was developed with support from Accenture, Global Energy Monitor, and Skarn Associates with access to other public and proprietary sources.

INSIGHT ONE:

The report found that although a majority of countries have a connection to large-scale mining, metals processing or mined materials, the distribution of these connections is uneven.

Of the 151 countries with mining

connections, China, the USA and Australia alone account for about 45% of all facilities noted in the dataset. Such facilities include both metallurgical and mine raw material processing facilities.

INSIGHT TWO:

About 80% of mines in the dataset produce one of four commodities as their primary output, with coal taking the lead and coal mines comprising 42% of all mines.

Another main commodity is gold, making up 17% percent of the mines analysed. North America and Central America host the largest number of gold mines.

Meanwhile, Asia has the largest number of mines producing the final two commodities, copper (12%) and iron ore (9%).

INSIGHT THREE:

At a regional level, the distribution of mines is often in different locations

LOAD & HAUL

The location of mines and facilities reflect the regions’ sector strengths and features

than the distribution of metallurgical facilities such as smelters, refineries and steel plants. This reflects regions’ sector strengths and geological characteristics.

For example, Europe has a larger density of metallurgical facilities than mines, reflecting its strong manufacturing background and its depletion of easily accessible highgrade ore deposits.

In the United States, mining activities occur more often in the west, while metallurgical facilities

are more often located in the east.

This is a similar split to Japan, where the southern half of the country hosts more metallurgical facilities and industrialisation while its mines remain in the north.

Overall, China has the largest number of metallurgical facilities (426), followed by the United States (120), India (87) and Brazil (65)

THE TAKEAWAY

Even basic datasets can inform policy and decision-making by

painting a broad picture of the mining industry and ensuring that available information is digestible.

As the ICMM continues to support robust record-keeping, it will likely become easier to monitor sector progress and anticipate the environmental, social and economic impacts of industry decisions.

For more information visit: www.icmm.com

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AUTONOMOUS OPTIONS

As more companies incorporate automated fleets into existing operations, they find the benefits outweigh the initial investment

T

ransport solutions specialist Scania has partnered with Australian mining services provider Regroup to launch a fleet of autonomous in-pit mining trucks. The autonomous rigid G 560 8x4 tippers will begin operations at Element 25’s Butcherbird Mine in Western Australia’s Pilbara region by late 2025.

Element 25 is an Australian mineral exploration and development company producing high-purity manganese sulphate monohydrate (HPMSM) for electric vehicle (EV) batteries. The fleet of 11 autonomous trucks will transport manganese ore.

“This fleet will lower operating costs and decarbonise operations,” said Scania Australia head of mining Robert Taylor.

The use of the autonomous fleet will reduce the need for drivers to remain on site. “The workforce will remain intact, but instead of working in hazardous conditions, they’ll be in control rooms, potentially from their hometowns. It’s a win-win for everyone involved,” said Regroup managing director Michael Still.

Although the initial fleet will operate on diesel engines, both companies aim to transition to electric energy in the future. “As Scania continues to prove its expertise in autonomy and electrification, we will expand our fleet with fully electric vehicles when they become available,” said Still.

In addition to the autonomous fleet, Regroup has also obtained a batteryelectric Scania 8x4 truck to be used as a water cart at the Butcherbird site.

INCREASING AUTONOMY

The decision to incorporate autonomous haulage technologies into existing operations is becoming increasingly common. The inclusion of automated haulage can support worker safety and productivity while lowering operational costs by optimising fuel usage and minimising equipment wear.

Just earlier this year, autonomous

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Autonomous rigid G 560 tipper

Autonomous Komatsu HD605-10

haulage system provider Pronto incorporated its automation technologies into quarry trucks from mining equipment manufacturer Komatsu North America.

Previously, the most advanced autonomy was reserved for the largest mines,” said Pronto CEO Anthony Levandowski.

The Komatsu Smart Quarry autonomous trucks use AI and rugged sensors to navigate haulage roads and perceive the environment. This enables 24/7 operation with minimal human intervention for mines of all sizes. The autonomous technology is available for existing Komatsu vehicles or available as new trucks, which come equipped with the self-driving system.

“This collaboration with Pronto accelerates our vision of smart, automated quarry operations,” said Komatsu senior director for customer solutions Jason Anetsberger. It’s a solution that helps drive productivity beyond what was previously possible

and can support efforts to enhance safety by facilitating the removal of workers from areas of potential hazard.”

The Smart Quarry Site fleet management and analytics suite can be paired with the Komatsu Smart Quarry autonomous system to provide real-time, data-driven insights.

LOOKING INTO THE FUTURE

Despite initial high investment costs, the adoption of automated haulage fleets is becoming increasingly common. As sensors and machine learning algorithms continue advancing, automation technologies will adapt to more complex environments, making them a sustainable option for the industry’s future.

For more information visit: www.komatsu.com or www.scania.com

LOAD & HAUL

HITTING THE HYDRAULICS Tailored hydraulic cylinders keep mining equipment moving Hydraulic cylinders are used in a vast range of mining technologies

H

ydraulic cylinders are a critical technology that keep mining equipment moving. They are used in a variety of mining activities both underground and in open pit sites, including excavation, drilling, bolting, crushing, processing and support.

For example, hydraulic cylinders help to operate the shearing equipment and position the longwall mining machine in longwall mining.

They also move drill rigs for roof bolting and even power the drills themselves. If the task involves the lifting of heavy loads or the positioning of tunnel roofs, it is likely that hydraulic cylinders are involved.

Producing an undercurrent of muscular power in a mining site, hydraulic drive technology must provide immense, precise power while withstanding the grime and dust of hazardous environments.

German hydraulic drive technology specialist HK Hydraulik Kontor GmbH offers a range of hydraulic cylinder products and services for the mining sector. These help to convert pressurised fluid into powerful linear force for heavy-duty tasks.

HK’s portfolio supports both straightforward replacements and complex new installations

“Our aim is to provide customers with cylinder solutions that perform reliably in the harshest environments,” said HK. “By combining standardsbased products with fully engineered special cylinders and a strong service offering, we support operators across the entire equipment lifecycle.”

HK’s range of hydraulic cylinders comprises different types of differential

cylinders for varying facility needs.

Some types of cylinders include plunger and telescopic cylinders, support and spring cylinders, flat cylinders (including wobbling piston variants) and short stroke units.

Special features include hydraulically releasing return springs, inner latches, purge air options and bellows for heat protection. Further tailored special units are available to incorporate options such as integrated valves and sensors, screwed-on valve trunnions, displacement encoders, special coatings and water cooling.

All standard cylinders by HK are manufactured to DIN, CETOP and major steelworks standards and offered with mounting options. These mounting options include hinge eyes, trunnions and flange mounts for fast integration.

HK hydraulic cylinders come with diagnostic, repair, optimisation and lifecycle services to increase their lifecycle and improve long-term reliability.

For more information visit: www.hk-hydraulik.com

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OPERATIONS MANAGEMENT

TersaClean recovers materials such as copper, nickel, zinc, cobalt and gold

NATURE’S Tersa Earth remediates mining waste, treats

GIFT M

ining operations produce over 100 billion tonnes of solid waste rocks, overburden, slag, ash and tailings worldwide each year.

This waste contains hazardous substances, including cyanide, arsenic, lead and mercury.

Waste management practices often require the use of plains, oceans, rivers and lakes as dumping grounds.

Sulphur-bearing waste rock, for example, is often deposited in piles near the mine site, which exposes it to the air and water. As the waste rock weathers from exposure, it contributes to an outflow of acidic water and acid rock drainage.

Meanwhile, tailings storage facilities also often exist underwater and are

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acid rock drainage and recovers metals with its microbial fuel cell technology

chemically treated. Leakage or a collapse of the storage dam can lead to life-threatening circumstances for humans and wildlife.

The damage from mine waste storage is not contained to the areas of storage, as runoff of contaminated water and fine-grained waste poses long-term risks to surrounding areas.

By 2040, it is estimated that over 75 trillion litres of acid rock drainage could be produced without the creation and prioritisation of mining remediation technology.

THE POWER OF MICROBIAL FUEL CELLS Regulations are shifting to minimise mine waste and prioritise more innovative, responsible methods of disposal.

One company using these methods is Tersa Earth Innovations, a Vancouver-based startup exploring sustainable mining solutions and essential metals recovery.

Tersa Earth’s technology, called TersaClean, uses a combination of microbial fuel cells, microbial-induced carbonate precipitation and advanced bioprocess engineering to break down contaminants and precipitate metals out of the water.

“We have a modular, stackable system that fits the tail end of a mine’s process,” says Tersa Earth cofounder and CEO Barinder Rasode. “If a mine is operating, we can optimise their current mining productivity, or we can clean up close tailing ponds, but we don’t

OPERATIONS MANAGEMENT

impede on the current system.”

TersaClean’s living microbes can detoxify the water and capture metals to reclaim the $20 billion worth of metals that are lost to tailings streams and ponds per year, just in North American alone.

A SCALABLE AND PORTABLE SOLUTION

TersaClean operates as a set of bioreactor modules that can be added in parallel to handle larger volumes of wastewater. Instead of requiring a large plant from day one, a company could start with a small installation treating a few cubic metres per day, and then replicate modules to expand as needed. Early pilots demonstrate throughput from 1,000m3 to 10,000m3 per day.

“We get pre-pilot samples from the company, and then we optimise our unit for the individual composition of that pond,” says Rasode.

The modules can be stored in shipping container-style units that are easy to transport to remote and rugged mine sites.

Existing mines can easily incorporate TersaClean into their systems, for example, into their

water management circuit. As water exits the tailings pond or seepage collection system, it flows through the TersaClean bioreactors and emerge purified. At this point, it would either be recycled back into the mining process or safely discharged to the environment.

CONTRIBUTING TO A CIRCULAR ECONOMY

Globally, the total opportunity of metals trapped in waste is estimated to be about $3.4 trillion.

TersaClean recovers elements such as copper, nickel, zinc, cobalt, and even precious metals such as gold. These elements are often in the form of metal sulphides or alloys, and can be refined and sold back into the market.

“Traditional methods have a really hard time extracting lithium, so 50% of lithium is still left as waste, and they need a lot of water,” says Rasode.

“What we’re able to do is remove the impurities so it’s only one process, and we can get up to 90% of the lithium out of the brine. Those kind of results are very exciting for us.”

So far, Tersa Earth has experienced recovery rates of up to 99% for metals such as copper from field and

lab testing. This enables companies to boost their production without additional extraction.

IMPLICATIONS FOR THE COMMUNITY

The environmental damage caused by mine waste runoff is a problem not just for mining sites, but for surrounding communities.

“One of the reasons this was important to me is I do believe that waste management equals health management,” says Rasode.

One of the goals of Tersa Earth is to eliminate accidents such as that of Victoria Gold in Yukon, where a heap leach failure caused a landslide, which released millions of tonnes of ore and cyanide-containing solution into the surrounding valley and waterways.

“We are a solution to a problem that has become a critical issue, for industry government, but also for our demand on metals and minerals,” says Rasode. “In order to get what we need, we need to do things differently.”

For more information visit: www.tersa.earth

Tersa Earth has a modular, stackable system that fits the end of a mine’s process

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OPERATIONS MANAGEMENT

UNDER THE SEA

How a Portuguese startup aims to accelerate seabed exploration to locate mineral deposits

DeepFocus can review previous survey results and support future exploration

DeepFocus CEO João Carvalho

T

he demand for critical minerals is increasing due to electrification and digital technology advances. These advances require large amounts of cobalt, nickel, copper and rare earth elements to progress.

Land-based mineral deposits for these critical materials are concentrated in just a few countries and the global supply chain is complicated by trade restrictions and instability.

As the need for these minerals is surging and supply is unpredictable, governments and mining companies are turning to the seabed as a potential source of critical minerals.

A NEW APPROACH

There is still a lot to learn about seabed mining. Not much is known about deep-sea ecosystems, some of which are completely unexplored.

The potential implications of seabed mining are not well understood, and neither are exploration methods to efficiently locate rich reserves.

Approaching seabed mining without

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a deep understanding of where critical minerals are located and the characteristics of the surrounding ecosystem could lead to high costs, inefficient resource use, missed opportunities and loss of investments.

EXPLORATION CHALLENGES

A recent webinar hosted by deep sea robotics developer Impossible Metals highlighted the potential of AI in seabed exploration. The webinar featured Portuguese AI-powered data analysis and consultancy startup DeepFocus, whose CEO João Carvalho described its technology and the importance of AI-based insights.

“The estimated lead time for discovery to production can take over 15 years and roughly 70% of that time is spent only in the exploration and resource evaluation studies. This represents a serious challenge,” said Carvalho.

Extreme pressure, low temperatures, darkness and corrosive conditions make ocean exploration costly and slow. A lack of existing data adds to

the challenge. According to studies referenced by Carvalho, the success rate of exploration is less than 1% as it takes vast amounts of data and expertise to accurately identify highvalue areas.

Even when using multiple survey technologies, there is a risk of spending enormous amounts of resources only to overlook a potential bonanza or determine that an area is not viable.

However, exploration is a vital first stage in the subsea mining process.

“If this first decision is done wrong, the probability of fulfilling the investment goal is highly diminished and potential for spending too much time and money on unpredicted exploration or in highly sensitive seabed areas is much higher,” said Carvalho.

HOW CAN AI HELP

Ai-based insights could optimise the exploration phase of subsea mining.

“We believe that AI can greatly enhance the discovery of these sights where you can find high value mineral

OPERATIONS MANAGEMENT

deposits in the seafloor and help make seafloor mining activities more friendly to the environment,” said Carvalho.

The ability to collect and automatically process robust datasets could help in identifying geological features, habitats and species, making it easier and less costly to estimate topography and pinpoint potential resource deposits in unexplored zones.

HOW DOES IT WORK?

DeepFocus enhances seabed exploration with its mineral and benthic habitat mapping technology.

DeepFocus adds satellite data, vessel data, sampling data and data from autonomous underwater vehicles (AUVs) to its database. The database is then run through a series of machine learning (ML) models to find the models with the lowest error and produce a predictive map.

Mineral resource characterisation can include a permissive area map, base and precious metals assessment, resource assessment and mineral inventory. Potential mineral deposits

can be characterised using Nodule.AI, Crust.AI and Sulphide.AI. These are ML workflows that process geological, geophysical, geochemical, ocean biogeochemical and physical data to inform target generation, resource estimation and exploration decisions.

Marine environment characterisation can include species spatial distribution mapping, species spatial richness mapping and vulnerable marine ecosystem mapping.

EcoSystem.AI is an ML workflow that processes geological, biological, geochemical, ocean biogeochemical and physical data to inform species distribution and richness, as well as conditions and factors that interact to characterise the ecosystem.

The predictive maps can be loaded onto any Geographic Information System (GIS) software to visualise the data and provide users with a rich understanding of the seabed.

For more information visit: http://deepfocus.pt

CASE STUDY The Marshall Islands are located in the northern part of the Central Pacific Basin within the Pacific Prime Crust Zone. This zone extends from Hawaii to the Marianas and is abundant in cobalt-rich ferromanganese crusts, making it a strong candidate for seabed mining.

In DeepFocus’ analysis of the region, AI-based mineral mapping was consistent with previous studies in assessing crust thickness and metal grades.

The company’s technology also identified several new target areas that previous surveys missed.

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19

STRIKING GOLD

OPERATIONS MANAGEMENT

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High concentrations of illite crystallinity are observable around the target area

Hematitic epithermal quartz vein with 20.8g/t gold at the Western Rim Target

A Nevada company is using airborne hyperspectral scanning and handheld spectrometer analysis to accelerate exploration

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ining company Nevada King Gold Corp has begun drilling at the Western Rim Target, a large and newly defined multidirectional vein corridor that follows associated subsidiary quartz veins along the western rim of the Atlanta caldera.

The 2.5km x 1.5km area lies 264km northeast of Las Vegas, Nevada within the company’s 51.6 km2 Atlanta Gold Mine project. So far, 25,000m of the 30,000m planned Phase III regional drill programme is now complete.

“While exploration at the Western Rim is still at an early stage, the target exhibits all the hallmarks of a large, potentially significant gold system,” said Nevada King exploration manager Cal Herro.

Numerous rock chip samples have been assayed throughout the target area showing gold mineralisation with gold grades up to 20.8g/t.

“The combination of alteration type, robust multi-element geochemistry, and strong multidirectional fault and vein patterns are indicative of favourable structural preparation – a key component of the Atlanta Resource as well as large epithermal gold systems across Nevada,” said Herro.

Nevada King’s mapping and sampling in and around the Western Rim area has demonstrated a consistent pattern of quartz veins hosting mineralisation consistent with the rest of the Atlanta district.

“Ongoing Phase III drilling at Western Rim will pursue Au-Ag mineralisation both within the volcanic-hosted quartz vein zones as well as along the TertiaryPaleozoic unconformity, similar to the company’s Phase I and II drill programmes within the ARZ,” said Herro. “We’re excited to begin drilling this target, as it represents one of the most compelling opportunities to expand the known gold potential within the greater Atlanta district.”

Nevada King began its exploration of the Western Knolls region in 2024 with geologic mapping, rock sampling and westward expansion of existing CSAMT coverage, a low-impact, nonintrusive, ground geophysical surveying method which produces a 3D resistivity model of the ground.

Nevada King is now using airborne hyperspectral scanning and handheld spectrometer analysis to accelerate exploration at the Atlanta Gold Mine project. Hyperspectral scanning obtains the spectrum for each pixel in the image of a scene which helps to map spaces and guide drill targeting by highlighting where hydrothermal fluids have altered the host rocks.

These technologies are providing a new layer of insight into mineral systems across the district and are directly guiding drill targeting.

For more information visit: www.nevadaking.ca

A WIRTGEN GROUP COMPANY

Blasting? No! Safety? Yes! www.wirtgen.com/mining

280 SM(i): Surface Mining combines safe mining operations with modern cost-effectiveness: the 280 SM(i) replaces the entire equipment otherwise needed for blasting, drilling and pre-crushing. It cuts costs, delivers mined raw materials of higher quality, and ensures more efficient exploitation of the deposits. Take advantage of innovative solutions from the technology leader. www.wirtgen.com

WIRTGEN GmbH · Reinhard-Wirtgen-Str. 2 . D-53578 Windhagen . T: +49 26 45 / 131 0

OPERATIONS MANAGEMENT

AN AUSTRALIAN-AMERICAN

ALLIANCE

The signing of a bilateral framework on critical minerals and rare earths could accelerate projects and reduce Chinese reliance Pictured: Alcoa’s Wagerup alumina refinery

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ustralian prime minister Anthony Albanese and American president Donald Trump have signed a bilateral framework on critical minerals and rare earths, which will support an accelerated pipeline of priority projects delivered by and for the two nations.

The United States–Australia Framework for Securing of Supply in the Mining and Processing of Critical Minerals and Rare Earths will deliver a supply chain between Australia and the USA for critical minerals and rare earths required for defence and electrification.

“Australia is home to much of the periodic table of critical minerals and rare earth metals that are vital for defence and other advanced technologies,” said Australian prime minister Anthony Albanese. “President Trump and I agreed today we will work very hard together in both our nations’ interests.”

A US-Australia Critical Minerals

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Supply Security Response Group will be established and led by US secretary of energy and the Australian minister for resources to identify priority minerals and supply vulnerabilities.

Using this information, the group aims to develop a plan to accelerate the delivery of processed minerals.

Australia and the USA will also each provide at least USD$1 billion in

The Arafura Nolans project features a mine and process facilties

OPERATIONS MANAGEMENT

investments toward a USD$8.5 billion pipeline of priority critical minerals projects in both countries over the next six months.

“We’ve agreed today Australia and America are going to make more things together with our historic framework on critical minerals,” said Albanese.

THE ALCOA-SOJITZ GALLIUM RECOVERY PROJECT

One priority project is the Alcoa-Sojitz Gallium Recovery project in Wagerup, Western Australia. The project will provide up to 10% of total global gallium supply. This is a trilateral project with Australia, the USA and Japan. Gallium is a vital material for the production of semiconductors, integrated circuits and light-emitting diodes, as well as defence technologies.

The joint venture company Japan Australia Gallium Associates (JAGA) will conduct a development study for gallium production in Australia at one of Alcoa’s Western Australian operating alumina refineries. If the project proceeds, following an investment decision at the end of 2025, the intention is for production to begin in 2026 to initiate a stable supply of gallium. Sojitz plans to sell the gallium produced to Japan and other countries with demand.

THE ARAFURA NOLANS PROJECT

The second project is the Arafura Nolans project in Australia’s Northern Territory. Once operational, Arafura Nolans will produce 5% of global rare earths. The project comprises a mine, process plant (beneficiation, extraction and separation plants) and related infrastructure located at Nolans site, 135km north of Alice Springs. This location was chosen for the Nolans Bore rare earths-phosphate-uraniumthorium (REE-P-U-Th) deposit, one of the largest deposits in the world.

A GROWING INDEPENDENCE FROM CHINA

The agreement between Australia and the USA supports the growing prioritisation of independence from Chinese dominance in the refining and processing of critical minerals and rare earth elements.

The Arafura Nolans project is located 135km north of Alice Springs

Currently, China accounts for about 70% of global rare earth extraction and about 90% of rare earth ore processing.

China’s current near-monopoly on gallium, in particular, has become problematic for the USA. China first restricted gallium exports to the USA in July 2023, requiring exporters to have a licence to ship gallium, as well as other materials, including germanium, antimony, graphite, and tungsten. A more stringent ban on direct sales to the USA was implemented by China in December 2024.

The impact of this ban on the USA is expected to be expensive, with prices more than doubling since July 2023.

Despite recent investments, the USA’s rare earths industry is not yet

able to fill the gap left by China’s restrictions. The country’s mining and processing capabilities are still in early stages and require significant long-term planning.

Although Australia is a major producer of critical materials, it is also heavily reliant on China for processing, particularly for iron ore.

The USA’s agreement with Australia can help both countries to bolster their positions in mining, separation, processing and manufacturing capabilities, as well as research and development.

For more information visit: www.pm.gov.au

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SPECIALIST EQUIPMENT

TRANSFERRING TORQUE

Dodge Industrial’s latest line of disc couplings can handle the heat

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rom pumps and fans to crushers and conveyors, disc couplings play an important role in many mining industry technologies.

In addition to transferring torque, disc couplings also accommodate shaft misalignment, dampen vibration and prevent the transmission of excessive loads. They handle heavy loads with high impact, and usually within dusty or hazardous environments, where lubricants are not a practical aid.

With such a long list of responsibilities and so many changeable environmental factors, the construction of reliable disc couplings is a challenging feat that requires attention to detail.

THE STRATOLINK DISC COUPLING LINE

Mechanical power transmission specialist Dodge Industrial has launched its StratoLink disc coupling line, offering improved capabilities from previous models.

“For decades, engineers have faced limited choices when specifying disc couplings, and StratoLink changes that,” says Dodge Industrial’s global product manager Vance Chavis. “By combining higher torque capacity, larger bores, easier rebuilds, and drop-in compatibility, we’ve created an exciting new alternative.”

The models in the new line deliver an average of 26% greater torque

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The StratoLink D71 is engineered for maxiumum torque

capacity and feature 11% larger bore ranges than existing designs on average. This helps to enable a lighter coupling that reduces loads and extends driven equipment life.

One feature of the new line is the bushing engagement system. This system eliminates hammering and other unsafe rebuilding practices, making rebuilds easier and up to twice as fast as loose disc pack couplings.

Additionally, drop-in interchange of the centre member assembly allows for easy replacement in existing applications without needing to

modify or move connected equipment.

A Manganese phosphate coating provides extended protection against corrosion.

The first model to launch is the StratoLink D71, which is engineered for maximum torque, simplified rebuilds and interchangeability in existing installations while meeting API 610 standards.

For more information visit: www.dodgeindustrial.com

The models in the new line deliver an average of 26% greater torque capacity and feature 11% larger bore ranges than existing designs

SPECIALIST EQUIPMENT

DRILLING DEEP Mincon’s hybrid impact technology brings hydraulics to the forefront

Floris Timmers, Epiroc; Martin Hjerpe, Epiroc; Joe Purcell, Mincon; Tom Purcell, Mincon HIT demonstrates increases in drilling speed and reductions in fuel usage

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raditionally, large-diameter drilling relies on rotary tools or pneumatic down-the-hole (DTH) systems, applying downward pressure to cut through rock formations.

Rotary tools use a rotating drill bit which cuts, grinds or crushes the rock and relies on the pull-down force of the rotational mechanism. Pneumatic DTH systems operate in a similar downward-orientated fashion, but use high-pressure compressed air to power a hammer directly behind the drill bit.

THE DRAWBACKS

Both rotary tools and Pneumatic DTH systems suffer from inefficient energy loss, particularly in challenging geological conditions and higher penetration rates.

The friction can cause rotary tools to wear easily, and energy can be lost between the rotary motor to the drill bit. Similarly, pneumatic DTH systems lose energy from the initial compression of air. In fact, more than 85% of electrical energy is lost as heat during the process.

A HYDRAULIC SOLUTION

Following 12 years of research and

development, Irish engineering company Mincon has recently released its hybrid impact technology (HIT), which replaces compressed air with hydraulic energy as its primary power source.

HIT transfers power to the bit more directly with reduced energy loss, leading to higher penetration rates and decreased fuel usage.

“The long-term future demand for mined minerals, along with the global decarbonisation goals, will require systems that offer much higher productivity while lowering carbon emissions,” said Mincon CEO Joe Purcell.

During the drilling of a 270mm hole size on an adapted Epiroc PV271 drill rig while testing at an Arizona copper mine, a HIT-powered system demonstrated significant increases in drilling speed and reductions in fuel usage per foot drilled compared to the mine’s current rotary drilling method.

In addition to Arizona, testing was also conducted in other demanding mining locations, including Ireland and Australia.

“We are proud to be able to support the mining industry with a new, next-level, sustainable drilling solution that will support the mining industry to reach their environmental

goals,” said Epiroc Tools division president Martin Hjerpe.

By delivering more metres per rig with less fuel, fewer rigs and operators are required to achieve the same output. Such reductions reduce overall drilling operations costs, as well as CO2 emissions.

HIT is designed for large-diameter blast hole drilling in medium-to-hard rock conditions in open-pit mining applications. It is built for single-pass production mining conditions using modern rotary platforms, further reducing time and costs. The HIT swivel is suited to any kind of rotation head, making it easy to incorporate, maintain and repair.

The HIT accumulator rod offers a supplemental oil supply to enhance hammer performance. It also protects the system by removing hydraulic pressure disturbances, allowing for higher system operating frequencies.

Over the next three years, Mincon will collaborate with Swedish mining equipment manufacturer Epiroc to integrate HIT technology on Epiroc’s rotary blasthole drill rigs.

For more information visit: www.mincon.com

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SPECIALIST EQUIPMENT

ADVANCED CRUSHERS A new range of jaw and cone crushers is eliminating manual intervention ENDURON ET series jaw crusher

ENDURON EC series liveshaft cone crusher

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ngineering company Weir has launched a range of Enduron jaw and cone crushers prioritising safety, productivity, sustainability and simple maintenance.

“We’ve listened closely to our customers and designed this range to meet their evolving needs,” says Weir global product manager of crushers Magnus Skorvald. “From safety and sustainability to ease of installation and maintenance, every feature is built to deliver real value on site.”

WHAT’S NEW?

The updated jaw crushers feature a redesigned hydraulic power unit which allows for true push-button control of closed side setting (CSS) adjustments.

This eliminates the need for manual intervention, potentially saving time while promoting the safety of operators and maintenance teams.

To ensure reliability, the hydraulic power unit supports consistent tensioning of the retraction springs.

The automation platform across all cone crusher models has also been enhanced. Optimised motor power and oil tank capacity reduces the hydraulic power unit’s CO2 emissions.

The range of Enduron jaw crushers now include Esco wear parts and liners to improve performance and reduce downtime by minimising

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ENDURON EP series pedestal (fixed-shaft) cone crusher

maintenance interventions and extending wear life.

The crushers also feature a newly designed hydraulic and lubrication power unit, a compact, plug-and-play system that reduces the crusher’s environmental footprint and simplifies installation. This unit makes the crushers suitable for sites aiming to optimise their infrastructure and minimise emissions.

IO-link digital sensors, Siemens PLC hardware and a humanmachine interface also provide easier integration and troubleshooting.

A CLOSER LOOK

The Enduron EP pedestal crusher has been engineered for secondary, tertiary and quaternary crushing applications where high quality, cubical aggregates are required at high production rates The range also includes the Enduron ET jaw crusher, which use two jaws,

one fixed and one moving, to apply compressive force, making it suitable for the first stage of material reduction where large rocks must be crushed at high production rates. It can be used to process precious metals and a wide spectrum of other minerals.

The Enduron EC cone crusher is the latest iteration of the live-shaft cone crusher design. It performs best in heavy-duty secondary and tertiary crushing applications. The Enduron EC works by crushing material, such as primary crushed ores, multiple times as it passes through the crushing chamber.

The crushers offer tailored solutions to meet the specific operational needs of each mining site while prioritising safety and sustainability.

For more information visit: www.global.weir

SPECIALIST EQUIPMENT

level voltage source inverter, the drives produce low-distortion output that eliminates the need for filters.

The four-circuit topology exceeds the capabilities of conventional two-orthree-level inverters.

REDUCED DOWNTIME AND ENHANCED LONGEVITY

Power cell redundancy and neutral rebalancing enable the technology to continue operating through the failure of a power module. In the event of a power module failure, quick swap-out capabilities also minimise downtime.

A ventilation system and redundant fans keep power elements cool, enhancing longevity and maintaining high system performance.

THE SPECIFICS

The medium voltage varaible frequency drives are UL-certified

DRIVING LONGEVITY Medium voltage variable frequency drives are prioritising precision while cutting costs

V

ariable frequency drives enable precise control over motor operation, regulating the speed and torque of alternating current (AC) motors.

This type of precision improves reliability and extends equipment lifespan by reducing mechanical shock, stress and general wear and tear on motors, bearings and belts.

Additionally, the lower overall energy consumption helps to minimise

a facility’s carbon footprint.

WOLONG DRIVES

Electrical equipment supplier Wolong Electric America offers medium voltage variable frequency drives designed to help the mining industry increase reliability, precision and lifespan while lowering emissions, all in challenging environments.

Built on a cascaded H-Bridge topology using an IGBT-based multi-

The all-copper pulse phase shift transformer reduces harmonics to the local grid to support low distortion and improved system compatibility.

They are offered as standard, starting with models at 1,000hp.

The drives are suitable for fans, pumps, compressors, blowers and conveyors, featuring a 4160V capacity spanning from 1000hp to 5500hp and 130amps to 635amps. Input voltage tolerance is designed at 4160V ±10%, with optional configurations from 3.3kV to 13.8kV, and input frequency at 50Hz or 60Hz ±5%.

The drives can control both legacy and modern motors, making them suitable for retrofitting.

COMPATIBILITY

The Wolong drive interface optimises user interaction and facilitates intuitive monitoring of operational status and fault alarms. Operators can access all drive parameters, view fault records, and integrate the system into existing site control platforms using the most common communication interfaces.

The medium voltage variable frequency drives are UL-certified, meeting all USA-based market requirements for the complete VFD unit.

For more information visit: www.wolongamerica.com

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HEALTH & SAFETY

CRITICAL CONNECTION Kathrin Geisler from i.safe Mobile explains how its 5G radio closes communication gaps and keeps miners safe

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he mining industry faces the constant challenge of ensuring the highest level of safety for employees, particularly underground. Traditional radio devices (PMRs) have been used in mining for decades, but their limitations – restricted channel capacity, limited communication range, high installation costs and expensive expansion – increasingly hinder modern safety protocols. For miners working in underground shafts, remote areas or hazardous zones, these limitations can be dangerous.

The IS440.M1 from i.safe Mobile closes these critical gaps: The 5G radio ensures secure and interferencefree PoC communication via public networks, campus networks (4G or 5G) or Wi-Fi in hazardous mining areas.

A gateway enables compatibility with earlier radio technologies and seamless integration into existing systems.

Special applications, including lone worker protection, are available via the App World platform from i.safe Mobile.

BEYOND THE LIMITS OF CONVENTIONAL PMR

The IS440.M1 transforms mining communication by eliminating conventional PMR limitations. Unlike previous systems with restricted channels, the device supports unlimited group calls, private encrypted channels and unlimited communication range within network coverage. Integration into existing infrastructure is seamless without costly system overhauls, enabling voice and video calls, fast data transfer and immediate emergency response.

COMPREHENSIVE LONE WORKER PROTECTION

Using special LWP applications, the device continuously monitors personnel and automatically detects potential emergencies through multiple triggers: Man-down detection identifies falls or sudden impacts and immediately alerts supervisors. Tilt sensors detect abnormal positions,

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The IS440.M1 is specially designed for harsh mining environments

while motion alarms report prolonged inactivity – crucial for detecting medical emergencies or environmental hazards. Workers can trigger manual SOS alarms via the dedicated red emergency button for rapid assistance.

Real-time location tracking enables rapid deployment of rescue teams, preventing time lost searching vast mining sites. This proves invaluable in underground environments where traditional GPS systems fail, as the device utilises 5G network positioning.

VERSATILE APPLICATIONS

The IS440.M1 offers more than radio functions: it acts as a mobile hotspot in hazardous areas, supporting up to 16 simultaneous connections and allowing teams in ATEX/IECExcertified zones to connect tablets, laptops or other devices.

It can be used as a bodycam, or as a fixed installation for surveillance tasks and maintains communication connections.

Compatibility with Peter Jones Click Fast Docks enables secure hands-free operation, essential when workers need both hands for tasks.

The device is designed for harsh mining environments with replaceable high-capacity batteries (2400 or

4800 mAh) for multi-shift operation, a powerful front-facing speaker that cuts through machine noise, and rugged design meeting ATEX/IECEx and ANZEx Mining certification standards. The dual SIM function ensures continuous connectivity, while Wi-Fi 6, NFC and Bluetooth 5.2 offer comprehensive connectivity options.

The 8MP AF front camera enables photos, videos and video calls. The eight-pin ISM interface supports various headsets and accessories, while the integrated belt clip ensures safe transport during demanding physical work.

INVESTMENT IN SAFETY

The transition from traditional PMRs to the IS440.M1 demonstrates commitment to personnel safety.

By combining 5G capabilities with specialised features for lone worker protection, location tracking and emergency response, mining operations gain comprehensive safety infrastructure to provide optimal protection for workers.

For more information visit: www.isafe-mobile.com

HEALTH & SAFETY

AN ARGUMENT FOR

SELF-RESCUERS

In the mining industry, a filter is never enough

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n high-risk industries such as mining, relying on filters to protect workers from toxic gases and dust comes with its risks.

Filters rely on ambient air and require there to be a certain amount of oxygen in the space to function properly. This means it cannot protect sufficiently against oxygen deficiency, despite oxygen deficiency being a common danger following explosions or fires.

Additionally, filters can generally only filter out specific gases or particles. They do not necessarily provide protection against the full range of gaseous hazards those on a mining site may encounter.

Should a filter become clogged by particles or moisture, its short lifespan can drop even further, leaving workers vulnerable to gases such as methane, carbon monoxide, carbon dioxide, hydrogen sulphide.

HOW SELF-RESCUERS CAN HELP

keep individuals safe despite the dangers the mining industry can pose.

In addition to purifying air, KO2 self-rescuers generate oxygen and absorb CO2 to provide breathable air in a closed circuit. They work independently from the ambient environment and are effective even when the surrounding atmosphere is toxic or oxygen-deficient.

KO2 self-rescuers facilitate a chemical reaction: Potassium superoxide (KO2) reacts with exhaled moisture and CO2 to release oxygen while absorbing CO2. This process allows an individual to breathe even when the surrounding air is unbreathable.

Compact and ergonomic, KO2 selfrescuers can easily be worn in refuge chambers. Despite the small size, the technology can last three times longer than filters while awaiting rescue.

EMSCAPE BY DEZEGA

Mine rescue equipment manufacturer Dezega offers EmScape, an Chemical-oxygen KO2 self-contained, emergency escape hood KO2 SelfRescuer that offers respiratory and self-rescuers are an alternative or visual protection during mining supplement to filters that work to emergencies.

EmScape protects against a range of toxic EmScape’s breathing elements often found in bag does not fires, including benzol, obstruct visibility chlorine and hydrogen cyanide.

The wide fireproof visor and flame-resistant hood protect the wearer’s vision and skin, while the elastic obturator prevents gas entry. The breathing bag does not obstruct the wearer’s visibility, and is still positioned high enough to prevent damage during movement.

For more information visit: www.dezega.com

KO₂ SELFRESCUERS: A HISTORY SOUTH AFRICA: A series of mine fires (Kinross, 1986), (Ermelo, 1987), (Middelburg, 1993) took over 260 lives and exposed the crucial limitations of filter-type self-rescuers.

Following these tragedies, the Mine Health and Safety Act (1996) required every underground miner to carry a self-contained self-rescuer compliant with SABS 1737 standard, which is now known as SANS 1737.

UNITED STATES: In 2006, three disasters occurred that highlighted the failure of filter devices in oxygen-deficient environments. The Sago Mine explosion (2006) trapped 13 miners for two days, with only one survivor.

The subsequent Aracoma Alma and Darby disasters killed a further seven workers. CO poisoning played a role in most of these deaths, leading to the MINER Act of 2006 and updates to 30 CFR § 75.1714, requiring that every underground miner have immediate access to an MSHA- and NIOSH-approved selfcontained escape breathing apparatus.

TURKEY: The country’s worst mining disaster in history was the Soma mine disaster (2014), where 301 miners died mainly from CO poisoning.

After this, Turkey’s ministry of labour and social security introduced stricter rules on emergency breathing devices, driving widespread adoption of self-contained systems.

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HEALTH & SAFETY

FUNDING

DIGITAL TRANSFORMATION

Sandvik has put its money where its mouth is to fund the mining industry’s digital transition Data-driven insights are becoming increasingly valuable for the mining industry

D

igitalisation can make the mining industry safer in many ways.

Automating dangerous tasks helps to physically remove workers from hazardous environments.

Technologies such as automated or remote-operated load and haulage, drilling, mineral processing and monitoring systems put distance between workers and the industry’s physical risks.

Simulations help workers to train and become comfortable in their skills prior to entering an unpredictable environment - whilst still encouraging innovation by allowing workers to test out new technological designs safely.

For situations where workers must still enter hazardous environments, wearable devices such as smart helmets, underground tablets and wearable sensors can alert them to danger and provide their location to emergency personnel.

Data-driven insights can paint a robust picture of potential equipment failures, real-time workplace conditions and causal patterns not obvious to the naked eye. Obtaining these insights can help miners to make educated decisions, with past experiences informing future scenarios.

Overall, the mining industry is experiencing a digitalisation movement in which optimised connectivity, data literacy and automation practices are all important parts of a responsible and safe mining community.

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WHEN DAT COMES FIRST

To prioritise the safety that comes with digitalisation, Swedish engineering company Sandvik has launched a technology programme to accelerate the mining industry’s digital transformation through datadriven innovation.

The programme, DataDrive’31, focuses on the development of new data-driven technologies and solutions that enhance safety, as well as productivity and sustainability across the whole mining value chain.

“DataDrive’31 is at the forefront of the technological transformation of the mining industry,” said president of mining at Sandvik Mats Eriksson.

“DataDrive’31 is a key driver for the growth of our mining business and demonstrates our commitment to leading the industry’s data-driven future.”

The six-year programme has a

budget of €80 million. It is funded through Sandvik, as well as through public organisation Business Finland, which has granted €16m for research and development for the first three years, with a further potential grant of another €16m pending.

“Business Finland’s support accelerates our planned research and development work in key technology areas and strengthens our competitiveness in global markets,” says Eriksson. “The strong technological expertise of Sandvik in Finland forms the foundation for this investment.

A mid-term review will be conducted after three years to evaluate progress before proceeding to the second phase.

For more information visit: www.sandvik.com

DATADRIVE’31 KEY OBJECTIVES INCLUDE: Enabling new services and products through data utilisation and commercialisation.

Integrating data-driven technologies into equipment, operations and aftermarket services to deliver end-to-end digital solutions.

Building predictive and prescriptive operating environments to support smarter, safer and more sustainable mining.

HEALTH & SAFETY

IS440.M1

Integrated belt clip for safe carrying Programmable keys (e.g. for PoC/PTT/ lone worker protection/SOS) Powerful 4800 mAh battery for extreme runtime as an optional accessory Amplified loudspeaker for noisy work environments Pre-installed i.safe MOBILE App World with tested and verified apps

ISM_MA0300_250918

5G Radio mining

isafe-mobile.com

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MATERIALS HANDLING

JUST ADD WATER Brooklyn-based startup Vycarb is harnessing natural processes to capture and convert carbon

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urrently, mining is responsible for 4% to 7% of global greenhouse gas emissions.

Under the 2015 Paris Agreement, mining companies are facing pressure now more than ever to reduce this figure. Global climate targets require deep cuts in mining emissions by 2050, with the aim of achieving net zero emissions. To reach the agreement’s ambitious climate goals, reducing emissions is vital, and so is active removal of CO2 emissions from the atmosphere.

HOW VYCARB ENTERED THE SCENE

A carbon removal startup in Brooklyn, New York is doing exactly that. Vycarb was founded by climate scientist and carbon chemist Garrett Boudinot.

Boudinot has a robust history

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studying carbon removal and its impact on climate change. Serving on the NY State Climate Impacts Assessment, running a carbon removal research programme at Cornell University and eventually receiving an Activate Fellowship, Boudinot combined his background in climate science with carbon measurement to develop an innovative way to remove, store, and measure carbon that accelerates natural carbon storage.

Founded in 2022, Vycarb has since grown to include a team of engineers, scientists, and industry experts. New York City’s East River hosts the company’s latest pilot project, which captures and removes CO2 from the water by combining it with water and alkaline minerals to create stable, permanent bicarbonate ions for longterm storage.

HOW DOES IT WORK?

Vycarb’s technology is rooted in principles of chemical oceanography and climate science, which is why its project location on the water, rather than in a laboratory, is key to its work.

“Because we target CO2 emissions co-located with water, we bypass the need for CO2 transportation infrastructure, which is not feasible for lower volumes of CO2 emissions,” says Boudinot.

Carbonic acid is neutralised through the dissolution reaction with alkaline minerals to form HCO3- (bicarbonate) and CO32- (carbonate) ions in water.

This is a naturally occurring process, so the natural environment of the river actually helps neutralisation.

The company’s real-time sensing quantifies incoming CO2, HCO3, and CO3 to ensure the resulting water chemistry is safe for release while still

MATERIALS HANDLING

effectively capturing and storing CO2 in water.

The technology can use low purity CO2, down to as low as 1.5% demonstrated, reducing energy and cost required compared to traditional storage or utilisation.

USES IN MINING

Vycarb uses available minerals and real-time monitoring to permanently store carbon

Some mining byproducts can be used as a source of alkalinity.

As this technology is in its early stages, it is important to note that many tailings may not be suitable without additional treatment. This is because the elemental composition of many tailings includes elements such as nickel, chromium, zinc and iron that could have a negative impact on water quality and ecosystems.

However, these parameters do not prevent some cases from being successful.

“In cases where tailings are low in contaminating elements, we can valorise those for our decarbonisation value chain. And where CO2 is emitted from centralised components, we can capture and store those CO2 emissions,” says Boudinot. “And critically we can use minerals already mined (like CaCO3) for new markets in the decarbonisation value chain with our technology.”

By using passive natural water flow, Vycarb is accelerating Earth’s natural carbon storage reaction. Although

INVESTMENT FROM RIO TINTO Rio Tinto invested in Vycarb’s pre-seed through their earlystage vehicle in partnership with investment company Founders Factory.

“Working with Rio has informed how our technology can scale with a major industry partner,” says Boudinot.

Vycarb has been working with Rio Tinto to inform its technology development, testing specific technology efficiencies, inputs, and outputs.

carbon storage is frequently impaired by greenwashing campaigns and met with frustration by mining companies, Vycarb’s natural solution developed by climate scientists, provides hope for a cleaner mining future.

For more information visit: www.vycarb.com

New York City’s East River makes the perfect “laboratory” for Vycarb’s latest pilot project

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MATERIALS & HANDLING

PREVENTING BELT DRIFT Martin Engineering’s training manager Jerad Heitzler breaks down the importance of maintaining belt alignment

W

hen the belt of a bulk handling conveyor drifts out of alignment, one side moves higher up the troughed idler path than the other.

This causes the load to shift off centre, making the situation worse the farther it travels. That is the point when safety degrades and costs skyrocket.

If there is a stop mechanism, it will grind everything to a halt and lead to unscheduled downtime. However, there are safe and easily retrofitted technologies that ensure the stop mechanism is rarely (if ever) needed.

Upper trackers are elevated slightly above the other idlers to add more force to the steering assembly

WHAT CAUSES BELT DRIFT?

A belt can either suddenly slip out of alignment or gradually drift off centre over time. Two main conditions that cause this are operating conditions and equipment conditions. Operating conditions include environmental or application factors, such as high winds or segregated loading. Equipment conditions encompass components from idlers to the belt itself.

OPERATING CONDITIONS Segregated loading – Particularly in applications like quarrying, mining, construction and demolition (C&D) and material recycling, fines can separate from larger materials and settle on the bottom of the conveyor. When transferred to a perpendicular (90º) transfer belt, larger material will settle on the far end of the belt, causing it to drift.

Support – Conveyors can experience regular misalignment when installed on uneven ground, soft ground or between towers where settling can affect alignment.

Wind – High velocity prevailing winds may necessitate a cover over the conveyor or pointed in the direction of common wind patterns.

Temperature – Extreme temperatures on one side of the conveyor can cause components to expand, leading to changes in

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Mistracking can put strain on the splice which can result in safety issues

The belt must touch all pulleys and idlers evenly to be effectively aligned

friction and belt contact.

Structure – The structure of the system may cause misalignment due to settling into the ground or weakening over time due to constant weight and vibration.

Outside force – If bumped by machinery or affected by seismic activity, it should be tested for levelling immediately.

freeze. This can lead to increased friction.

• Aligned – A single idler that is slightly out of alignment can trigger drift down the belt path.

Adjusting idler supports for belt alignment is ill-advised, as a new belt installation will require recalibration.

• Touching the belt – The belt must touch all pulleys and idlers evenly to be effectively aligned.

Uncentered loading – If the material is not loading centred then the uneven weight distribution will cause the belt to drift. A scoop-shaped loading chute that slows material and distributes it at the centre of the belt can help.

Belt and splice – If the belt is poorly manufactured or stored improperly, it can bow or camber.

Poor installation of a vulcanised or mechanical splice can result in belt tracking problems.

EQUIPMENT CONDITIONS Idlers and pulleys – All rolling components steer the belt. To ensure proper alignment, rolling components must be: • Clean – A fouled pulley face can cause slippage, leading to belt rippling, excessive friction, and higher power consumption. A fouled roller face may be too slick to roll.

• Rolling – Dust and spillage can gum up roller bearings and pulley machine parts, causing them to

MATERIALS & HANDLING

PROBLEMS AND INDICATORS OF MISTRACKING

When the belt mistracks, the indicators will be apparent, especially if the system is equipped with a stop mechanism. The main reason for a stop mechanism is preventing the belt’s contact with the frame. Aside from the expensive belt edge damage, the friction can break the splice or ignite combustible dust or cargo, potentially causing a fire or explosion.

As one side of the belt rises higher, material spills along the belt path.

Cleanup requires shutting down the system so workers can do it safely. This can raise labour costs. Like belt friction on the mainframe, frozen idlers from fouled roller faces and bearings caused by spillage can damage the belt. It degrades the less-protected bottom side of the belt. Damage to one side of the belt produces mistracking.

Alignment provided by the lower trackers ensures the belt is centred for proper loading

Below: Shifting material causing mistracking

WHY ARE AUTOMATED TRACKING SYSTEMS EFFECTIVE?

Automated tracking makes microadjustments using sensing arms with small rollers at the end that detect minor changes in the belt’s path. The force of the belt against the arms in any direction other than the centre adjusts the steering assembly proportionally to the belt’s drift, guiding it back toward the centre.

By adjusting the belt immediately, the material is more likely to shift back to the centre rather than move with the drift of the belt, which can worsen the issue.

For additional steering power, the assembly elevates the steering idler approximately 10mm to 20mm higher than the rolls of the adjacent conventional idlers. The centre roll or pivot roll increases the belt’s pressure on the tracking device, improving the corrective friction between the belt and the aligning roll.

When the belt mistracks, the indicators will be apparent, especially if the system is equipped with a stop mechanism A seized idler wears down from belt friction, creating a potential fire hazard

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MATERIALS HANDLING

Operators and design engineers need to take the behaviour of the material into account for safety

WHERE TO PLACE AUTOMATED BELT TRACKING DEVICES

Ideally, the upper tracking device should be installed after the load zone on belts wider than 1000mm. The force of the material drop – especially large raw material – causes material to shift, potentially putting more weight on one side. Due to a slight amount of belt sag, material can also shift when the belt encounters idlers. By adjusting the belt directly after leaving the enclosure, the material stream is steered to the centre.

Some longer conveyors may require additional units to retain alignment.

To avoid units competing and contradicting each other’s steering action, they should be positioned approximately 20m to 50m apart.

Proper return roller (or lower tracking device) placement is critical. This ensures the belt encounters the takeup or gravity pulley correctly. Although there may be some drift due to sag, the belt is flat on the return, so crowned rollers that are wider at the centre

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help train the belt back to the centre.

Maintenance experts recommend installing a lower tracking device approximately five times the belt width in distance before the tail pulley.

LINING UP TO SAFETY AND EFFICIENCY

Mistracking is like a pest infestation.

Ignoring it makes it worse and in-house solutions rarely work

Why is belt tracking so important?

Safety is the main concern. Aside from lost production due to unscheduled downtime, there are also associated spillage cleanup costs, clouds of dust, and broken equipment. Mistracking is like a pest infestation. Ignoring it makes it worse and in-house solutions rarely work, so in most cases, a professional and lasting solution is required. Automated belt tracking offers peace of mind, less maintenance, safety, and a quick return on investment.

For more information visit: www.martin-eng.com

MATERIALS HANDLING

The DEScycle TRL7 demonstration facility is currently being built and will support the Return project

THE RETURN PROJECT A new consortium plans to support a sustainable, circular e-waste recycling system

E

lectronic waste is one of the world’s fastest-growing waste streams, with an annual growth rate of 3% to 5%. According to the World Health Organisation, an estimated 62 million tonnes of e-waste were produced globally in 2022 alone. Less than a quarter of this waste was recorded to have been recycled.

Traditional recycling methods often fail to recover the full value of critical raw materials. E-waste recycling requires the extensive processing of hazardous materials from electronic devices that are often not designed for disassembly. For these reasons, the recycling infrastructure for e-waste is lacking.

THE RETURN PROJECT

A new European consortium has launched the research and innovation project Return, to support the

Traditional recycling methods often fail to recover the full value of critical raw materials

creation of a sustainable, digitally enabled system to recover valuable materials from complex e-waste.

Co-funded by the European Union’s Horizon Europe programme and Swiss State Secretariat for Education, Research and Innovation (SERI), Return aims to reduce Europe’s reliance on traditional, energy-intensive extraction methods. In doing so, the project will also help to break Europe’s dependence on carbon-intensive imports.

The Return consortium comprises a range of European companies and research institutions to ensure a diverse set of expertise.

The consortium partners include: DEScycle (United Kingdom), Minespider (Germany), GAP Group (United Kingdom), Cycleco (France), MoreThanDigital (Switzerland), Iconiq Innovation Ltd (United Kingdom), PX Group (Switzerland), OSAI Automation Systems (Italy), Jean

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MATERIALS HANDLING

Monnet University (France).

“The Return Project represents a significant step towards reshoring Europe’s critical raw material supply chains and transitioning to a circular economy,” says CEO of the project coordinator DEScycle Dr Leonidas Howden.

THE STRATEGY

Running from 2025 to 2028, the Return project is developing a scalable, sustainable and economically viable plan to overcome the barriers to e-waste recycling.

“By transforming e-waste from an environmental liability into a valuable circular resource, we’re creating a secure, sustainable supply of critical materials, supporting Europe’s green and digital transitions and creating green jobs within the EU,” says Howden.

“Our collaborative approach brings together leaders in chemical engineering, digital technology, industrial automation and sustainability to build a model that can be scaled across the industry, directly supporting the goals of the EU Critical Raw Materials Act.” During the 36-month project duration, Return will move from laboratory-scale validation to precommercial demonstration.

KEY RETURN PROJECT INNOVATIONS INCLUDE: n eco-friendly chemical A recovery process replacing traditional, energy-intensive smelting Automated sorting systems to improve efficiency and material purity Digital Product Passports (DPPs) to track materials throughout their lifecycle A Dynamic Digital Marketplace (DDM) to facilitate trade of recovered materials and components

REPLACING SMELTING

A crucial part of the project is the eco-friendly chemical recovery process, which will replace traditional, energy-intensive smelting.

“Conventional smelting of e-waste relies on blending with copper concentrates at vast industrial facilities processing over 90,000t

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A CLOSER LOOK AT DESCYCLE’S DEEP EUTECTIC SOLVENTS TECHNOLOGY 1. Operation at 50ºC – 80ºC, compared to >1,500ºC for conventional pyrometallurgy 2. Consistent demonstration of 99% metal recovery rates across initial target metals. Comparatively, pyrometallurgy typically achieves 95% recovery 3. LCA data from DEScycle’s initial process configuration demonstrates significant carbon savings compared to incumbent technologies. Per tonne Cu recovered, primary mining emits 4.6t CO₂eq, smelting emits 4.3t CO₂eq, DEScycle MVP emits, ~0.89t CO₂eq. Strategic estimated emission is 0.29t CO₂eq, significantly improving resource efficiency 4. Residual plastic polymers remain inert, enabling reuse in new products. These are destroyed in hydro/pyro met 5. Closed loop solvent recovery system employed and no excess acid use. Acids not readily regenerated in hydrometallurgy 6. Closed vessel process with low-hazard solvents ensures no detrimental exposure to workers or environment.

Pyrometallurgy has several safety concerns including production of hazardous wastewater and slags, toxic air metal particulates (elements) and release of gaseous SO2 contributing to acid rain per annum at extreme temperatures exceeding 1,500°C,” says DEScycle project manager Dr Dhivya Puri.

Although this method is traditionally useful for bulk recovery, it is energy-intensive and causes environmental and health-related damage through toxic emissions and complex waste streams.

This, combined with the capital intensity, permitting difficulties and lack of scalability, has led to traditional methods being unable to accommodate the current e-waste generation rate.

“At DEScycle, we are pioneering a cleaner, more agile alternative.

Our solution enables decentralised recycling, with 2,000tpa-10,000tpa processing units designed for integration with upstream recyclers,” says Puri. “This proximity to feedstock

not only reduces transport and handling losses but also enables more responsive, modular deployment across diverse geographies.”

DEScycle’s process is built on Deep Eutectic Solvents (DES), a novel class of green chemistry.

DES enables selective dissolution of target metals from e-waste, enabling their recovery through tailored precipitation, adsorption or electrochemical techniques. This approach offers a lower-temperature, lower-impact pathway to urban mining, supporting the Return project, a circular economy and emerging EU sustainability directives.

For more information visit www.descycle.com

MATERIALS & HANDLING

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MATERIALS HANDLING

CUSTOMISABLE

CONVEYORS

The conveyor moves product vertically, horizontally, at any angle and around corners to fit specific facility layouts

Adapting to changing facility conditions is becoming increasingly important in materials handling

F

lexibility is a crucial feature of conveyors in the mining industry. The ability to adapt to changing conditions and carry large loads while preventing bottlenecks is key to a durable and efficient materials handling system.

TUBEPRO DRAG CONVEYOR

The TubePro tubular drag conveyor by industrial equipment supplier Hapman is a solution engineered to transport mining materials with precision, even for facilities with strict containment requirements.

The conveyor is suitable for challenging mining applications, engineered to convey blended, friable, large particle or smearing materials without compromising product integrity. Product is transported en masse between flights, exposing it to minimal turbulence and reducing the risk of abrasive degradation.

Its dust-tight design can safely handle dusty, odorous, toxic or hazardous materials, in part due to its heavy-duty Schedule 40 pipe construction, or Schedule 80 as an optional upgrade. The slotted round flanges and continuously welded, offset flanged connections create an interlocking pipe structure. This design assists with efficient assembly and an overall rigid conveyor system.

The TubePro operates at high torque and low speed for energy-efficient performance and lower operating costs.

The conveyor can also stop and restart while fully loaded to minimise waste and reduce downtime during operation.

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TAILORED OPTIONS

To reduce fatigue, wear and elongation, multiple chain and flight options, including round link, drop forged rivetless and engineered sealed pin chains are available.

Enhancements include the Airknife, Chain Hammer, Brush Box, and SelfCleaning Discharge Gate.

The conveyor can move product vertically, horizontally, at any angle, and around corners, with configuration of inlets and outlets

to fit specific facility layouts.

Customisable run lengths and bend angles help to further accommodate specific installation needs.

For more information visit: www.hapman.com

ENHANCEMENTS Airknife: Uses a focused stream of air to remove residual material from the chain and flights, ensuring a clean and efficient operation.

Chain hammer: An impact shoe assembly attached to the free end of the spring projects. When energised, movement of the spring plate causes the impact show to reciprocate and strike the flights. This provides mechanical agitation to dislodge stubborn material, reducing buildup and carryover.

Brush box: Usually used for waste material, using dual spinning brushes to remove stuck debris from flights and chain, which helps to prevent carryover and support thorough cleaning.

Self-cleaning discharge gate: An intermediate discharge point that can be installed at any location along the carry side of the tube conveyor, acting as a bomb bay door and allowing for full discharge.

Vibrating hammer: Placed at discharge points to free material that might otherwise cling to the chain flights.

Roller Tracker

........................................

Tracker™ HD / Lower

........................................

........................................

Tracker™ HD / Upper

Tracker™ Reversing

artin's belt alignment products provide immediate, continuous precision adjustment — keeping conveyor belts aligned under the demanding conditions of heavy loads and high speeds. Proper tracking prevents edge damage, extends belt life, reduces equipment wear, and keeps material in the flow stream — eliminating the fugitive dust and spillage that lead to costly cleanup, production delays, and worker safety risks.

MATERIALS HANDLING

LOW-COST LITHIUM

A white paper from Lilac Solutions details the cost advantages of a new ion-exchange technology for lithium extraction Gen 5 Lilac IX is reported to deliver significant improvements in performance and cost

L

eading provider of direct lithium extraction (DLE) technology, Lilac Solutions, has released its fifth-generation ion exchange (IX) technology, which it claims delivers significant improvements in performance and cost as well as a white paper detailing the advantages of the technology.

Gen 5 Lilac IX increases IX media productivity and durability, enhances eluate quality, and simplifies brine pre-treatment, driving down capital and operating costs for lithium producers. Developed and manufactured in the USA, Lilac’s technology establishes and strengthens supply chains for critical minerals while eliminating reliance

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on Chinese-made components.

Alongside this release, Lilac has published a technical white paper documenting Gen 5 performance, field validation, and cost modelling across multiple brine resources.

THE CHALLENGE OF HIGH COSTS

“Lithium producers are under intense cost pressure as prices remain volatile and the resources needed for new supply are increasingly complex,” said Lilac Solutions CEO Raef Sully.

“Our Gen 5 technology gives producers a clear path to low-cost lithium production from a wider range of brine resources.”

The Gen 5 technology leverages the same proven equipment package

used in Lilac’s Gen 4 pilot and demonstration plants with a scalable, modular design, standard components, and 10x lower water consumption compared with AA. Gen 5 has been validated in recent field pilots with challenging brines, including the ultralow-grade Great Salt Lake brine in Utah (70 mg/L Li) and oilfield brines in Europe.

“Lilac’s Gen 5 technology represents a real opportunity for brine developers,” said Lilac Solutions founder and CTO Dave Snydacker. “Many brine projects have been trying for years to implement conventional adsorbents but have struggled with low performance and high costs. This is an exciting moment to rethink ion exchange.”

MATERIALS HANDLING

PERFORMANCE EXAMINED Gen 5 Lilac IX provides good performance when compared with conventional alumina adsorbents (AA), according to the company. Four key attributes enable significant reductions in project costs: olids tolerance: IX system allows passage of 70x larger S particles, enabling use of low-cost multi-media filtration and avoiding expensive ultrafiltration often required

by AA. edia productivity: The lithium production rate per M volume of IX media is 20x higher than AA, reducing the required number of reactors and first fill media volume. edia durability: Delivers up to 10,000 cycles before M replacement, much higher than competing IX technologies. luate quality: 7x higher lithium concentration and E higher purity with 100x lower boron:lithium ratio than AA, simplifying downstream concentration and purification.

ADVANTAGES

Projects incorporating Gen 5 Lilac IX are projected to rank in the first quartile of the global cost curve, with C1 costs ranging from US$3,200 to US$5,500 per tonne of lithium carbonate equivalent (LCE), including the planned full-scale commercial facility at the Great Salt Lake. Gen 5 expands the range of viable brine resources, enabling firstquartile costs across both high- and low-grade brines while maintaining a smaller environmental footprint than legacy brine and hard rock extraction methods.

Lilac’s technology builds on field experience from seven completed pilot and demonstration plants in Argentina, Chile, the USA and Europe, validating high lithium recoveries, strong impurity rejection, and reliable operations across a wide range of brine grades and types.

For more information visit: www.lilacsolutions.com

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MATERIALS HANDLING

STEADY STRIDES Saudi Arabia’s decisive investment into its mining resources is paying off

D

uring the last decade, Saudi Arabia’s mining industry has experienced significant growth.

While the country placed 104th in the Fraser Institute Mining Investment Attractiveness Index in 2013, it jumped up to 23rd place in 2024.

Saudi Arabia has also made strides in the Policy Perception Index (PPI) and Mineral Potential Index (MPI) since 2013, showing a move from 82nd to 20th place, and 58th to 24th place respectively.

WHY THE RAPID CHANGE?

Saudi Arabia’s swift success in the mining industry is the result of several factors – untapped mineral resources, governmental support and the prioritisation of technological innovation.

“Our focus remains on maximising the economic value of our mineral resources, creating jobs for citizens, and localising supply chains,” said Saudi Arabia’s vice minister for mining affairs Khalid Al-Mudaifer.

The report references several factors that are responsible for the vast improvements across the mining industry, such as broad regulatory transformations covering security of tenure, taxation, environmental legislation,

Mining has become a key driver in industrial and economic growth for Saudi Arabia

infrastructure and community engagement.

BEHIND THE SUCCESS Recently, Saudi Arabia has built a globally competitive investment environment, underpinned by clear

SAUDI ARABIA HAS EXPERIENCED IMPROVEMENTS IN KEY INDICATORS BETWEEN 2013 AND 2024, INCLUDING: 3 05.8% improvement in the clarity and effectiveness of mining administration, from 17% in 2013 to 69% in 2024, ranking 11th globally.

8 2.2% improvement in clarity of land use for mining activities, from 45% in 2013 to 82% in 2024, ranking 7th globally.

1 02.2% improvement in labour regulations, from 45% in 2013 to 91% in 2024.

8 1.8% improvement in the quality of geological databases, from 33% in 2013 to 60% in 2024.

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regulations, competitive incentives, infrastructure and accessible geological data – including one of the most extensive geological surveys of the Arabian Shield.

“Mining is no longer a traditional sector; rather, it has become a key driver of industrial and economic growth, and we are committed to building on this momentum to ensure sustainable success.”

The country’s Mining Exploration Enablement Programme was also listed as an effective tool for reducing investment risks and increasing confidence in early-stage projects.

The programme is a government initiative designed to boost mineral exploration by providing financial and other support to companies holding exploration licences.

The increase in tangible regulations, incentives, data and programmes has contributed to the rapid increase in Saudi Arabia’s success.

Control dust and spillage.

For over 40 years, the largest mining companies in the world have put their confidence in Richwood’s innovative material handling solutions.

When it comes to solving problems with dust and material containment, Richwood achieves success with engineered passive dust containment systems. Application-specific solutions optimize efficiency through sealed and protected load zones without the need for vacuums, filters or other additional equipment. The reduced wear and tear on equipment and controlled dust and spillage create a safer and more productive work environment. Worry-free load zones are designed and built by Richwood every day.

What would it mean for your productivity if dust and spillage issues were eliminated? Contact Richwood today for a review of your application.

Rely on Richwood!

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before and after installation of Richwood Containment System

Belt Cleaning Systems Impact Protection Systems Material Containment Systems Pulley Lagging Wear Liners Complete Transfer Chutes

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SKILLS ZONE

Sandvik’s Automine surface drilling training simulator prepares trainees

THE VALUE OF SIMULATION SOFTWARE Companies and governments are increasingly investing in simulation technology to train the next generation of mining workers

D

igital simulation is a powerful decision-making tool, modelling the complexity and dynamics of real systems, technologies and possible scenarios.

Simulation models can be particularly useful for training, creating decision-making storylines and opportunities for experience without bringing workers near potentially hazardous equipment until they are ready.

Simulation training is increasingly being adopted by mining companies for its many advantages.

SAFETY IN SIMULATION Earlier this year, the Canadian government’s research and innovation

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fund invested CAD$650,000 to develop a virtual research and training facility that uses digital twin technology at College of the North Atlantic (CNA), in partnership with software company GRi Simulations.

The resulting project is currently underway, with GRi Simulations using data obtained by CNA’s reality capture team to develop software and build a platform reflecting real-world mining situations. CNA will host a space for research on how to remotely operate machinery using GRi Simulations software and simulators.

“This unique facility will advance collaboration, innovation and training to help position Newfoundland and Labrador and Canada as leaders in the mining sector’s digital transformation

and adoption of remote operations, automation and artificial intelligence,” says GRi Simulations VP of operations and business development Steve Dodd.

Government investments such as this are leading the trend toward simulation as a training tool and supporting the development of specialised simulation companies.

Software company Simformotion, for example, recently released its High Reach Scaler simulator, which creates a realistic underground mining environment featuring Fletcher controls and machine exercises.

The exercises, motion system and VR help trainees to learn tipping points with greater depth perception while practicing different techniques.

Trainees can also learn pre-operation

SKILLS ZONE

Fletcher Simulators high reach scaler system

machine inspection, start-up and shutdown procedures.

“We recognise that safety in mine operations is critical, which is why the new Fletcher Simulators High Reach Scaler system teaches operators how to accurately, efficiently and safely remove loose or unstable rock and debris from tunnel walls and roofs,” says Simformotion CEO Lara Aaron.

“This procedure helps ensure the mine is safe before other workers and machines enter the area. As operators learn and practice the real-world skills on the authentic Fletcher controls, they also stay safe in the virtual, simulated mine environment.”

TRYING OUT THE TOOLS

In addition to lowering accident rates and encouraging a healthy safety culture, simulation training also helps to keep mining equipment in production, lowering fuel and maintenance costs, as well as

emissions. This is why some mining companies are investing in developing their own simulation technology.

Simulator supplier Immersive Technologies is another simulation company that has been busy this year.

Immersive Technologies supports simulation of major OEM mining equipment, including technology from Komatsu, Caterpillar, Liebherr, Hitachi, Volvo, Toyota, Scania, Iveco and Belaz.

The company recently released the LX3+ and LX6+ Advanced Equipment Simulator for surface mining. Building on the LX platform range, the new technology introduces motion base functionality to enhance realism and effectiveness in early-stage mining equipment operator training.

“The addition of the motion base functionality provides mining operations with a powerful tool to accelerate workforce readiness while optimising simulator utilisation and cost,” says Immersive Technologies VP of engineering Karen Joseph.

Immersive Technologies LX6+ advanced equipment simulator

Training applications for the new range include mine-site familiarisation, emergency response preparedness and new-hire onboarding.

Mining company Sandvik Mining has also recently launched the AutoMine surface drilling training simulator.

Trainees can use the simulator to operate up to three of the same type of rigs simultaneously while practicing processes such as path planning, autonomous production cycle management and real-time monitoring of drilling progress.

The simulator camera views replicate those in actual operations with authentic rig petals and controls contributing to a realistic, hands-on experience.

HOW SIMULATION WORKS

Data collection: Data collection is an important starting point for simulation. This could include mathematical models, sensor data, equipment specifications, geological analysis and logistical patterns such as transport routes, shift patters and operation schedules.

Model Creation: Software is used to incorporate the statistics collected into a 3D model of the mining operation.

The more data there is, the richer the model can become and the more realistic the final product will be. Realworld variables such as equipment failures and shift schedules can add an extra layer of realism.

Ready to run: Once the simulation technology is implemented, trainees can run different scenarios with a range of variables. Since simulation can predict outcomes with accuracy based on real-world data, it is easy to test different “what if” scenarios without impacting real-world production or equipment.

VALUE IN REALISTIC SIMULATION TRAINING

Simulation is a valuable training tool to provide real-world experience without the risk and expense. As governments and companies continue investing and experimenting, the technology for creating realistic mining scenarios will keep growing.

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SHOW PREVIEW

MOROCCO INTERNATIONAL MINING CONGRESS: A LEADER IN SUSTAINABLE MINING

M

orocco holds 70% of the world’s phosphate reserves and is a big player in the mining industry. The country is also actively pursuing sustainable mining through its legislation, investments, and the creation of shows such as the Morocco International Mining Congress and Exhibition (MIMC).

The second-ever MIMC will be held this year at the end of November. A new show on the scene, MIMC was created by the Mining Federation of Industrial Minerals of Morocco (FDIM) and AME Trade Ltd. The purpose of this year’s show is to contextualise Morocco’s sustainable developments and showcase how the country can act as an industrial and technological leader in Africa and worldwide.

Topics at this year’s show include critical minerals for the energy transition, regional partnerships throughout Africa and technological innovation. Featuring 90 speakers and 48 exhibitors, the show will host over 800 attendees from 30 countries.

The show will take place on the 24th to 26th of November at the Pickalbatros Hôtel du Golf in Marrakech.

For more information visit: www.imc-morocco.com

Index to advertisers

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Hägglunds

OBC

Master Builders Solutions

39

Hilliard Brake Systems

51

Nasaco

43

Hilliard Corporation

IFC

Richwood

45

Seal Saver

5

Wirtgen

21

ASC Sensors

9

i.safe Mobile

31

Cirrus Research

31

JVK Filtration

19

Di-Corp

39

Martin Engineering

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SHOW PREVIEW

RESOURCING TOMORROW: AN OPPORTUNITY TO RESPOND

T

o kick off the month of December, Europe’s largest mining show, Resourcing Tomorrow, is back to welcome over 2,000 mining executives, government ministers, investors, and other industry leaders.

Timed just weeks after COP30 in Brazil, Resourcing Tomorrow acts as a space for the global mining community to respond to the commitments made to global climate and sustainability goals. It is an opportunity for the international exchange of ideas, with attendees from over 100 countries present.

THIS YEAR’S RELEVANT TOPICS

As the mining industry continues to become increasingly proactive in the energy transition from fossil fuels to electricity, the paperless conference will broach topics such as waste

reduction, recycling technologies, resource efficiency and supply chains for electric vehicles.

Additional topics to be explored will include AI, automation, data analytics and the intersection of critical minerals and global geopolitics.

Over 300 mining and industry leaders will share their expertise across three theatres, encouraging dynamic discussion and supporting the advanced networking options offered by the conference.

NETWORKING OPPORTUNITIES

Resourcing Tomorrow Connect is an AI-driven meeting platform that will help to bring attendees together, with last year’s show hosting over 2,300 meetings. The click of a button will help you to schedule meetings away from the hustle and bustle of the expo floor.

ATTENDANCE

Resourcing Tomorrow will take place on the 2nd to 4th December at London’s Business Design Centre. In line with the conference’s support of the energy transition, the Business Design Centre has transitioned to 100% renewable energy sources since 2019.

For more information visit: www.resourcingtomorrow.com

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YOUR GUIDE TO DISTRIBUTORS, SUPPLIERS AND MANUFACTURERS IN THE INDUSTRY

CIRRUS RESEARCH

CONN-WELD INDUSTRIES, LLC.

DIEMME FILTRATION

At Cirrus Research, we specialise in the design, manufacture, and distribution of high-quality noise measurement instruments and solutions.

Conn-Weld Industries, LLC is an engineering firm and 400,000 sq. ft. manufacturing facility providing a full product line of vibrating screening equipment, sieves, and various components serving the mining industry.

Diemme Filtration has the widest range of filter presses available on the global market in terms of size, design and technical characteristics. The equipment is tailor made and designed according to the needs of the specific application.

T +44 (0)1723 891655

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E sales@cirrusresearch.com

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W www.cirrusresearch.com

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RICHWOOD HILLIARD

J.H. FLETCHER & CO

RICHWOOD

Hilliard offers a diversified product line for industrial applications in a wide variety of industries. Hilliard products are designed, manufactured and sold according to our customers' applications.

Celebrates their 80th anniversary of serving the underground mining industry.

Fletcher world renowned roof support, is accompanied by an entire product line, which serves the coal, industrial mineral, metal, and construction industries.

Richwood designs innovative solutions for the worldwide bulk material handling industry.

Clean conveyors and sealed and protected load zones from site specific solutions mean lowered maintenance costs, safer work areas and more productive operations.

T +1 607 733 7121

T +1 800 543 5431

T 304-525-5436

E rdoud@hilliardcorp.com

E sales@jhfletcher.com

E info@richwood.com

W www.hilliardcorp.com

W www.jhfletcher.com

W www.richwood.com

GET INVOLVED For more information and to get your company in front of buyers, both in print and online for 12 months, contact... e advertising@setform.com t +44 (0)207 253 2545

www.engineerlive.com

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Thunder Hägglunds

An electric start to a lasting boom.

That’s more than a sound you hear. It’s expectations being shaken. One small change that sets the stage for so much more. When the new Hägglunds Thunder resonates with your needs, the result is electrifying. Learn what a difference a single difference can make at www.hagglunds.com.

Hägglunds is a brand of Rexroth.