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The August issue of International Mining Engineer will be well-suited to those interested in automation, AI and sustainability.
Two extended pieces explore new sustainable mining technologies from companies that are fresh on the scene, and that could play a substantial role in moulding the future of the industry.
One of articles, the special feature (page 8), reveals how a surging demand for copper could potentially be met using new Norwegian subsea technology, without disrupting the sea’s ecosystem. The other piece (page 34) brings us to the USA, where an innovative startup aims to open up sustainable rare earths delivery to the west using waste and a natural microbial process.
Automation crops up throughout this issue, accelerating everything from sorting and haulage to tool repair. Rapid Rails (page 10, for example, details how an automated, electric and modular rail system could transform haulage roads, adapting to mine sites both old and new.
An article from ABB explains the value of an interoperable robotic arm for the automated charging of electric vehicle fleets, preventing drivers from having to exit the vehicle, while also introducing the potential for a driverless future. Meanwhile, Smart Sorting (page 24) covers the implementation of AI-powered ore sorting to assist high-volume processing plants. AI also makes an appearance in Laser Focus (page 16), where it enhances metal laser deposition to repair tools quickly.
Saskia Henn Editor
Scouring the seabed New Norwegian subsea technology could feed increasing copper demand
Rapid rails
Automated, electric rail system adapts to various mine sites
Power with purpose
powerful engine boosts productivity and lifespan
18
20
Tailored transmissions How attentive servicing minimises downtime
De-risking drilling The importance of choosing durable rods
close-up on combatting whole body vibration
How a suppression system captures particles at the source
Implementing digital transformation in explosive environments
benefits of prioritising return-on-prevention
PUBLISHER
Jerry Ramsdale
EDITOR
Saskia Henn shenn@setform.com
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Nicola Brittain nbrittain@setform.com
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Luke Wikner production@setform.com
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rare earths delivery to the west
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Setform’s international magazine for mining engineers is published four times annually and distributed to senior engineers throughout the world. Other titles in the company portfolio focus on Process, Design, Transport, Oil & Gas, and Power.
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SCOURING THE SEABED
How a Norwegian startup will extract subsea copper using a closed-loop system that protects the environment. Nicola Brittain reports
WHAT IS GREEN MINERALS
Originally from an oil and gas background, entrepreneur Ståle Rodahl set up Green Minerals in 2020 after being informed about the considerable copper deposits in Norwegian seabed. That the Norwegian government had recently voted through a seabed minerals act (2019) gave Rodahl the green light. The seabed comprises three types of mineable surface: nodules containing largely manganese and rare earth minerals, cobalt-rich crusts, and sea floor massive sulfides (SMS)
Seabed minerals are a significant copper resource, and the demand for copper doesn’t look like it’s going to ease anytime soon
containing copper, gold and silver. Green Minerals plan to mine this last category. “Seabed minerals are a significant copper resource, and the demand for copper doesn’t look like it’s going to ease anytime soon,” he says. Such a project is unlikely to be taken on by a traditional mining company since the environment and conditions are so different.
THE TEAM
The project has involved around 15 engineers to date, although the team expands and contracts according to need. Rodahl describes the company
DEMAND FOR COPPER
Copper, also known as the red metal, is likely to see an exponential increase in demand over the next decade, according to the IEA.
The increase in demand is likely to come in large part from electric vehicles (EVs) and the batteries they contain. A similar 2024 report from analyst firm IDTechX entitled “Copper Demand for Cars 2024-2034: Trends, Utilisation, Forecasts” also predicts this rise. It explains that the demand for copper from the automotive industry was just over 3MT (1MT = 1 billion kilograms) in 2023 but is set to increase to 5MT in 2034, marking a 4.8% compound annual growth rate (CAGR).
This growth in demand continues to be driven by energy applications such as EVs, as well as storage, renewables and solar panels. For copper, the rapid expansion of grid network investment in China was the single largest factor of demand growth over the two years. Despite a slowdown in EV deployment in some markets, energy technologies continued to drive demand growth for major battery metals, contributing to some 65 to 90% of total demand growth over the past two years.
The IEA predicts that supplies of the metal will fall 30% short of the amount required by 2035 if nothing is done, analysis by the International Energy Agency predicts.
RESEARCH INTO THE PROJECT
In Norway companies don’t get a license to explore or do research, rather this is the province of academic institutions, often financed by the government which now has 20 years’ worth of research. This information is freely available and includes data on mineral deposits, weather patterns and more.
THE SETUP
as “currently a small and non-revenue generating R&D company set up to assess the viability of the deep-sea minerals project”. Still in its nascent stages, the company is set to go into operation in the first-quarter 2026.
CONSORTIUM
The company relies on a consortium of companies for the technology required. This includes OSI, a company with experience of operating riser systems for Allseas/TMC nodules, and Japanese consortium SMD, a company that delivers mining machines for SMS mining projects.
The company will operate on a semi-submersible platform
This machine carefully targets deposits, then chews at the bottom of the sea
The company will operate from a semi-submersible platform for reasons of stability. Several operators will be acting as miners from a hub on this platform. A pressure exchange chamber will sit in the sea beneath; and a riser, with one line going up two lines going down sits beneath this (pulling material up to the surface, and redepositing sea water on the sea bed). The riser operates as a closed loop system. Connected to the riser is the SMD mining machine itself.
EXTRACTION
This machine carefully targets deposits, then chews at the bottom of the sea. It features counterrotating teeth that chew inwards and a mouth that sucks up the material, then sends it via the riser to the pressure exchange chamber through the platform to a carrier vessel alongside.
HOW DOES THE TECHNOLOGY OPERATE?
The mining equipment was validated via the 2015 project VAMOS conducted in Bosnia at a flooded open pit. This project provided requisite data on cutting, plumes, slurry and manoeuvrability of the chewing machine. The difference with the Green Minerals setup will be the significant pressure the machine faces underwater, but as Rodahl explains, modifying the machinery is easy enough. “SMD has already done this for machines going down to 4,000m, while Green Minerals will only be operating at between 1,000m and 3,000m,” he says.
In terms of speed, the riser, the system pulling the material up towards the surface, is deployed
at 300m per hour, and the whole system is deployed in ten hours. “It’s so fast you can hardly believe it,” Rodahl says.
ENVIRONMENTAL CONCERNS
Plumes, in which debris from a mud or sandy bottom rise and join sea columns, have in the past been flagged as a potential concern for the subsea ecosystem – however this is not an issue for Green Minerals according to Rodahl since the Norwegian Continental Shelf is effectively rock. Another concern for such an operation might be how noise impacts sea life but as Rodahl explains, there are no pumps beneath the platform and the system’s noise is below the natural noise in the surrounding environment.
The mining equipment was validated via the 2015 project VAMOS. This project provided requisite data on cutting, plumes, slurry and manoeuvrability of the chewing machine
PLANS TO OPERATE IN OTHER SEAS
The system has been specifically designed for the harsh Norwegian sea. The weather window for producing is around 200 days a year since wave height and lengths are higher than in other waters. A dis-connectable turret solution has been designed to deal with difficult weather. Rodahl says that operating elsewhere is perfectly possible and that the company has an MOU to operate in the Pacific, but plans to put its attention on Norway in the near term.
As of April 2025, 32 countries around the world support a ban, moratorium or precautionary pause on deep-sea mining, citing the absence of a robust regulatory framework and insufficient scientific understanding of the environmental impacts of deepsea mining, according to the global energy watchdog the IEA. However, the extensive studies done by the Norweigian government into the impact of closed loop mining of the sort conducted by Green Minerals arguably allows such companies to explore and extract with minimal impact on the subsea environment.
The system was designed specifically for the harsh Norwegian sea
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.
RAPID RAILS
How Riino’s automated, electric rail system is redefining haulage from mine to mill. Saskia Henn reports
Decarbonising haulage is no simple task
Haulage is one of the most emission-intensive parts of mining operations, responsible for 30% to 60% of mine site emissions. This is primarily driven by diesel-powered truck fleets operating over long distances on surface mines, with high fuel burn, idle time, and maintenance overhead contributing heavily to emissions.
While the environmental impact of these vehicles is significant, what they accomplish is a necessary part of mining operations. Around the world, diesel truck fleets carry billions of tonnes of ore across mine sites each year, supporting the extraction of valuable geological materials and minerals.
Because of the vital contribution of haulage and its diesel-soaked roots in the industry, decarbonising the process is no simple task. Constant reliance on haul roads means that existing haul roads as a blueprint across rough terrain. Any sustainable method replacing diesel trucks must be capable of traversing steep inclines and declines and fit through tight workspaces.
INTRODUCING RIINO
Canadian mining consultant Riino is creating a solution that can operate across a range of difficult terrains. The company aims to replace diesel
trucks with fully electric, automated rail haulage.
The company began in CEO Aaron Lambert’s basement six years ago, with a demonstration site under its belt in Sudbury, Ontario, and full-scale pilot site hopefully around the corner.
Riino’s modular fixed-path rail system can adapt to suit a mine’s haulage routes, even those along tight areas, sensitive terrain and inclines and declines up to 20%. This includes underground and overground conditions, where the rail could avoid wildlife crossings by reaching up to 20 feet in the air, for example.
“Every site has its own unique needs, its own unique structure,” says Riino director of communications and marketing Miranda McColman.
In fact, the structure of a mine could change with the implementation of
the Riino rail system, as the system operates on a narrow, fixed rail guideway that requires less space than a fleet of diesel-powered trucks.
The guideway also reduces or eliminates grading, overburden removal, and surface compaction. The railway system could help to achieve up to 20% to 30% less overburden stripping on surface due to narrower infrastructure.
SAFER MINE SITES FOR MORE FLEXIBLE OPERATIONS
In addition to changing the nature of haul roads throughout the mine, Riino’s automated rail system also creates a safer, more flexible mine site. By removing diesel trucks from haul roads, exposure to dust, noise and vibration is reduced.
The rail system supports fully
The rail system can achieve a 20% incline or decline
autonomous operation, with optional layers of remote monitoring and emergency breaking. human-error that occurs in vehicle interactions, reversing, blind spots and operator fatigue is also minimised.
“Riino can actually build and integrate into a mine network, going from mine to mill, having those switches on the rail,” said McColman. “So we can actually create a little network within the mine area.”
The fixed-path system simplifies traffic planning and eliminates cross-traffic and fuel supply logistics. “It would depend on the needs of the mine, but in theory, the rail itself lies over terrain if it’s flat, meaning we don’t have to dig up anything,” says McColman.
The rail guideway also shrinks the
environmental footprint of haulage corridors, road maintenance and weather-related downtime, as it can operate in -40°C to 40°C.
ACCOMMODATING BOTH OLD AND NEW SITES
Traffic planning for new mine areas can be supported by Riino’s railway system. New ore bodies are in harder-to-reach areas with unreliable fuel access and power availability. Generally, the ground on these frontier locations is uneven or sensitive.
The modular assembly of Riino’s rail system allows initial access to areas that a fleet of diesel trucks could not traverse as easily.
However, the rail system is not just for new deposits. The reality is that many existing mines are facing the daunting
RIINO IS DESIGNED FOR BULK, HIGHTHROUGHPUT HAULAGE OF:
Run-of-mine (ROM) ore Concentrates
Waste rock and overburden
Aggregates and backfill materials
Containerized cargo
Irregular Cargo Mine Supplies
A CHANGING INDUSTRY
While diesel truck fleets have not yet been pushed to the side, their high fuel burn, idle time, and maintenance overhead contribute heavily to emissions and operation costs.
Solutions such as Riino’s railway system are changing the way mine sites look, sound and operate. Safety, adaptability and ease-ofuse will be key in helping mine site operators find haulage solutions in a rapidly changing industry.
task of transition their operations into a more sustainable operation.
“We can tack on to enter any energy source. Rhino can still be used if the energy is diesel generated on that mine site,” says McColman. “So we still support that mine going into the energy transition.”
With Riino’s infrastructure designed for adaptability, the rail system can fit into a mine regardless of its current stage in its sustainability journey.
This approach enables mine sites to make decisions that are best for their sites while still contributing to a sustainable mining future.
The system could help to achieve up to 20% to 30% less overburden stripping
An automated rail system creates a safer, more flexible mine site
POWER WITH PURPOSE
How the QSK95 engine boosts productivity and lifespan,
by Nebil Awad Baqhum, Cummins senior product manager
For miners, the performance of ultra-class haul trucks is critical to overall productivity. These machines do the heavy lifting, moving hundreds of tons of material every hour, often in harsh environments and at high altitude. At the heart of this performance is the engine.
While many operations rely on proven mid-range horsepower platforms to power vehicles, there comes a point when pressure to optimise cost per tonne, improve uptime, and simplify fleet logistics leads to a decision on whether to upgrade engine power.
To better understand this moment and the myriad factors at play, engine designer and manufacturer Cummins has put a spotlight on the comparative performance differences between products within its engine range, to assess where and when miners might make the jump up in size.
PUTTING THEORY TO THE TEST
To test when a larger engine can create value within mining, Cummins conducted a detailed, controlled simulation study. The analysis compared the Cummins QSK95 with
the smaller, 3,500-horsepower QSK78 in both 320t and 400t trucks across eight real mine haul routes.
The routes reflected actual operating conditions, including varied distances, steep grades, and high-altitude terrain, with variations in load, engine condition and driver behaviour all factored into calculations. Most of the sites simulated were located more than 3,100m above sea level and the study was based on single equipment condition. The goal was to evaluate cycle time, fuel efficiency, performance, productivity and total cost of ownership.
THE RESULTS ARE IN
Producing up to 4,400hp, the QSK95 is Cummins’ most powerful engine. It is also the most powerful available in the ultra-class haul truck category. Engineered as a clean sheet design with mining requirements in mind, the QSK95 delivers performance, reliability, and durability in ways that directly impact total cost of ownership and mining productivity.
The results from the extensive Cummins simulation study showed that a 400t haul truck powered by the QSK95 was 11% more productive than
the same truck with a 3,500hp engine.
Compared to a 320t truck with a 3,500hp engine, the QSK95-powered 400t truck delivered a 24% boost in productivity.
Compared to a 3,500hp engine, the QSK95 is expected to deliver up to 29% longer life to overhaul. That means more operating hours, fewer interventions, and lower total lifecycle costs.
While the larger engine was found to use more fuel, the overall cost of production per tonne remained similar.
The QSK95 moved more material, faster, helping to offset increased fuel costs with greater efficiency.
SMARTER FLEET STRATEGY, SAME PRODUCTION
The biggest opportunity from the study came into focus at the fleet scalability level. With faster haul rates, miners are able to reduce the number of trucks in operation while maintaining output. This creates the potential for major savings in areas such as labour, maintenance, and parts.
This smaller-fleets-with-biggerengines approach can simplify operations for miners and increase
Haul Truck 980 AZPG
Cummins’ biggest engine features single stage turbocharging that delivers full power at high
productivity, especially at remote or high-altitude sites where uptime is critical, and available staffing is limited.
However, it’s important that miners consider the risk of fewer trucks and potential productivity lost when trucks come out of operation for maintenance or unexpected downtime. The QSK78 remains a strong engine for many applications where more flexibility is required, and site profile is better suited.
PROVEN PLATFORM
The QSK95 was built to meet mining demands. It is a clean-sheet design, developed to meet the toughest mining conditions - from extreme temperatures and high altitudes, to heavy duty cycles and long service intervals.
Cummins’ biggest engine features single stage turbocharging that delivers full power at high altitude, external oil coolers for easier service access and four turbos instead of six, reducing overall complexity. A V16 layout and reinforced block minimises noise and vibration for miners, with fewer moving parts and stronger bearings helping to extend engine life.
More than 1,200 QSK95 engines are already in service across different sectors in 36 countries, working in some of the toughest conditions an engine can perform in. In mining, the QSK95 is also supported by Cummins’ service network and digital monitoring tools like PrevenTech.
These tools provide real time, overthe-air insight into engine performance, helping operators identify issues early, reduce unplanned downtime, and make data-informed decisions on variables like driver behaviour and downrating that can improve fleet productivity.
LOOKING AHEAD
As the mining sector adapts to challenges, decisions about haul fleet strategy are becoming more data driven and critical to overall site efficiency.
Engine choice is no longer just about horsepower - it is about total uptime
How do bigger engines and increased production affect your overall production costs? Let's compare 3500 and 4400 hp engines in 320T and 400T trucks. Powering Mine Site
Productivity
QSK95
The most powerful Cummins mining engine available
value, serviceability, and cost per tonne. The QSK95 offers miners a powerful option that can boost productivity, simplify operations, and provide long-term value in some of the most demanding conditions on Earth. For miners who are ready to move more,
faster and with fewer interruptions, the QSK95 is ready to power a change.
NEW NIOBIUM SUPPLY
The University of Birmingham and CBMM, global leader in Niobium production, partner to drive innovation in carbon recycling
The project aims to ensure the future supply of Niobium
The University of Birmingham, UK, and Brazilian-based CBMM, have partnered on a project to ensure the future supply of Niobium, a non-critical but rare and important metal and an essential component for a carbon recycling technology that could radically reduce emissions from energy- and carbon-intensive foundation industries.
CBMM, a global leader in the production of Niobium products, will work with Birmingham researchers led by Professor Yulong Ding to improve the efficiency of production, and reduce the cost of Niobium compounds for use in the closedcarbon-loop technology for foundation industries such as steel-making.
USING PEROVSKITES
The project is related to a technology that uses Niobium-based perovskites, which turn the CO2 emitted from industrial processes into carbon monoxide (CO), which is then fed back into the process, creating a closed carbon loop.
The Niobium-based perovskite has a 100% selectivity for CO production, meaning that CO2 passing through the material is transformed only into CO, and this type of perovskite was used when Birmingham researchers
modelled a novel adaptation for existing blast furnaces that could reduce steel-making emissions by up to 90%.
A major advantage of this closedloop carbon-recycling approach lies in its applicability to retrofit existing industrial processes, in a way that significantly reduces the need for major infrastructural replacements.
This facilitates large-scale adoption and minimises the stranded assets. Additionally, the perovskite technology operates at a lower temperature compared to conventional alternatives, resulting in a reduced costs and energy efficiency gains.
PEROCYCLE TO HELP WITH COMMERCIALISATION
The outcomes will help advance the commercialisation of the decarbonisation technology through PeroCycle, a spin-out backed by the University of Birmingham and Anglo American, with venture-building led by Cambridge Future Tech.
CBMM’s involvement will ensure the necessary support for future scalability of Niobium-based perovskite production. “This partnership represents an important step in the search for viable and sustainable solutions to the
challenges facing global industry. We are looking at a promising solution for industrial decarbonisation, especially in the steel sector, due to its potential technical and economic feasibility. Furthermore, the use of Niobium across different markets reinforces our commitment to innovation and sustainability,” says Leonardo Silvestre, executive innovation manager at CBMM.
The project will explore its use not only in steel-making but also in other industries.
“Foundation industries such as steel-making, which provides essential materials to a wide range of other industries, are major emitters of CO2 and amongst the hardest sectors to decarbonise,” says Professor Yulong Ding, chamberlain chair of chemical engineering, and founder of the University of Birmingham’s centre for energy storage. “We are pleased to work with CBMM on this project, which aims to deliver a decarbonisation solution that is not only technically and economically viable, but also environmentally sustainable.” For
LOW COST OF PRODUCTION
SUSTAINABLE OPERATIONS
POWER: BALANCED
Can mining satisfy the world’s hunger for raw materials – and meet environmental targets too?
With Cummins’ help, it can. Our range of mining engines, made even cleaner and more e icient through technologies like alternative fuels and advanced monitoring, are helping mining explore a future that can be both sustainable and profi table. It’s power: balanced.
LASER FOCUS
The Fraunhofer Institute of Lasers is accelerating tool repair with an AI-led system. Saskia Henn reports
Mining tools experience mechanical and abrasive stress throughout their lifespan. Harsh operating conditions accelerate tool deterioration while time and safety considerations add repair pressure from all sides.
LASER METAL DEPOSITION
Laser metal deposition (LMD) is a process where metallic filler material is applied locally to a substrate using laser radiation. The laser, acting as a precise and energy-efficient heat source, selectively melts the material as the processing head moves relative to the component. LMD can be used for functional coatings, component repair, or additive manufacturing of new parts.
“One of the key benefits of LMD is its targeted and rapid energy input, which enables precise thermal control. This minimises residual stresses, distortion, and undesired structural changes, making the process suitable even for delicate or thin-walled components,” says member scientist at the Fraunhofer Institute for Laser Technology (ILT) Max Zimmermann.
The Aachen-based research institute develops laser beam sources, optical components and systems, photonic technologies and laser material manufacturing processes. This includes the field of LMD.
THE AI-SLAM PROJECT
In LMD, preparing and programming the machining paths is timeconsuming and labour-intensive.
The AI-SLAM project addresses this challenge, aiming to make the entire LMD process autonomous and sensor driven. A Canadian-German consortium has been formed for this purpose, consisting of Braintoy, Apollo Machine & Welding Ltd, BCT Steuerungs- und DV-Systeme GmbH, McGill University and Fraunhofer ILT, funded by the Federal Ministry of Education and Research BMBF and the National Research Council of Canada NRC.
One of the benefits of LMD is its targeted and rapid energy input
The resulting system integrates laser scanning, automated path planning and AI-supported parameter optimisation and quality assurance. AI predicts optimal process parameters, detects defects and ensures high reliability even when dealing with varying geometries, materials, or component conditions.
“AI serves as an intelligent support tool, taking over routine tasks.” says Zimmermann, the AI-SLAM project manager,
The AI analyses sensor data – such as geometric scans, thermographic images, and process signals – to determine key LMD parameters such as laser power, feed rate, and powder mass flow. The system can detect issues such as pores, bonding defects, or insufficient layer overlaps, in some cases even in real time during the process.
“This semi-automated process
The LMD and EHLA are compatible with almost all metallic materials, as well as stainless steels, bronzes, and high temperature alloys. APPLICATIONS INCLUDE:
Drill heads and chisels – protection against abrasion from hard rock
Bucket teeth and loading shovels –extended service life through hard coatings
Conveyor screws and pump components –resistance to erosion and cavitation
Crushing tools – targeted wear protection in high-stress zones
significantly reduces the time needed for setup and improves process stability, even for unknown or non-uniform components,” says Zimmermann.
EXTREME HIGH-SPEED
The Institute is also developing extreme high-speed laser material deposition (EHLA). Powder is melted by the laser beam while still in flight above the component, allowing for extremely high feed rates – several hundred metres per minute compared to just a few metres per minute in conventional LMD. This enables the deposition of thin, dense, and well-adhered layers, typically 25µm to 300µm thick, while increasing productivity.
Fraunhofer ILT has a 40-year history in LMD research
TAILORED TRANSMISSIONS
ZF’s Ralf Matke explores the impact of unexpected downtime and how specialised services can prevent it
The mining industry experiences vast challenges that robust, reliable equipment can help to manage
MEETING MINING CHALLENGES WITH ROBUST GEARBOX SOLUTIONS AND SERVICES
The mining industry faces numerous challenges, including health and safety concerns, geopolitical risks, fluctuating demand and the need for constant technological innovation. These challenges necessitate robust and reliable equipment to ensure continuous operation and minimise downtime. Industrial gearboxes in mining equipment must withstand harsh conditions and heavy loads.
THE IMPORTANCE OF SPECIALISED SERVICES
Specialised services for gearboxes are essential to address unexpected malfunctions and minimise downtime. These services include rapid damage analysis, availability of spare parts, well-trained technicians, and a global network of service points. Quick repairs or replacements help maintain mining operations’ efficiency and productivity.
Service is crucial for smooth operations in an open pit mine. Preventative maintenance and overhaul of drive units require close planning and coordination between the operator and supplier. In the event of unplanned incidents, a service organisation must respond quickly and efficiently.
INTRODUCING ZF INDUSTRIAL DRIVES
ZF Industrial Drives’ gearbox portfolio covers all mining applications, from raw material extraction to final processing. This includes crawler excavators, draglines and stationary equipment such as apron feeders, mills and crushers. As the only full liner for drive technology on the market, ZF Industrial Drives offers a comprehensive range of large gearboxes with torques from 100,000Nm to 7.2 million Nm.
With over 20,000 planetary gears proven in the mining industry for more than 30 years, the company has the expertise to provide reliable
service. Downtime is costly for operators, with potential losses running into thousands of dollars per hour. The worst-case scenario is unplanned downtime, which requires a quick reaction and solution to avoid high costs for replacement components and production downtime.
“Service begins with the awarding of the order for a new gear,” says Mark Patzak, head of Industrial Gearbox Service in Witten. “Robustness and reliability of the new gear are top priorities for trouble-free operation of the machines, whether stationary or mobile. Experience, analyses, and feedback from the field are already flowing into the development of new generations and product updates.”
ZF is setting standards with its transmissions. The Redulus4F series features a significant increase in output torque by up to 40% to 80% compared to previous series, resulting in higher robustness and service life of the components. The same results of increased performance and robustness are evident in mobile drives.
“Despite the highest reliability and robustness in dealing with extreme conditions in mining operations, even our transmissions reach their limits,” continues Mark Patzak. “Whether unplanned or at the end of the calculated service life, competent, reliable service is essential.”
PREVENTATIVE MAINTENANCE
To optimise maintenance intervals, ZF uses its proven condition monitoring system ProVID, which offers access to information on the current condition of transmission components whenever needed. Maintenance and overhauls, previously carried out according to fixed plans, are now initiated, planned and carried out variably at the best possible time. ProVID also enables early detection of possible damage, allowing for a response long before a damage event occurs. By planning a repair and providing necessary components early, unplanned downtime is avoided.
The company uses a global gearbox pool to keep common gearboxes and spare parts in stock for the fastest delivery in the event of a failure
WHEN SPEED IS CRUCIAL
The advantage of a service organisation geared to the mining industry’s needs is evident in the case of a sudden, unexpected malfunction, where speed is crucial. Qualified contacts on-site for rapid damage analysis, worldwide short-time field service availability based on a global partner network, and well-trained service technicians on-site are basic offerings from ZF Services.
Close contacts and cooperation between the organisation onsite and specialists at headquarters enable quick repairs or even transmission replacements. Alternative repairs are carried out at ZF service points or authorised partners in the regions, equipped and certified according to ZF standards for industrial gearbox sizes.
The company uses a global gearbox pool to keep common gearboxes and spare parts in stock for the fastest delivery in the event of a failure. The components are “ready for pick-up”, guaranteeing immediate availability and minimising downtime.
A professionally reconditioned exchange gearbox is a cost-effective and ecological alternative to using a new one. The products are in “like new” condition in terms of function, reliability, and service life, giving them a second life. This commitment to sustainability and responsibility for the future is underlined by knowledge and innovations.
REDUCING DOWNTIME, SAVING MONEY
Today’s modern service offers more than just maintenance or replacement of a gearbox. Suppliers such as ZF bear responsibility for its products throughout their entire life cycle and beyond. Supported by modern condition monitoring and forwardlooking planning, downtimes can be minimised, saving money and resources - the key to sustainable and customer-focused service.
Suppliers such as ZF bear responsibility for products throughout their lifespan
DE-RISKING DRILLING
Di-Corp drilling and manufacturing technology expert Chris van Schaayk explains why consistency is key when choosing coring rods
Far too often in mineral exploration drilling, coring rods were considered interchangeable. As long you were buying your drill steel from a reputable dealer and drilling in standard ground conditions, there wasn’t a large difference between one rod and another. Thus, for a lot of drillers, the biggest consideration when choosing rods was price. You need a lot of rods to get to core and contracts are competitive, so focusing on the cost per rod is understandable.
CHOOSING A DRILL ROD
Choosing a quality, consistently manufactured drill rod is essential to a successful drilling program, and interchanging between manufacturers’ products (although it often does work) can add a significant layer of risk. Unlike API joints used in the oil industry, there is no standard for dimensions on exploration drill rod threads. Exploration rod designs have a tapered interference fit and a very thin wall to work with, so tolerances are inherently tight
during manufacturing. Due to these facts, variations in fit between manufacturers can exist.
WHAT TO CONSIDER
Modern drilling involves deeper, harder-to-access deposits, frequent deviations, automated rod handling, and a competitive, volatile global mineral exploration market. In these conditions, a failed rod or mismatched
In 2025, rod failure should be the exception, not the rule
A rod string is only as strong as its weakest connection
Variations in fit between manufacturers can exist
rod connections could cost you a shift tripping out bent tubes or fishing out broken ones. Or worse, losing a hole altogether.The risks aren’t just incurred by drilling companies. Mine owners must also consider what failed rods mean to them. Delays in the completion of drilling programs have the potential to push back decisions on development, wasting precious time and of course money.
REDUCING THE RISKS
Choosing more durable, consistently manufactured rods can reduce these risks. That means looking for thread forms designed to eliminate areas of high stress concentration and deliver high tensile and tortional strength. To find this, it is helpful to look for providers with a reputation for using high quality steel and applying the highest quality control measures to machining and surface treatment processes. And mostly, it means not mixing rods and rod string components
(including adaptor subs and locking couplings) from multiple manufacturers. A rod string is only as strong as its weakest connection, from the water
Choosing a quality, consistently manufactured drill rod is essential to a successful drilling programme
swivel to the core barrel. Mismatching threads with a rod string component can cause rods to fail. Saving small amounts of money on adapters isn’t worth putting a rod string in danger. The fact is, in 2025 rod failure should be the exception, not the rule. Drillers that only choose equipment on cost or mix products from multiple manufacturers expose themselves to greater risk than necessary. In today’s challenging and competitive environment, it is time to stop evaluating drill rods and components primarily on price and start evaluating the cost associated with the risks of rod failure. Choosing a more durable, better engineered rod string may cost more up front, but will save money in the long run.
SAFE, SUSTAINABLE CHARGING
Vedrana Spudic from ABB reports that an automated charger for electric mining trucks is enhancing operational efficiency
In modern mining environments, vast underground networks bring people in close proximity to heavy machinery. Movements are coordinated and swift, with potential hazards around every corner. But, in a place where there are already automations and remote operations at scale, how do we replace some of the last human tasks?
The industry is close to fully autonomous work – removing people from the danger zones, increasing safety and building up sustainability. This article will focus on one innovative technology that comes from ABB’s research and development departments, with subsequent collaboration and testing with mining industry partners.
FROM CONCEPT TO REALITY
Currently undergoing a programme of cold and hot weather testing in Sweden and soon in USA, ABB’s Technology Demonstrator eMine
Robot Automated Connection Device (Robot ACD) is a new power charging solution for mining trucks.
Robot ACD, designed by ABB in collaboration with the industry, including Swedish mining company Boliden, and mining machinery manufacturer Komatsu, automatically connects and charges electric mining trucks without human intervention.
As the name suggests, Robot ACD comes from R&D activity under the company’s eMine approach that combines technologies for
electrification, automation and digitalisation in mining with a focus on decarbonising heavy vehicle fleets, which currently account for more than a third of emissions in a mine.
When charging a domestic electric vehicle, the driver would ordinarily be required to step out, move around the vehicle and manually plug in their electric connection. However, in the mining location, it is necessary to
The eMine Robot Automated Connection Device (ACD) is a high-power and fully automated charging system for mining trucks
The interoperable robotic arm automates the connection and charging process
The eMine Robot Automated Connection Device (ACD) will enable further interoperability, synergy of connections and interfaces for charging
have many adaptations, for example, being ruggedised to withstand harsh environmental conditions, and automated to ensure safety – complete with sensors and vision systems for precision and efficiency.
SAFETY AS THE MAINSTAY
Automating processes and individual activities in the mine have become standard over the last decades, but manual interventions remain. One of the most important aspects of the Robot ACD is the impact it will have on workforce safety.
Mining has always been dangerous, but there are increasing ways to mitigate risks and remove people from the frontline altogether. With Robot ACD’s powerful, interoperable robotic arm, vision system and accurate sensors, the technology is compatible with megawatt charging system/ ruggedised megawatt charging system (MCS/R-MCS) and quick charging connector (QCC) pin types, automating the connection and charging process. The Robot ACD enables personnel to stay in the safety of the haulage truck cabin, while the high-power charging process takes place.
The industry is on a trajectory towards automated and autonomous operations. Technologies like eMine Robot ACD are essential for applications that meet new needs and grow possibilities.
SUSTAINABILITY IN ACTION
The Robot ACD is a key component of ABB’s eMine initiative, which aims to electrify the mining industry and reduce its environmental footprint. Electric mining trucks, charged in the field by the Robot ACD and the associated eMine FastCharge system, will produce significantly lower emissions compared to their diesel-driven counterparts. This shift reduces greenhouse gas emissions and improves air quality in mining areas, benefiting both workers and surrounding communities.
Moreover, electric equipment generates less heat and noise, creating a more comfortable work environment. The reduction in diesel particulate matter and other pollutants leads to better health outcomes for workers, who are no longer exposed to harmful emissions. Mining teams, including with mining company Boliden, have shared their comments on the cleaner, quieter and safer working environment.
FUTURE OPERATIONS AND BENEFITS
The transition to electric mining equipment, facilitated by technologies like the Robot ACD, also bring substantial economic benefits. According to McKinsey & Company, an all-electric mine can reduce operational costs, as electric
equipment can cut energy costs by 40 to 70% and maintenance costs by approximately 30%. This is because there are fewer moving parts and less wear and tear than in traditional diesel machinery. These savings translate into more efficient and cost-effective mining operations, allowing companies to invest in further innovations and improvements.
Additionally, the Robot ACD’s interoperability ensures compatibility with various electric mining trucks and charging systems, including anticipated future technologies. This flexibility enhances the overall efficiency of mining operations, as different equipment can work together seamlessly. Trucks can be charged during scheduled breaks or downtime, minimising disruptions and maximising productivity.
In conclusion, ABB’s Robot ACD can enhance safety, promote sustainability and bring economic benefits. Reduced emissions mean improved air quality, and, of course, benefits from the steady supply of minerals and metals needed for modern lifestyles and energy transition over the long term.
For more information visit: https://new.abb.com/mining/ emine/fastcharge
SMART SORTING
A new AI-powered ore sorting technology offers precision and flexibility, reports Saskia Henn
Mines are being exhausted and ore grades for many minerals are falling around the world.
One way to manage this is to use technology that makes the most of existing ores. Optimising the sorting process helps to accomplish this.
CHALLENGES IN ORE SORTING
Traditional ore sorting, while a crucial part of mining, has its drawbacks.
Detection of low-grade material and subtle mineralisation can be challenging. Real-time adaptation to fine-tune the balance between grade and recovery is often not possible, resulting in lower concentrate quality and more gangue entering the product stream.
TOMRA’S SOLUTION
As AI, ML and deep learning have entered the picture, so have opportunities for more flexible and precise sorting methods.
Sensor-based sorting specialist Tomra Mining has developed an AI-powered ore sorting technology called Contain, designed to enhance the recovery of inclusion-type ores that are hard to detect with traditional methods.
“There are limits to what humans can do, and machines now complement our abilities quite effectively,” says Tomra software team lead Stefan Jürgensen.
Contain uses convolutional neural networks to analyse x-ray imagery in real time, classifying rocks based on the probability of subsurface ore mineral inclusions.
Field trials at Austrian mining company Wolfram Bergbau showed that when Contain was integrated with Tomra’s existing sorting technologies COM XRT and Obtain, customers could either boost plant throughput by 8% with no loss in recovery or cut ore losses by 33% while maintaining throughput. This is
Stefan Jürgensen, Tomra software team lead
possible through Contain’s improved detection accuracy, which allows operators to fine-tune the balance between recovery and throughput based on their priorities.
The technology works for a wide spectrum of ore grades and complex mineralisations that traditionally result in high misclassification or excessive product loss, such as in tungsten, nickel and tin ores.
Jürgensen likens using Contain to a human carefully examining all sides of a rock and taking the time to compare it to others. “Our machine classifies 1000s of rocks per second, but on the same quality level. That’s the difference,” he says.
TRAINING THE SYSTEM
The system has been trained on tens of thousands of inclusion-type ore samples, like tungsten, nickel and tin, which form distinct patterns on x-rays. Tomra is currently testing on further, similar inclusion-type commodities and is exploring expansion into other minerals.
Training with different types of rock allows the system to adapt to
different deposits, creating complex, deep neural networks to accommodate diverse environments.
“Humans are very good at detecting patterns everywhere in the world. But the machine has no clue about the world, and therefore we have to present more of the world to the system,” says Jürgensen.
“But at the same time, because it’s able to understand and analyse so many more samples, it’s actually able to see some things that we miss, because we can’t really take the images of 10,000 rocks into our head.”
WHAT DOES IT MEAN?
Contain helps high-volume processing plants to maximise concentrate grade, minimise valuable material loss and accommodate cost constraints.
As the mining industry evolves, deep learning can preserve both mineral quantity and quality. For
SNAPPY SOLUTIONS
How modular, tool-free fastening methods on filter plates are making a difference
In the mining industry, time truly is money. Downtime in dewatering processes can mean production losses in the range of thousands of euros per hour.
While the dewatering process is necessary to reduce the water table level and enable efficient mining operations, every minute that a filter press stands still counts.
This is exactly where SnapFit on filter plates set a new standard in efficiency and reliability.
WHAT IS SNAPFIT TECHNOLOGY?
SnapFit is a tool-free, mechanical fastening method that allows components - in this case, membrane or chamber filter plates - to be quickly and securely connected without screws, bolts, or special tools.
The parts (the membranes, feed shoes, or covers) “snap” into place, ensuring a firm fit with minimal manual effort.
Although inspired by applications outside the field of solid-liquid separation, this fixing technology has become a useful tool in the mining industry’s dewatering processes.
ADVANTAGES IN HARSH MINING ENVIRONMENTS
Mining applications are demanding. Abrasive slurries, high throughput, and
rugged conditions push conventional components to their limits. Traditional plate systems often require long installation or maintenance times, especially during membrane replacements or inspections.
The simple assembly option reduces labour and downtime, and the screwless installation prevents screws from falling into the filter cake trough.
WITH SNAPFIT:
The change process of membranes on filter plates is up to 80% faster No special tools are required, saving time and reducing risk of injury
Maintenance personnel can replace individual elements on-site and on demand
Downtime is drastically reduced, keeping production moving
FLEXIBILITY MEANS LESS DOWNTIME
Mining sites often operate around the clock. The modular SnapFit system enables quick adaptation to changing process conditions, such as switching between chamber and membrane operation or replacing damaged components without full system disassembly.
This flexibility translates to higher system availability, lower labour costs and faster return to operation after maintenance.
SnapFit’s simple assembly option reduces labour and downtime
The modular SnapFit system enables quick adaptation to changing conditions
ECONOMIC IMPACT
A large filter press with hundreds of plates can take hours to reassemble using conventional systems. With SnapFit, installation times are shortened dramatically, meaning lower total maintenance costs and maximum equipment uptime - a clear financial benefit in high-output mining facilities.
FUTURE OF FILTER PLATE ASSEMBLY
For mining operations where every minute of downtime counts, SnapFit filter plates offer a smart, rugged, and cost-effective solution. They simplify handling, increase safety, and most importantly, they save time and money where it matters most.
For more information, visit: www.jvk.de
TAKE A SEAT
How inertial sensor specialist ASC is combatting effects of whole-body vibration with its seat pad accelerometers
SEAT PAD ACCELEROMETERS FOR A HIGH-PERFORMING WORKFORCE
Every day all over the world, truck drivers, machinery operators and mining engineers are exposed to mechanical vibrations. Interacting with any kind of vehicle or heavy machinery inevitably causes wholebody vibration (WBV), which is the vibration transmitted through the seat or feet of a worker while operating machinery or standing on vibrating ground.
VIBRATION RISKS
WBV is a concern across many industries using heavy machinery, with the mining industry claiming a spot at the top of the list.
Prolonged exposure to vibration may lead to serious potential health risks and other consequences including injury, sick leave and work disruptions, as well as longterm disabilities. These can include nervous system dysfunction, musculoskeletal disorders and joint and ligament problems.
In the mining industry, making contact with significant vibration loads may be unavoidable. However, easily installed inertial sensor technology, available through German inertial sensor specialist ASC Sensors, allows for continuous monitoring of WBV exposure, ensuring that industry norms and medical standards are met and that neither your workforce nor your business suffers.
AN ACCURATE AND FLEXIBLE SOLUTION
Through its partnership with vibration sensor manufacturer Metra Messund Frequenztechnik (MMF), ASC offers the KS963 Seat Pad WBV Accelerometer.
This triaxial IEPE transducer has been specifically designed to measure and analyse whole-body vibration according to ISO 2631, ISO 8041, ISO 10326-1 and ISO 7096. The regular or constant monitoring for real-world WBV exposure helps to evaluate compliance with these regulations, identify potential risks and implement appropriate mitigation and vibration control measures.
The lightweight IEPE accelerometer combines accuracy and reliability with long-term consistency and stability. It features integrated memory for an electronic data sheet (TEDS), streamlining data recording and analysis. Its 100mV/g output and
measuring range of +/-60g ensure comprehensive coverage of all vibration measurements.
Equipped with a two-meter cable, the seat pad accelerometer offers ample reach for diverse applications. The sensor is embedded in a flexible rubber cushion to capture those vibrations transmitted to the body. The versatile sensor can be easily removed from the cushion for calibration.
HEALTHY WORKFORCE FOR HEALTHY BUSINESS
The simple-to-use ASC KS963 Seat Pad WBV Accelerometer provides a ready, convenient solution for keeping on top of WBV-related challenges in today’s mining workplaces.
The technology’s accurate capturing and long-term monitoring can provide valuable insights into the level of vibration exposure experienced by individuals. Beyond that, it can help to to assess and analyse the root causes of WBV and help manage the risks associated with prolonged vibration exposure.
On that basis, you can take proactive measures to minimise the impact of workplace-related vibrations transmitted to the human body and strengthen the health and well-being of your workforce – as well as that of your business.
For more information, visit: www.asc-sensors.de
The seat pad can be embedded in the seat for constant monitoring or placed on top of the seat for temporary measurements.
The KS963 sensor converts accelerations into vibration magnitude values
isafe-mobile.com
CRITICAL DUST CONTROL
Dynaset’s electric high-pressure dust suppression systems are tailored to integrate with modern mining needs
Dust control is a critical concern in the mining industry, where airborne particles pose risks to worker health, equipment longevity, and environmental compliance. Traditional dust suppression methods often fall short, either by being inefficient or introducing new challenges.
Dynaset’s high-pressure dust control system has been used in the mining industry for years. Now, the manufacturing company has pioneered advanced electric highpressure dust suppression systems tailored to the needs of the evolving electric machinery world.
HPW-DUST HIGH PRESSURE DUST SUPPRESSION SYSTEM
HPW-DUST High Pressure Dust Suppression System is designed for machinery commonly used in mining, drilling and quarrying. The heart of the system is a HPW Hydraulic High Pressure Water Pump. This system utilises the hydraulic power of the machine to generate a fine mist that effectively captures and suppresses dust at its source. The atomised water mist binds dust particles without excessive water usage, preventing the worksite from becoming muddy and ensuring optimal water consumption.
EPW-DUST HIGH PRESSURE DUST SUPPRESSION SYSTEM
With the increasing adoption of electric machinery in mining, Dynaset introduced the EPW-DUST High Pressure Dust Suppression System in January 2025. This system harnesses the machine’s electric power and produces a high-pressure water mist, effectively controlling dust emissions in mobile and stationary applications. Available in both AC and DC versions, the EPW-DUST system offers versatility to meet diverse operational needs. Its precision-engineered nozzles atomise water into a fine mist,
capturing dust particles directly at their source, thereby improving air quality and worker safety.
TAILORED SOLUTIONS FOR MODERN MINING
Dynaset dust suppression systems are engineered to integrate seamlessly with various mining equipment,
Dynaset dust suppression systems are engineered to integrate seamlessly with various mining equipment
ENVIRONMENTAL AND OPERATIONAL BENEFITS
Implementing high-pressure dust suppression systems offers several advantages:
Enhanced worker safety: Reduces exposure to harmful dust particles, improving respiratory health and overall safety.
Improved equipment longevity: Minimises dust accumulation on machinery, reducing wear and maintenance needs.
Environmental compliance: Helps to meet stringent environmental regulations by controlling dust emissions at the source.
Operational efficiency: Low water consumption prevents the worksite from becoming overly saturated, maintaining optimal working conditions.
including drilling rigs, crushers, and material handling machinery. The systems are designed to be compact and efficient, ensuring minimal impact on the machine’s performance while maximising dust control. Whether operating in urban environments or remote mining sites, these systems provide a reliable solution to manage dust emissions effectively.
As the mining industry continues to evolve, the need for effective and sustainable dust suppression solutions becomes increasingly important.
DYNASET’s HPW-DUST and EPWDUST systems represent the forefront of dust control technology, offering tailored solutions for both traditional and electric machinery. By adopting these advanced systems, mining operations can achieve cleaner, safer, and more efficient work environments, aligning with both regulatory standards and best practices in environmental stewardship.
The system generates a fine mist to capture and suppress dust at the source
The system integrates with various mining equipment
UNDERGROUND DIGITALISATION
Kathrin Geisler of i.safe Mobile explores how the company’s intrinsically safe mobile technology is bringing coal mining into the digital age
The coal mining industry faces a crucial challenge: implementing digital transformation in potentially explosive underground environments. While open-pit mining uses modern technologies, underground mining requires special mobile devices with international mining certifications that can withstand extreme conditions while providing reliable communication and data processing functions.
Digital transformation in coal mining is critical to operational efficiency, worker safety and regulatory compliance, requiring devices that function reliably in hazardous areas while providing connectivity for modern mining operations.
THE DIGITAL TRANSITION
Underground coal mining requires integrating various communication technologies. The transition from traditional radio systems to 5G networks presents opportunities and challenges. Legacy systems cannot be abandoned overnight, but the benefits of advanced digital communications are significant.
Modern mining operations require devices that function reliably in hazardous areas while enabling predictive maintenance, real-time monitoring, and emergency response systems. 5G integration into existing infrastructure enables gradual modernisation without interrupting standard operations.
KEY EQUIPMENT CATEGORIES
Coal mining digitalisation requires a comprehensive ecosystem of intrinsically safe mobile devices meeting specific operational requirements, such as those from i.safe Mobile.
5G radios: Next-generation radios like the IS440.M1 enable secure pushto-talk communication over public, campus or Wi-Fi networks in hazardous areas. Features include replaceable batteries, amplified speakers for noisy
environments and programmable emergency functions. Gateway integration ensures interoperability with existing technologies.
Intrinsically safe 5G smartphones: High-performance smartphones such as the IS540.M1 feature advanced processors for demanding industrial applications. These devices feature high-resolution displays, professional cameras and secure interfaces. Replaceable batteries ensure reliable operation during shifts.
Video: Communication capabilities have revolutionised troubleshooting and emergency response in underground operations. In one case, an equipment malfunction traditionally requiring several days for surface technician induction was resolved in one hour through live video streaming between underground operators and surface experts. This significantly reduces downtime and costs.
These devices prove invaluable in emergency medical situations where emergency services cannot quickly reach underground locations. Medical professionals can provide critical guidance via video communication technology, potentially saving lives.
Industrial tablets: Large-screen tablets serve as mobile workstations for data visualisation and process control. Devices like the IS940.M1 from i.safe Mobile integrate into network infrastructure via 5G, 4G or Wi-Fi 6 connectivity. Advanced processors enable real-time data analysis and remote monitoring.
High-performance scanners: Special barcode scanning solutions
enable data capture in hazardous areas. These systems combine trigger-handle scanners with connected smartphones, offering scanning capabilities up to 18m. Integration with i.safe Mobile smartphones eliminates separate batteries or wireless connections.
ENHANCED SAFETY AND OPERATIONS
Modern Ex-safe devices incorporate programmable emergency buttons for lone worker protection and secure mounting systems. Advanced battery management enables multi-shift operations while dual-SIM capabilities ensure communication redundancy. Real-time communication improves surface-underground coordination, predictive maintenance reduces downtime, and data acquisition systems enhance inventory management. Advanced cameras enable remote collaboration, reducing hazardous area inspections.
FUTURE-READY INFRASTRUCTURE
Integrating certified intrinsically safe mobile devices with advanced technologies like network slicing and edge computing, coal mining operations can safely accelerate digital transformation. This infrastructure enhances safety, improves efficiency, and ensures reliable communication in hazardous environments.
The IS540.M1 features advanced processors for demanding industrial applications
WORK SMART NOT HARD
Jerad Heitzler, training manager for Martin Engineering, explains why solid instruction and well-designed conveyor accessories keep your pockets filled
Protecting workers should be the top priority for any employer, especially those on the front line of materials processing. Beyond the substantial financial consequences of a workplace injury or fatality, the impacts are felt profoundly by an employee’s family, their coworkers, and the wider community.
Thus, investing in safe, wellengineered equipment and prevention-focused training that helps protect workers from injury or illness is essentially investing in people, company culture, and the community. Martin Engineering’s technicians are increasingly applying their expertise to help operators control maintenance risks by sharing their knowledge and installing equipment that improves safety.
RETURN ON PREVENTION
Although return on investment (ROI) is a common calculation when installing new conveyor accessories,
some safety experts emphasise the return on prevention (ROP). This longterm strategy prioritises equipment with safety engineered into the design, allowing for more ergonomic servicing, faster and easier access, and other improvements that make maintenance less dangerous and more desirable to do. Although safer equipment is typically a larger initial capital investment, the whole life return is in faster maintenance with less downtime, longer equipment life, and, importantly, a considerably lower chance of an incident, reducing the overall cost of operation.
THE REAL COSTS OF ROI
Calculating ROI on conveyor safety is specific to each operation, but in general, they can be broken down into “direct costs” and “indirect costs”: Direct costs are explicitly associated with an accident or illness. In general, these include fines, medical bills, insurance
premiums, indemnity payments and temporary disability payments. Indirect costs include a variety of other expenses resulting from the incident. They include:
Cleanup time and product loss
Equipment repair/replacement
Purchase/installation of safety components
Overtime to fill in for the missing worker
Cost of hiring, training and equipping new employees
Legal fees and litigation costs
Increased insurance premiums
Production delays and missed shipment targets
Reduced employee morale, greater absenteeism
Negative publicity
Increased scrutiny by regulators
THE PRICE OF ACCIDENT RECOVERY
To demonstrate the benefits of safety to a company’s bottom line, the Occupational Safety and Health
Ash Grove Chanute Return Tracker
Administration (OSHA) in the USA created the online tool, ‘$afety Pays’, which uses company-specific economic information to assess the potential economic impact of occupational injuries on that firm’s profitability. The program estimates direct costs (claim cost estimates provided by the National Council on Compensation Insurance) and indirect costs (provided by the Stanford University Department of Civil Engineering) and weighs them against financial details supplied by the company.
RETURN ON PREVENTION
The commonly-used ROI model calculates the time frame in which the capital expenditure on new equipment is recaptured through the improvements. If a proposed project meets budget expectations and has a payback period of less than one year, plant management usually approves it.
Working with abstract numbers implicitly creates pushback, making it more difficult for safety-conscious managers to obtain approval for their
proposals. However, the hard costs of worker injuries and fatalities are very real. The ROP model illustrates the direction and strength of occupational safety and health programs in helping to achieve company goals.
GOOD DESIGN IS SAFE DESIGN
The death or serious injury of a worker is always tragic and can have long-term impacts for all those involved. Investigations usually reveal that incidents could have been
ROP prioritises equipment with safety engineered into the design
prevented with the right knowledge and behaviours, combined with practical and cost-effective safety improvements. The ROP on durable, well-designed conveyor accessories and professional training makes good financial sense and can lead to a safety culture that ripples throughout the company’s balance sheet.
Good design is safe design
ulk material that gets stopped due to obstruction can cause some serious and costly problems: unscheduled downtime, potential injuries, lost production, and diminished profits.
Martin®Air Cannons are the best way to clear accummulation or buildup, simplify maintenance and ensure continuous flow. Our cannons feature innovative valve designs that deliver more power with less air volume — highly effective with challenging wet and sticky materials.
Don’t get jammed. Martin delivers material flow solutions so you can maintain throughput, improve safety and reduce operating costs.
The
MICROBIAL MINING
An innovative startup aims to open sustainable rare earths delivery to the west, while contributing to the circular economy. Nicola Brittain reports
facilities and supply chain
Rare earth manufacturers have tended to be based in China, but with defence technologies, alloys, optical equipment, heavy magnets for EVs and many more applications dependent on these elements, the west has become increasingly aware that it needs to develop its own production facilities and supply chain - particularly in light of the recent China US trade wars.
REEgen, a sustainable rare earth startup based in Ithaca, New York, is well placed to help bring the US up to speed. The company, cofounded by CEO Alexa Schmitz and CTO Sean Medin, uses synthetic biology to solve environmental issues caused by rare earth mining. It
west has become increasingly aware that it needs to develop its own production
was founded in February 2022 and spun out of Cornell University.
THE COMPANY’S BACKGROUND
As a post-doc in the lab of Dr Buz Barstow, Schmitz focused on identifying the genetic elements of a bacteria called Gluconobacter oxydans which enables the leaching of rareearths. During her research, she found that she could engineer the microbe to increase the rare-earth bioleaching process threefold by targeting a series of genes to construct powerful recombinant strains.
Medin, also originally a researcher at Cornell University as a PhD student in the Barstow Lab, looked
Alexa Schmitz, CEO
at how bacteria naturally interacts and binds with rare-earth metals. His work looked at ways of engineering and selecting microbes that would bind to certain metals with higher affinities than others. This binding characteristic can effectively be used as a mineral separation mechanism to enhance the selection of certain metals out of the surrounding solution. The boost in fermentation combined with the binding and leaching process seemed to make the duo’s combined work a commercial opportunity, particularly given the trade situation with rare earths.
THE SUSTAINABLE ELEMENT
Although there are many mining companies popping up in the US and even Europe that are scouting for rare earth minerals, most aren’t yet ready to start producing - this is where REEgen can help. Although the company can work with these mines to help provide clean tech for their flow sheets; a core element of their work, and one that is clearly close to Schmitz’s heart, is the ability to retrieve rare earths from waste material produced by other companies. Coal ash, spent petroleum catalysts, and mine tailings are just some of the waste products containing rare earth metals. In addition to these industrial outlets that produce these products, REEgen is in talks with electronics and metal recycling companies to figure out where the rare earths might be recovered from existing material streams. One, a metal recycling smelter, forms an oxidised byproduct (slag) in its furnace that is high in rare earths. The company has to skim off and dispose of this slag. “Our removing and using this material as our feedstock, is a win-win for everyone,” Schmitz says. “We like to think of ourselves as urban miners – we access minerals that are already out of the ground.”
NON-TOXIC, LOW COST
The non-toxic nature of the product is another selling point. The bacteria is the sort used in kombucha and is so non-toxic that a person could “stick their hand in the tank,” Schmitz explains. This compares with traditional leaching chemicals, such as sulphuric or hydrochloric acid which are considered hazardous and can create impossible challenges in some work places. REEgen can therefore work with companies that would not be open to conventional leaching processes.
WORK WITH OTHER COMPANIES
Unsurprisingly, given its sustainable credentials, REEgen is also focused on promoting a circular economy and industrial symbiosis – where the normally discarded byproducts of one industry feed into another. The company can also use the same processes to recover other critical metals such as lithium or nickel from waste, thereby offsetting the need for more extraction. In addition, the solids remaining after REEgen extracts the metals from slag can be used in concrete by builders. Normally the slags can’t be used for this purpose because of their heavy metal content, but with the metals removed, REEgen’s solid byproduct will be much safer for construction.
THE COMMERCIAL ELEMENT
REEgen has a very clear road map to commercialisation. It already received Phase 1 Small Business Innovation and Research (SBIR) funding of $275k from the National Science Foundation in August 2023 and is waiting on final word for their phase 2 grant of $1.25m. The company will use the funds to design and construct a compact, low intensity unit which can be co-located with slag production at a smelter. It can tap directly in the
Sean Medin, CTO
Within the next 12 to 18 months
we expect to start selling hundreds of tonnes of these products per year
non-toxic bacteria is the sort used in
partner company’s plant and process their slag. REEgen aims to have this designed within the next three months, and a pilot unit constructed by the end of this year.
REEgen expects to install its first full-scale commercial unit by the end of 2026 and do a test run in early 2027. This unit will cost less than $1m to build and yield up to $5m in critical metals products per year at full capacity.
In addition, the company has several customers interested in buying rare earths and is already sending them samples. “Within the next 12 to 18 months we expect to start selling hundreds of tons of these products per year,” Schmitz says.
For more information, visit: www.reegen.tech
WHAT ARE RARE EARTHS?
There are 17 rare earth elements in total, including the fifteen lanthanides along with scandium and yttrium.
The metals are typically found together in the earth’s crust, locked up in complex mineral structures, making them difficult to leach and purify.
These elements all have a property (optical, magnetic or something else) that makes them important for modern electronics.
Magnetic EV motors and wind turbines are driving the market for rare earths, in particular, neodymium (Nd), praseodymium (Pr), dysprosium (Dy) and terbium (Tb)
The combination of certain rare earth elements enhances their useful properties. For example when Dy and Tb are added to Nd and Pr the latter two elements can sustain higher temperatures without demagnetising. This is important for permanent magnets, as used in EVs and wind turbines.
REEgen’s
kombucha
CRUCIAL CURVES
Overland conveyors help to reduce costs and environmental impact, reports Kilian Neubert of Beumer
Group
Curved overland conveyors present a sustainable and affordable alternative to traditional truck fleets
Mine operators face constant pressure to reduce costs and environmental impacts. One key area for improvement is the transportation of bulk materials. Overland conveyors present a viable alternative to traditional truck fleets, offering lower operating costs, lower emissions and the potential for smarter mining.
Curved overland conveyors can cope with rough, fragmented or mountainous terrain, enabling transportation routes that would be impossible using trucks. They eliminate the need for intermediate transfer points, reduce fossil fuel consumption, noise and dust, and improve site safety by eliminating multiple vehicle movements.
MINE CONVEYOR TECHNOLOGY
There are three main conveying solutions for mining materials transfer:
Curved trough belt conveyor: The most common overland conveying solution, it can achieve throughputs of up to 14,000tph with a single conveyor length of up to 15km or even more, depending on throughput, terrain and other factors. Curved trough conveyors can handle large lump sizes and have the capacity to generate power on downhill sections. This technology can manage incline and decline angles up to 20 degrees, but horizontal curves require long radii.
Pipe conveyor: Also known as a tube conveyor, this solution can achieve
Choosing the best conveyor technology is dependent on several factors
throughputs up to 6,000tph with a single conveyor length up to 7km. Pipe conveyors can handle steep incline and decline rates of up to 30 degrees and can accommodate tight horizontal curves. The carry and return pipe conveyors are enclosed, which protects the environment from spillage and protects the materials. Pipe conveyors are best suited for bulk materials with small to medium particle size.
U-belt conveyor: This system is a combination of the trough and pipe conveyor. The belt is shaped in a U on the carry side and can have a similar trough or a pipe belt on the return side. U-belt conveyors have a maximum throughput of approximately 10,000tph and can handle tight horizontal curves at incline and decline rates up to 25 degrees. They are suitable for various material sizes, including large particles.
SMARTER MINES
Mining conveyor systems can be equipped with sensors to gather data for condition monitoring and predictive maintenance, enabling mine operators to optimise efficiency and uptime. For example, the system can monitor the state of idlers, belts, drives and bearings,
as well as record material flow rates, belt tensions and belt drift. Expert data analysis can determine why an alarm was triggered and look for patterns in frequency or causation of failures to continuously optimise operations.
CONCLUSION
Overland conveyors can significantly reduce a mine’s operating costs and improve environmental performance. Choosing the best conveyor technology is dependent on several factors, including the required mass of material to transfer in tonnes per hour, the characteristics of the terrain and the nature of the material, plus any environmental protection requirements. Capturing data from conveyor performance adds an important new dimension, offering the ability for continuous improvement. Mine operators should work with an experienced materials handling partner to identify the best solution for their application.
For more information, visit: www.beumergroup.com
INTELLIGENT INNOVATION
How mining equipment manufacturers can balance reliability and innovation
Anticipating the needs of the mining industry can be challenging when regulations, demands and expectations are constantly shifting. Ensuring that innovations prove their usefulness at an ore deposit is key.
There are ways to ensure that mining equipment hits the ground running, that can be incorporated during the early stages of innovation.
One equipment manufacturer, Bobcat, has developed an innovation strategy designed to stay ahead of the curve while remaining in touch with industry needs.
PAY ATTENTION TO THE DATA
Statistics are more accessible than ever, with a range of technology such as drones, virtual reality, GPS equipment and real-life images painting a robust picture of specific mine site needs as well as industry trends.
“We now have access to enormous amounts of data that are important for the execution of the work, but the construction site itself also generates enormous amounts of data. In our view, information about the work area and object detection are extremely important,” says Bobcat’s vice president of global innovation Joel Honeyman.
Object detection, for example, can help to map out routes for autonomous vehicles and uncover non-visible objects such as underground pipes.
Companies are sitting on a wealth of data
“We use GPS equipment, among other things, because it is very accurate and can map all static objects in a terrain perfectly. This can be done using real-life images, but also with virtual reality, which you can project onto a display in the cabin or wearables such as VR glasses,” says Honeyman. “This data not only makes manoeuvring with (autonomous) machines easier but also enhances safety.
EMBRACE PARTNERSHIPS
Bobcat works closely with other companies to apply new technologies, opening up its capabilities in a shorter period than if it worked alone.
Bobcat maintains several partnerships with relevant companies, including high-resolution radar technology company Ainstein, automated commercial lawnmower manufacturer Greenzie, agtech software company Agtonomy and 3D scanning and VR specialist Trimble.
“We come up with solutions, develop them and ultimately apply them to our machines,” says Honeyman. “We introduce our customers to innovations as quickly and as extensively as possible in order to optimise them based on their experiences.”
KEEP IT SIMPLE
Innovation can, and to an extent, should be based in practicality. Companies are looking to simplify their equipment while working efficiently and meeting sustainability goals.
“You don’t necessarily need earthshattering innovations or superadvanced technology for this,” says Honeyman. “The greatest added value is often in the basic things that make machines easier to use and deliver better performance.”
Even small adjustments such as buttons for automatically performing standard actions like lifting the bucket can result in time savings.
Overall, companies are sitting on a wealth of data from their own culture, customers and competitors. While fresh ideas are a necessary component to a company’s innovation strategy, an approach based in practicality roots ideas to industry needs and provides a base from which innovation can bloom.
For more information, visit: www.bobcat.com
LANTERN RING 2.0
INTRODUCING THE SLR® System
• Up to 5x More Crush Resistant
• Clog Resistant and Reusable
• Allows for Improved Flow and Pressure Equalization
VS
PATENTED PRODUCT
ROTATING SHAFT SEALING EXPERTS
The Hägglunds Quantum power 560 has a maximum power output of 2,535kW
HIGH-SPEED HYDRAULICS
How a robust hydraulic motor enables efficiency at higher belt conveyor speeds
Hydraulic direct drive systems are a familiar sight on belt conveyors, thanks in part to characteristics that prolong drive system and conveyor lifetime. Yet despite their advantages for reliability and durability, they have been most attractive in the lower speed range. Thanks to a hydraulic motor with significantly greater efficiency at higher speeds, their application range is now widening.
ADVANTAGES OF HYDRAULIC SYSTEMS
Compact and lightweight, hydraulic direct drive systems are well suited to machines like belt conveyors. The hydraulic motor mounts directly on the pulley shaft, while the rest of the system can be placed where it fits best, without foundations or alignment issues.
Hägglunds, a specialist in hydraulic direct drive systems, has supplied the mining industry with many conveyor belt drives. Most have employed the Hägglunds CB hydraulic motor, which was recently renamed Hägglunds Quantum. Today, that motor is joined by the Hägglunds Quantum Power, which shares its DNA but also creates new, efficient opportunities.
OPERATIONAL ADVANTAGES OF HYDRAULIC SYSTEMS
Soft starts that help reduce belt stretching and extend belt life
Perfect process feed rate control through fully variable speed
Unlimited starts and stops with no risk of overheating
100% load sharing that reduces shaft and pulley stresses
Possibility to drive both head and tail
The Hägglunds Quantum Power 560 tips the scale at 1,520kg
EFFICIENCY CHALLENGES AT HIGHER SPEEDS
Until now, hydraulic direct drive systems have been most competitive for specific types of belt conveyors. They have excelled on slow-moving conveyors, typically operating below 50rpm, or on faster conveyors that start and stop frequently – where electromechanical drive systems are usually overdimensioned to avoid overheating.
Higher speeds require more hydraulic fluid to pass through the motor, which has meant increased pressure and efficiency losses. Thus, on fast-moving conveyors where operations are smooth, electromechanical systems have often had the upper hand.
NEW MOTOR DESIGN MINIMISES LOSSES
With the new Hägglunds Quantum Power motor, Hägglunds has changed the equation – not only for belt conveyors but also for other mining equipment, such as mills, crushers, kilns and continuous miners. Built upon the Hägglunds Quantum concept, the Hägglunds Quantum
Power has the same interfaces and small frame sizes as its sister motor, but it features an innovative internal design and a range of other enhancements.
A new connection block, which has eight main ports of 2in in diameter, combines with an optimised distributor and refined internal channels to provide more flow to the radial pistons – with minimal losses, which reduces operating pressure.
The result is a hydraulic motor whose efficiency at higher speeds aligns with that of an electromechanical solution, which brings the other advantages of a hydraulic direct drive back into play.
EFFICIENCY IMPROVEMENT
To exemplify the difference, one can compare motors of equivalent size in a high-power belt conveyor application, requiring 75kNm of torque while running at 65rpm. Both the Hägglunds Quantum 400 and the Hägglunds Quantum Power 400 could supply the necessary torque, but their energy consumption at this higher speed would differ significantly.
Over one year of continuous operation, calculated as 8,000 hours (accounting for planned maintenance), the Hägglunds Quantum Power would save around 312MWh compared to the Hägglunds Quantum. This equates to 138t of CO2 – or the energy used
Over one year of continuous operation, calculated as 8,000 hours (accounting for planned maintenance), the Hägglunds Quantum Power would save around 312MWh compared to the Hägglunds Quantum
by 127 electric cars with an annual mileage of 12,000km. Looking at it another way, the input energy saved would be roughly 7% of the shaft output in same time frame.
EXTENDING LIFETIME AND ENERGY SAVINGS
There are several aspects of the Hägglunds Quantum Power that enhance its lifespan. These include reinforcements, such as a diamondbased piston coating and an improved cam roller design, but also monitoring and service aspects, including a builtin temperature sensor and separate seal retainers that allow easy seal changes from the outside. All these features are standard, as is the motor’s ability to work with Environmentally Friendly Lubricants (EALs).
While the Hägglunds Quantum
motor remains the appropriate choice for many belt conveyors, the Hägglunds Quantum Power makes a long-lasting hydraulic direct drive system feasible for many more. At higher speeds, its minimised losses and the resulting reduction in operating pressure mean an even longer motor lifetime.
Between higher efficiency, extended motor lifetime and the overall ability of a hydraulic direct drive system to safeguard the belt conveyor it drives, the Hägglunds Quantum Power gives sustainability-conscious mining customers reason to consider a hydraulic solution – even at higher speeds.
For more information, visit: www.boschrexroth.com
With a speed range up to 170rpm, Hägglunds’ improved hydraulic drives increase material flow and saves energy
STANDARDS SEPARATION
A non-toxic, non-volatile Nasaco reagent is conquering pyrite depression
Pyrite (FeS2), is the most abundant sulphide mineral and is commonly found alongside valuable minerals like chalcopyrite, sphalerite, galena and gold. Pyrite is classified as a gangue mineral. Its economic insignificance means one thing in mineral processing: it needs to be removed.
However, separating pyrite from economically valuable minerals in flotation circuits is not straightforward, as understanding pyrite flotation is complex. Pyrite can be classified into three forms. Each behaves differently and needs its own strategy to depress it.
NORMAL PYRITE
In traditional sulphide flotation, xanthates (ROCSS) are the most commonly used collectors. Interestingly, “normal” pyrite doesn’t float with xanthate. Instead, it floats when dixanthogen is formed – an oxygen-dependent process.
On the plant, two competing reactions for oxygen take place:
Reaction 1: Oxygen oxidises xanthate to form dixanthogen on the pyrite surface. It requires relatively high xanthate concentration and dissolved oxygen (high eH) to form dixanthogen. Note: dixanthogen is unstable at a pH > 11.
Reaction 2: Oxygen also oxidises the iron in pyrite; the result of this is pH-dependent:
At high pH, iron precipitates as ferric hydroxide, coating the surface with a hydrophilic layer and thus the pyrite won’t float.
At low pH, oxidation leaves behind a sulphur-rich, hydrophobic surface, which means that pyrite will float.
Whether oxygen helps or hinders pyrite flotation is a race between these two reactions and how fast the specific pyrite species oxidises. The takeaway is that it’s important to operate at high pHs to depress “normal pyrite”.
LOCKED PYRITE
If the pyrite is locked in Cu-sulphides, Ni-sulphides or similar value minerals, it will float with the host mineral.
If pyrite recovery is still an issue after optimising pH, grinding media and reagents, it’s important to check for pyrite locking using a scanning electron microscope. Nasaco offers these services to determine the degree of locking and to propose possible solutions.
Pyrite depression changes the surface properties of minerals
PREVENTING AND REVERSING COPPER ACTIVATION
To stop pyrite from becoming copper-activated, the strategy starts at the source:
Change grinding media type: Less oxidation and minimises low-potential environments where copper activation thrives.
Add lime to the mill: The exact mechanism for why this is effective is not fully defined. Nevertheless, adding lime to the mill has been found to be an effective method in practice.
Prevention alone is rarely enough as copper ions are also often present in process water. Cyanide has traditionally been used to deactivate copperactivated sites. It forms stable complexes with the copper, thereby restoring it to “normal pyrite”.
The toxicity of cyanide is a significant drawback in processing.
A SAFE AND EFFECTIVE SOLUTION
Nasmin 1032 is a non-toxic, non-volatile reagent that does not gas off at low pHs. Nasmin 1032 strips copper from pyrite surfaces, like cyanide, and restores it to “normal pyrite”. It also reduces pulp electropotential, limiting oxygen’s role in dixanthogen formation.
COPPER-ACTIVATED PYRITE
Copper ions (Cu2+) adsorb onto reactive sulphur sites on pyrite, especially in low-oxygen (lowelectropotential) conditions, like in the grinding mill. Once activated by copper, pyrite begins behaving like a Cu sulphide mineral. It will thus float with xanthate (low xanthate concentrations, low dissolved oxygen) and doesn’t need dixanthogen to form.
This copper activation can arise from:
Galvanic interactions between pyrite and chalcopyrite in the mill.
If there are copper ions in the process water. Contact with grinding media.
A lot of copper activation takes place in the mill, as the grinding media oxidises during the milling process, thereby consuming oxygen and creating a low electropotential environment where copper activation readily occurs. It’s important to limit copper activation. Otherwise, the pyrite will start acting like chalcopyrite and will float even at high pH.
MODERN MONITORS
A flush water sensor from SealRyt is reducing maintenance and eliminating fouling
In abrasive and high-solid mining environments, one persistent challenge for plant maintenance teams is ensuring consistent, uninterrupted flush water flow to packing and seal systems. Insufficient flush flow can accelerate wear, lead to premature packing failure, and ultimately contribute to costly, unplanned downtime for critical pump assets.
THE NEED FOR RELIABILTY
Traditionally, flush circuits rely on manually adjusted valves and basic mechanical gauges. However, turbulence, scaling, or particulate contamination in process water can often foul traditional inline flow meters, leading to inaccurate readings or undetected flow restriction. As plants move toward predictive maintenance strategies, there is a growing need for more reliable and data-rich monitoring solutions to protect seals and minimise unplanned interventions.
A SOLUTION IN ACTION
A recent installation at a mid-sized mineral processing facility in North America highlights how an integrated, clog-resistant flow monitoring assembly can improve day-to-day maintenance outcomes. The plant’s maintenance team needed a solution for monitoring flush water supplied to gland packing on a bank of slurry pumps handling high-solids tailings. Sediment buildup and scaling had repeatedly caused legacy flow meters to clog, making it difficult to verify whether target flow rates were being maintained.
The new solution combines a clampon, digital ultrasonic flow sensor with a compact manifold that includes an adjustable ball valve, check valve, and pressure gauge. Unlike inline meters that contact the process fluid directly, a clamp-on sensor measures flow externally, which virtually eliminates fouling and reduces maintenance needs. Hybrid detection ensures the
sensor can capture accurate flow data even in turbulent or partially aerated water – a common condition in mining applications.
Another practical benefit is visibility. With flush lines often routed behind guarding or installed at floor level, operators sometimes overlook regular checks of flow and pressure gauges. The new system includes a bright digital readout visible from a safe distance or from overhead catwalks. Programmable high and low flow alarms, along with onboard data logging of up to one year, provide additional safeguards for identifying trends and taking corrective action before packing damage occurs.
From a controls perspective, integration with plant SCADA is increasingly essential. In this case, the unit’s IO-Link and Modbus/TCP capabilities allowed the maintenance team to tie real-time flush flow data into their existing condition monitoring dashboard. Over several months, the recorded data helped establish more consistent flush settings across multiple pumps and reduced the frequency of unplanned packing replacements.
A PRACTICAL STEP FORWARD
While flush water circuits may be a relatively small part of overall pump operation, their performance can have an outsized impact on seal life and total cost of ownership. Modernising these circuits with accurate, clog-resistant monitoring is a straightforward step plants can take to support reliability goals, reduce manual inspection time, and build better operational awareness in remote or high-risk areas.
For operations facing abrasive or variable process conditions, clampon flow measurement combined with digital visibility represents a practical step toward more reliable sealing performance and less unscheduled downtime.
A clamp-on sensor measures flow externally
HANDS-ON
How Rokbak’s practical training prepares workers for real-world results
By nature, mining is an everychanging industry that attracts proactive learners. The industry’s practical skills are often most easily gained through real-life scenarios. Scottish hauler manufacturer Rokbak follows this approach, with its training happening on the workshop floor with tools in hand.
Rokbak’s aftermarket training manager Tommy Moore has moulded the programme according to his own training journey, which began on the assembly line physically building haulers.
“You can talk all day pointing to a picture, but it’s not the same as walking a group of technicians over to a machine, showing them the component and demonstrating how it works right there in front of them,” Moore says. “When we discuss a part of the truck, we work on that part. We have a full workshop here at our headquarters in Motherwell, Scotland, where we can strip a machine down and rebuild it. That’s how people truly learn.”
Moore moved into mechanical engineering, rewriting the standard operating procedures for building trucks. This gave him a granular understanding of every nut, bolt and system and cemented his appreciation for experiential learning.
Hands-on
TAILORED TRAINING
Rokbak training programmes are tailored to each participant. The four-day courses, complete with a test track, are held at the Motherwell facility. Moore and his colleagues often contact participants in advance to understand any specific issues they are facing, allowing them to set up practical demonstrations to solve realworld problems.
“Being able to physically strip down an axle or transmission and have technicians get their hands on it is something we are very fortunate to be able to do,” says Moore. “We want them to leave here 100% comfortable with the truck.”
SEEING THE SAVINGS
In addition to familiarising learners with the workshop floor, a practical training programme also relieves pressure from consumable parts, thereby saving money.
“If an operator isn’t using the retarder correctly, they can burn through a set of brakes three times quicker than they should. By teaching them certain driving techniques, we save the customer money and keep their truck
running,” says Moore. “A big part of our training is showing field engineers and operators how to use the truck’s technology properly, like the retarder and gear-changing techniques.”
SPEAKING THE SAME LANGUAGE
An aspect of practical training Moore finds particularly useful is that it gets industry players, regardless of background, language or culture, on the same page.
“You can’t keep a group of 15 technicians interested with a presentation in a meeting room, especially when there might be some language barriers,” he says.
“But get them out on the iron, doing tests, checking pressures and diagnosing issues together – that’s a language everyone understands.”
While the mining industry faces its share of challenges, hands-on training is rewarding when the time and resources are applied.
IMARC: AUSTRLIA’S LARGEST MINING EVENT A
ustralia’s largest mining event, International Mining and Resources Conference (IMARC) will be held between 21st to 23rd October at Sydney’s International Convention Centre (ICC).
Touted as Australia’s “most influential mining event”, IMARC will have a particular focus this year on collaboration in the face of a volatile and uncertain global economic landscape. Six concurrent conferences will cover the entire mining value chain, featuring panel discussions and strategic keynote presentations.
The show’s 10,500+ attendees can expect to wander among over 500 exhibitors, and 550+ speakers. Over 120 countries will be represented at the event, with 50 nations represented at a government or ministerial level.
The international nature of IMARC will allow attendees to expand their networks, learn from influential figures, explore investment opportunities and collaborate with leaders across the globe.
IMARC takes place on Gomora, land of the Gadigal people of the Eora Nation. Indigenous Women in Mining and Resources Australia (IWIMRA) and Aboriginal Enterprises in Mining, Energy and Exploration (AEMEE) are the events’ First Nations partner for the 2025 event.
The conference will feature First Nations speakers from around the world, explaining environmental and cultural heritage challenges, and exploring how mining can boost the employment, skills and economic participation of the First Nations communities in which they operate.
IMARC has support from founding partners of the Victorian Government, Austmine, and AusIMM, and are supported by its host partner, the NSW Government, along with Austrade. For
AIMEX: A SOUTH AUSTRALIAN PERSPECTIVE
For the first time in the 50+ year-old-show’s history, AsiaPacific’s International Mining Exhibition (AIMEX) will relocate to Adelaide. This year’s show will take place 23rd - 25th September at the Adelaide Showground.
The show’s move to Adelaide highlights South Australia’s growing prominence and influence in mineral exploration, particularly copper.
South Australia’s minister for energy and mining Hon Tom Koutsantonis will officially open AIMEX 2025.
Across three days, panels and deep dives on industries trends will analyse topics such as decarbonisation, autonomous innovation, future workforce needs, safety, uranium, green iron and copper. Attendees can also expect a major focus on the future of green steelmaking, Australia’s role in fuelling global nuclear demand and South Australia’s emerging projects.
Among the companies in attendance will be BHP, Hitachi, Magnetite Mines and Boss Energy
An expanded floorplan will feature multiple conference stages and new verticals: Transformative Technology and the Research and Development Hub. Presentations and exhibitions will expose attendees to opportunities to connect with Asia-Pacific’s community of mining suppliers and professionals.
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
W www.cirrusresearch.com
HILLIARD
A leading manufacturer of modular and caliper brakes designed for demanding applications in the mining industry. Our braking systems are engineered for reliability and performance in critical equipment.
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.
T +1 800 543 5431
E sales@jhfletcher.com
W www.jhfletcher.com
DIEMME FILTRATION
Diemme Filtration has the widest range of filter presses available on the global market in terms of size, design and technical characteristics. The equipment is tailor made and designed according to the needs of the specific application.
T +39 0545 20611
E info@diemmefiltration.com
W www.diemmefiltration.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
W www.richwood.com
Control dust and spillage.
For over 40 years, the largest mining companies in the world have put their confidence in Richwood’s innovative material handling solutions.
When it comes to solving problems with dust and material containment, Richwood achieves success with engineered passive dust containment systems. Application-specific solutions optimize efficiency through sealed and protected load zones without the need for vacuums, filters or other additional equipment. The reduced wear and tear on equipment and controlled dust and spillage create a safer and more productive work environment. Worry-free load zones are designed and built by Richwood every day.
What would it mean for your productivity if dust and spillage issues were eliminated? Contact Richwood today for a review of your application.
Rely on Richwood!
Bend the laws of size, strength and speed.
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. Take your operations to a new dimension of productivity with Hägglunds. We drive what drives you.
Hägglunds is a brand of Rexroth. www.hagglunds.com
