Digitalisation is the overarching theme of this issue of International Mining Engineer. Although the mining sector is not always quick off the mark when it comes to embracing new technologies, bringing full digitalisation to mine sites is inevitable if they are to remain as well-functioning operations. As our fascinating interview with Glenn Kerkhoff (page 6) highlights, cloud-based platforms with OT/IT integration and information sharing are enabling mining operators to break down siloes within their organisations and improve overall efficiency. “Mining companies are finding new ways to mine smarter, not harder,” explains Kerkhoff.
An excellent example of the ‘smarter, not harder’ approach can be found in our interview with communications technology expert, Kevin Quillien (page 22), who explores how tailings dams can deploy modern communications networks to maintain their structural integrity and overhaul their approach to monitoring.
Digitalisation is also the theme of our article on page 26 entitled The Digital Revolution. Here, Bruno Castro details how digitalisation is not only about new technologies; it also involves a cultural shift to embrace digital mindsets.
Elsewhere in the issue our usual high-quality coverage showcases other technologies that, although they may not be digital themselves, certainly get connected into the abovementioned digital networks. Together, this combination of digital and physical tools is what keeps mines moving.
Louise Davis Editor
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NOVEMBER 2024
CLOUD CONTROL
An expert in advanced software solutions explains how mining companies across the world can deploy new digital tools to modernise – and greatly improve – their daily operations
AUTONOMOUS ALLIANCE
Two tech giants join forces to develop a new autonomous haulage solution
EFFICIENCY DRIVE
Are engine upgrades a smart path to greater efficiency?
ELECTRICAL ASSISTANCE SCHEME
Mine transportation system based on an electric trolley
DRILL & BLAST
14
PERFECT PARTNERS
An Australian project showcases how two experts are working together to develop a drill rig that aims to push the boundaries of autonomous mining
17
18
THE NEXT GENERATION
Drill rods designed with the modern miner in mind
DRILLING DEEP
Discussion of the technical evolution of precision drilling from mining to the geothermal energy sector
COVER STORY
LOAD & HAUL
20 NETWORKING OPPORTUNITY
Digitally connecting challenging sites such as tailings dams has long been an issue for those who manage them, but a robust communications network can get these sites better connected
24 RISE OF THE MACHINES
How small-scale autonomous robotic systems fill operational and safety gaps in mining operations following primary fleet automation
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EDITOR
Louise Davis
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26 THE DIGITAL REVOLUTION
How digitalisation is delivering enormous benefits in mining operations across the world 31 DATA DELIVERY DRIVE
Introducing a new digital tool designed to further maximise uptime of gearless mill drives in mineral processing 32 REPAIR NOT REPLACE
By refurbishing large mining equipment. one expert is reducing costs, along with metal waste and harmful emissions
IN CASE OF EMERGENCY
An expert in emergency refuge chambers explains how his firm’s solutions are keeping miners safe across the globe 37 SAFE AND SOUND
Exploring how a new 5G radio solution delivers improved safety and communication in the mining industry 38 SAFE REFUGE
Recent advances in real-time gas monitoring for refuge chambers
How sophisticated coatings solutions can improve a variety of materials handling applications in the lithium mining sector
44 MOBILE MATERIALS MANAGEMENT
Exploring the advantages and infrastructure requirements of all-electric operation of mobile crushing and screening plants 46 CONTROLLING CARRYBACK
Why dabbling in dribble chutes can pay dividends
Revealing the highlights of The Mining Show in Dubai
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.
How mining companies can benefit from the latest digital solutions
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MINE OF INFORMATION
An expert in advanced software solutions explains to Louise Davis how mining companies can deploy digital tools to modernise – and greatly improve – their operations
Like many engineering sectors, mining operations generate (and rely on) a great deal of data. But unlike some more tech-forward sectors, mining hasn’t always been great at joining up its various data points – either in terms of collection, transmission or indeed usage of said data. But, says Glenn Kerkhoff, Global Industry Principal, Mining, Metals & Minerals at AVEVA, things are beginning to change for the better. “Current trends in the use of industrial data in mining include the integration of different data types into a common unified data repository. This includes times-series data, transactional data, geospatial location data, business systems data,” explains Kerkhoff. “Digital twins and simulation models are also being increasingly used to enable ‘what-if’ scenarios and optimise operations.”
According to Kerkhoff, many of today’s mining companies are looking for cloud-based platforms with OT/ IT integration and information sharing, allowing them to break down siloes within their organisations and improve overall efficiency using an
integrated data and insights approach. He adds: “They’re also looking for ways to incorporate software and technology from different vendors into an overall solution, in a seamless and integrated approach. AVEVA’s cloudbased industrial intelligence platform, Connect, helps customers address these challenges.”
The Connect data services platform provides a scalable, secure industrial data management service. By building a connected data ecosystem, companies quickly explore AI and predictive analytics, monitor remote assets, increase efficiency, and drive digital transformation. Kerkhoff notes: “Many mining companies use Connect to aggregate, share, and contextualise data securely from multiple site operations to corporate, as well as with external stakeholders (such as equipment OEMs). It allows
Glenn Kerkhoff, AVEVA
AVEVA’s OT tools can assist mining companies in modernising their approach to monitoring and management
for seamless and secure integration with other systems, including OT applications and IT business systems.”
DIGITAL REVOLUTION
Connect is just one component among many in AVEVA’s digital mining tools portfolio and Kerkhoff explains that in general, the company is focused on operational technology (OT)
solutions that provide performance improvements. He comments: “We have decades of experience with technology solutions focused on improving reliability and availability, utilisation and efficiency, productivity, overall equipment effectiveness, and value chain optimisation.”
Vast experience goes a long way in selling and marketing new technologies, but mining is a sector that’s known for being quite riskaverse when it comes to deploying new tools. Has Kerkhoff encountered much reluctance to embrace new concepts when dealing with this industry? “It’s true that mining has been ‘traditional’ or ‘old-school’ and slow to adopt new technologies,” he acknowledges. “For many decades, miners have not had a strong focus on OT solutions. They relied more on increasing equipment and plant capacity to meet production targets, rather than using advanced operational technology to improve availability, utilisation, efficiency and productivity.”
But, says Kerkhoff, change is certainly afoot: “Several factors have forced mining companies to rethink the adoption of OT and advanced analytics solutions. These factors include workforce shortages, Covid constraints, new environmental social and governance (ESG) targets, the need to decarbonise and reduce greenhouse gas emissions, and the need to improve workforce health and safety.
“Mining companies are finding new ways to mine smarter, not harder. To produce more, with less. More tons with less waste, less equipment, less infrastructure, less workforce, less carbon fuel, and less environmental impact. All while maintaining product quality. And to do this involves technology, operational technology!”
Several factors have forced mining companies to rethink the adoption of OT and advanced analytics solutions
RISE OF THE MACHINES
It would be remiss not to ask an expert in digital technologies for his thoughts on the role of AI, and Kerkhoff confirms that it is being used to solve problems and generate value across the mining industry. He explains:
“In production, AI is helping with operations management and optimisation – increasing productivity, throughput, and maintaining quality.
AI also assists in ore/waste identification to increase recovery and reduce dilution. For advanced automation and machine autonomy, AI is critical. Driverless operations of heavy mobile equipment significantly improve productivity and safety. For advanced decision support, AI plays an important role. By collecting, integrating and interpreting vast quantities of data from many different data sources, meaningful production insights can be presented to operations management for better decision making. In maintenance, predictive analytics is helping to provide early warnings on machine and component failures. This helps improve maintenance processes to increase reliability and availability and reduce maintenance cost.”
Kerkhoff also notes that in other areas, such as geology, AI is helping improve processes for locating and delineating mineral resources.
“AI computer vision can provide rapid interpretation of geological information, improving the speed and accuracy of geological modelling. Advanced analytics and machine learning can also be used to improve the process and increase likelihood of finding new mineral deposits,” he details.
FUTURE-FOCUSED APPROACH
Kerkhoff cites many recent advances in OT, including machine autonomy, remote operations, electrification, and process automation. But he says there is still a long way to go: “Mining companies understand they must
change their ways to maintain their license to operate in the future. And we are well positioned to provide OT solutions to the mining industry. Our expertise spans execution and process control through to real-time, time-series data and analytics and a wide range of applications for
Modern software solutions can minimise the risks of unplanned downtime and keep operations running smoothly
production, maintenance, advanced and predictive analytics, process simulation, enterprise visualisation and much more.”
However, Kerkhoff does point out that the 24x7 nature of mining increases the risk associated with new technology adoption. “Any technology set-back can mean lost production,” he states. That risk is somewhat minimised by the fact that most AVEVA solutions are being integrating into existing control and execution systems. “For example, in processing and metallurgical plants, much of our technology is integrated to existing DCS control systems. For heavy mobile equipment, we integrate to existing onboard electronics systems and to office-based fleet management and machine guidance systems. Therefore, improving a customer’s productivity and efficiency using AVEVA capabilities is a lower risk,” explains Kerkhoff.
TRACK & TRACE TECHNOLOGY
When asked to highlight a recent customer success story, Kerkhoff recalls that a large iron-ore producer performed a digital technology project with AVEVA to improve reliability of critical assets and enhance iron-ore traceability from pit to port. Detailing this, Kerkhoff says: “The customer had several business challenges to address. Top of the list was that the reliability of critical equipment needed to improve to support a mine expansion project. The client also needed to increase throughput to full nameplate capacity by debottlenecking production operations. Not to mention, the company also lacked an inventory tracking and traceability solution for iron-ore movement from pit to port.”
Kerkhoff describes the customer’s goal as being to produce the highestgrade, lowest-emission iron ore, whilst tracking and reporting production, energy and greenhouse gas emissions. “The producer wanted to enable systems across the whole operation to make decisions automatically on live operational data, using Industry 4.0 concepts. And the team wanted to determine a robust and efficient way to transfer data across company OT and IT systems multiple times per day,” he reveals.
Several AVEVA solutions were deployed to solve these challenges, as Kerkhoff explains: “Our Operations Control solution was installed in multiple control rooms to integrate process control data via SCADA. Our PI system was implemented, including data archive, asset framework, asset analytics and event frames. This solution provided very large volumes of operational data, with context, using streaming calculation, to automatically pinpoint important events in operations. Our Predictive Analytics product was implemented using machine learning for critical assets to provide early warning anomaly detection. And our Production Management solution was used to implement process models for pit to port material tracking, inventory, and product traceability.”
The customer also reaped the benefits of the Connect Data Services platform, which was implemented for cloud integration, advanced analytics, and data sharing, across all parts of the iron-ore producer’s operations.
Commenting on this holistic and thorough project, Kerkhoff says: “By adopting an integrated solution, the customer was able to achieve outcomes such as improved real-time health tracking of critical equipment. This solution allowed the producer to determine equipment anomalies during operation and determine iron-ore inventory levels across various parts of the value chain. The operator also gained improved visibility of iron-ore material flow through mining, crushing, processing, rail, and port. These technologies
were also integrated via Connect Data Services to provide companywide business intelligence and decision making.”
A BRIGHT – AND DIGITAL – FUTURE
With regard to what’s next for AVEVA, Kerkhoff reports plenty of progress still to come, explaining that the Connect platform’s capabilities are continually being expanded: “This includes the development of various OT software solutions around engineering, production, maintenance, energy and sustainability. In addition, Connect allows us to integrate OT and IT, to include business solutions and ERP systems.”
Kerkhoff and his team are also well aware of the value of crossindustry partnerships in bringing digitalisation to mining. “We are busy growing our ecosystem of technology partners – including system integrators, SaaS experts, and customer technology developers – who will provide even more features for many different use cases, on Connect,” he confirms.
Ultimately, says Kerkhoff, mining companies will inevitably embrace digitalisation regardless of any risks they may face in embracing new solutions. “For mining companies to exist in today’s modern world with its wide range of new constraints, adoption of digital and advanced technology solutions will be key. Miners need technology now to meet the demands of tomorrow’s mining industry and enable them to succeed in the future,” he emphasises.
LET’S GET
DIGITAL
AVEVA offers a variety of digital technologies to the mining sector. Mining companies use its PI System to collect data from critical equipment in the mineral value chain, including drilling, blasting, loading, hauling, and crushing, grinding, floatation, and drying. Meanwhile, the Production Management product allows mining operators to increase operational profitability, agility and competitiveness. Mining firms use the Predictive Analytics tool to determine when equipment and machinery is showing anomalous behaviour and is operating outside of normal limits. And they use the Asset Information Management solution to aggregate information from multiple sources and formats, including engineering data, 3D models, reporting, laser scans, ERP, operations and many other data sources
Finally, many mining companies use AVEVA Unified Operations Center (UOC) to monitor all aspects of operations, including mining, processing, transport and logistics, from pit to port.
AVEVA’s Unified Operations Center (UOC) enables improved monitoring of all parts of a mine’s operations
AUTONOMOUS ALLIANCE
Two tech giants join forces to develop a new autonomous haulage solution
Building on the ongoing cooperative efforts between Liebherr and Fortescue, the two companies will further combine their areas of expertise to develop and validate an autonomous haulage solution (AHS). The AHS will be integrated with the zero emission haul trucks that the companies are currently co-developing, with the aim to be the first AHS operating zero emissions vehicles globally.
In August 2023, Liebherr announced the deployment of a fleet of four T 264 autonomous trucks in Western Australia for onsite validation, which marked the next stage of the firm’s development of a new autonomy product for the mining industry. This onsite validation is currently taking place in partnership with Fortescue at its Christmas Creek mine site, in a purpose-built facility for validating zero emission and autonomous haulage technologies.
“With our teams now fully integrated, Liebherr is excited to formally announce our partnership with Fortescue to
collectively develop and deploy our Autonomous Haulage Solution,” says Oliver Weiss, Executive Vice President, R&D, Engineering, and Production, Liebherr Mining. “We have always prioritised market-led product development and we are privileged to be partnering with Fortescue. Our collaborative efforts will be beneficial for not only Fortescue, but all customers who choose to implement Liebherr technology products on their sites.”
BUILDING THE FUTURE TOGETHER
Liebherr and Fortescue’s partnership to develop and validate the AHS was formalised in March 2023. Since then, the team has finalised the definition of the system and is now developing its extensive features and functionalities for validation.
As part of the AHS development, the two companies will develop an integrated fleet management system and a machine guidance solution, capable of being used independently on human-operated sites. Upon
completion of system validation, the AHS will be deployed across Fortescue mine sites.
“Our deep expertise in autonomous haulage that has come from operating over 200 diesel autonomous haul trucks across our mine sites, has enabled Fortescue and Liebherr to develop a fleet management system that uniquely targets efficiency and unlocks untapped capacity in our fleet,” comments Dino Otranto, Fortescue Metals Chief Executive Officer.
Otranto adds: “The partnership with Liebherr has enabled us to jointly develop the fleet management systems, which provide us with an OEM-agnostic solution that can be integrated with any autonomous platform including trucks, drills, watercarts or any other heavy mining equipment. This critical technology puts our business in full control of our development priorities and roadmap.
The AHS – including the fleet management system and machine guidance solution – will also be made available to customers worldwide as part of Liebherr’s expanding technology portfolio.
“This development will allow us to offer the global market a complete AHS including a fully integrated fleet management system and machine guidance solution,” says Oliver Weiss. “These innovative technologies form part of our expanding range of technology products and are another step forward in our strategy to become a total solution provider for the mining industry,” he notes..
Four T 264 autonomous trucks will be validated in Australia
Murray Clifford asks if engine upgrades are a smart path to greater efficiency?
EFFICIENCY DRIVE
HSE Mining in Australia is reaping the benefits of engine upgrades
As mining companies worldwide formulate strategies to transition to more sustainable operations without impacting cost of production, can engine upgrades help to bridge the gap to future technologies? One mining contractor in Australia has discovered that they certainly can.
Targeted upgrades that equip older high-horsepower mining engines with some of the technology fitted to the latest engines can pay big dividends. One company that has recently discovered this is HSE Mining, a contractor based in Australia.
The South Walker Creek coal mine in Queensland’s Bowen Basin produces some 6.5Mtpa of ROM coal from its open cut operations. In 2017, HSE Mining embarked on an upgrade programme for its 2,500hp Cummins Tier 1 QSK60 engines in six Komatsu 830E haul trucks, with a view to reducing its carbon footprint.
HSE’s cost benefit analysis of the proposed upgrade demonstrated clear
potential for improved engine life and fuel savings.
The Cummins solution chosen by HSE (named ‘Advantage’ in some territories) focused on the fuel system, with a key upgrade to the fuel injection in which the early high-pressure unit injection system (HPI) is replaced by a high-pressure modular common rail system (MCRS) standard on Cummins’
latest generation high horsepower engines. The upgrade featured other innovations in combustion technology engineered for Tier 4 Final and Stage V emissions compliance, currently the most stringent off-highway emissions standards in the world.
MEASURED ADVANTAGES
HSE’s cost benefit analysis of the proposed upgrade demonstrated clear potential for improved engine life and fuel savings
The MCRS upgrades brought a raft of operational improvements for HSE Mining. Notably, the operator observed that in-cylinder combustion technology was able to deliver a dramatic reduction of more than 60% in diesel particulate emissions with no aftertreatment. This naturally benefitted maintenance too, with less soot loading in oil.
The metrics for fuel consumption were equally positive. The operator was able to identify a 3% reduction across the first six Komatsu 830E trucks using the new fuel system technology. These fuel consumption gains naturally resulted in GHG
emissions benefits with carbon dioxide (CO2) lowered by more than 500,000kg for six trucks over their operation cycles of 6,000hours/year.
The operator’s Tier 1 engines were previously being changed out at 22,000 hours, extended to 26,000 hours based on fuel burn. With the upgrades in place, 32,000-hour engine change-outs became typical. One unit ran to 36,000 hours without issue.
The longer life effectively eliminated one engine change-out in the 80,000hour life of the truck chassis. Engine component life was also robust, with minimal mid-life component change-outs. Engines since returned to Cummins Master Rebuild Centre have had no core damage or additional core charges, underlining the top-level maintenance practices at the mine.
HSE Mining’s Maintenance
Superintendent Aaron Poli recognises the impact of the upgrades. “By upgrading, we’ve significantly reduced our carbon footprint and diesel particulate emissions as well as achieving major cost efficiency gains by burning less fuel and gaining longer engine life,” he notes.
SUPPORT BEHIND THE TECHNOLOGY
“If we do have a drama, it’s all handson deck from the Cummins team in Mackay, from the fitter on the floor, up through to Wade Ford (product support representative) to Glen Jones (branch manager),” Poli explains. “It’s not often I’ve seen a branch manager get involved as much as I’ve seen Glen Jones involved, which is a positive,” he comments.
Fuel system upgrades are presently available from Cummins Master Rebuild Centres globally.
Murray Clifford is with Cummins. www.cummins.com
ELECTRICAL ASSISTANCE SCHEME
Escondida BHP has begun environmental processing to have a transportation system based on an electric trolley. The project will allow the mining company to advance BHP’s global target of net zero operating greenhouse gas emissions by 2050.
It considers an investment of approximately US$250 million for the installation of infrastructure that will electrically assist the movement of extraction trucks in areas where the highest fuel consumption currently takes place.
Escondida BHP submitted an Environmental Impact Statement (DIA) to the Environmental Impact Assessment System (SEIA), to advance in the “Implementation of the Mining Truck Electrification System in Escondida Norte” project, which seeks to assist the movement of these pieces of equipment inside the mine by means of a trolley system.
The project includes the construction of a new electrical substation and transmission lines both inside and around the Escondida Norte pit. These facilities will electrically assist the movement of
trucks inside the mine in the areas where they go up loaded with ore and, consequently, consume more fuel. With this new technology, instead of using diesel, they will be propelled by electrical power, thus reducing the operational greenhouse gas emissions and improving productivity associated with truck performance given the higher travel speed.
Company president, Alejandro Tapia, said that “the electric trolley system is one of the initiatives with which we seek to move towards a safer and more sustainable way of operating hand in hand with technology. This project will allow us to reduce the fuel consumption of our extraction trucks and thus advance our goal of net zero operational greenhouse gas emissions by 2050.”
The HSE Mining team has a close working relationship with the Cummins engine experts
PERFECT PARTNERS
An Australian project showcases how two experts are working together to develop a drill rig that pushes the boundaries of autonomous mining
The SmartROC D65 is an autonomous rig garnering praise for how precise it is
We’ve entered Nick Howlett’s sandpit.
That’s what it feels like, anyway. It’s deep in the Outback, 1,500km north of Perth. Take a 90-minute flight from the Western Australian capital, drive 20 minutes into the Iron Bridge mine, past its expansive camp, then past the mine’s operations centre and towering crusher.
Wend your way further, climbing beyond the central pit, and there you’ll find an Epiroc SmartROC D65 surface drill working a drill pattern. The rig finishes a hole, collects its pipes and trams to the next in the sequence. It
could be a typical blast-drilling scene, but for one striking difference – there’s no operator in the cabin.
Five kilometres away, back down the hill in the mine’s operations center, Howlett watches by video link as the SmartROC D65 drills another hole. And another. And then another. He smiles. Welcome to the future of autonomous mining.
Iron Bridge is an ambitious joint venture mining project between Fortescue Metals Group subsidiary FMG Magnetite and Formosa Steel IB, the US$3.9 billion operation producing high-grade magnetite. “It’s great to be working with Epiroc here at Iron
Bridge and seeing the SmartROC D65 drill in action,” says Graham Howard, Director of Operations at Iron Bridge.
You can find an occasional shard of magnetite sitting on the Martian-red earth. The beguiling black mineral is scorching hot under the 45ºC sun. Those kinds of temperatures make this an ideal place to trial any equipment, autonomous or not. But Iron Bridge presents other opportunities to put this new test version of the SmartROC D65 Autonomous through its paces. The magnetite is buried in hard rock beneath metres of looser clay-like soil and then transitional earth,
HISTORY LESSON
Established in 2003, the Western Australian-based Fortescue Ltd. now ships more than 190 million metric tons of iron ore annually. It is one of the most costeffective iron ore producers in the world. Fortescue has been pursuing automation and autonomous solutions for well over a decade. In 2012, it introduced its first autonomous haulage truck and was the first company in the world to deploy an autonomous haulage system on a commercial scale.
We’ve spent a lot of time perfecting how the rig drills autonomously
meaning the rig is drilling under various conditions. “We want that,” says Howlett, an Epiroc Automation Specialist. “It’s how we develop and make a good product.”
NATURAL SELECTION
Fortescue has a reputation for being a forward-thinking mining house. It has been pursuing autonomous solutions for well over a decade, making it a natural partner in the SmartROC D65 Autonomous programme.
Epiroc and Fortescue entered a partnership in 2021 to trial this MKII version of Epiroc’s SmartROC D65 Autonomous. This project followed a 2018 SmartROC D65 Autonomous MKI pilot project in Canada. A successful test would provide Fortescue with an autonomous blast drill solution and Epiroc with vital test intel under realistic mining conditions.
“There’s no doubt autonomous is the way the industry’s going,” says Epiroc Australia General Manager and MD, Wayne Sterley. “And that
speaks to the inherent productivity, efficiency and safety gains of autonomous solutions.”
An autonomous SmartROC D65 rig’s advantages aren’t down to pure speed but tend to accumulate over time via a clever use of autonomous subsystems and the high quality and consistency of the holes it produces.
“A manual operator could maybe beat us over an hour or so, but that’s not what it’s about,” Howlett says. “It’s about consistency. When the operator goes for a break, we drill. If there’s blasting nearby, we drill. And our shift changes tend to be shorter.
“We’ve spent a lot of time perfecting how the rig drills autonomously, including water control, how it starts a hole, and the tricky aspects of collaring. We’ve also tuned it for different types of ground, with five different settings. You set these different parameters, the operator selects one and the drill gets to work.”
The SmartROC D65 Autonomous has also had an edge in pre-split
drilling. At Iron Bridge, operators drill up to 30m at an angle, meaning it’s relatively easy for unintended deviations in holes. The autonomous rig has been more precise in these scenarios, making for better drilling predictions and, in turn, easier drill plan adjustments.
Consistency also has positive impacts on equipment life cycles, with the SmartROC D65 MKII Autonomous rig’s autonomous algorithms using components such as cylinders, feed chains, rotation heads, and rock drilling tools more optimally.
TESTING, TESTING…
At its test site, the rig looks similar to a manually operated drill but features lidar and cameras on the machine’s front, back and top. There are also automation mode (“safe-to-board”) lights for transitioning from remote to local operations. Surrounding traffic cones mark out the SmartROC D65 MKII Autonomous rig’s “geofence,” or perimeter of autonomous operations.
Nick Howlett operates the SmartROC D65 MKII Autonomous rig’s teleremote station inside Iron Bridge’s air-conditioned operations centre
Still, the real magic happens at the tele-remote station back at the Iron Bridge operations centre.
Inside Iron Bridge’s air-conditioned nerve centre is a hive of activity, with rows upon rows of personnel tapping away at workstations. The SmartROC D65 MKII Autonomous rig’s tele remote station sits in a separate low-lit control room. It features two joysticks, a touchscreen like that inside the rig, and three additional LCD screens that display critical operational information – hole and drill pattern progress, a video stream from the rig’s onboard camera system, and the drill’s technical state and alarms. And yet it just needs an internet connection and the station could be in Perth, where many Iron Bridge personnel live, or indeed anywhere in the world.
“Like any new tech, there’s been some scepticism,” Howlett says. “But
[Fortescue] has begun to advertise for jobs for autonomous operators and there’s been a lot of interest. One of the lads told me he sees it as an opportunity to see more of his family in Perth.”
“We have the opportunity to put people in a safer working environment, and help them be more productive,” Sterley adds. “By taking on this digital transformation, we’ll attract more talent into the industry.”
So, what’s next for the SmartROC D65 Autonomous programme? After success at Iron Bridge, the focus is now on tackling autonomous contour mining at Fortescue’s nearby Solomon Hub.
“There’s a lot of knowledge about path planning and obstacle detection but not about tramming for contour operations,” Howlett says. “Those are wicked challenges. We’re looking forward to giving it a crack.”
SUCCESS STORIES
The two firms cite several keys to success in their efforts thus far.
Partnership is top of the list: Epiroc’s autonomous SmartROC D65 test programme has benefited from having a willing partner such as Fortescue. A successful test has provided Epiroc with valuable information under realworld mining conditions and Fortescue with a best-in-class autonomous solution.
Conditions are the second key: the Australian Outback is a tough place to drill, and the SmartROC D65 MKII
Autonomous has been tasked with drilling through different densities of earth and rock, making for ideal real-world test conditions.
The Pilbara region of Western Australia is the ideal place to trial any equipment, autonomous or not, with summer temperatures regularly eclipsing 45°C Inside view of the SmartROC autonomous rig
Third on the list is support: close collaboration onsite between the Iron Bridge and Epiroc teams has provided a continuous feedback flow. Thanks to communications with Epiroc’s programmers in Sweden, even minor software updates have been quickly delivered and applied.
The fourth key to success is technology: Epiroc has been at the forefront of autonomous drilling since its first autonomous drill was released in 2014. It has made strategic autonomous acquisitions, giving it an edge for developing new products.
Last on the list is consistency: success at Iron Bridge comes down to consistency, with the SmartROC D65 MKII
Autonomous capable of drilling during blasting and operator breaks. It has demonstrated a particular edge in production and pre-split drilling.
Today’s drilling environment involves challenges that previous generations rarely – if ever – faced. From deeper, harder-to-access deposits to operational challenges with automated rod handlers, to tighter margins from a more competitive and volatile global mineral exploration market, today’s driller needs efficient solutions for difficult situations.
It’s for these reasons that Di-Corp created its new wireline drill rods: S-Maxx. Specifically designed to meet the needs of today’s modern driller, S-Maxx drill rods’ dual-start thread and anti-jamming features will help drillers reach greater depths and achieve new limits.
CLUE’S IN THE NAME
The S-Maxx name comes from two parts: a patented “S” shaped interlocked profile thread and the “maximum” performance delivered by the rod. The dual-start S thread delivers more surface area and contact than previous thread forms, resulting in faster make and breaks and what the company claims is the highest torsional and tensile strength in the market.
The innovation in the new product comes from the S-shaped thread. The curvature of the load flank creates a self-locking thread profile resistant to bulging while the large corner radii improve fatigue cycling by eliminating areas of high stress concentration, improving the cycle life of the joint.
The dual-start thread allows for a finer thread pitch, enabling
THE NEXT GENERATION
Andy Sayers introduces drill rods designed with the modern miner in mind
more threads to be engaged without sacrificing make up speed. This provides a more even load distribution along the length of the thread, improving performance when compared to traditional designs. An additional, patented anti-jam feature prevents cross threading and jamming to ensure quick and easy make up
Di-Corp’s new S-Maxx drill rod end caps
and allows the driller to remain out of harm’s way.
The new S thread and anti-jamming features are machined onto Drillers Edge tubing, undergoing the same manufacturing processes that have given Di-Corp rods a global reputation for durability. The result is a coring rod that delivers max rod life, max joint strength, max depth capacity, and max efficiency.
TAKE YOUR DRILLING TO THE MAXX
“Today’s driller is dealing with a more competitive and volatile global mineral exploration market,” says Di-Corp’s Manufacturing Technology Manager, Chris Van Schaayk. “When margins are tight, efficiency is key. With S-Maxx, users gain efficiency by preventing cross threading – resulting in faster trips back in the hole and getting back to putting core in the box. They gain efficiency from more durable rods, resulting in reduced downtime, and smoother shifts at the rig. Who wants drama at the drill site? By investing slightly more on drilling rods, you gain lower cost per metre drilled throughout the project.”
Drilling has changed and drillers need drill rods that change to meet today’s challenges. The S-Maxx family are next-generation drill rods specifically designed for the modern mining environment.
Andy Sayers is with Di-Corp. www.di-corp.com
A closer look at the S-Maxx drill rods
DRILLING DEEP
Markus Nowack explores the technical evolution of precision drilling from mining to geothermal energy
Earth is a hot planet – about 99% of its mass exudes temperatures higher than 1,000ºC. This offers vast potential for the production of electricity and heat, which innovative geothermal energy companies are tapping into.
However, drilling down several thousand metres through diverse geological layers requires high-tech tools and equipment that withstands the extreme pressures and temperatures found at such depths. To succeed with this challenging task, the geothermal energy sector leverages insights and technologies gained from mining industry exploration drilling that helps uncover probable future reserves. As exploration drilling, too, involves cutting deep into the earth’s surface to collect rock and mineral samples that can be analysed to determine the location and size of potential mineral deposits.
In both these industries, the use of appropriate sensor technology to ensure precise drilling results is of crucial importance. Knowing the exact drilling path – and keeping neatly to it – is essential. So too are shock and heat resistance, to prevent the strong vibrations and high temperatures while drilling through the rock strata from skewing measurements and outcomes.
QUARTZ-BASED INERTIAL SENSOR SOLUTIONS
To succeed with its quest for cost-effective, sustainable energy drilling, the geothermal industry is enabled by German inertial sensor technology specialist ASC Sensors. The company has recently broadened its portfolio to include quartz-based accelerometers and digital IMUs manufactured by Japan Aviation Electronics Industry (JAE).
JAE’s high-performance servo quartz-based accelerometers of the JA-5 and JA-25 series, now available through ASC in the German-speaking
The use of appropriate sensor technology to ensure precise drilling results is critical
Knowing the exact drilling path is essential for both mining and geothermal energy applications
markets, are particularly suitable for the challenges faced in geothermal drilling.
Key features include an operational temperature range of up to +200ºC, high shock and vibration resistance (1,500g survival) as well as low/ medium measurement range (+/-4g). Their resolution of 1 µg, low noise and excellent long-term stability of scale factor and bias (<2mg over one year combined) makes them ideally suited for inclination measurement.
Due to their outstanding properties, JAE quartz accelerometers are also used in other high-demand applications beyond geological drilling. For ASC, the newly created partnership complements the company’s traditional portfolio of advanced analogue, digital and smart sensors. Working together, the joint German-Japanese team is now able to provide customers with novel, tailored, sustainable solutions to minimise risks and add value to their business.
LASER-FOCUSED
For almost 70 years, JAE has been researching, developing and
manufacturing quartz-based sensor technology for aviation, aerospace, automotive, railway, semiconductor, energy, construction engineering and other demanding applications.
In February 2024, the company signed a collaboration agreement with ASC Sensors to ensure access to JAE’s technology for customers in Austria, Germany and Switzerland, in addition to ASC’s own portfolio of highly innovative inertial sensor solutions.
“Our team is proud of our highly innovative, research-driven heritage,” says Yuichi Kocha, General Manager Aerospace at JAE Europe. He adds: “Solving customer needs is the absolute centre of our attention. In ASC, we found that same customer focus, a high degree of flexibility and, above all, terrific technical skills that ensure the best utilisation and service of our sensors where they can create most value.”
Markus Nowack is an application engineer at ASC Sensors. www.asc-sensors.de/en
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.
Krucial Connect provides a drop-in private network for enterprises to digitise any location on Earth private
NETWORKING OPPORTUNITY
Digitally connecting challenging sites such as tailings dams has long been an issue for those who manage them. Tech innovator Kevin Quillien explains to Louise Davis how a robust communications network can get these sites better connected
Kevin Quillien, CTO, Krucial
Operators of tailings dams and storage sites have an obligation to maintain structural integrity, so accurate, real-time monitoring is critical
Right: Mining equipment features lots of data points that need to be transmitted and monitored accurately
Ensuring the structural integrity and monitoring the environmental impact of tailing dams is critical, given the potential risks they impose, says Kevin Quillien, Co-Founder and CTO of the UK-headquartered communications company, Krucial. “Traditionally, conventional in situ geotechnical instruments such as piezometers, inclinometers or manual water sampling are used and read by operators, and it is not uncommon for these readings to be manually inserted into spreadsheets or other data recording applications,” explains Quillien. “But given tailings dams are often located in remote or off-grid locations and range in size from a few to a thousand hectares,
this can take up a lot of resources and the data collected using manual resources often does not represent a current indication of the environment.”
The telecoms tech expert also points out that is imperative to monitor the potential water quality impact from water run-off due to rainfall or other reasons: “Operators have a duty to ensure environmental compliance to local regulations,” he states.
Luckily for said operators, Quillien and his team at Krucial have recently developed a new solution – Krucial Connect – that aims to modernise how operators conduct tailings dam monitoring. Describing the solution, Quillien says: “Krucial Connect provides a drop-in private network
DELIVERING DIGITALISATION
The Krucial Connect solution provides a private dropin network to digitise any location. This means mine operators can deploy the system on a site and benefit from continuous and autonomous data transfer from hundreds of sensing devices across a 15km range, from any location.
The solution is off-grid capable with multiple in-built power options, including renewable energy sources, and sends data via multibackhauls across cellular or satellite, depending on what is available. The solution is robust to extreme environments and ensures data continues to flow through storms or power outages.
for enterprises to digitise any location on Earth, even the most remote where no other infrastructure is present on site. Users can transfer data to/from hundreds of industrial IoT, sensing or control devices, within a 15km wireless range from a central gateway to any data application, digital twin or AI on the cloud.”
Further detailing this advanced comms technology, Quillien says: “Robust for extreme environments and off-grid capable, Krucial Connect utilises multi-backhaul satellitecellular connectivity to ensure continuous data is available anytime from anywhere. We’re giving decision makers access to the data they need to cut cost, reduce risk and improve sustainability.”
Like many other sectors, the mining industry still relies on a lot of manual intervention, including for monitoring of facilities such as tailings dams
With regard to how the solution achieves its mission to assist mining operators, Quillen explains that, “Deploying industrial Internet of Things (IoT) devices combined with a drop-in robust communication network, such as Krucial Connect, allows for a continuous in-depth analysis of site conditions at any mining facility. Readings are transmitted autonomously directly to existing business systems or any data analytical platform meaning critical data is available and accessible by operators at any time even away from site.”
CONTINUOUS MONITORING
For tailings dams, a remote monitoring solution that is robust for any environment and off-grid capable means that key personnel will be notified of changes to structure integrity when it happens, regardless of available infrastructure or location of a dam. “Therefore, swift action can be taken to support the integrity of tailings dams before a failure occurs that could result in catastrophic damage,” details Quillien. “Additionally, it reduces the risk of breaching environmental regulations by continuously and autonomously monitoring the environment in and around the dams.”
When speaking with Quillien, it becomes clear that the mining sector is crying out for solutions such as his. “Like many other sectors, the mining industry still relies on a lot of manual intervention, including for monitoring of facilities such as tailings dams,” he states. “Automation of monitoring can make this more cost effective and provide more, better-quality data
on which to base decision making, improve safety, and meet regulatory and reporting requirements.”
Quillien mentions that existing automated monitoring solutions are often constrained by vendor lock-in, focusing on a limited set of parameters dictated by the specific technology, sensors and software of the provider. “Krucial recognises that comprehensive monitoring of tailings dams needs to span across multiple domains such as geotechnical and environmental monitoring and bring together a wide variety of technologies from across different vendors to optimally meet the needs of different sites and customers,” he confirms.
Quillien notes that Krucial Connect is built on a secure open architecture and is compatible with a wide range of devices on the ground to transfer data seamlessly and. “Once spec’d to meet the needs of a client, the solution is easy to set-up and can be deployed with no specialist skills required. Deployed in mere hours no matter the site location, clients gain access to critical data from a wide range of devices monitoring parameters ranging from local weather, water levels, soil conditions, dam structural conditions, underground conditions, water quality and more,” he says.
RETROFIT REVOLUTION
A further advantage of the system is that as it’s able to operate independently from any local or existing infrastructure, Krucial Connect has the ability to easily retrofit assets to unlock the benefits of digital twinning and automated monitoring. Commenting on this point, Quillien observes: “For an
industry with a significant number of legacy and ageing assets such as mining, Krucial Connect offers the ability to modernise operations and enhance efficiency.”
MODERNISING MINDSETS
As well as legacy systems, mining often offers up the challenge of legacy mindsets, too. It’s not exactly a sector that is well-known for embracing new technologies; technical evolution in mining tends to be slow and cautious. So, how then, does Quillien sell his solution to such a tough audience? “The industry itself is in desperate need of new site management solutions and ways to streamline operations whilst staying compliant to stringent environmental regulations,” he believes. “With ageing infrastructure and increased numbers of decommissioned (or soon to be decommissioned) sites, the onus
The Brumadinho dam disaster occurred on 25 January 2019 when a tailings dam at the Córrego do Feijão iron ore mine suffered a catastrophic failure
to monitor these sites still lies with the operators. Replacing legacy systems or outdated infrastructure can be daunting and overwhelming to any industry, but the larger operators in the sector are already making moves to adopt industry 4.0 and it
is natural that the rest of the sector will follow.” He also points out that, “Individual operators don’t want the costly job of replacing entire systems or ageing infrastructure, so the adoption of technologies that can seamlessly integrate with existing
HOW IT WORKS
Mine operators can simply connect IoT devices, such as sensors, to securely transmit data via LoRaWAN from their assets, sites, infrastructure and buildings. Krucial Connect automatically switches between satellite and cellular, so operational data keeps flowing. Durable and futureproof, it can be deployed anywhere – even at more remote and hardto-reach mine sites. And thanks to a robust Application Programming Interface (API), users can easily integrate with internal systems and workflows, so they have the data they need to make informed business decisions quickly and efficiently.
systems and have the ability to retrofit ageing infrastructure is essential to see return on investment.”
In his experience within the global mining sector thus far, Quillien reports that suppliers to the industry are keen to work alongside Krucial to “enable the easy adoption of remote monitoring technologies that can enhance efficiency, safety and boost sustainable practices industry-wide.”
He also predicts that initial deployments will soon create a snowball effect once mining operators witness the benefits of having such improved monitoring and connectivity. “Adoption of digital innovation is inevitable for all industries, even if the adoption is slow at first,” says Quillien. “However, the benefits reaped by the utilisation of cutting-edge technologies such as remote monitoring, AI or digital twins are boundless.”
Right: Krucial Connect allows for a continuous in-depth analysis of site conditions at any mining facility
The Krucial Connect solution aims to join the data ‘dots’ and improve monitoring operations
Zach
RISE OF THE MACHINES
Savit reveals how small-scale autonomous robotic systems
fill
operational and safety gaps in mining operations following primary fleet automation
Robotic systems are being developed to tackle the enablement issues surrounding adoption of autonomous mining equipment
As the adoption of automated mining haul trucks and drills continues across the industry, operations that incorporated autonomy earlier are now finding gaps. Not gaps within the capabilities of this technology; but instead how autonomy interacts with broader operational requirements. In most cases, additional questions raised by autonomous haulage and drilling solutions precipitate the identification of these gaps.
Although the safety benefits of autonomous operations generally drive implementation, unanswered compliance questions about
autonomous vehicles persist. How does a duty shift change with continuous operation? When are inspections required if no operator shift change occurs?
While operators work to answer these and establish best practices for emerging technologies, a more pressing question emerges: “what comes next?”
Mines aiming to increase their autonomy, reduce labour costs and increase productivity will seek to take the next steps in automation. This pursuit inherently leads continuous improvement teams in one of two directions: filling enablement gaps or automating the next group of equipment.
FILLING ENABLEMENT GAPS
Each of the new, large-scale automation efforts in mining require nonautomated activities for effective operations. Fuel, lubrication, drilling bits, steel and water all need to be provided for autonomous solutions in haulage and drilling operations. Without these consumables, drilling
operations would cease. A clear path to enhancing the efficiency of these operations is automating the delivery and replenishment of these consumables.
Fortunately, forward-thinking companies are developing robotic systems to address these gaps. Consider robotic refuelling solutions such as RAPID, Stratom’s autonomous refuelling, recharging and liquid transfer system. Originally developed to refuel military helicopters and autonomous convoys, the novel system has been adapted for the mining industry to accommodate fuelling autonomous haul trucks.
Robotic refuelling technology relies on visual or lidar scans for localisation, a robotic arm and connection to existing fuelling infrastructure. In addition to providing consumables for autonomous vehicles, this technology can also reduce human exposure to slip, trip and fall hazards in challenging climates.
For autonomous drills, the issue is more complicated. Although autonomous delivery of consumables is feasible – even in rugged mining
environments – loading and unloading present additional hurdles. Robotic arms will be the key to solving this challenge, but the technology still requires adaptation and real-world testing.
Looking ahead, autonomous inspections will facilitate greater operational freedom for autonomous equipment. Only maintenance needs (preventative or reactive) will limit a vehicle’s utilisation and availability in the future.
AUTOMATING THE NEXT GROUP
Autonomous vehicles made the first inroads into mining before the turn of the last century. Although many of the world’s largest operations are pushing the envelope with autonomy, adoption rates vary. Autonomous fleet purchases are driven primarily by Australia, with Canada in a distant second. These purchases are increasing in size and frequency and almost exclusively focus on the primary fleet – large haul trucks, LHDs and large drill rigs.
The logical next step is automating smaller ancillary vehicles and their work — the secondary fleet. This secondary fleet is critical to the operation of the mine and currently requires significant labour.
The delay in automating these ancillary vehicles is due to the specificity and technical nature of
their tasks. The primary fleets’ tasks are sometimes less technical than those of the secondary fleet and are an easier target for automation. This next stage often requires new, more complex autonomous behaviours, sensing techniques as well as different integration into fleet management systems (FMS) than haulage and drilling.
Developing these repeatable yet valuable autonomous behaviours is challenging but possible. It will, however, require serious cooperation between mining operators and technology firms that understand the specific requirements of mining environments and can deliver robust solutions capable of thriving in those conditions.
DRIVING THE PROCESS FORWARD
Identifying these gaps only becomes possible after initial autonomy deployment. Although critical to the long-term success of any technologically adept operation, these are secondary concerns for operations just now embracing autonomy.
Mines that have successfully implemented large-scale autonomy will be well positioned to adopt secondary fleet or enablement automations. Once the operation is ready, the process for implementing these smaller-scale autonomy and
robotic solutions is similar to the previous iteration. Consequently, operators will likely approach these new technologies with less fear and hesitancy and more wisdom. A greater understanding of the workplace culture and integration methods will facilitate a quicker path to achieving value from these technologies.
These examples represent just some of the gaps identified after automating large-scale, primary fleets. As an industry, we should explore all possibilities to achieve the safest, most efficient production possible. Addressing operational and safety gaps with autonomous robotic systems empowers the mining industry to continue evolving and enhancing mine productivity and worker safety.
Zach Savit is with Stratom: www.stratom.com
The RAPID autonomous refuelling, recharging and liquid transfer system
THE DIGITAL REVOLUTION
Bruno Castro reveals how digitalisation is delivering big benefits in mining operations
Digitalisation is a term most often associated with smart factories, and conjures up images of clean, sterile manufacturing spaces populated only by robots. But digitalisation can also be a catalyst for change in heavy industries such as mining. So, what is the transformative potential of digitalisation and what specific benefits does it offer for mining operators in terms of improving efficiency and productivity?
BENEFITS OF DIGITALISATION
Digitalisation is essentially the process of integrating digital technologies into mining systems, machines and components in order to garner valuable data. Collecting, understanding, and interpreting this data can offer significant improvements in availability, efficiency, and capacity.
The potential benefits of digitalisation include increased efficiency. Digitalisation enables automation and streamlines mining processes. Total machine interactivity and networking improve plant availability and allow mining companies to make smarter decisions.
Data analysis is another benefit. The ability to collect, store, and analyse vast amounts of data allows mining
companies to gain insights into their operations that inform better decisionmaking and improve performance.
On the cost reduction side, better visibility of resources helps mining operators cut costs by enhancing process efficiency, reducing waste, and optimising resource use (such as water and energy).
Safety also benefits. In addition to anti-collision systems, digital solutions can create a safer working environment by enabling remote control of mining equipment and supporting predictive maintenance regimes.
It would be remiss not to mention the benefits in terms of sustainability, too. Digitalisation supports sustainable mining practices by minimising environmental impacts, reducing waste and optimising the use of resources. It also helps track and manage compliance with environmental regulations by collating real-time data and facilitating report generation.
Digitalisation can also assist with workforce retention. Like many other industries, mining faces a skills gap due to an ageing workforce. Digitalisation enables automation of some traditional or repetitive tasks, but also attracts a more tech-savvy generation into the industry who are more likely to engage with digital tools and systems.
MINING FOR INFORMATION
Implementing digitalisation across the entire existing mining operation in one hit would require significant investment, so mining operators should instead look to digitalise processes that offer the highest return on investment. For example, keeping track and control of the material flow during handling is one of the most important differentiators for an efficient and integrated mining operation and for the end-users.
Material tracking systems (MTS) based on digital solutions enable the observation, measurement, administration, calculation, and prediction of material transport processes. Using data from various sensors – including laser scanners, belt scales, radar measurement, ultrasonic sensors and cameras – a digital MTS can deliver insights into material distribution and merge, provide intelligent routing functions, and prevent overloading and chute plugging. The ability to monitor and track materials in real time also enables timeslot shift modelling, better material quality management and material transport management to optimise belt capacities across multiple jobs. Crucially, MTS also deliver the precision measurement of volume and mass to achieve an
Digitalisation improves mining operations today but also enables better planning for tomorrow
SPECIALIST EQUIPMENT
optimal price/performance ratio, achieving accuracies of up to 0.5%.
Stockyard management systems (SMS) is another mining process that benefits from digitalisation. In this case, digitalisation can streamline, automate and simplify the scheduling, control, monitoring and documentation of material handling and storage. Effectively, an SMS combines stockpile management and material tracking to improve efficiency and give mining operators total visibility of their assets. Stockpile management is only a part of the material handling in the plant, but linking it digitally to combine all loading, unloading and transport processes enables a virtual model of all the material handling. It consolidates automatic process control at the PLC/DCS level with a management system at the IT level. This combination of stockpile management and advanced PLC automation enables fully automatic operation of the stockyard because every job parameter – schedule, pile location, material parameters, pile height, flow rate, etc. – can be planned
in the SMS system. Digitalisation in this case can deliver fully automatic machine positioning in compliance with the anti-collision functions, a fully automatic stacking operation, automated management of material blending and a fully automatic reclaiming operation with material quality monitoring.
The same digitalisation principles can be applied to other essential mining tasks, such as train loading systems (TLS). But digitalisation doesn’t just radically improve day-today operations: it can help to plan for the future, too!
MODEL MINES
A huge benefit of digitalisation is its ability to let us explore different scenarios virtually before we build them in reality. These virtual models are referred to as digital twins. They offer the ability to try out new concepts, such as different equipment configurations, before committing to investment. This saves money by preventing poor development, makes engineering decisions easier, and
Digitalisation enables automation and streamlines mining processes
gives confidence that the project can be delivered effectively without any unforeseen impacts.
A further key benefit of the digital twin is as a training tool. It can be used to train operatives in a controlled environment without disruption to normal operations and in total safety.
Digital twins also play a key role during operation and maintenance. They hold all the data about every piece of plant and equipment, and can be used to analyse the existing design and suggest improvements.
In one real-life example, a mining operator was experiencing issues with belt flip on a tripper car. Wind shields had been installed but they proved ineffective. The real operational data combined with digital simulations, enabled the operator to analyse the airflow and forces being applied to the belt by the wind. Based on this analysis, the team was able to work with the equipment supplier to identify effective ways to reduce the forces by up to 60%, dramatically reducing the likelihood of further belt flip incidents.
Digital twins are also adept at fault-finding, because they can continuously analyse real-time data to spot performance patterns that may indicate a part is beginning to fail. This in turn makes predictive maintenance much easier and prevents unplanned downtime –particularly if the equipment supplier offers a hotline or remote support backup that can be triggered by an alert from the digital twin.
JOINED UP THINKING
Digitalisation can bring big improvements when applied to various mining processes, but the biggest benefits are derived when all the different systems within a mine are digitally connected to create a smart mine. Full connectivity means that data and information from all machines can be consolidated and displayed in just one single front-end dashboard, delivering visibility and predictability to optimise current and future operations. It also enables smooth interaction between machines,
operators and manufacturers on a whole new level.
The seamless transfer of information from one system to another requires software to act as a facilitator. Typical use cases for coupling with software systems include: exporting job statistics to job administration systems; supplying material quality and quantity data at feeding and discharge points’ coupling production with material inventory systems; interfacing with material blending machines; and direct coupling with the control PLC / DCS system for plant control. There is also the potential to allow third party access to systems, which opens up the potential to use remote solutions for monitoring and maintenance.
Connectivity on this scale can throw up IT compatibility and data security considerations. Working with a digital engineering specialist that can not only understand a business’s digitalisation goals but can also help it to achieve the connectivity that will enable the
transformation of its operating and IT systems is therefore advisable.
TAKEAWAY
Digitalisation is not only about adopting new technologies; it also involves a cultural shift to embrace digital thinking and innovation. It can lead to significant competitive advantages, such as improved operational efficiency, enhanced customer satisfaction, and the ability to rapidly adapt to market changes. However, few mining operators have the resources inhouse to optimise their systems and make the transition to smart mining immediately. Partnering with a company that can help to prioritise implementation, act as your digital integrator and offer a full turnkey solution is the way to go.
Castro is head of Digital Technology, Minerals & Mining at Beumer Group: www.beumergroup.com
Bruno
Digitalisation can deliver benefits such as automatic machine positioning
DATA DELIVERY DRIVE
Engineering giant ABB has developed a new tool within its Ability Predictive Maintenance for Grinding (PMG) platform, designed to make troubleshooting and diagnostics in mineral processing faster and more efficient than ever before.
Traditionally, troubleshooting for grinding technology has required the onsite presence of an engineer or a direct remote access to the plant to identify the source of problems. The new cloud-based application named Trendex will give users of the platform visibility of fault data in high resolution three seconds before and 1.3 seconds after the event. Trendex works by automatically pushing event files to the cloud and linking event data with the transient records, providing users with near-instant access to operational data from any internet-connected device. It also delivers improved diagnostic and visualisation features to help engineers quickly restore production.
Eliminating the need for a direct remote connection while granting almost immediate access to the eventrelated signals in high resolution results in significantly faster response times in case of a trip. In a process such
Customers will have full visibility and improved diagnostic data points
Introducing a new digital tool designed to further maximise uptime of gearless mill
drives in mineral processing
as grinding, where every operational minute counts, unplanned downtime has a significant impact on the business, damaging profitability and productivity. Trendex’s addition to the PMG platform will empower users, regardless of location, with real-time data to identify faults when they happen, pinpoint the root cause quickly, and swiftly return operations to full production.
EXTRACTION OPERATION
ABB gearless mill drives (GMDs) are vital to efficiently extracting critical minerals, such as copper, from increasingly low ore grades in global locations. The challenge for the industry is to meet the growing demand for critical minerals fuelling the energy transition by ensuring all relevant infrastructure is available and in place.
“Unscheduled downtime is a challenge anyone in the mining industry is familiar with,” says Carlos Miguez Fernandez, Global Product Manager for Service, Business Line Gearless Mill Drive, ABB. “However, in recent years, we are seeing systems are under increasing pressure to operate with maximum uptime due to market
demands. We are constantly looking for ways to improve equipment availability and reduce operational costs –Trendex is the latest development in this ongoing mission. It will enhance our predictive maintenance platform for grinding, providing additional advanced real-time insights.”
EASY ACCESS SOLUTION
The Ability PMG platform is an advanced digital service to maintain, assess and analyse GMD systems. It provides easy access to GMD system parameters and allows visualisation of performance, considering past activity and real-time data, and assesses future maintenance requirements. It aims to extend the lifetime of grinding assets through better use of resources, support non-stop operation and avoid unforeseen downtime. When paired with the Grinding Connect mobile app, users can expect live notifications for precise fleet management and monitoring. With the addition of Trendex, users will now be able to get instant access to the event-related signals in high resolution as long as they have an internet connection, anywhere, anytime.
REPAIR NOT REPLACE
Screens, feeders and exciters are used in the harshest of mining environments and undergo a great deal of wear and tear in the field. Sandvik in Jandakot, Australia refurbishes this equipment, restoring it and reusing as many components as possible during the rebuild. What can’t be reused is often recycled.
THE ECONOMIC BENEFITS
The refurbishment process saves customers’ money and cuts down on materials and CO2 emissions. In 2023, approximately 1,000 tons of metal was reused, and an estimated 1,900 tons of CO2 emissions prevented thanks to refurbishing rather than producing equipment from scratch.
“Refurbishing is a vital part of our business today,” says Matt Gentile, Vice President Operations, Sandvik Rock Processing, Australia. “We sell new screens to customers and every two to three years on average, they come back here for refurbishment. It takes several weeks to strip, inspect and decide what to reuse and replace. When completed you can’t tell the difference between a new and a refurbished screen.”
EXTENDED LIFECYCLE
A screen can last for a significant number of years if well maintained with scheduled refurbishments, Gentile adds. “We have examples of screens that have been refurbished five or six times, since the programme started.”
Sandvik screens can weigh over 50 tons and require a team of four to eight trained technicians to refurbish them. “It’s hard work that requires up to 500 hours to complete a full stripand-inspect. We carry out a thorough assessment, including water blasting and sand blasting the components,
By refurbishing large mining equipment such as feeders, screens and exciters, one company is reducing costs – along with metal waste and harmful emissions, too
and non-destructive testing of high stress areas to determine if there is fatigue cracking. It’s a big job with inherent risks and requires a strong emphasis on performing the work safely,” says Gentile.
When completed, customers essentially get a brand-new screen, but at a lower cost. Any updates to the product or design changes are also made in the refurbishment process so the customer receives the latest in product optimization. It is also safer and more operationally efficient for customers to refurbish their equipment rather than relying on infield repairs, adds Gentile.
REDUCING COSTS AND OPTIMISING ASSETS
The refurbishment programme for customers was kicked off in 2011, at what was then a part of Schenck Process Group. The mining-related business was acquired by Sandvik in
2022. The refurbishment programme began during a mining boom, at a time when major capital investments were being made in equipment, says Gentile. “Customers were looking to reduce costs and optimise assets.
Today we still haven’t seen any similar programmes of this scale. Nowhere else is it a core part of the business,” he states.
In 2023, more than half of the exciters, screens, and feeders built at Sandvik Rock Processing Solutions in Jandakot were refurbished. This adds up to about 480 exciters and nearly 100 screens. And, while Sandvik mainly refurbishes its own products, it can refurbish competitors’ products as well. Over the years, several thousand products have been refurbished in total and the demand is increasing.
“Customers have come to rely on our refurbishment programme,” says Gentile. “It has become as much a part of their business as ours.”
Sandvik Australia began its popular refurbishment programme back in 2011
IN CASE OF EMERGENCY
Dave Maust, an expert in emergency refuge chambers, tells Louise Davis how his firm’s solutions are keeping miners safe across the globe
Strata offers semi-permanent ERCS that are mounted on wheels
According to Dave Maust, General Manager of Chambers at Strata Worldwide, the development and use of emergency refuge chambers (ERCs) came about as a natural response to the increasing need to better manage safety at mines. “Following years of experience, and with many advancements in technology, underground mining safety practices have evolved considerably over the years,” begins Maust. “Operations have discovered that it is imperative to have a contingency plan in place for the possibility of an unforeseen event leaving miners unable to evacuate. The necessity to supply a source of breathable air, isolated from the surrounding atmosphere, has led to the development and expansion of emergency refuge alternatives in many underground facilities around the world.”
Maust recalls that during a five-month period in 2006, three underground coal mining incidents in the USA resulted in the deaths of 19 miners. These events drove the US legislature to implement the 2006 MINER Act: “These regulations made it a requirement that all US underground coal mines have refuge alternatives in place; enough to shelter all workers in-bye at any given time, for a standard duration of 96 hours.
Sufficient breathable air, food and water, as well as lavatory facilities were specifically required.” He notes that additional mining and tunnelling industries, as well as other countries around the globe, have established alternative refuge regulations. Maust says: “Often, mines elect to implement these structures into their safety plans voluntarily; all in an effort to ensure the highest level of safety preparedness for their personnel.”
ERCS come into use when unexpected events occur that compromise the air quality and render miners stuck in situ for the time being. “When emergency strikes and workers are unable to escape, providing them with a safe and isolated environment is critical,” explains Maust. “Having refuge chambers or a safe room in place, immediately provides the workers with a supply of clean air, lighting, water and food while also being adaptable to each mine or tunnel’s needs.”
EXPERT ADVICE
Strata is one of the well-known names in ERCs. The company offers a range of solutions – including coal mining chambers – but the focus here is on its innovations for hard rock mining chambers. And a tailored approach is at the heart of the company’s ethos. Explaining, Maust says: “Although refuge chambers have become a
critical part of underground health and safety in mining and tunnelling, there is no ‘one size fits all’ solution. In some circumstances, a fixed refuge chamber is the best solution, but in others it might be necessary to move the chamber frequently as the working section progresses.” Maust strongly advises mines looking to invest in ERCS to consult with experts such as Strata so that the best solutions for the specific application can be achieved.
With regard to Strata’s own offerings, Maust highlights the chambers’ low cost of ownership and their simple intuitive operation as two key selling points. “They are also easy to service and maintain,” he points out. “The gas detection systems use a unique exchangeable sensor module design that can be calibrated at the surface. And a computerised monitoring system provides on-going maintenance data to be reported.”
In line with firm’s tailored approach, Maust explains that the chambers meet the specific needs of each customer, with multiple options available, all of which are tailored per application. He notes that: “The chamber structure can be divided into segments and assembled underground if the mine has restrictions in its shaft size or handling capabilities. This breaks the chamber down into smaller sections for delivery. Additionally,
Cutout of view of Strata’s latest chamber
wheels and hitch packages can be added to assist in handling and manoeuvring.” Maust is also well versed in dealing with different requirements for different geographic regions.
“Regulations for chambers – such as construction, spacing, air supplies, etc. – vary industry to industry and country to country. There is no one set of rules. The US coal mining industry has clear-cut regulations and requirements, but it’s not the same outside of coal,” Maust details. To handle this variety of operating environments and regulations (and enable it to sell to a global audience), Strata offers a base chamber model with several features primarily related
to life support – such as the air provided, carbon dioxide scrubbing, power, seating, and instructions. “Then we offer a long list of available options and upgrades,” explains Maust.
READY TO GO
Once all customer requirements and add-on options are determined, the chamber is built to spec and the mine receives it ready to install. Adding a further layer of safety, Maust reveals that chambers are commissioned and inspected after placement/installation. “We can train mine personnel to do this, or we will go to the mine site to perform the inspections ourselves. The mine operator decides which option works best for them,” he says.
For one remote mine location, Strata held an online video call with the mine personnel as they completed the commissioning: “We were able to check the chamber and settings virtually and lead the mine personnel through the procedure,” confirms Maust.
NETWORKING OPPORTUNITY
When asked what the biggest challenges associated with deploying ERCS at mine sites are, it’s not the extreme environments or the fact that any downtime in operations is not well tolerated that Maust highlights. Rather, he says, the biggest challenge occurs when a mine wants to include the remote monitoring system, and the chamber system needs to be connected to the mine’s underground network. “Depending on what network and technology they have, it can be challenging to configure our technology to theirs, but we always find a solution,” Maust explains.
On another challenging front, Maust recalls a recent success story where a project in Saudi Arabia had an immediate need for 16 of Strata’s 20-person chambers. “We were able to supply the first three chambers from inventory from our Australian facility, and then supplied the remainder from the US once they were fabricated. We also manufacture chambers in South Africa and have manufactured some in Kazakhstan as well. We have global availability and responsiveness,” states Maust.
Strata has recently launched a new economical and versatile, lightweight ERC
A look inside one of Strata’s chambers
Steve Levien describes how a new 5G radio solution delivers improved safety and communication in the mining industry
Private mobile radio (PMR) networks have been an integral part of mining operations for years. As the industry progresses, there is a shift towards digital PMR technologies, and with the advent of 5G comes the opportunity to revolutionise mining communications and provide greater fl exibility, functionality and safety - particularly important in hazardous areas.
Despite the need for digital transformation, the investment required means that not all areas can be converted immediately. This is where private 5G mobile networks come into play, meeting growing connectivity needs with higher coverage, bandwidth and security. Reliable communication is essential for team coordination on large mining sites, both underground and above ground, in hazardous and nonhazardous areas.
KEY BENEFITS FOR THE MINING INDUSTRY
A major advantage of private 5G networks is E2E network slicing, which allows the network to be divided into different sections with different priority levels. This is particularly useful in mining, where critical communications can be assigned to their own section to maximise safety and reliability. The integration of different radio technologies ensures that mobile
SAFE AND SOUND
workers can communicate seamlessly with remote teams, increasing overall operational efficiency.
A NEW TOOL
i.safe Mobile, a leading provider of intrinsically safe mobile devices, recognises the unique requirements of the mining industry. The company’s latest development, the IS440.M1 5G radio, has been developed to support the digitalisation of communication in hazardous environments. With its conventional radio design, it can be seamlessly integrated into existing communication devices such as two-way radios (TETRA, DMR and analogue PMR) via a PoC bridge server. This step-by-step digitisation approach is both efficient and costeffective.
CUSTOMISED FUNCTIONS
The IS440.M1 5G radio supports 3GPP Release 15 and is equipped with a reliable chipset. Key features include a powerful, removable battery (available with 2,400 or 4,800mAh to enable long operating times and multi-shift operation). The products also boasts a strong front speaker: over 105dB, ideal for noisy mining environments. A further benefit comes in the form of large operation elements: PTT button, rotary knob for channel selection and an SOS button for emergencies. Robust connectivity is also on offer
via a dual-SIM with automatic network switching, Wi-Fi 6, NFC and Bluetooth 5.2. Safety and optimised usability can be found in the integrated belt clip for safe carrying. The final benefit is compatibility: the product supports the main public 4G/5G frequency bands, CBRS spectrum and B68 for public safety applications.
The device also has an 8-pin ISM interface for connecting headphones. In emergencies, the alternative SIM or Wi-Fi connectivity of the public network ensures seamless communication.
ADDRESSING MININGSPECIFIC NEEDS
The rugged design of the IS440.M1 ensures durability in harsh mining conditions. The transition to 5G and the increasing demands in explosion hazardous areas highlight the need for such advanced technology. The IS440.M1 5G radio is tailored precisely to meet these demands, ensuring safety, reliability, and enhanced communication in the mining industry. The IS440.M1 with ATEX/IECEx and ANZEx Mining approvals will be available shortly.
Steve
The IS440.M1 was designed to address mining sector needs
The GuardIAN Intelligence System integrates smoothly with existing MineARC refuge chamber systems
SAFE REFUGE
Phil Hinton presents recent advances in real-time gas monitoring for refuge chambers
Monitoring gas levels in refuge chambers is key to keeping mining personnel safe
In the complex and often dangerous world of underground mining, ensuring the safety of personnel is paramount. One crucial aspect of this safety involves monitoring gas levels to avoid hazardous situations. The GuardIAN Intelligence System, particularly when integrated with the GuardIAN gas nodes, offers an innovative approach to gas monitoring. This system not only helps personnel keep an eye on the atmosphere inside a MineARC refuge chamber but also provides crucial information about the surrounding environment, all while maintaining real-time updates to the control room above ground.
WHY GAS MONITORING IS CRITICAL
In emergencies, such as a mine collapse or explosion, refuge chambers provide a safe haven for miners. These chambers are equipped with life-supporting systems, but their effectiveness depends heavily on maintaining a safe atmosphere inside. However, knowing what’s happening outside the refuge chamber is just as
crucial. Gas levels, including harmful substances such as carbon monoxide (CO), methane (CH4), and hydrogen sulfide (H2S), can fluctuate rapidly and pose a significant risk if not monitored effectively.
The GuardIAN Intelligence System, coupled with GuardIAN Gas Nodes, provides a comprehensive solution to these challenges. It enables realtime monitoring inside and outside the refuge chamber. The GuardIAN gas nodes are strategically placed to monitor gas levels both inside and outside the MineARC refuge chamber. While personnel are safe inside the chamber, the system continually checks the external environment for dangerous gas concentrations. This dual monitoring ensures that any hazardous changes outside the refuge are detected promptly, allowing for informed decision-making.
The GuardIAN Intelligence System integrates smoothly with existing MineARC refuge chamber systems. This integration ensures that gas data collected by the GuardIAN gas nodes is directly communicated to the refuge chamber’s monitoring system.
This means that personnel inside the chamber are kept informed about the gas levels outside, which is critical for assessing the safety of potential evacuation routes or the need for extended confinement.
LIVE DATA FOR THE CONTROL ROOM ABOVE GROUND
The benefits of the GuardIAN Intelligence System extend beyond the refuge chamber. The data collected by the GuardIAN gas nodes is transmitted in real-time to the control room above ground. This live information allows operators and safety officers to monitor the situation comprehensively, making it easier to coordinate emergency responses and ensure that all safety protocols are being followed.
By providing real-time data on gas levels both inside and outside the refuge chamber, the GuardIAN system enhances safety and decision-making. The control room can analyse trends, predict potential hazards, and take proactive measures based on the live data received. This capability is
crucial in high-pressure situations where every second counts.
The GuardIAN Intelligence System is designed with user-friendliness in mind. It offers a clear, intuitive interface that simplifies the monitoring process. Both personnel inside the refuge chamber and control room operators can easily understand and interpret the data. Additionally, the system includes customisable alerts to notify users of any critical changes in gas levels, ensuring that immediate action can be taken when necessary.
ELEVATING MINE SAFETY
Personnel safety is paramount in the demanding environment of underground mining. A high standard of safety relies on effective gas monitoring both inside and outside refuge chambers. The new system provides a vital solution for real-time gas monitoring. By keeping both the refuge chamber occupants and the control room informed with live data,
this system enhances safety, improves decision-making, and supports coordinated emergency responses.
Investing in the GuardIAN intelligence system means equipping a mining operation with an advanced tool that ensures better protection for every team member.
Innovative mobile devices for ATEX/IECEx and mining with the most advanced technology.
Phil Hinton is with MinerARC Systems: https://minearc.com/
GuardIAN Connect underground network and MineARC refuge chamber
Control dust and spillage.
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PROTECTION POLICY
Alexander Ruiz details how sophisticated coatings solutions can improve a variety of materials handling applications in the lithium mining sector
Evaporation pool used during lithium mining
As the global demand for lithium continues to surge, driven by the rise of electric vehicles and renewable energy technologies, the maintenance challenges faced by lithium mining operations have become increasingly critical. Belzona, a leader in industrial protective coatings, is addressing these challenges head-on with its innovative polymeric solutions. Designed to combat corrosion, abrasion, and chemical damage, the firm’s coatings are playing a pivotal role in extending the life of critical mining equipment, supporting the industry’s efforts to meet growing demands while promoting sustainability.
POLYMERIC SOLUTIONS
Batteries are a highly sought-after product due to the ever-growing need for green electric appliances and devices. Phones, solar panels, and electric vehicles (EVs) all need batteries to operate, and this has led to an increase in the need for materials used to manufacture batteries. Lithium is one material whose need has increased tenfold. Some of the already large lithium mines in South America, Asia, and Australia have had to expand to meet the high demands of energy and tech companies.
Lithium-ion batteries play an important role in reducing climate change. EVs reduce the need for petrol and diesel fuel. In addition, energy companies use lithium-ion batteries to store electricity generated from wind and solar farms to mitigate the use of energy generated from coal and natural gas. However, lithium mining does have its drawbacks. It is responsible for over 1.4 million US tons (1.3 million metric tons) of carbon annually. For every one US ton (0.9 metric ton) of mined lithium, 16.5 US tons (15 metric tons) of CO2 are released into the air.
ENVIRONMENTAL IMPACT
Additionally, the lithium mining process is very intense for the surrounding environment. Part of the process involves extracting lithium from saltwater reserves. It risks polluting the local water sources, threatening humans and local animal and plant biodiversity. The batteries themselves can also be harmful to the environment. They can leech damaging chemicals and other byproducts into the environment when they are discarded. It can cause fires, water pollution, air pollution, and health problems. Despite the negatives, the current process is the most
cost-effective way to obtain lithium; however, other materials are being researched to manufacture greener batteries (earth.org).
HOW IS LITHIUM MINED?
The current process involves drilling underground to access mineral-rich brine found under salt flats. Then, the brine is pumped into large evaporation pools on the earth’s surface. The sun slowly evaporates the brine pools over months or years leaving behind minerals like potassium, sodium, and lithium. The lithium is then extracted in different ways but usually involves a chemical process by which reagents are incorporated to form a saleable compound of lithium at a processing facility that can be transported to customers.
There are other less common lithium mining processes, such as extracting directly from mineral ore. During this process, the mineral is extracted, heated, and pulverised. Then, it is combined with reagents to create a slurry that is heated, filtered, and concentrated via evaporation to produce a saleable lithium form.
SOLVING CORROSION
Corrosion is a common maintenance problem found in lithium mines due to the presence of brine, a water-based
Pump repaired with Belzona 1111 (Super Metal) after suffering from corrosion due to saltwater medium
solution high in minerals, especially salt. Brine accelerates corrosion because of an increase in dissolved ions, which allows electrons to move freely between the brine and metal substrate causing rust. A metal object does not need to be submerged for corrosion to occur as increased moisture in the air and salt spray can also rust metal substrates.
A manufactured paint or coating can stop corrosion because it can prevent the ions from interacting with the metal substrate. Belzona polymeric coatings are applied on various substrates from aluminium, steel, iron, and more to stop the materials from corroding. During lithium mining, equipment, and assets often find themselves in the presence of brine or moisture. A pump is used to transport brine from the underground reservoir to the evaporation pools. The pump can suffer from rust and corrosion due to the mineral-rich water; however, a Belzona 1000 series coating can prevent the piece from corroding. The coatings also repair the piece
as specific products such as metal repair epoxy paste, Belzona 1111 (Super Metal), and corroded metal repair material, Belzona 1121 (Super XL-Metal) can help rebuild metal loss. Rebuilding can reduce the need for a new part especially the downtime from waiting for a new part.
Other equipment in contact with water or moisture such as froth flotation cells, pressure leaching tanks, filters, centrifuges, evaporators, mixers-settlers/ extraction columns, and electrolysis equipment can all potentially be coated with a Belzona 1000 series to protect them from further corrosion and replacement.
SOLVING ABRASION AND PHYSICAL IMPACT
The equipment may become physically damaged also as it deals with rough materials such as mineral particles of varying sizes. The particles can slowly deteriorate the surface of metal or rubber equipment. Pumps are an example of equipment that is physically damaged by solid particles,
but conveyor belts and loaders are also a great example of two pieces of equipment made of different materials that suffer from similar damage. Both assets carry and transport lithium and other solid materials. During this phase of the lithium mining process, the assets endure harsh wear and tear, damaging their integrity. Holes will appear in conveyor belts and metal loss will slowly abrade the surface of the loader.
Belzona can provide a quick returnto-service with the Belzona 2000 series, a product line engineered to repair flexible components. Tears and abrasions on conveyor belts are repaired without the need for hot work with the company’s elastomer products which provide a much-needed increase in durability, elasticity, and tear resistance. Additionally, loaders and other metal equipment such as filters, haul trucks, drills, crushers, and grinding mills can be coated with the 1000 series to rebuild metal substrates that have abraded. Belzona 1311 (Ceramic R-Metal) and other products in the range can rebuild the equipment’s surface while safeguarding it from further abrasion. The coating creates a sturdy barrier between the rough material and the substrate, and it is reinforced by the composition of the coating.
CHEMICAL-RESISTANT COATINGS
Reagents are an important part of lithium mining. Usually, these reagents are strong chemicals like sulphuric acid. Additionally, depending on the mining process, it can involve hightemperature reactions. Coatings in the 1000 and 4000 series include products to protect assets during high-temperature operations or with chemicals. If there is a high concentration of sulphuric acid (98%) then Belzona 4311 or Belzona 4341 would be an appropriate choice. Lower concentrations can be resisted with other 4000 series coatings; however, any coating performance is highly dependent on temperature.
Belzona 1511 (Super HT-Metal) or Belzona 1813 offer high-temperature resistance of up to 150°C and 200°C respectively. They have been formulated to protect metal surfaces
from abrasive attack (1813) and corrosive attack (1511) at high temperatures and are resistant to a wide range of chemicals.
GREENER LITHIUM MINING
Lithium mining is integral to the production of batteries that power a variety of essential green technologies, from EVs to renewable energy storage systems. Despite its significant environmental footprint, including carbon emissions and potential water pollution, advancements in mining processes and material science are making strides toward mitigating these impacts. One of the critical challenges faced by the industry is the maintenance of equipment exposed to harsh conditions, such as corrosion, abrasion, and chemical attack.
Belzona’s range of polymeric solutions offers robust protection and repair options for mining equipment. By preventing corrosion, repairing physical damage, and providing chemical and high-temperature resistance, these solutions not
only extend the lifespan of critical assets but also enhance operational efficiency and safety. As the demand for lithium continues to rise, the application of innovative maintenance solutions such as these will be crucial in supporting sustainable mining
practices and the transition to a greener, more sustainable future.
Alexander Ruiz is with Belzona: www.belzona.com
Conveyor belts are prone to physical damage from mineral particles
MOBILE MATERIALS MANAGEMENT
screening plants
Exploring the advantages and infrastructure requirements of all-electric operation of mobile crushing and
Mobile crushing and screening plants that are operated with electricity instead of diesel fuel are regarded as particularly environmentally friendly because they do not emit CO2 on site. They are also ahead in terms of costeffectiveness in the long term. Sustainable, low-emission solutions are in demand, and companies can position themselves on the market as future-oriented providers with electrically operated mobile plants. Although the initial investment costs are higher, they are quickly amortised due to the fuel savings.
“Our mobile plant train in the sample calculation consists of a jaw crusher Mobicat MC 120 Pro, cone crusher Mobicone MCO 110 Pro as a secondary crusher and a downstream screen machine Mobiscreen MSC 953 Evo. The plant train consumes an average of approximately 77 litres of diesel per operating hour. In the electrified version, it has an average current consumption of 302kW per operating hour. The maximum power requirement is 542kw“, says Tobias Böckle, head of Product Management at Kleemann. “The energy requirement must first be provided by the infrastructure and is ideally met by electricity from renewable sources. A sustainable and quickly cost-efficient solution is to use an in-house photovoltaic power supply,” says the expert.
A suitable design of the infrastructure in advance is of decisive important for efficient use.
Tobias Möß from Wolff & Müller explains: “First of all, the actual energy requirements of the plant and the demand of all already existing consumers should be determined. How much power is needed on the entire company premises? The load profile must also be taken into account. When are the power peaks, when are the times with lower consumption?” Möß adds: “The individual load profile can be obtained from the energy supplier or network operator. Many companies already have a transformer on their premises that adapts the voltage to requirements and, for example, provides low voltage for systems. Once the required power has been calculated, it is necessary to check whether the available transformer is sufficiently dimensioned. Does it deliver the required power? The amount of power that can be drawn from the transformer is indicated on the type plate.”
It is also important to consider where the main distribution is located on the site and where the system will be used. Good planning here is a precondition for efficient operation. For example, the electrical energy required to supply the plant is not transformed to low voltage directly at the transfer station, but is instead routed over the medium-voltage level across the site to the plant – the cable cross-section can therefore be much thinner, making the cable easier to handle and significantly cheaper.
At the mobile plant, a second transformer converts the current into low voltage to operate the
mobile crushing or screening plant. The aim here is to develop a suitable individual concept.
RAPID ROI
With a solid foundation, the investment costs are amortised after around six years – or even sooner, depending on the energy concept. From this point on, allelectric operation will save considerable operating costs year after year.
Here is an overview of the switch to electricity as an example: with the diesel-powered plant, there is no need for additional investment in the infrastructure apart from the fuel costs. The cost of diesel fuel varies greatly depending on the country and region, so any savings depend on the difference in price between diesel and electricity.
Electrically operated crushing and screening plants are initially more expensive due to their special equipment, plus the cost of cables (depending on the length of cable required) and a transformer.
All-electric operation incurs initial investment costs, but these pay off in the medium term. In many cases, climate protection regulations lead to stricter requirements. The electric drive is a decisive advantage, for example, when local authorities demand emission-free operation in city centres. “Especially in combination with your own PV system, electrical operation becomes a climatefriendly, cost-efficient concept in just a few years, which not only provides the operating company with financial benefits, but also reflects the company’s efforts to achieve greater sustainability,” Tobias Böckle is convinced.
Interlinked Kleemann plant train with an external power supply option
eft unchecked, fugitive material in any form can be extremely dangerous and expensive — to workers’ health, to belt conveyor components, to your bottom line. Martin’s transfer point products such as belt support, sealing and tracking minimize spillage and airborne dust problems. When bulk material transfer systems are properly designed and maintained, operations run cleaner, safer and more efficiently. Think Clean.®
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ApronSeal™ Skirts
Belt Trackers
Dust Curtains
CONTROLLING CARRYBACK
R. Todd Swinderman explains why dabbling in dribble chutes can pay dividends
Air cannons prevent clogging and help direct the flow of material
As belt conveyor cargo travels over the idlers on the carry run, the weight of the cargo and the undulating surface causes dust and fines to adhere to the belt and lodge into cracks and gouges. Upon discharge, material that does not fall with the main cargo stream and remains clinging to the belt’s return is known as “carryback.” If it is not cleaned from the belt by a primary and secondary cleaner, the carryback falls from the belt and accumulates in piles under the belt, building up as spillage or becoming airborne dust. Studies have shown that mitigating carryback can reduce fugitive spillage and dust by up to 90% while increasing idler and belt life by 25-30%.
Material that is cleared by a primary or secondary cleaner is collected on a slope in the rear of the head chute called a “dribble chute.” However, cleaning these fines increases the volume of material passing through the head chute and can build up directly under the head pulley. To control buildup and chute clogging, a vibrating dribble chute and mounted air cannons were developed to reduce downtime from clogging and cleaning and increase production.
A CLEAN BELT IS AN EFFICIENT BELT
If a belt has no cleaners, operators should expect to add labour to their budgets to clean spillage and replace fouled components from excessive dust and carryback. When spillage is
left to build up, the belt rides on the dried pile of abrasive material which prematurely erodes the belt covers and damages the unprotected return resulting in a lower belt life. Further down the return path, carryback can foul rollers and spills into walkways requiring regular maintenance to retain efficiency and adequate workplace safety standards. Without adequate cleaning, a belt in a heavy-duty dry bulk handling operation can carryback more than 0.5 tons (0.45 tonnes) of material per hour. The addition of just a primary cleaner will still experience carryback, leaving only an average of 0.02 lbs/ft2 (100 g/m2) on the belt. Adding multiple cleaners can get the carryback level down to 0.010.004 lbs/ft2 (50 to 20 g/m2) on the
A vibrating dribble chute uses a low friction UHMW liner activated by rotary vibrator
belt. Depending on the speed of the belt, length of the system and the space in which it is operating, this amount of average carryback would keep spillage levels sustainable and dust levels relatively compliant to workplace air quality regulations.
Using a high-quality belt cleaning system drastically reduces carryback, dust and spillage, but also introduces a design dilemma resulting in faster build up on the dribble chute. Depending on the characteristics of the application, the design of the dribble chute is an important consideration. Material buildup on them requires addressing to maximise production efficiency.
Some heavy-duty applications might require two primary cleaners and a secondary cleaner between the discharge and snub pulleys which can result in a lot of buildup. Due to space restrictions from a small head pulley, tertiary cleaners might be the only option, so designers recommend a vertical dribble chute. Vertical
Top Left: Carryback dislodged from the belt by a return idle. Top Right: Inadequate cleaning leads to carryback build up and potential encapsulation
To control buildup and chute clogging, a vibrating dribble chute and mounted air cannons were developed
dribble chutes are also prone to buildup and clogging and are difficult to clean. If only a tertiary cleaner is allowed, catch pans are often used to gather carryback from idlers when the conveyor path crosses environmentally sensitive areas, roads or walkways.
DRIBBLE CHUTES: CATCH OR RELEASE?
Some methods of controlling carryback capture the material for cleanup and others aid flow and release it back into the cargo stream. Capture systems such as drip pans or catch pans are often designed to be lowered or hinged making cleanup faster but still expose the worker to hazards as large build ups can break loose while cleaning.
Instead of catch pans, some systems allow material to drop below the system and are cleared by drag chain or pusher conveyor. These can be effective in operations with larger aggregate but may run into
issues if loads are unbalanced or moist fines are left to harden during downtime. Operators who use this method have reported that the extra power required to run these systems is costly and more labour is needed to keep systems functioning than they previously predicted.
The most basic flow aid is the use of water to saturate the discharge and keep it flowing onto the receiving belt. Although some applications can attribute silica content, magnetic properties and surface friction for buildup, moisture is a large factor in adhesion (buildup on surfaces) and cohesion (buildup of material upon itself). Most bulk solids begin to lose adhesion strength at 15% moisture, so not using enough water makes the carryback stickier, whereas oversaturation could cause problems since many processes cannot tolerate the addition of water.
One highly effective and field proven method is installing a sloped chute with a low friction “active”
Using proven flow technology like a vibrating dribble chute and air cannons working in tandem will promote more uptime and greater production
surface. A vibrating dribble chute is a vibrator attached to a floating low friction liner to make the surface active using vibration and gravity to move the material toward the discharge stream. In some cases, whole chutes can be isolated to make the applied vibration more effective.
AIR CANNONS FOR TRANSFER CHUTES
Air cannons have demonstrated to be highly effective for aiding flow and eliminating clogging of difficult materials in large chutes. The benefit of air cannons is that, when properly mounted, they dislodge material in typical buildup prone areas such as corners and low angle surfaces. Air cannons release pulses of compressed air to shear buildup from surfaces. They are simple devices with one moving part that only requires compressed air and a trigger method. The cannons can be discharged manually as needed or on a timed sequence.
The cannons are pointed in the direction of the cargo flow providing
consistent and efficient production. Firing sequences are accomplished with a simple timer set at an interval based on the cycles of material flow. Intervals can be fine-tuned for fluctuations in humidity or freezing where clogging is more prevalent, or during changes in volume, material type or belt speed, when added flow aids are required. Adjustments to firing sequences are accomplished manually by a nearby solenoid box or can be routed to a centralized logistical system.
Another use of air cannons on dribble chutes is to angle the nozzle downward behind a heavy flexible curtain that ripples when the air cannon is fired, dislodging the adhered material from the surface. Ideally, the curtain would be made from a rubber material with a slick low-friction face that is easily replaceable once it is worn.
IN SUMMARY
Problems associated with carryback – such as cleaning spillage, clearing
buildups and unclogging chutes – used to be considered a cost of doing business. For operators experiencing excessive buildup from carryback, labour costs and workplace safety concerns might require a review of the discharge zone design of their belt conveyors.
Over time, when calculating for labour and lost production, unplanned outages to manually clean spillage can justify the cost of a total discharge zone redesign. This includes a larger head pulley, the adequate number of cleaners for the application, and a complete transfer chute configuration with flow aids. Using proven flow technology like a vibrating dribble chute and air cannons working in tandem will promote more uptime and greater production.
R. Todd Swinderman is President Emeritus, Martin Engineering.
Hinged drip pans designed to be lowered with winches
CIRRUS RESEARCH
At Cirrus Research, we specialise in the design, manufacture, and distribution of high-quality noise measurement instruments and solutions.
T +44 (0)1723 891655
E sales@cirrusresearch.com
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HILLIARD
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.
T +1 607 733 7121
E rdoud@hilliardcorp.com
W www.hilliardcorp.com
CONN-WELD INDUSTRIES, LLC.
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.
T +1 304 487 1421
E sales@conn-weld.com
W www.conn-weld.com
J.H. FLETCHER & CO
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.
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DYNASET
Dynaset is the global leading manufacturer of hydraulic generators, power washers and compressors. The company’s technology increases the productivity of mobile machinery from small vehicles to heavy machines.
T +358 3 3488200
E info@dynaset.com W www.dynaset.com
RICHWOOD
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 304-525-5436
E info@richwood.com
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MIDDLE EAST MINING SHOWCASE
Now in its 16th year, The Mining Show in Dubai is the region’s only exhibition and conference that gives visitors the opportunity to capitalise on the development and change in mining across the Middle East, Africa and South Asian region. The 2024 edition takes place from 26-27 November at the Festival Arena, Dubai.
The two-day conference programme will host over 150 industry-leading speakers from across the region and beyond. With conference tracks themed around Investment, Sustainability, Innovation, Tech and Automation, and Operations and Maintenance, this is a great chance to attend over 40 sessions of free content across the two days.
On the exhibition side, visitors can discover 200 brands, including
international pavilions all showcasing the latest technology and products on the exhibition floor, from mineral exploration to the development of operations from the biggest names in the industry including: Rema Tip Top, Quarry Mining, McLanahan, Globelink China Logistics, and many more.
From key projects, the latest opportunities in mineral exploration, reformation of codes and regulations, and development of operations across several exciting countries, The Mining Show is the only annual opportunity for visitors to meet buyers in the region.
As well as the indoor exhibition spaces, the outdoor Heavy Machinery Showcase Area spans 1,200m2, connecting many of the top heavy machinery companies with decisionmakers in the Middle East mining
sector. Featuring over 20 exhibitors displaying a variety of equipment, such as excavators and dump trucks, this area provides an excellent platform for product launches and engaging in sales discussions.
The exhibition spans 12+ product categories including: Exploration equipment; Production and processing equipment; Professional advisory services and investment; Heavy equipment and machinery; Safety and sustainability solutions; Government; Drill and blast; Data and analytics; Automation and digitisation solutions.
In mining and materials handling, the Hägglunds Quantum Power motor reshapes reality with shared DNA. Adding a slim new connection block to the proven Hägglunds Quantum, it opens up an unthinkable space – stretching to 170 rpm while retaining full torque capacity at high efficiency. For belt conveyors, crushers, sizers, surface miners and more, it’s time to enter the Quantum domain: www.hagglunds.com/quantum
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