Global Mining Review - January 2024

JANUARY/FEBRUARY 2024 VOLUME 7 ISSUE 1

“MAXIMIZE SAFETY AND PRODUCTIVITY BY PROVIDING REAL-TIME AIR QUALITY DATA AND EMERGENCY MESSAGES ON A LARGE DISPLAY THAT INTEGRATES WITH ANY NETWORK.”

Safety in Numbers.

Eliminate guesswork and know with confidence when it’s safe to move about the mine.

SuperBrite™ Marquee Display SuperBrite™ Marquee Display provides fail-safe, real-time data by ensuring only current information is displayed – preventing unsafe old data from display when network is off-line. Easily integrated into wireless or Ethernet network and written to directly from any Vigilante AQS™ or Zephyr AQS™ stations, SCADA, DCS, PLC or HMI control system.

maestrodigitalmine.com

CONTENTS 03

Editor’s Comment

05

Guest Comment

07

Industry News

10

Product News

12

Navigating Global Challenges And Opportunities

19

24

Ian Sanders, Global Mining & Metals Sector Leader, Deloitte Global, presents 10 trends that could define 2024 for the mining and metals industry.

Unlocking Efficiency And Sustainability

49

De-Risking Tailings Management

53

The Next Generation Of Engineers Of Record

56

Embracing Generative AI In Mining

60

From Pitstops To Payloads

Digging Into Converged Wireless Networks

Paul May, Innovative Wireless Technologies, USA, evaluates the advantages of wireless mesh technology for the digital transformation of subterranean operations.

The Future Of Energy-Efficient Haulage

Nik Gresshoff and Matt Youngblood, Railveyor, Canada, review how operators can cut costs and emissions by implementing an electric haulage system.

30

Belt Cleaner Monitoring: The Smart Way

36

Too Soon On The Scrapheap?

41

44

Travis Vliem, Flexco, USA, outlines how implementing an IoT system into a mining facility’s belt cleaning process can boost performance and profitability.

Leslie David, Conveyor Belt Specialist, describes the causes and effects of conveyor belt wear and tear, as well as the reasons why there are such huge disparities in operational lifetime and durability between one manufacturer and another.

Seeing The Bigger Picture

Miguel Valenzuela, Dyno Nobel Americas, examines how adopting a broader perspective can optimise mill throughput and boost profits.

Piia Suvio and Tomi Ravattinen, Metso, Finland, address the comprehensive tailings and water-driven solutions that can guide the mining industry towards a more sustainable future.

Simon Acutt, Weir Minerals, Australia, explores how strategies such as pipe loop testing and coarse particle flotation can help promote sustainability in tailings management.

Sam Abbaszadeh and Amanda Adams, Stantec, USA, assess the opportunities to attract the next generation of tailings engineers in a Q&A with Will Owen, Editor of Global Mining Review.

Bibhrajit Halder, SafeAI, USA, details how generative AI can enhance a wide range of functions in the mining industry.

Will Owen, Editor of Global Mining Review, conducts a Q&A with Gonzalo Otegui and David Rogers, McLaren Applied, to learn about the benefits provided by technologies brought over from motorsport to the mining industry.

64

DLE: A Game Changer For Battery Metal Demand

68

The Power Of Satellite Communications

73

A New, More Strategic, Way To Mine

77

Preventive Maintenance For Peak Productivity

Alberta’s Volt Lithium profiles its direct lithium extraction technology and outlines its course to commercial production across North America.

Joel Schroeder, Intelsat, explains the benefits of implementing satellite communications in digital mining operations.

Glenn Barlow and Ross Milne, Dassault Systèmes, France, consider how companies can adopt strategic mine planning and parametric design to improve flexibility and revenue.

Thiago Henrique Buoso, Haver & Boecker Niagara, Brazil, discusses how choosing the right condition monitoring system can minimise downtime and maximise ROI.

ON THE COVER Built to meet the rigorous demands of mining, IWT communication networks keep users connected with voice, text, tracking, data, and more.

follow

@Mining_review

like

MiningReview

join

Global Mining Review

Copyright © Palladian Publications Ltd 2024. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. All views expressed in this journal are those of the respective contributors and are not necessarily the opinions of the publisher, neither does the publisher endorse any of the claims made in the advertisements. Printed in the UK. CBP019982

INDUSTRY LEADING UNDERGROUND BLASTING SYSTEM Designed with an easyto-use application and limited user interaction, BlastWeb II provides the best solution for any remote underground blasting application.

Visit us at Booth #1125 to learn more.

Editor’s Comment WILL OWEN EDITOR, GLOBAL MINING REVIEW

A MANAGING EDITOR James Little james.little@globalminingreview.com SENIOR EDITOR Callum O’Reilly callum.oreilly@globalminingreview.com EDITOR Will Owen will.owen@globalminingreview.com EDITORIAL ASSISTANT Jane Bentham jane.bentham@globalminingreview.com SALES DIRECTOR Rod Hardy rod.hardy@globalminingreview.com SALES MANAGER Ryan Freeman ryan.freeman@globalminingreview.com PRODUCTION MANAGER Kyla Waller kyla.waller@globalminingreview.com ADMINISTRATION MANAGER Laura White laura.white@globalminingreview.com DIGITAL ADMINISTRATOR Nicole Harman-Smith nicole.harman-smith@globalminingreview.com DIGITAL CONTENT ASSISTANT Kristian Ilasko kristian.ilasko@globalminingreview.com DIGITAL EVENTS COORDINATOR Merili Jurivete merili.jurivete@globalminingreview.com EVENTS MANAGER Louise Cameron louise.cameron@globalminingreview.com Global Mining Review (ISSN No: 2515-2777, USPS No: PENDING) is published 10 times per year

by Palladian Publications Ltd., and distributed in the USA by Asendia USA, 701 Ashland Ave, Folcroft, PA. Application to Mail at Periodicals Postage Prices is pending at Philadelphia, PA, and additional mailing offices. POSTMASTER: send address changes to Global Mining Review, 701 Ashland Ave, Folcroft, PA. 19032.

Annual subscription (10 issues) £50 UK including postage, £60 overseas (airmail). Claims for non-receipt must be made within four months of publication of the issue or they will not honoured without charge.

new year is upon us, and it already promises to be a very significant one. Not only is 2024 an Olympic year – Paris is set to host the 33rd edition of the Summer Games and 17th Summer Paralympic Games, the biggest event ever organised in France1 – but The Economist has declared it “the biggest election year in history”.2 With over half the Earth’s population expected to go to the polls for local, regional, or general elections, there is little doubt that we will see ground-breaking developments taking place on several levels on the global political stage as the year plays out.

With regards to our own industry, ground-breaking by its very nature, 2024 will unquestionably be another significant year. The global mining and metals industry faced upheavals in 2023, due to economic and geopolitical uncertainties which disrupted commodity markets and continue to do so today. Success in 2024 will be contingent on purpose-driven strategies, adaptive planning, sustainable practices, and technological innovation.

To explore these themes further, make sure to check out Ian Sanders’, Global Mining & Metals Sector Leader, Deloitte Global, article on page 12 of this issue. Titled ‘Navigating global challenges and opportunities in mining and metals’, the article presents a summary of 10 trends that could define 2024 for the mining and metals industry. A link to Deloitte’s full 2024 mining outlook report is included in Ian’s article.

The theme of ‘technological innovation’, or a lack thereof, has defined the mining industry for a long while now. It has been frequently characterised as ‘slow to embrace change’, especially in terms of technology, but we are increasingly seeing this narrative begin to shift as more and more steps forward are taken by key players, carving out a path for others to follow.

This latest issue of Global Mining Review contains several examples of this in action.

To name a few: Innovative Wireless Technologies evaluates the advantages of wireless mesh technology (p. 19); Flexco outlines how implementing an IoT system can boost performance and profitability (p. 30); SafeAI details how generative AI can enhance a wide range of functions (p. 56); and Intelsat explains the benefits of implementing satellite communications (p. 68).

Bearing these in mind, it is not always necessary to reinvent the wheel to make progress. The value of optimising existing assets and practices should not be overlooked.

Dyno Nobel speaks to this in its article, ‘Seeing The Bigger Picture’, (p. 41), which is another must read.

Furthermore, 2024 is set to be another big year for sustainability in the mining industry.

Don’t miss Weir Minerals and Metso’s latest articles (p. 49 and 53) discussing how tailings management solutions continue to be key to making mining green.

It suffices to say that there is a lot going on in the mining industry right now, and it is an exciting place to be. I am looking forward to attending SME MINEXCHANGE at the end of February to hear about more of the latest news first-hand. Make sure to visit myself and the rest of the Global Mining Review team at booth 919. Copies of this issue will also be available at PDAC 2024 in Toronto (3 – 6 March).

References

1.

2.

‘The Olympic Games of Paris 2024’, Paris 2024, www.paris2024.org/en/the-olympic-games-paris-2024/ ‘2024 is the biggest election year in history’, The Economist, (13 November 2023), www.economist.com/ interactive/the-world-ahead/2023/11/13/2024-is-the-biggest-election-year-in-history

Palladian Publications Ltd, 15 South Street, Farnham, Surrey, GU9 7QU, UK t: +44 (0)1252 718999 // w: www.globalminingreview.com

WEAR STEEL EVOLUTION HAS PASSED AR450, USE HARDOX® 500 TUF Make sure your next equipment delivers extraordinary productivity and service life.

Hardox ® 500 Tuf combines the hardness of Hardox ® 500 with the toughness of Hardox ® 450.

This wear resistant steel is also tough enough to perform as a structural steel, allowing for stronger and lighter excavator buckets.

30%

8%

100%

Hardox 500 Tuf wear steel delivers up to 30% longer service life than an ordinary AR450 steel or…

…save 8% or more weight to reduce the strain on the excavator as well as the fuel consumption and CO2 emissions.

Guaranteed flatness, thickness, and bending performance, making fabrication more reliable and minimizing waste in production.

LONGER WEAR LIFE ®

Learn why Hardox® 500 Tuf makes extraordinary earthmoving equipment. www.hardox.com

LIGHTER

GUARANTEED

Guest Comment WILSON MONTEIRO GLOBAL BUSINESS LINE MANAGER FOR GEARLESS MILL DRIVES, ABB

S

hortfalls in copper production are predicted to reach crisis point by 2030, with an annual deficit of 5 million t – ultimately impeding global sustainability goals. This alarming prognosis stems from a surge in demand driven by the exponential growth in electric vehicles and myriad other electrification applications, surpassing current production capacity.

Demand for refined copper to meet global decarbonisation efforts is poised to nearly triple by 2050 compared to 2020 production levels, with a projected surge from the 20 million t produced in 2020 to an estimated 57 million t. This means the world is challenged with sustaining an annual upswing in copper production of between 20 – 30% within the next seven years – that is a capacity on par with the current outputs of major producers Chile and Peru combined.

New mining operations are an increasingly urgent necessity and there are a number of industry projects awaiting decisions – yet many investors are waiting until the price is right, and this poses a major bottleneck risk when it comes to building the infrastructure needed in time.

Copper mining companies must process ore grades that are increasingly low, with 1 t of copper in every 100 t of rock at best. They typically do this with advanced and scalable grinding technology solutions.

The industry workhorse for driving mills has been the gearless mill drive (GMD), which facilitates the extraction of copper from raw materials through grinding processes demanding minimal energy input.

ABB is one of only two producers of GMDs in the world and building these very large units takes time.

This equipment challenge becomes two-fold when taking into account the forecasts of future ore grades being even lower than present, so much so that double the ore will need to be processed for the same amount of copper.

The integration of technology, alongside investments in new mining ventures, will be pivotal in ensuring that the world secures the essential copper and other metals required for the energy transition while maintaining cost-effectiveness and limiting the environmental impact of extraction.

The need to extract and process additional metals, while mitigating the already precarious and

prominent issues associated with global warming this presents, is a formidable challenge for the sector.

Mining currently contributes approximately 7% of total greenhouse gas emissions globally, with diesel combustion in machinery alone responsible for half of this substantial environmental footprint.

Efforts by mining enterprises to reduce carbon encompass multiple initiatives to shift machinery from diesel to electric wherever feasible. Additionally, they are actively engaged in designing machinery fuelled by alternative energy sources like hydrogen and ammonia. This concerted endeavour aims to significantly curtail, if not eliminate, the reliance on fossil fuels in mining equipment, such as trucks, loaders, and excavators.

Another pivotal undertaking involves the digital transformation of equipment, systems, and procedures, with the primary objective of optimising operational efficiency within mining operations.

For instance, in the realm of GMDs, a multitude of predictive analysis systems are already in place to monitor equipment uptime. These sophisticated systems empower companies to proactively address maintenance requirements, thereby guaranteeing peak availability and efficiency for their machinery.

Artificial intelligence (AI) is heralding a new era of innovations in mining equipment, enabling advanced performance and operational analyses.

This transformative technology delivers a broader spectrum of insights, notably in engine operation, enabling proactive measures to preclude issues and, crucially, conducting in-depth assessments of processed ore quality.

The shift towards digitising operations is imperative due to the heightened demand, compelling mining companies to prioritise maintenance procedures and pre-emptive failure mitigation. In this environment, even the slightest efficiency improvement holds significant value.

All in all, the integration of technology, alongside investments in novel mining ventures, will be pivotal in ensuring that the world secures the essential copper required for the energy transition while maintaining cost-effectiveness. The biggest risk we face is investment decisions being too little and too late.

Palladian Publications Ltd, 15 South Street, Farnham, Surrey, GU9 7QU, UK t: +44 (0)1252 718999 // w: www.globalminingreview.com

FRAGTRACK GEOSPATIAL

™

UNMATCHED GEOREFERENCING ACCURACY OF FRAGMENTATION SAMPLES

Gather fragmentation insights

Improve accuracy

Maximise productivity

Improve blast outcomes

FRAGTrackTM GeoSpatial unlocks operational and technical insights by providing georeferenced samples which correlate blast design and orebody information to blasting performance.

FRAGTrack™ GeoSpatial is a fragmentation, georeferencing technology that provides an accurate location for fragmentation samples. The ability to georeference particle size distribution samples provides significant opportunities to derive insights that have not previously been possible, enabling operations to obtain fragmentation information in a region or sub-domains of a blast, thereby enabling continuous improvement of blast outcomes.

To learn more about FRAGTrackTM and how it can support your operations today, please contact your local Orica representative or visit orica.com/FRAGTrack

World NEWS MAURITANIA TAKRAF secures contract for iron ore project

T

AKRAF Group has announced the signing of a major contract with Société Nationale Industrielle et Minière (SNIM) for the supply of a complete iron ore crushing, screening, and material handling system, along with a train loading station for the F’Derick project in Mauritania.

The F’Derick iron ore deposit, known for its natural richness in hematite, is part of SNIM’s iron ore complex in Mauritania. With current production of approximately 12 million tpy, SNIM aims to increase this to 18 million tpy through the development of the F’Derick project, thereby contributing to the country’s iron ore production.

The contract, signed at the end of 2023, marks a key milestone as SNIM begins development work on site. An inauguration ceremony was held in the presence of Mauritanian President of State

Mohamed Ould Ghazouani, underscoring the importance of this collaboration.

Delivery of the equipment to the port of Nouadhibou is expected to be completed in approximately two years.

Commenting on the award, Thomas Jabs, CEO of TAKRAF Group, said: “This project is of paramount importance to the country of Mauritania and is a testament to the excellent cooperation and expertise of SNIM and the TAKRAF Group. Our teams from Europe, South Africa, North America, and Asia will work seamlessly to leverage their skills and knowledge.

We would like to thank SNIM for their trust in our capabilities, the State of Mauritania for their support, and all the planning and design teams involved. This award underlines our global strength in delivering complex bulk handling systems.”

SWEDEN Epiroc launches three new electric drills

E

piroc has announced the launch of its latest electric-driven drills, the Pit Viper 271 XC E, Pit Viper 275 XC E, and the Pit Viper 291 E. Part of its Smart and Green Series, Epiroc’s electric-driven Pit Viper drills deliver the same performance with zero exhaust emissions, zero fuel consumption, and a lower carbon footprint.

The Pit Viper 271 XC E is capable of drilling single-pass holes up to 18 m, with diameters up to 270 mm. The Pit Viper 275 XC E handles single-pass holes up to 11 m, with diameters reaching 270 mm.

Both drills can be configured with the XC package to provide 42.5 t bit load capacity.

The Pit Viper 291 E delivers a powerful performance, capable of drilling single-pass holes up to 18 m, with diameters up to 280 – 311 mm. All three rigs are supported by a substantial 42 t bit load capacity that ensures reliable and effective drilling.

Epiroc’s latest electric-driven blasthole drills are designed for an era of cleaner and more

sustainable operations, offering cutting-edge automation features that optimise productivity and enhance safety and accuracy through live work elimination.

Cynthia Rodriguez, Global Product Manager – Large Blasthole, expressed her enthusiasm, stating, “These electric-driven Pit Viper drills exemplify Epiroc’s unwavering commitment to accelerate change in the mining industry. By combining advanced automation solutions with sustainability, we are offering state-of-the-art drills and paving the way for a safer, more efficient future in mining operations.”

The introduction of these three drills signifies Epiroc’s electrification of its complete Pit Viper lineup, providing electric alternatives for each drill in the series.

These drills deliver a more sustainable operation and are equipped with advanced automation, featuring smart functionalities that enhance operational safety, accuracy, and productivity. global mining review // January/February 2024 7

WORLD NEWS Diary Dates Investing in African Mining Indaba 05 – 08 February 2024 Cape Town, South Africa www.miningindaba.com SME MINEXCHANGE 25 – 28 February 2024 Phoenix, USA www.smeannualconference.com PDAC 03 – 06 March 2024 Toronto, Canada www.pdac.ca/convention CIM Connect – Convention & Expo 12 – 15 May 2024 Vancouver, Canada www.cim.org/events Discoveries Mining Conference 21 – 23 May 2024 Mazatlán, Mexico www.discoveriesconference.com Euro Mine Expo 28 – 30 May 2024 Skellefteå, Sweden www.euromineexpo.com Exponor Chile 03 – 06 June 2024 Antofagasta, Chile www.exponor.cl Elko Mining Expo 06 – 07 June 2024 Elko, USA www.exploreelko.com/top-events/ elko-mining-expo/ MINExpo INTERNATIONAL® 24 – 26 September 2024 Las Vegas, USA www.minexpo.com To stay informed about upcoming industry events, visit Global Mining Review’s events page: www.globalminingreview.com/events

8 January/February 2024 // global mining review

AUSTRALIA Liebherr and Fortescue repower

excavator to electric configuration

L

iebherr Mining and Fortescue have successfully converted an R 9400 excavator from a diesel to an electric powertrain. The repowered machine was commissioned at Fortescue’s Christmas Creek mine site in Western Australia.

This is the first time in Liebherr’s more than 40 years of working with electric excavators that the company has repowered one of its excavators from diesel to electric configuration during the standard service life of the machine. A hydrogen Offboard Power Unit (OPU) designed and developed by Fortescue will be used to power the newly converted R 9400 E and is currently undergoing site-based testing within Fortescue’s purpose-built zero emission testing area at Christmas Creek.

The repowering of the R 9400 E reflects the collective efforts of both Liebherr and Fortescue to develop zero emission solutions for mining. Experts from both Liebherr and Fortescue were involved in the project, which took place at Liebherr-Australia’s Perth branch in Western Australia.

“Liebherr is delighted that Fortescue has chosen to collaborate with Liebherr in our joint efforts to accelerate the pathway to a mining future without fossil fuels. This repower project demonstrates that decarbonisation is also possible with Liebherr machines previously supplied with diesel engines”, explained Oliver Weiss, Executive Vice President of R&D, Engineering, and Manufacturing for Liebherr Mining.

GLOBAL Sandvik and Barrick extend global

framework agreement

S

andvik Mining and Rock Solutions and Barrick Gold Corp. have extended a global framework agreement, enhancing the long-term partnership between the OEM and mining major.

Sandvik and Barrick will aim to improve safety, productivity, and sustainability through implementing the latest technology advancements. The agreement will be guided by operational and relationship KPIs. “Sandvik Mining and Rock Solutions supplies value-adding technologies for our global mining operations,” said Glenn Heard, Mining Executive at Barrick. “This mutually beneficial cooperation will help ensure we continue our growth journeys in the areas of automation, digitalisation, and electrification in order to drive improvements across our sites.”

The extended framework agreement includes Barrick’s rollout of Sandvik’s Remote Monitoring Service (RMS) to its entire global underground fleet of more than 200 connected Sandvik trucks, loaders, and drills. RMS has already reduced maintenance costs, while increasing uptime across Barrick’s Sandvik fleet.

Under the framework agreement, Sandvik and Barrick will also develop a long-term BEV strategy and define BEV transition plans in line with Barrick’s objective to be carbon neutral by 2050.

PROVEN SIZING SOLUTIONS Lower costs and increase energy efficiency with MMD Sizer solutions For over 40 years MMD have remained at the forefront of Sizer innovation. Combining unrivalled technical expertise and experience, we develop tailored Sizer™ solutions that optimize efficiency, improves safety, and delivers high productivity.

The MMD Sizer’s consistent product size and minimal fines generation, together with the ability to process any combination of wet, sticky, hard or abrasive material, has proven to be an effective formula for many industries such as; energy, precious and industrial metals, industrial minerals and recycling. The MMD Sizer’s performance and controlled product size has also led the way to develop groundbreaking reliable In-Pit Sizing & conveying systems and bulk ore sorting systems.

MMD’s support and service excellence will ensure your system always delivers optimum performance. Discover how we can deliver the complete sizing solution for your specific needs.

WWW.MMDSIZERS.COM

MMD Bulk Ore Sorting Systems

PROdUCT NEWS

O

rica Digital Solutions is focused on developing technologies that seamlessly connect customers’ physical and digital worlds, so they can readily understand and optimise operations at every step of the value chain, from exploration to processing.

With fragmentation being a key metric of drill and blast performance, Orica Digital Solutions has expanded its range of FRAGTrack™ technology, a state-of-the-art fragmentation measurement tool designed to provide rapid insights into the outcome of blasting processes.

Throughout 2023, new variations to the suite were released and now include FRAGTrack Gantry, Front-End Loader, and Crusher. These market-first technologies provide operations with increased scope to capture fragmentation data across various stages of the load and haul process. This includes autonomous capturing of fragmentation information at a loader dig face with FRAGTrack Front-End Loader, oversize material detection across all models and sizes of haul trucks

Figure 1. FRAGTrack™ GeoSpatial automatically georeferences samples to correlate blast design and orebody information to blasting performance.

10 January/February 2024 // global mining review

with FRAGTrack Gantry, and installation of FRAGTrack Crusher at crusher feed points to measure particle size distribution (PSD) of material during tipping operations.

These innovative configurations use advanced vision technology to improve productivity through fragmentation profile analysis, facilitating blast optimisation for downstream improvements.

Furthermore, with the release of FRAGTrack GeoSpatial in late 2023 (Figure 1), Orica Digital Solutions is now taking fragmentation measurement and analysis a step further with the ability to unlock operational and technical insights by providing georeferenced samples to correlate blast design and orebody information to blasting performance.

The ability to georeference samples generates significant opportunities to derive insights that have not previously been possible, allowing customers to obtain fragmentation data in a region or sub-domain of a blast, and thereby enabling continuous improvement of blast outcomes.

Rajkumar Mathiravedu, Orica Digital Solutions Vice President, said: “Orica is continually growing its digital offerings for customers to align with the swift digital transformation across the industry. Our software ensures that every blast is executed precisely and achieves the desired outcomes. This level of accuracy translates into significant cost savings and improved resource utilisation for our customers. We are shaping the future of mining, and our digital solutions are a testament to our ongoing commitment to innovation, safety, productivity, and sustainability.”

This year, Orica celebrates 150 years of innovation, continuing to deliver smarter, safer, and more sustainable solutions for the world’s mining and infrastructure industries.

Orica’s blasting solutions are automated, digitised, and connected, providing actionable data and insights for customers to improve downstream benefits. Orica is continually improving its core blasting products and services, including advancements in blast design, WebGen™ wireless initiating systems, and explosives offerings in 2024.

Orica is continuously developing and expanding technology into areas that assist the mining industry to mobilise the Earth’s resources more efficiently and responsibly. This includes utilising advanced technology and innovation from mine to mill to accelerate global decarbonisation efforts.

Challenge your material limits Nothing should stand in the way of your productivity – least of all the materials you move. With our compact Hägglunds direct drive systems, you can adapt easily to the job at hand, taking advantage of full torque at an infinite range of speeds. And should an overload try to stop you, the drives’ low moment of inertia and quick response will keep your machines protected. We’ll support you too, with an agile global network and smart connectivity to bring you peace of mind. Driven to the core.

Hägglunds is a brand of Rexroth. www.hagglunds.com

12 January/February 2024 // global mining review

Ian Sanders, Global Mining & Metals Sector Leader, Deloitte Global, presents 10 trends that could define 2024 for the mining and metals industry.

F

or mining and metals companies across the globe, 2023 was a year characterised by upheaval.

Heightened levels of economic and geopolitical uncertainty shook commodity markets and impacted business activities, and continue to do so. Pressure from stakeholders to better the efficiency of existing assets and to act collaboratively with peers, suppliers, and competitors to tackle environmental and social challenges remained high, with the unwavering expectation that companies would apply the highest environmental, social, and governance (ESG) standards throughout.

These are just a few of the complex demands that the industry faces in 2024. To prevail will not be easy, but for companies that act now to lean into change and prepare for ongoing volatility, work collaboratively to speed up project permitting, invest in exploration, and address skills shortages, there is greater opportunity to succeed.

This year, Deloitte Global’s ‘Tracking the trends’ report looks at ways that mining and metals organisations can rise to the challenge and gain advantages in 10 key areas.

meet rising demand for critical metals and minerals, companies will need to put even greater effort into building trust.1 Part of the answer could lie in enhancing the organisation’s ‘purpose’.

A clear purpose articulates why the organisation exists, what problems it is here to solve, and who or what it wants to be to each person and player it engages with.2 Purpose-led companies aim to go beyond making money to become agents of human idealism and societal progress. When people care about a company and the change it is bringing about in the world, that company becomes more valuable and advantaged.3 Canadian startup, Common Good Mining, is a good example of a purpose-led mining company. Its experts are developing a new approach to mining that maximises returns for stakeholders, shareholders, and the environment.4 Mining and metals providers are already influential forces for economic development in many regions and, if they can harness the power of purposes, they have the chance to drive social development and environmental restoration too.

Trend 1 – Putting purpose at the heart of mining and metals: Creating social momentum

Trend 2 – Navigating global uncertainty: Building capacity to thrive in the face of disruption

Mining and metals companies have worked hard over the past decade to change the narrative surrounding their businesses. However, as operations expand to

As businesses shift away from vertical integration – towards an ecosystem approach and networks

global mining review // January/February 2024 13

grow and become more intricate – changes in markets, politics, and regulation, as well as their impacts, are transmitted further. This coupled with today’s fast-moving, digitally supported, business environment requires mining and metals companies to become more agile to capture opportunities created by disruption and minimise or manage associated risks.

One way to do this is through dynamic strategic planning, which enables businesses to proactively adapt to changing scenarios. Scenario planning is another tool which encourages executive teams to explore different business situations. By challenging assumptions and testing strategies in a hypothetical environment before making decisions, companies can better equip themselves to handle different challenges.

Shell has been using scenario-based planning to help inform its strategy since the 1970s. The company’s scenarios team has developed two long-term models of the world’s energy system which test, quantify, and explore the ranges for future scenarios. When viewed together, they offer a perspective on the current global energy landscape, as well as the ability to model various futures.5 Embedding optionality within an organisation’s strategy and portfolio could also help by allowing businesses to exercise different options to meet their overarching goals as situations and priorities change.

Trend 3 – Dealmaking for future-focused growth: Rethinking minerals and metals investments

As the energy transition reshapes the mining and metals landscape, companies are seeking new ways to maintain their competitive edge and increase access to valuable resources. For some, capital allocation into mergers and acquisitions (M&A) is helping to shape their portfolios, while for others, organic growth into new markets is the order of the day.

Nonetheless, mining and metals companies are not the only ones with an agenda in critical metals. With supply shortfalls predicted in many key commodities, consumer firms – including automotive manufacturers and defence companies – are now considering direct investments in mining and refining in addition to offtake commitments.

Dealmaking has an increasingly important role to play in expediting the commercialisation of mining and metals projects, and alternative investments, particularly those from governments, could help to lower the risk associated with projects and encourage more cautious investors to get involved. Much more strategic dealmaking is expected to be seen in 2024 and beyond.

Trend 4 – Working toward net-zero: Building capacity and future-proofing ESG strategies for a credible transition

The private sector has a vital role to play in accelerating a credible energy transition, and in ensuring beneficial outcomes for all stakeholders. As providers of the raw materials needed to create sustainable infrastructure,

14 January/February 2024 // global mining review

low-carbon technologies, and electrify transportation, mining and metals companies are perfectly positioned as agents for this change. Organisations that act swiftly could be rewarded through enhanced resilience and value generation opportunities.

A Climate Transition Action Plan (CTAP) founded on science-based net-zero targets supported by goals over short, medium, and long-term time horizons is central to achieving this. Effective CTAPs are informed by achievable decarbonisation pathways and supported by capital allocation frameworks, operational and organisational impacts, and portfolio optimisation.6 Leadership is also key, and mining and metals organisations could look to collaborate with their customers, suppliers, regulators, traditional owners, and competitors to create material change and, where necessary, act as an orchestrator for joint projects and activities.7 For instance, Vale recently partnered with the Port of Açu in Brazil to study the development of a decarbonised steelmaking Mega Hub. Both companies will seek to attract investors and clients to build and operate the direct reduction plant using natural gas, which will be available at the port, and possibly to convert to green hydrogen for the production of hot briquetted iron with near-zero carbon emissions.8

Trend 5 – Collaborating with governments to rethink regulation: Unlocking critical resources through permitting

According to the Energy Transitions Commission, there is no fundamental shortage of any raw materials needed to support the global transition to a net-zero economy. The issues are therefore ramping up supply fast enough to decarbonise economies before crucial climate tipping points are exceeded, and ensuring that mining occurs in a sustainable and responsible way.9 Project evaluation and development are central to both.

Regulatory reform undertaken in consultation with key industries and rightsholders could influence the flow of capital and talent to and from jurisdictions, enhancing their competitiveness. Areas that might benefit from attention include project sequencing, and the integration and amalgamation of review processes. In many jurisdictions, a big opportunity for permitting lies in collaborating with Indigenous communities, which provides possibilities for direct participation in projects and the fruits of their success.

For example, in 2015, Cameco and Pinehouse Business North (PBN) – the economic development arm of the northern village of Pinehouse Lake, Saskatchewan – developed procedures to increase PBN’s capacity to complete projects at various Cameco sites. The project provided financial support and training to PBN as it executed three contracts at the McArthur River site.10 Ultimately, ensuring projects receive appropriate reviews, while delivering the required volume of metals supply, is a challenge that miners and regulators should tackle collaboratively.

Mining solutions for a sustainable future

WE1850-3 hybrid wheel loader

2650CX hybrid shovel

From optimizing existing fleets with technology to providing hybrid and emission-free equipment, we are committed to

helping customers increase the sustainability of their operations.

Learn about the power of using regenerated energy, while

reducing fuel burn, with Komatsu’s SR hybrid drive system: komatsu.com/sr-hybrid-drive

© 2024 Komatsu Ltd. or one of its subsidiaries. All rights reserved.

Trend 6 – Going back to grassroots: Nourishing growth through investments in exploration

Attitudes towards exploration, both from the mining and metals industry and investors, are currently a tale of two halves. In copper, companies are investing to expand high-grade, profitable assets, rather than exploring for and developing new projects. In contrast, battery metals have seen an explosion in spend on both exploration and development, leaving catching up to do regarding evaluating, permitting, and downstream processing.

Several factors have contributed to this dichotomy, but at the core is a historical fluctuation in investment in exploration based on commodity prices. To ensure a plentiful pipeline of projects, miners may need to spend more on exploration instead of relying heavily on the acquisition of junior companies. Organisations could also better align their exploration efforts with their strategic direction, focus on the attraction and development of talent, and harness technologies, such as artificial intelligence (AI), to reduce the cost of campaigns and speed up the identification and evaluation of targets.

The key to success lies in starting now or doubling down on efforts, to minimise potential critical metal supply deficits and enable the manufacturing of clean energy and associated technologies.

Trend 7 – Addressing workforce challenges through a skills-based approach: Equipping mining and metals companies for the future

Challenges surrounding talent have dominated mining and metals headlines over the past 12 months, from skills shortages and the need to upskill current employees, to the implications of an aging workforce. These are not stand-alone issues that can be solved independently.

Instead, they are indicative of the need for broader change in the way the industry values and treats talent.

One way to do this is by refocusing operating models on skills rather than jobs. This allows organisations to tap into the full range of workers’ capabilities and to find new ways of working. Research has found that organisations which embed a skills-based approach are 107% more likely to place talent more effectively, and 98% more likely to retain high performers.11 The skills-based approach applies at both a micro and macro-level. For example, in Saskatchewan, Canada – a key region for future critical metals production – research showed that this approach could cut the talent gap in half to 2030, by almost 2400 workers.12

Trend 8 – Unlocking new value in existing assets: Balancing complex priorities and meeting supply demand through operational optimisation

In addition to speeding project developments, organisations are focusing their efforts to extract greater value from existing assets. Operational efficiency and productivity improvement initiatives continue to be a

16 January/February 2024 // global mining review

known way to do this. Advantaged organisations will seek the combination of operational technologies and advanced visualisation and analytical tools to revolutionise decision-making and change the paradigm in long-standing functions, such as mine planning and maintenance, while also improving operational metrics.

With a solid data foundation in place, companies can use a more sophisticated and integrated approach to address the wide-ranging requirements and constraints that they face today.

Ultimately, making greater use of widely available tools, such as simulation and mathematical optimisation, could help miners and metal producers to turn their data into a significant business advantage by driving more predictable operational outcomes, saving money, and bettering operational safety and sustainability. In turn, these practices can be expected to help satisfy wide-ranging stakeholder expectations and bring new supply online for future-critical metals and minerals.

Trend 9 – Bringing Generative AI into mining and metals: Capitalising on current and future opportunities

For mining and metals companies, implementing Generative AI (Gen AI) presents a range of exciting opportunities, including addressing energy security and improving profitability, generating operational efficiencies whilst maximising resilience, and reducing emissions.

Traditionally these organisations tend to be slow to adopt new technologies, but they have an advantage in this domain, as most possess exclusive and proprietary data that can be used to finely calibrate Gen AI models for specific requirements and value-driving cases.

In the near term, Gen AI will likely have an impact on mining and metals organisations mostly through workforce productivity and efficiency. For instance, in the back office, employees are beginning to use tools such as Microsoft Copilot to handle emails, schedule meetings, and write documents. Developers could also use Gen AI to enhance efficiency when writing code, ensure its compliance with standards, and reduce the risk of cybersecurity issues. In the future, organisations could use Gen AI’s ability to simulate, model, and generate data-driven insights to support supply chain resilience, and more.

By exploring and investing in foundational Gen AI skills and tools now, mining and metals companies could acquire valuable insights, adapt to its nuances, and evolve alongside the advancing technology. This could position organisations to leverage the full capabilities of Gen AI as it reaches maturity.13

Trend 10 – Gaining agility and competitive advantage through next-gen approaches to outsourcing

Continued evolution in the global risk landscape with a focus on sustainability and increasing regulatory requirements, has seen organisations seek new ways to reduce costs and evolve their capabilities in an agile and

non-labour-intensive manner. Many are now turning to next-generation third-party delivery models (TPDM) for certain business functions, including cyber security, data and analytics, and ESG reporting.

These combine cost reduction and discrete value-addition to support complex processes, applications, or full business functions that require specialised expertise, such as cloud operations, hosting, or infrastructure support.

Both metals and mining companies work with TPDM in safety analytics to improve the safety standards and performances in these organisations. These TPDM gain access to multiple data sources and apply cutting-edge AI technology to detect risk factors and trends in each operational area.

Read more

To read Deloitte’s full ‘Tracking the trends’ report visit www.deloitte.com/ trackingthetrends

our time’, Deloitte, (August 2023), https://www.deloitte.com/au/en/ issues/climate/empowering-leaders-tackle-issue-time.html 8. ‘Vale to develop Brazilian mega hub for decarbonized steelmaking’, Engineering & Mining Journal, (28 September 2023), https:// www.e-mj.com/breaking-news/vale-to-develop-brazilian-mega-hubfor-decarbonized-steelmaking/ 9. ‘Material and resource requirements for the energy transition’, Energy Transitions Commission, (July 2023), https://www.energytransitions.org/new-report-scale-up-of-critical-materials-andresources-required-for-energy-transition/ 10. ‘Cameco-Pinehouse Business North development Project’, Cameco 2016 Sustainable Development Report, (2016), https:// www.cameco.com/sustainable_development/2016/supportivecommunities/indigenous-peoples-relations/case-study/ 11. CANTRELL, S., GRIFFITHS, M., JONES, R., and HIIPAKKA, J., ‘Building tomorrow’s skills-based organization’, Deloitte, (2022), https://www. deloitte.com/global/en/issues/work/skills-based-organizations.html 12. ‘Building tomorrow’s skills-based province: An evolution from jobs to skills for the mining industry’, Deloitte Canada, (2023) 13. NUTTALL et al., ‘The Generative AI Dossier’, Deloitte, (4 December 2023), https://www2.deloitte.com/us/en/pages/ consulting/articles/gen-ai-use-cases.html

References 1.

2.

3.

4.

5.

6.

7.

TAYLOR, A., NANA, P., and MOUTIA-BLOOM, J., ‘How mining & metals companies can make ESG work in a downturn’, White & Case, (22 September 2022), www.whitecase.com/ insight-our-thinking/ mining-metals-2022-howmining-metals-companiesmake-ESG-work-downturn O'BRIEN, D., MAIN, A., KOUNKEL, S., STEPHAN, A.R., ‘Purpose is everything’, Deloitte Insights, (15 October 2019), www2.deloitte.com/us/en/ insights/topics/marketingand-sales-operations/ global-marketingtrends/2020/purposedriven-companies.html ‘Companies for the people’, Isaac by Deloitte, (2023) ‘Approach’, Common Good Mining, [accessed 9 January 2024], https://www. commongoodmining.com/ ‘Shell Scenarios’, Shell, (2023), [accessed 28 November 2023], https://www.shell.com/ energy-and-innovation/ the-energy-future/ scenarios.html ‘Credible Transition to Net Zero: Practical insights for getting started written

by CEOs, for CEOs’, Climate Leaders Coalition, (29 November 2023), https://www.climateleaders. org.au/publications/ credibletransition/ WANNAN, K., BERRY, E., and PRAWER, B., ‘Leading in the Age of Climate: Empowering leaders to tackle the issue of

YOUR MINING MACHINE DESERVES THE BEST CHAINS Cincinnati Mine Machinery Company designed and installed the first Dual Sprocket Conveyor Chain. Our unique design utilizes superior metals and a proprietary heat treatment process for unparalleled strength. Our Dual Sprocket Conveyor Chain runs longer and stronger which means less downtime and lower cost per ton. So when it's time to choose, choose the strongest chain under the earth. For over 90 y e a r s , C i n c i n n a t i M i n e M a c h i n e r y c o n t i n u e s t o b e T H E S T R O N G E S T L INK.

Contact us at 1•513•728•4040 or visit cinmine.com to learn more about Cincinnati Mine Machinery products.

PROSPECTORS & DEVELOPERS ASSOCIATION OF CANADA

2024 THE WORLD’S PREMIER MINERAL EXPLORATION & MINING CONVENTION

REGISTER AT pdac.ca/convention | #PDAC2024

MARCH 3-6 Metro Toronto Convention Centre Toronto, Canada

NETWORK

Connect with delegates from 130+ countries

DISCOVER

Experience 1,100 exhibitors showcasing the best of the industry LEARN Expand your knowledge with hundreds of hours of programming led by international experts

INVEST

Engage with institutional, private and retail investors, plus senior executives

2024

Creating connections since 1932

Paul May, Innovative Wireless Technologies, USA, evaluates the advantages of wireless mesh technology for the digital transformation of subterranean operations.

M

ining, tunnelling, and subterranean industrial operations are now realising the benefits of a technology convergence that unites underground voice, location services, and data communications into holistic wireless networks. Previously, single-purpose underground wireless networks had coverage and capacity issues, which limited communications for periodic production updates or sufficient communications capability for emergency responses. The typical deployment of analogue FM radios over a leaky feeder-based infrastructure supported voice PTT communications, but coverage changes in working sections, along with interference from equipment movement, frequently resulted in spotty service. However, over the past decade, there has been an increasing adoption of more resilient digital communication networks that support a wide variety of real-time updates for production status, location and asset tracking, environmental conditions, equipment operational performance, and workforce safety initiatives. The transmission of this voice, location, and broadband data is increasingly unified over a single, converged wireless network that supports mobility underground and ensures adequate bandwidth for managerial control above ground.

global mining review // January/February 2024 19

Converged networks

Converged networks are not new, and for most industrial applications they are the fundamental component for an Internet of Things (IOT)-based digital transformation.

However, the architecture of converged wireless networks varies widely based on environmental conditions and anticipated number of users, and above-ground technologies optimised for wide-area coverage and high user density have not transferred well for subterranean applications. When deploying wireless networks underground, the key performance indicator for success is radio frequency (RF) propagation. Technologies that work well above ground, delivering terrestrial coverage for large numbers of users, are not scalable downward to be cost-effective for the smaller workforces located in a tight subterranean environment. One wireless technology – mesh radio systems – hits the sweet spot for both underground coverage and cost-effective scalability for tens of users to thousands of users. For this reason, mining and tunnelling companies have adopted wireless mesh networks providing digital voice, data, and location services for mobile users.

Wireless mesh technology

Using wireless mesh technology combined with wireless and fibre backhaul, these converged systems are rapidly replacing the previous generation of stovepipe radio systems and legacy data networks that provided underground operations with limited services in areas of spotty, fixed coverage.

Figure 1. Wireless mesh nodes provide both voice communications and Wi-Fi. The node connects to the fibre network to provide connectivity to surface operations.

Wireless mesh technology is a self-forming network, where radio networks establish the routing through the mesh links as the equipment gets installed. Self-forming allows the rapid deployment (and, as necessary in mines and tunnels, the re-deployment) of voice and data services in underground working sections. Mesh networks – which use multiple RF links to connect any two points – are also self-healing, which provides inherent redundancy. With mesh networks, when one RF link is blocked due to interference, the network nodes will automatically re-route the call across other redundant links. While the wireless mesh nodes, which establish the radio coverage area, can be extended for miles underground, wireless broadband, ethernet, and fibre backhaul provide cost-effective connectivity to the above-ground operations centres.

Moreover, the broadband backhaul supports the data capacity for additional applications, such as sensor networks, production reporting e-forms, and video monitoring.

Case studies Mesh and Wi-Fi integration

Examples abound of the use cases that take advantage of this converged wireless technology. For example, when the former Homestake gold mine in Lead, South Dakota, was converted into a deep underground science laboratory, the mining contractor for the lab required a wireless voice and data network to support the excavation of hundreds of thousands of tonnes of material, thousands of feet below the ground. Their solution was to deploy a wireless mesh network using Innovative Wireless Technologies, Inc. (IWT) SENTINEL Uniti Nodes to provide voice and Wi-Fi communications. The SENTINEL Uniti Node delivers both coverage and local wireless backhaul. At convenient locations underground, the SENTINEL system connects into a customer-provided fibre network to supply connectivity with the surface operations centre. The SENTINEL Uniti Nodes provide the voice coverage needed for mining operations and data connectivity for raise bore machines and other critical equipment. As the excavation proceeds, the SENTINEL Uniti Nodes allow for the movement of the primary coverage areas with minimal (or no) gaps in coverage, and without having to re-route the hardwire backhaul.

Mesh and microwave integration

Figure 2. A wireless mesh network, combined with a digital point-to-point microwave network, provides connectivity across miles of rugged terrain, back to key above-ground locations.

20 January/February 2024 // global mining review

Another example of the converged voice and data network is in use for a multi-year improvement project for the San Francisco Mountain Tunnel (SFMT) in California. The SFMT supplies water from Sierra Nevada foothills to 2.7 million San Francisco and other Bay Area customers. The project is necessary to repair the 19 miles of the 100-year-old aqueduct, as well as to construct new tunnels to facilitate maintenance and improve water quality. To complete this work, the tunnelling contractor needed a communications deployment network that supported both above-ground and belowground operations. The SFMT is in remote mountain canyons and the communication system needed to be efficiently installed and removed during winter shutdown months when the tunnel is drained and available

HEAR TODAY and tomorrow

and the next day and next year

and the year after that....

Clear voice communication that you can actually HEAR in a noisy environment is just one of the many capabilities of an IWT SENTINELTM System.

And, because IWT is a trusted partner to the mining industry, we are committed to providing innovative solutions both today and well into the future.

SME MINEXCHANGE Booth 1630

iwtwireless.com

for maintenance. The chosen solution was an IWT SENTINEL mesh network combined with a digital point-to-point microwave network to provide connectivity back to key above-ground locations. The SENTINEL network delivers voice communications, as well as personnel and asset tracking underground. To supply the wireless network coverage, the tunnelling contractor selected IWT Battery Mesh Nodes, which have internal and external battery options that allow standalone deployments for weeks or months without replacement or recharging. With the Battery Mesh Nodes, coverage areas can be deployed in a matter of minutes, as the nodes are strung up along the tunnel. Key also to the solution was the use of solar-powered digital point-to-point microwave on towers along the tunnel path.

This backhaul network connected the underground elements of the radio network during the winter maintenance period, as well as providing connectivity for the aboveground elements of the radio network throughout the year.

underground operations, but did not want to replace their legacy above-ground radio system. The mine selected a SENTINEL mesh radio for their mining operations, and IWT provided a digitally connected Land Mobile Radio (LMR) Bridge to supply the patching with existing above-ground analogue LMR network. The LMR Bridge allows for a direct interconnection between the two radio networks, utilising a platform that can be, if desired, further network-connected for audio distribution to multiple monitoring points.

Additionally, SENTINEL network extensions go beyond LMR to include telephone and public address (PA) networks as well. With IWT’s Phone Connect feature, authorised SENTINEL handset users can initiate or receive telephone interconnect calls. IWT customers can also extend their PA system as an input on the radio network that allows announcements made over the PA system to pass to SENTINEL handset users as well.

Mesh and land mobile radio integration

The data side of a converged network can also be extended from the wireless mesh network though ethernet or fibre connections. One data use case is IWT’s Wireless Gas Monitors (WGMs) used in coal mining and other potentially hazardous environments. In Grafton, West Virginia, metallurgical coal mines have implemented WGMs connected through the mine’s SENTINEL voice communications and tracking radio network. If the WGM senses a gas level that meets the alarm threshold for the monitored gas, the WGM alarms are transmitted digitally through the radio system to dispatch operations directly to worker’s radio handsets. The mine further extended the alarms from the WGMs to connect their FactoryTalk™ HMI software using IWT’s ServerLink™ application. ServerLink supplies connections to industrial automations and control systems using Open Platform Communications – Unified Architecture (OPC-UA). OPC-UA is a secure transport protocol that provides a standardised interface for SENTINEL WGMs to report status updates into comprehensive mining or industrial automation control and monitoring management systems.

Converged digital networks not only bring innovative technologies to subterranean operations, but they also bring additional service life to existing investments. An example of this can be found at a limestone mine in Sherwood, Tennessee. This mine, which produces high-calcium lime for agriculture and industrial and mining dust control applications, needed to improve communications for their

Mesh and third-party integration

Digital transformation

Figure 3. Automated location services provide asset tracking for optimal usage, while personnel tracking supplies critical information for emergency responses.

22 January/February 2024 // global mining review

The deployment of converged communications systems is a critical step in the digital transformation of the mining and tunnelling industries. These communication systems – defined by the integration of voice, location services, and data – allow mining and tunnelling operations to simultaneously increase both safety and efficiency. Workers using wireless mesh networks rely on scalable voice coverage, audio voice quality, and priority for emergency communications. Automated location services provide asset tracking information to determine optimal usage routines, while personnel tracking supplies critical information for emergency responses. Data from equipment that connects to converged networks autonomously publishes production data, provides status updates, and, through integrated analytics, transforms that collected data into actionable information. Using the disruptive innovation granted by a converged network, mines, tunnels, and subterranean operations can move into the information age to become a high-technology industry.

VISIT US AT

BOOTH #1217 FEBRUARY 25-28, 2024

PHOENIX, AZ

DEMANDING CONDITIONS

DEMAND JENNMAR

SAFETY, SERVICE, AND INNOVATION G LO B A L H E A D Q UA R T E R S

•

(41 2 ) 9 6 3 - 9 07 1

•

P I T T S B U R G H , PA U S A

•

W W W. J E N N M A R . CO M

For more information on our portfolio of diverse and complementary brands visit us at www.jennmar.com.

I

n today’s mining industry, companies face increased pressures: lower ore grades, deeper mines, increased labour and material costs, and the call to decarbonise operations, among others. Prioritising these concerns is a complex undertaking. Companies choosing a direction can look for activities and technologies that address multiple objectives.

The single greatest target for decarbonising mining operations is material haulage. A recent report by McKinsey estimates that traditional material haulage accounts for 36% of the emissions generated by a typical mine – the most significant emissions-generating activity.

In order for mining companies to achieve stated decarbonisation targets, OEMs are racing to develop material haulage solutions that reduce emissions. One alternative to truck haulage that is currently installed in applications around the globe is the Railveyor autonomous, fully electric material

24 January/February 2024 // global mining review

haulage solution. The real-world performance of the Railveyor system has now been validated at Agnico Eagle’s Goldex mine

by CanmetMINING, providing a useful comparison to existing diesel haulage and potential BEV fleet systems.

The understudied complexity in swapping diesel for batteries

Every deposit and mine plan is unique – and there are many valid material transport strategies, each with their own ideal use case. Replacing diesel truck haulage with battery electric vehicles (BEVs) is an increasingly attractive solution to miners.

However, replacing fleets with BEVs places additional burdens on operations that are becoming more commonly known. On the user level, designing and implementing battery charging, storage, and disposal strategies is a novel and complex project.

On a societal scale, economically sourcing the raw materials for

Nik Gresshoff and Matt Youngblood, Railveyor, Canada, review how operators can cut costs and emissions by implementing an electric haulage system.

Figure 1. The Railveyor autonomous material haulage system at Agnico Eagle’s Goldex mine has been evaluated for real world energy consumption by CanmetMINING.

a transition to electric vehicles for material haulage in mining – in addition to serving the massive projected demand for similar batteries in personal and commercial transportation – presents serious challenges.

The existing power generation and electrical grid infrastructure would also need to be substantially upgraded in order to handle the projected demand from BEVs. In a report from April 2023 titled ‘Electrifying mines could double their electricity demand’, McKinsey modelled the increased electricity demand created by simply swapping diesel trucks for their battery-powered counterparts. McKinsey claims that electrifying just the existing global iron ore industry would require the generation of additional electricity equivalent to 10 –15% of Australia’s current consumption.1 The increased demand caused by electrification, including charging infrastructure for BEVs, may also be massive at the

level of a single mine. In estimates calculated in 2023 by Warm Springs Consulting and released at the Electric Mine Conference in Tucson, Arizona, a theorised large open-cut mine in Australia might need 56 MW of electricity to support the charging infrastructure for a fleet of BEV trucks with trolley assist and dynamic charging. Even at a less productive mine, operators must ask if they can account for an extra 10 – 20 MW of power for a BEV haulage electrification project.

With those figures in mind, the mining industry must seek ways to not only electrify haulage, but also to make haulage intrinsically more energy-efficient. Increasing energy efficiency may reduce costs (in lower fuel/electricity expenses) and aid in decarbonisation (by lowering greenhouse gas emissions), cutting across multiple issues.

Forward-thinking mining companies are smart to explore

global mining review // January/February 2024 25

operations with just a single worker to monitor the system from a mine control room. Composed of trains with steel wheels riding on light steel rails and driven by stationary electric drive stations, Railveyor achieves high energy Not just electric but more efficiency by reducing rolling resistance, increasing the energy-efficient payload-to-vehicle-weight ratio, and utilising innovative Railveyor is an intelligent material haulage solution that electric motors. integrates with existing control infrastructure and allows In a study comparing the economics and energy efficiency of competing haulage systems, Warm Springs Consulting reported: “Diesel-electric haul trucks are estimated to have the highest GHG emissions of the specified hauling methods at 0.096 kg CO2e/tkm. This is directly related to the high emissions factor of diesel fuel and limited haul capacity per truck.

The hauling method with the lowest emissions is the Railveyor system, with an estimated 0.012 kg CO2e/tkm.

“Based on average diesel and electricity prices, the hauling method with the highest fuel operating cost is estimated to be diesel-electric haul trucks at US$0.043/tkm. Railveyor is estimated to have the lowest fuel operating cost Figure 2. Chart from Warm Springs Consulting contrasting the power capacity requirement and microgrid cost between Railveyor and BEV fleet at just US$0.003/tkm. The hauling method with haulage solutions. the highest operating cost not including fuel cost is estimated to be long haul diesel trucks at US$0.069/tkm. The lowest non-fuel operating cost is estimated to be Railveyor at US$0.005/tkm.”2 Railveyor’s customer, Agnico Eagle Mines, saw the potential value of the system’s low OPEX and emissions when they selected Railveyor as the material haulage system at the Goldex mine in 2017. In 2023, the findings of a study of power consumption by the AEM Goldex Railveyor system have been published by CanmetMINING, an agency under the umbrella of Natural Resources Canada. As part of the 360 Electric Mine research project, CanmetMINING aims to help accelerate the mining industry’s transition from fossil fuels to the use of electric energy and reduce the amount Figure 3. Theoretical scenario presenting the estimated NPV in an opencast of greenhouse gases produced in the sector. mine between diesel trucks, BEVs with trolley assist, and Railveyor.

Within the study of the Goldex Railveyor system, CanmetMINING measured daily electricity usage, ore hauled, and Railveyor train trips taken.

The conclusions confirm that the Railveyor system at Goldex is operating within 6% of estimated energy usage levels, requiring 0.989 kWh to move one tonne of ore one kilometre. Taking the average electricity price in Quebec, this equates to a cost of US$0.07/tkm.

“Since 2018, the implementation of the Railveyor system at Goldex has had a positive impact on our operations. It allowed us to raise the bar on our production,” stated Christian Lessard, Maintenance Superintendent of Agnico Eagle’s Goldex mine, “As a leader in sustainable mining, we were pleased to facilitate CanmetMINING’s study of Railveyor’s electricity Figure 4. Chart from Warm Springs Consulting showing Railveyor as the consumption. We believe that the projected and estimated lowest cost per tonne-kilometre (tkm) and lowest Scope 1 and 2 GHG emitting solution between a variety of systems. measured electricity consumption figures BEV-based haulage solutions, and they are wise to investigate other innovations in the material haulage space as well.

26 January/February 2024 // global mining review

CUSTOM BUILT SOLUTIONS FOR ANY APPLICATION Fletcher takes pride in being an industry leader of designing, engineering, and manufacturing custom mining equipment for underground applications. With an unwavering commitment to innovation and excellence, Fletcher has set the gold standard in the mining sector. Through a combination of innovative technology, meticulous craftsmanship, and a deep understanding of the mining industry, Fletcher continues to redefine the landscape of underground mining equipment. Fletcher is not just known for their advanced machinery but also for the company’s dedication to safer mining practices.

Contact Fletcher today to start your next custom built solution. @FLETCHERMININGEQUIPMENT WWW.JHFLETCHER.COM 1.800.543.5431 J.H. Fletcher & Co. cannot anticipate every mine hazard that may develop during use of these products. Follow your mine plan and/or roof control plan prior to use of the product. Proper use, maintenance and continued use of (OEM) original equipment parts will be essential for maximum operating results. 2024 J.H. Fletcher & Co. All Rights reserved.

®

compare favourably and validate our decision to select Railveyor as our material haulage method at Goldex.”

“Oftentimes, when new customers first encounter the energy efficiency offered by Railveyor, they find it hard to believe,” added Railveyor Executive Vice President of Sales & Marketing, Nik Gresshoff. “We are proud to see that the CanmetMINING study of Railveyor’s energy use validates our claims. We are even more pleased to be able to deliver that value to Agnico Eagle at Goldex.”

Looking ahead to the future of energy-efficient haulage

In coordination with Agnico Eagle Mines and Railveyor, CanmetMINING presented a summary of the study at the Mining Diesel Emissions Council’s (MDEC) 1st Annual Mining Vehicle Powertrain Conference (MVPC) held in early October 2023 in Toronto. Readers may view the presentation at mdec. ca/2023, under the title ‘Mine Electrification Research: Goldex Railveyor Study’.

Throughout the next year, CanmetMINING may continue to expand on the conclusions of the study by conducting comparative analysis of competing haulage methods for presentation at major mining industry conferences.

Concurrently, Railveyor aims to make electrical demand estimates even more precise by incorporating learnings from the Canmet study into their engineering process.

Next-gen Railveyor systems may deliver increased efficiency, due to the greater availability and more economic price point of drives supporting regenerative braking – a feature not selected for incorporation into the system at Goldex.

Figure 5. Chart from CanmetMINING presentation at MDEC showing a measured Railveyor is a solution that cuts across energy use trend line in the Railveyor system. multiple issues for the modern miner. In addition to aiding decarbonisation, increased physical efficiency saves on energy cost.

Railveyor’s fully automated material haulage system allows for a mine to maintain or improve productivity in volatile and demanding labour markets. Moreover, removing workers from potentially hazardous material haulage areas diminishes risk and enhances safety.

“With the worrying context of climate change, it becomes important for the mining industry to reduce their production of greenhouse gases”, says the report from CanmetMINING, “The use of the ‘TrulyAutonomous’ system is a concrete Figure 6. General overview of Railveyor material haulage system at AEM’s example of a system making it possible to Goldex mine. achieve this target for mines that have access to a low-intensity GHG-emitting electricity grid.

This technology has proven itself at Goldex mine.”

References

Figure 7. Railveyor system measured energy usage broken down by energy use category.

28 January/February 2024 // global mining review

1. HENRIO M., VAN DER ENDE O., MOTTA G., and KUMAR RAY, R., ‘Electrifying mines could double their electricity demand’, McKinsey, (24 April 2023), https://www.mckinsey.com/industries/metalsand-mining/our-insights/electrifying-mines-coulddouble-their-electricity-demand 2. BIEG A., SAMSON M., BELL Z., SCHUYLER J., and ZINSSER A., ‘Comparing Haulage Options For Reduced Greenhouse Gas Emissions and Costs’, Warm Spring Consulting, (3 November 2022), https://www.warmspringsconsulting.com/project/ materials-transport-racing-to-net-zero/

30 January/February 2024 // global mining review

Travis Vliem, Flexco, USA, outlines how implementing an IOT system into a mining facility’s belt cleaning process can boost performance and profitability.

T

he mining industry is in the midst of a revolution.

Updated safety protocols have drastically decreased harmful incidents to workers.

Specialised belt conveyor products have pushed the boundaries of profitability. Recent technological improvements have given plants data that drives key decisions.

This widespread adoption of belt technology has prevailed in the past few years, with the implementation of a smarter and more sophisticated system for conveyor belt monitoring. Simply put, mining facilities are getting onboard with IOT.

What is IOT?

IOT stands for the ‘Internet of Things’, and is often referred to as ‘Industry 4.0’.

Conceptually, IOT is all about taking a holistic view of a technological system, identifying potential problem areas, and seeing which parts fit together to create the most productive and efficient process.

The simplest way to demonstrate how an IOT operates is to consider the example of the ‘smart home’.

A security camera system can notify its user of a disturbance, a smart speaker or display device can be prompted to start music in the living room, and a digital thermostat’s temperature can be changed from the checkout line of the grocery store.

All these pieces communicate by way of one key denominator: a wireless connection via Wi-Fi, Bluetooth®, or cellular technology.

IOT for mining facilities

Where exactly does the mining industry intersect with IOT? Just like the data collected in a smart home, the data collected in a mining facility helps drive decisions and yield better results.

By installing IOT technology throughout key areas of the belt conveying process, mining facilities can better analyse their belt conveyor performance. One such area that has been the focus of many IOT systems is the belt conveyor cleaning system.

Whether it is a primary cleaner, precleaner, or a secondary cleaner, every belt cleaner is an essential component of a belt conveyor system. Not only do they efficiently remove excess carryback from the belt, but they also can add an extra layer of safety to a plant’s operations.

global mining review // January/February 2024 31

IOT developers know how important a properly maintained belt cleaning system is for mining facilities.

As a result, many of them are focused on creating innovative solutions that give plant managers the tools they need to make better decisions.

Some of these IOT solutions have become increasingly advanced in recent years. Through cloud-based and real-time dashboards, users can get a better understanding of specific problems that a plant is experiencing and how they can go about fixing them by using data.

Generally, an advanced level IOT system can provide both a technician and their manager with valuable intelligence on current and future issues.

For example, they could immediately be notified of a simple equipment failure, such as if a belt experiences a rip or the cleaner blade becomes disengaged. More advanced systems can broach into the category of condition monitoring and look for irregular performance patterns, such as an elevation in the rate of wear on a cleaner blade. Other compelling features are predictive maintenance insights, which can help predict future belt downtime incidents by using past performance and data.

Once a mining facility implements an IOT system, it can often better analyse belt performance, all within a convenient digital platform. This allows managers to get a real feel for how their operation is currently performing and provides a better inherent value to their company’s bottom line.

IOT benefits for conveyor belt cleaners

Instituting a full-fledged IOT system into a mining facility’s belt cleaning process brings immense value to a mining facility’s overall performance and profitability. In short, implementing IOT gives plants an Early Detection, Early Resolution (EDER) system that helps address issues before they can wreak havoc across a plant.

IOT is not just a preventative maintenance measure; there are long-term and effective benefits. Whether a plant manager needs to increase throughput, improve working conditions, or avoid costly maintenance and replacements, choosing IOT is the ideal solution.

Improved safety

Figure 1. After installation, maintenance teams can seamlessly connect to their IOT system and receive quick real-time data.

Figure 2. IOT systems are versatile and can be installed in many locations across heavy-duty plants.

32 January/February 2024 // global mining review

The most important everyday factor for mining facilities is maintaining worker safety.

On the surface, this is seen through wearable safety gear and PPE such as high-visibility clothing, hard hats, and hearing protection. Using these precautions is not a complete guarantee of safety though, as it is left in the hands of the plant’s workers to actually use them.

For protection that is not dependent on the individual worker, mining facilities might consider implementing a top-of-line IOT solution.

The industry’s most impressive platforms can be installed quickly, with some having the ability to attach seamlessly in under five minutes. Such devices can even be coupled to the digital twin of their belt cleaner, so users can bridge the physical device and digital platform to map out a site asset system digitally. This helps to transmit real-time data to an easily digestible dashboard that can be accessed through an internet web browser or smart device.

Within some platforms, users can access critical data on their system specifications, cleaner engagement and run time, blade wear, maintenance logs, and more.

The data that is collected then allows plant managers to dictate which areas necessitate actions or inspections, and ultimately remove workers from potential harm’s way by minimising unnecessary exposures. Moreover, with its predictive technology, users can accurately map out when a belt cleaner may need repair or replacement

Resistant to Acids, Alkalis, Salts, Etc.

High Conformability & UV Resistant

PROTECTIVE ENCASEMENT SYSTEM FOR COLUMN BASES & STEEL STRUCTURES The Denso Covercoat™ System is designed to provide corrosion prevention for steel & concrete columns, support legs, structural steel and more. Covercoat offers a hard-wearing waterproong protective coating that is easy to apply with minimal surface preparation required for long-lasting corrosion protection.

Keep Updated

Follow us for the latest mining and minerals processing news

www.linkedin.com/showcase/globalmining

www.densona.com Call: 281-821-3355 E-mail: info@densona.com

down the line, ensuring that belts are less susceptible to potential safety issues and downtime-causing incidents.

This effectively frees up time for workers that plant managers can then allocate elsewhere.

Cost and time savings

Increased belt lifespan

Having an IOT in place brings about traditional savings.

From decreased material loss, to significantly lowering potential belt replacement costs, implementing an IOT system puts money back into the pockets of heavy-duty mining facilities.

However, this is not where the savings end. With a connected IOT system, managers can make more informed decisions on when a repair team needs to be deployed.

With predictive measures in place, they can strategically predict when maintenance needs to be performed and where they may need to focus their attention in the future.

The cleaner the belt, the longer it lasts.

With an IOT programme installed to continuously monitor belt cleaning systems, plants are always in the know on belt cleaner performance. By utilising the data that is collected, a plant manager can make better decisions on issues that arise, further extending the lifespan of the belt being monitored.

Although something like a belt tracker or trainer is a great preliminary solution to keep a belt from misaligning, accidents can and will happen. When an IOT device monitoring for those conditions has been properly installed, users can help ensure that misalignment will be addressed quickly. If a belt were to become misaligned, a well-designed IOT system can automatically generate a notification, so its users can take immediate action and further protect the life of the conveyor belt.

Evolving conveyor data technology As time has progressed, belt conveyor technology has become more advanced. From increasingly customisable mechanical belt fastening systems, to newly released quick-performing belt skivers, the mining industry is only moving towards a more technologically savvy workforce.

Although all of those have undeniably brought incredible value to the entire mining industry, they do not quite compare to what digital solutions can elevate them to with data integrations and reporting. They may have an immediate and direct impact on material, but digitisation efforts are allowing plant managers to continue to think more in the long term.

Figure 3. Many heavy-duty industries can benefit from instituting an IOT, especially mining facilities.

Figure 4. An IOT system can help decrease downtime incidents, and better ensure that belt cleaners perform optimally.

34 January/February 2024 // global mining review

Conclusion

A consistent theme throughout this article is that the days of ‘set it and forget it’ are no longer an option. Data gathering and insights are here to stay, and are only going to continue being a game changer for all heavy-duty mining facilities.

IOT brings data to the forefront. Advanced programmes can review thousands of data points throughout belt conveyor systems and provide users with co-related real observations and events.

Over time, and through the implementation of additional IOT devices, these data points will culminate and lead to further correlations. With the information that is gained, users can pinpoint more specific areas that could lead to belt failures. Furthermore, the introduction of automation tools, machine learning, and other powerful instruments means that users’ systems will automatically stay updated with the latest and best available solutions.

All in all, the IOT is here to stay. Now is an excellent time for mining plant managers to consider what impact an IOT solution would have and how they can go about installing one in their facility. For better long-term success, choose the future of mining technology.

High Quality Aggregate & Coal Mining Turn-Key Solutions Tabor™ Reverse Incline Vibrating Screen

Gundlach™ Multi-Roll Crusher

OEM Screen Manufacturer

Lower Operational Costs

Polyurethane, Wedge Wire, and Profile Wire screens

Slow roll speed, low horsepower reducing power consumption

TH™ Drives That Last

Flexible Machine Configurations

High Performing, Durable, Long-lasting

Maximum control of product crushing

Ease of Maintanence

Minimal Repair Downtime

Patented QuickChange Spring System

Easily replaceable coupling mounted rolls

terrasource.com • elginseparationsolutions.com

Global Publication

A global industry requires a global publication Subscribe online at: www.worldcoal.com/subscribe

®

Our OEM spare parts are always a better choice: better value better performance better safety better service and engineering support with every purchase.

36 January/February 2024 // global mining review

Leslie David, Conveyor Belt Specialist, describes the causes and effects of conveyor belt wear and tear, as well as the reasons why there are such huge disparities in operational lifetime and durability between one manufacturer and another.

T

he wear and tear that takes place on the outer covers of rubber conveyor belts is commonly referred to using the umbrella term ‘abrasion’. However, there is more to the wearing process than simply abrasive wear. As a general rule, 80% of conveyor belt surface wear occurs on the top cover of the belt with approximately 20% of wear on the bottom cover.

Wear on the top cover is primarily caused by two actions.

First and foremost is the abrasive action of the materials being conveyed, especially at the loading point or ‘station’ and at the discharge point where the material is effectively ‘accelerated’ across the belt surface. This kind of abrasion is particularly associated with ‘fine’ materials, such as sand or gravel, which literally act like a piece of coarse sandpaper constantly scouring the rubber cover.

Cutting and gouging

A second major contributor to wear and tear is the cutting and gouging of the rubber surface caused by materials that have sharp edges such as larger, coarser aggregates and rocks.

Again, this largely occurs at the loading and discharge points.

The heavier and sharper the material, the greater the damage it can cause, especially if loaded from height. It is important to bear in mind that the ability of a belt cover to withstand wear is not only due to its ‘abrasion resistance’, because much also depends on the cover rubber’s overall strength and its resistance to cut and tear propagation. If that resistance is low, then a small, seemingly insignificant area of damage in the cover can easily increase in size due to the continuous material loading and the relentless flexing around the drums and pulleys. In time, this damage will spread and link up with another area of damage. Consequently, small pieces of damaged rubber are effectively cut out from the surface rather than being simply worn thinner.

Wear on the bottom cover of the belt is mainly caused by the friction contact with the drum surface and idlers. The rate and uniformity of this type of wear can be adversely affected by other factors, such as misaligned or worn drums and idlers set at incorrect angles or an unclean environment. Belt cleaning systems, especially steel-edged scrapers, can also cause wear to the top cover surface.

global mining review // January/February 2024 37

An invisible cause of premature wear

There are also two other ‘invisible’ but highly destructive and vastly underrated forces: ozone and ultraviolet light.

Ozone

Ozone (O3) occurs naturally in the upper atmosphere. It is continuously formed by the action of solar ultraviolet radiation on molecular oxygen (O2). At high altitude, ozone acts as a protective shield by absorbing harmful ultraviolet rays. Wind currents carry O3 to the atmosphere at the Earth’s surface.

However, at low altitude, ozone becomes a pollutant.

Ground-level or ‘bad’ ozone is created by the photolysis of nitrogen dioxide (NO2) from sources such as automobile exhaust and industrial discharges, and is known as ozonolysis.

Figure 1. Abrasive material is effectively ‘accelerated’ across the belt surface.

Ozonolysis causes cracks to form in rubber that is under tension. The cracks are always oriented at right angles to the strain axis. The dynamic stress that a conveyor belt undergoes while in operation is considerable and ozone attack occurs at the points where the strain is greatest.

The mechanical stress, combined with the friction created between drums and idlers, activates an oxidation process causing the rubber to become brittle, lose strength, and increasingly unable to withstand abrasive wear.

Ultraviolet light

Ultraviolet light from sunlight and artificial (fluorescent) lighting accelerates rubber deterioration because it produces photochemical reactions that also promote the oxidation of the rubber surface, resulting in a loss in mechanical strength. This is known as ‘UV degradation’.

The problem is ever-present even in the most moderate of environments. The combined effect of the ozonolysis and UV degradation means that cracks steadily grow until catastrophic failure occurs. Over time, the repair of splices also becomes increasingly difficult as the adhesion properties of the rubber diminish.

Yet another problem is that moisture seeps into the cracks and penetrates down into the belt carcass. In multi-ply belts, the fibres of the weft strands of the plies expand as they absorb the moisture. This in turn causes sections of the carcass to contract (shorten), as the weft strands pull on the warp strands of the ply, which can result in tracking problems that can be very difficult to pinpoint.

Fortunately, almost complete protection against the catalogue of problems caused by ozone and ultraviolet is relatively easy to achieve by using antioxidants within the rubber compound. Unfortunately for end-users, however, laboratory testing reveals that some 90% of belts sold in Europe, Asia, and Africa have virtually no protection, the reason for which will be explained later.

Selecting the right cover grade: Abrasion standards and test methods

Figure 2. The cracks are always oriented at right angles to the strain axis.

Figure 3. Pollution problems – fine particles of dust penetrate the cracks and are then shaken out on the return run of the belt.

38 January/February 2024 // global mining review

The two most commonly referenced standards for fabric reinforced belting are the international ISO 14890 (with abrasion resistant classes H, D, and L) and German DIN 22102 (with abrasion resistant classes Y, W, and X). In Europe the longer-established DIN 22102 standard is still very often used, although the most current version of this standard references the ISO 14890 on most topics, making both more or less identical. Generally speaking, the DIN grade ‘Y’ (or ISO 14890 closest equivalent grade ‘L’) relates to ‘normal’ service conditions and DIN grade ‘W’ (close to ISO 14890 grade ‘D’) for particularly high levels of abrasive wear. DIN grade ‘X’ (close to ISO 14890 grade ‘H’) is regarded as the most versatile because in addition to resisting abrasive wear, it also has good resistance to cutting, impact (from high drop heights), and gouging caused by heavy, sharp materials. To achieve these characteristics, the rubber compound needs to contain a higher than usual element of natural rubber (NR), and is therefore the higher priced option.

The test method for abrasion (ISO 4649 / DIN 53516) is quite simple. Abrasion resistance is measured by moving a test piece of rubber across the surface of an abrasive sheet mounted on a

revolving drum. It is expressed as volume loss in cubic millimetres, for instance 150 mm³. It is important to remember when comparing abrasion test results (or promises) that higher figures represent a greater loss of surface rubber, which means that there is a lower resistance to abrasion. Conversely, the lower the figure, the better the wear resistance.

Thicker is not always better

As a rule, the difference in thickness between the top cover and the bottom cover should not exceed a ratio of more than 3 to 1.

However, in an attempt to extend operational lifetime, many conveyor belt users resort to fitting belts with extra thick covers.

This is often a mistake, because covers that are too thick can cause other problems. The fact is that the most important factor is the ability of the rubber to withstand abrasion, cutting, gouging, and exposure to ozone and ultraviolet, and it is here that the reasons for the enormous differences in durability and longevity can be found.

It is all about the quality of the rubber

The conveyor belt market is hugely competitive. As a result, price is invariably the number one purchasing criteria. Rubber forms some 70% of the volume mass of a conveyor belt and more than 50% of the cost, so it represents the biggest opportunity for manufacturers to achieve price competitiveness. It is therefore not surprising that the primary cause of rapid belt cover wear is low-grade ‘economy’ rubber that has inadequate resistance to

Figure 4. ISO 4649 / DIN 53516 abrasion testing.

abrasive wear and cutting rather than rubber that has been engineered to provide a high level of resistance. This is also the reason for the huge disparities between one manufacturer and another in terms of price.

Cost cutting: How it is achieved

Because of its adaptability, most of the rubber used to make conveyor belts is synthetic. Dozens of different chemical components and substances are used to create rubber compounds that can cope with the demands placed upon them.

These chemical components and additives are very costly, so a

THE UNBEATABLE VALUE OF FENNER DUNLOP CONVEYOR BELTS Lowest lifetime cost

Safer for humans and the environment

There are many different types of belt constructions, rubber cover combinations, and specialist products available in the Fenner Dunlop range. What sets Fenner Dunlop apart from the rest is that every single belt we make has one thing in common – it has been designed to be the toughest, best performing and longest-lasting conveyor belt of its kind in the world. It is not uncommon to see Fenner Dunlop belts running for several years on applications where the belts had previously only lasted a matter of months or even weeks.

We are the leading advocates of compliance to EU and UK regulations relating to the use of potentially hazardous chemicals, preparations and substances. This includes the use of substances of very high concern (SVHC) and Persistent Organic Pollutants (POPs). Sadly, to minimize costs, many European manufacturers choose to completely ignore these regulations while manufacturers located outside of EU member states and the UK are not even subject to them.

To find out more about conveyor belts that solve the toughest problems and provide the lowest lifetime cost please visit www.fennerdunlopemea.com

Figure 5. Cost-cutting opportunity – rubber represents 50% of the cost of making a conveyor belt.

combination of using low-grade, unregulated chemicals at the absolute minimum levels (or in some cases not using them) all contributes towards the manufacturer’s ‘lowest possible price’ objective. Perhaps the best example of these omissions are the antioxidants needed to protect against ozone and ultraviolet light exposure. They are regarded by most manufacturers as an avoidable cost, which explains why, as stated earlier, some 90% of belts sold in Europe, Asia, and Africa have virtually no ozone or UV protection.

Despite the crucial role that it plays, yet another cost-cutting opportunity involving the rubber is carbon black polymer, which is a key component and makes up around 20% of a typical rubber compound. For example, carbon black prolongs belt life by slowing the ageing process. It also acts as an important reinforcing compound. Good-quality carbon black is costly, so belts offered with significantly lower prices are virtually certain to contain low-grade carbon black, which is most likely to have been made by burning scrap car tyres rather than the much more complex, scientific methods used to make good-quality carbon black.

A clue to the use of poor-grade carbon black is often a strong, pungent smell, whereas good-quality rubber should have little or no smell at all. Much more seriously, low-grade carbon black can contain carcinogenic chemical residues that are dangerous for people and the environment.

A direct connection

The huge disparities in operational lifetime and durability between one manufacturer and another are mirrored by equally huge disparities in price. The connection, of course, is no coincidence. As with most products, the price reflects the quality.

To quote the old saying, price is what you pay, but cost is what you spend. The mathematics regarding cost are simple – belts that last appreciably longer and require less intervention cost much less.

Worldwide Coverage

Global coverage on technology and market trends in the mining and minerals processing industries Subscribe online at: www.globalminingreview.com/subscribe

Miguel Valenzuela, Dyno Nobel Americas, examines how adopting a broader perspective can optimise mill throughput and boost profits.

I

n today’s mining industry, getting the most from a mining operation’s performance to reduce costs and increase production must go beyond individual processes; a broader view of the entire value stream is needed. However, what is the best way to go about it?

Dyno Nobel’s Drill to Mill™ initiatives take optimisation beyond explosives and blasting, combining expert insight with its range of products to provide real solutions throughout the mining process.

In a recent project, Dyno Nobel implemented a Drill to Mill initiative that helped a large metals mine gain US$58.1 million

in added value over a single year and optimise their operation for years to come.

Background: Identifying value-driving opportunities

A surface metal mine identified an opportunity to improve mill throughput for their hard ore as a significant value driver.

Several rock types posed a challenge to mill throughput, due to their hardness and grindability characteristics. The mine plan showed that the tonnes of the rock types classified as hard ore would increase significantly throughout the next several years,

global mining review // january/february 2024 41

so the mine engaged Dyno Nobel to execute a Drill to Mill initiative with a focus on increasing the fines percentage (particularly the -0.5 in. size fraction) going to the SAG mill circuit by 10%, through improved and optimised blasting practices.

Mill modelling showed that even the slightest improvement in the -0.5 in. size fraction reporting to the mills would significantly improve overall mill throughput, thereby adding value to the operation in pounds of copper produced.

Dyno Nobel’s ‘Beyond the Bench’ approach views the entire mining process from drill to mill as a value stream, with small changes in drilling and blasting contributing to large value-adds by the time the blasted material reaches and is run through the processing circuit. In a partnership with the customer, Dyno Nobel deployed its people, processes, and technology and executed a Drill to Mill initiative. This yielded significant value to the operation over the past year, with continued value added for several years to come.

Project goals: Improve mill throughput by increasing fines percentage

Figure 1. Baseline material.

The primary goal for this project was to improve mill throughput for their hard ore by increasing the mine’s fines percentage in the -0.5 in. size fraction. In order to achieve this goal, Dyno Nobel would examine the entire mining process in a Drill to Mill initiative to identify areas for improvement, optimise drilling and blasting, and ensure the desired results were met.

Process: Outcome-based fragmentation using Drill to Mill

The Drill to Mill process has four steps: 1) Baselining, 2) Analysis, 3) Optimisation, and 4) Control and Measure.

During baselining, rock characteristics were collected from geologic data along with current customer drilling and blasting designs. Blasted material was gathered from the hard ore and then stockpiled and screened to establish the baseline particle-size distribution (PSD) curve for each material type of interest. Photo fragmentation analysis was also performed during this phase.

With the baseline established, the initiative moved to the analysis phase. Several Dyno Nobel fragmentation models were calibrated using the baseline PSD data and then re-run at different design parameters to optimise the fragmentation in each rock type, targeting an improvement in the -0.5 in. size fraction. The site then chose the design they wanted to use to Figure 2. Optimised material. start the optimisation phase.

Blasts were executed at the new optimised design over several months during the control and measure phase. A second round of sampling, photo analysis, and screening concluded the control and measure phase and were used to measure the results of the optimised blasts compared to the baseline. Mill modelling was then re-run with the Figure 3. Drill to Mill optimised blast results vs. baseline weighted average PSD by rock type.

42 January/february 2024 // global mining review

new optimised blast PSD curve to predict mill throughput improvements. In addition, current and historical mill throughput data was used to verify the throughput improvements predicted by the mill modelling and achieved throughout the initiative.

Technology and processes applied: Drill to Mill and Dyno Nobel products

TITAN® 5000G emulsion with DIFFERENTIAL ENERGY2 (ΔE²) technology was used for all of the Drill to Mill blasts. The ability to vary emulsion density from hole to hole, as well as vertically within each individual blasthole, allowed Dyno Nobel to place the explosive energy where it was needed most. The DigiShot® Plus 4G Commander electronic initiation system allowed for safe, accurate, and precise blast initiation, with the sequence designed specifically to optimally fragment the rock type blasted.

The Drill to Mill process for this customer was structured to optimise drill and blasting, collect baseline data before making changes, gather results after optimisation, compare and validate the data gathered, initiate discussions with the customer to help them continuously improve, and ensure that the optimisation scenarios implemented were sustainable long-term.

Outcome

Using the Drill to Mill process, the site achieved and exceeded its mill throughput goals for the first time in its history. Changes to burden and spacing, explosives density, stemming length, blast initiation timing, and priming practices produced measurably better rock fragmentation, particularly in the targeted -0.5 in. size fraction. Conservative estimates by the customer show a minimum of a 15% growth in mill throughput by increasing the -0.5 in. size fraction by approximately 5% to nearly 10% over the course of the year.

Based upon the customer’s calculations, the Drill to Mill process over the past year showed a monetised value-add to the operation of US$58.1 million. Additional downstream benefits in truck and shovel cycle times, bucket fill factors, extended GET and shovel rope wear, crusher power consumption, and mill power consumption are anticipated.

By gathering the data throughout the Drill to Mill process, several future opportunities for optimisation were discovered. The primary focus of the Drill to Mill initiative at this site moving forward is to continue to optimise fragmentation in the other rock types identified as hard ore, and use customer Smart Drill data to optimise pattern loading. The Dyno Nobel hardness algorithm and DIFFERENTIAL ENERGY² technology will be used to take advantage of available drilling data and further optimise energy distribution throughout every blasthole in a shot.

By optimising the entire value stream rather than focusing on single processes, Dyno Nobel’s Drill to Mill initiatives are changing the way mines approach their goals, including production, costs, and overall performance.

Roadmap You have a decarbonization target.

What’s next? Let us build a roadmap to lead your journey to net zero. stantec.com/net-zero-mining

I

n the dynamic realm of mining, sustainability and efficiency emerge as pivotal concerns. The imperative for environmentally responsible practices and the persistent quest for heightened productivity prompt mining companies to explore inventive solutions.

Positioned at the forefront of this transformative industry is Metso, a global leader in sustainable minerals and metals processing technologies. Metso’s approach encompasses tailings and water-driven solutions, offering a comprehensive strategy to tackle the challenges and opportunities confronting modern mining. This article delves into four key facets of Metso’s strategy: n Embracing higher pressures and bigger filters. n Leveraging digital technologies for water management.

44 January/February 2024 // global mining review

n The economic benefits of tailings processing solutions. n Service solutions for tailings management.

Embracing higher pressures and bigger filters

As mines grow, the demand for more efficient dewatering solutions becomes apparent. Metso, cognisant of this trend, has innovatively addressed the challenges posed by higher pressures and the need for larger filters. A significant contribution is their high-pressure filtration technology, allowing for the efficient dewatering of tailings at notably higher pressures than conventional methods. This method minimises the volume of slurry that needs storage and management, contributing to a more sustainable approach to tailings management.

Piia Suvio and Tomi Ravattinen, Metso, Finland, address the comprehensive tailings and water-driven solutions that can guide the mining industry towards a more sustainable future.

Figure 1. Up to 90% water recovery with high-performance filters.

Metso’s strategy involves the utilisation of filtration equipment, including filter presses and pressure filters, designed to meet the rigorous demands of modern mining operations. This not only enhances operational efficiency but also contributes to a reduction in the environmental footprint associated with tailings disposal and management. The company’s larger filters, such as the Larox® FFP filtration technology, enable mining companies to process greater volumes of material, increasing overall productivity. Moreover, Metso’s expertise in filtration technology ensures that these larger filters are reliable and efficient, minimising downtime and maintenance costs.

The combination of high-pressure filtration and larger filters aligns seamlessly with Metso’s commitment to sustainability by reducing the amount of water in the tailings and the volume of

storage required. This translates to decreased environmental impact and lower long-term costs for mining companies.

Leveraging digital technologies for water management

In the era of modern mining, digital technologies play a crucial role in optimising processes and reducing costs. Metso, recognising the significance of these innovations, integrates them into its solutions, particularly in the context of water management. n Sensors: Advanced sensors are incorporated into Metso’s solutions to monitor and control water usage in mining operations. Real-time data from these sensors offers valuable insights into water usage, measuring parameters such as

global mining review // January/February 2024 45

water flow, quality, and levels, which enables informed decision-making and process optimisation. n Big data: Analytics, facilitated by Metrics Monitoring and Performance Centers, process the voluminous data generated by mining operations. This aids in identifying patterns and trends, allowing mining companies to gain a better understanding of water consumption and take proactive steps to reduce waste and enhance efficiency. n Digital twins: Digital twin technology is another tool in Metso’s arsenal, enabling the creation of a virtual replica

of a mining operation. This allows for the simulation of different scenarios that combine operational data and expertise, delivering an insight-driven performance that gives efficient management of variability in mining and metallurgical operations with Geminex™. In the context of water management, digital twins allow for the optimisation of water usage, helping miners minimise costs and environmental impact. n Automation and control systems: Metso’s solutions are equipped with advanced automation and control systems, enabling real-time monitoring and control of water-related processes. This ensures efficient water use and mitigates risks associated with overconsumption or water contamination. Advanced control systems, such as their thickener optimiser, improve thickening performance by controlling the key variables of a thickener, including underflow density, the overflow solids content, and the thickener inventory level.

By integrating these digital technologies into their solutions, Metso empowers mining companies to operate more sustainably and efficiently, with reduced water consumption benefitting both the environment and operational costs.

Figure 2. Stricter environmental regulations are shifting the focus toward tailings management and water resource efficiency.

Figure 3. Up to 85% reduced plant footprint with the compact and efficient design of the Inclined Plate Settler (IPS).

Figure 4. End-to-end thickening, filtration, pumps, and material handling portfolio.

46 January/February 2024 // global mining review

The economic benefits of tailings processing solutions

Beyond the evident environmental and social benefits, Metso’s tailings processing solutions offer economic advantages to mining companies, making them a win-win for both the industry and the planet. The benefits and advantages conveyed include the following: n Reduced environmental liabilities: Traditional tailings storage can lead to long-term environmental liabilities, including the risk of dam failures and water contamination.

Metso’s solutions, with their focus on dewatering and dry stacking, significantly reduce these liabilities. This, in turn, minimises the financial risks associated with potential environmental damage and costly cleanup efforts. As part of Metso’s Planet Positive offering, the thickener and clarifier Reactorwell™ feed system ensures low flocculant usage, bringing significant environmental and cost efficiencies to operations. n Lower operating costs: Efficient dewatering reduces material volume, leading to lower transportation, storage, and maintenance costs. Metso’s extensive conveying and stacking portfolio leads to lower transportation costs, as well as reduced storage and maintenance requirements.

Metso’s comprehensive and versatile range of slurry pumping solutions also improves slurry handling efficiency, minimises operating costs, and increases the overall productivity of the entire plant. n Improved resource recovery: Metso has a track record for innovation, with a diverse portfolio of thickening and clarifying products that not only remove water efficiently, but also enable better recovery of valuable minerals from the tailings. This enhanced resource recovery can significantly boost a mining company’s revenue by turning waste into profit. n Enhanced product quality: Dewatered tailings are typically more stable and easier to handle. This can lead

to improved product quality and fewer product losses, ultimately increasing the revenue generated from mining operations. n Optimised water usage: By reducing water consumption and optimising water-related processes, mining companies can cut their water-related costs. The possibility of treating and reusing process water results in lower fresh or raw water intake. Additionally, efficient water management can mitigate the risks of water shortages or restrictions, further protecting the bottom line. n Community and regulatory approval: Responsible tailings management practices that prioritise the environment and community well-being can lead to quicker project approvals and reduced regulatory hurdles. This can expedite project development and reduce associated costs. n Financing alternatives: Metso offers alternative financing models to assist in funding large tailings equipment or plants with extended payment terms. This enables customers to focus on their business’ cash flow, while ramping up a state-of-the-art dry-tailings solution.

Service solutions for tailings management

Metso’s tailings services provide a comprehensive solution from investment through the entire plant life cycle, ensuring that mining companies receive tailored solutions that align with their sustainability goals.

This four-phase approach supports sites at every stage: 1. Solution planning: Metso ensures equipment meets or exceeds operational requirements. Their integrated programmes, including KPIs and cost-per-tonne commitments with best operational cost, enhance profitability while reducing operating costs and risks.

2. Operational planning: Looking ahead, Metso provides training, spare parts, equipment testing, maintenance strategy, shutdown planning, and more. Their experts ensure a smooth production start-up and quicker ramp-up with customisable LCS packages.

3. Operational excellence: During this phase, Metso offers continuous improvement with lower costs and risks. The company’s global team of industry professionals uses plant data to optimise processes, improve recoveries, and reduce energy, chemical, and water consumption.

4. Modernisation and extension: Metso offers cost-effective, sustainable solutions to prolong a plant’s life. Upgrading equipment with the latest technology increases capacity and profitability. Refurbishments restore and optimise equipment to its original condition, ensuring continued production.

Metso’s solutions, coupled with comprehensive services, can guide the mining industry towards a more sustainable and economically viable future. In the face of growing demand for larger mines, Metso showcases that responsible mining is not only possible, but can also be more profitable, redefining the future of mining one sustainable step at a time.

ALIMAK INDUSTRIAL ELEVATORS

ELEVATE OPERATIONAL EFFICIENCY The Alimak elevator is the perfect solution for both underground and surface mining applications, such as pelletizing plants, smelters, concentrators, and other ore processing plants. Alimak elevators have been enhancing operational efficiency and safety for the global mining industry since 1957.

• Built to perform in the world’s harshest environments • Enhances operational efficiency, HSE performance and reduces maintenance costs • Unparalleled track record in reliability and durability Visit our website for further information.

alimak.com

Join us for 3 days of immersive program where you can elevate your expertise with: Expert-led short courses An educational technical program Innovative panel sessions Technical presentations

Join us for social events to increase your network and connect with industry leaders

Tap into targeted opportunities to capture leads and engage with the mining industry face-to-face!

May, 2024

VANCOUVER CONVENTION CENTRE, WEST BUILDING JOIN US!

Our annual event is back under a new name: CIM Connect

convention.cim.org

Simon Acutt, Weir Minerals, Australia, explores how strategies such as pipe loop testing and coarse particle flotation can help promote sustainability in tailings management.

M

ining companies are subject to varying regulatory regimes, but one thing that is common across almost all jurisdictions is that it is getting more challenging to obtain approval to construct new tailings dams. Even when they are approved, it is a much longer and more arduous process than it was in the past. There are important safety and environmental reasons for this; nonetheless, it inevitably has operational consequences.

For instance, some miners, rather than embarking on what can be a multi-year process to get approval for a new dam, are opting to manage their tailings with their existing infrastructure. As a result, miners are moving their tailings around their site a lot more than they did in the past.

As a case in point, an Australian operator recently wanted to mine a previously unmined area of their asset. The area was located near the existing tailings dam. Time did not allow for the approval and construction of a new tailings storage facility (TSF), so they decided to fill up an old pit with the tailings.

Consequently, this increased transfer of tailings indicates a rising demand for pipelines at many sites.

Alongside this demand come operational challenges and additional risks that need to be thoroughly assessed and managed. Pipelines – both concentrates, as well as tailings pipelines – constitute significant capital and operational expenses, so it is vital that they are correctly designed to prevent failures.

There are a lot of pipe design models available and digital tools are increasingly used when designing pipelines; however, new systems are dewatering higher solids concentrations, which means it is more common

global mining review // January/February 2024 49

for slurries to contain larger particles. As a result, pipe loop testing is a vital part of de-risking pipeline designs.

De-risking pipeline design

The Weir Technical Centre (WTC) in Melbourne, Australia, is a global hub, providing slurry, tailings, and pipeline solutions to its customers worldwide. Working closely with miners and EPCs, its pipe loop test facility provides design inputs to pipeline designers in order to de-risk the designs.

Mineral slurries vary in many ways – mineralogy, particle size distribution (PSD), solids concentration and chemistry, etc. – which means each slurry behaves differently when in a pipe system. Therefore, pilot test work is important to help determine the best solution for each customers’ sites, while reducing the overall design risk.

For instance, Weir Minerals can run a variety of tests to identify possible issues. The testing can determine how the slurry behaves when pumped in a range of different conditions, solids concentrations, and velocities, as well as simulating pump failure and a possible restart event.

Pipelines also consume a significant amount of energy, so testing can assist with motor selection. The outcome ensures the pump and motors selected will provide the right tool for the job and the optimal operating window for mine site staff.

Optimising pipeline design

Pipeline selection – in terms of size, material, as well as possible lining options – is integral to the success, efficiency,

Figure 1. Weir Minerals’ Cavex® DE hydrocyclone cluster repurposes tailings in a South American mine.

Figure 2. Weir Minerals’ Linatex® hose in a tailings slurry transfer application at a Mongolian mine.

50 January/February 2024 // global mining review

and longevity of the system. Because of the lengths of some of these pipelines, even small improvements can have significant operational impacts. For instance, Australia is a big country with very long overland pipelines. The surface area across the inside of the pipes means that even small reductions in friction loss, as well as the selection of connection methods, can significantly reduce the energy required to transport the slurry and, hence, the operation’s carbon emissions.

Weir Minerals also utilises intelligent equipment monitoring systems to provide pipeline operators with increased control over performance and maintenance schedules. A network of smart sensors connected to the operator’s digital control system (DCS) measures wear, which is then displayed via an easy-to-use digital traffic light system to enable quick visual identification of the condition of the hose or spool lined with Weir’s Linatex® rubber products or Vulco® rubber. Less than 50% wear is green, between 50% and 70% wear is yellow, greater than 75% wear is red – indicating it is time for preventative maintenance.

Reducing water consumption

One of the other major sustainability challenges relates to the need to reduce water consumption, particularly in regions experiencing water scarcity, such as Latin America and parts of Australia. This is increasingly becoming an operational imperative for miners, while also driving regulatory change. There is a growing consensus in the industry that, if mines are going to maintain their social licence to operate and meet their sustainability targets, they have to improve the way they manage their water.

Some operators achieve this by recovering the valuable ore at a coarser size fraction, thereby reducing the fines in the tailings stream and making the product easier to manage.

Weir Minerals has a cooperative agreement with Eriez to ensure that it can offer coarse particle flotation (CPF) systems to customers when it is the ideal solution.

Eriez’s HydroFloat® CPF technology permits the use of coarser, rougher grind sizes, delivering the operator additional reductions in grinding energy requirements.

The recovery or efficiency of conventional flotation is strongly related to the particle size of the ore. Conventional flotation only achieves high efficiency in a narrow interval in the middle of the range, typically 50 – 130 µm.

Eriez’s HydroFloat® CPF represents a major step forward in terms of recovery, by extending flotation efficiency over a size range that is two to three times greater than conventional flotation machines’ limit.

CPF produces this result by combining features that facilitate particle collection and mass transfer, including fluidisation water to enhance lift, counter-current contacting, a plug-flow residence time distribution, and a zero-order froth. This amounts to CPF allowing the effective flotation size range for copper to be increased to approximately 400 µm.

As a result, the P80 is shifted to significantly coarser sizes.

This, in turn, reduces the volume of fine feed in the distribution, thereby enhancing overall recovery,

reducing energy, or allowing increased throughput for the same energy, as well as creating safer, sand-like tailings for disposal.

Dam wall construction

In the aforementioned regulatory environment, some miners are utilising these sand-like tailings to raise their dam wall and expand the capacity and life of their TSF. In most instances, the tailings simply need to be dewatered, which can be done with cyclones.

CPF technology is obviously not employed at all mines; in these instances, delivering a product that can be used for dam wall construction is dependent on the site’s particle size distribution. In some cases (PSD permitting) it can be achieved by multi-staged cycloning. The crucial characteristic of the sand – the thing that ensures the dam wall’s structural integrity – is that it is relatively free-draining, which is defined as sand with a set minimum limit of approximately 15% passing minus 200 mesh (75µm), depending on the site requirements. This requirement helps prevent liquefaction, the process by which water-saturated, unconsolidated sediments are transformed into a substance that acts like a liquid.

This is particularly important in earthquake-prone regions, like Latin America, where seismic activity poses a significant risk to the structural integrity of TSF dams.

In an effort to help its customers alleviate these twin challenges – expanding their tailings capacity, while ensuring TSFs remain safe – Weir Minerals developed its

Cavex® DE hydrocyclone, a two-stage classification and separation system incorporated into one piece of equipment.

With a conventional hydrocyclone, 35 – 40% of mass is usually sent to the underflow, but, with the Cavex® DE hydrocyclone, it is around 45 – 55%, making it 10 – 15% more efficient than any other hydrocyclone on the market – while also producing the free-draining sand-like tailings required for dam wall and buttress construction.

This technological and operational trend is another factor driving the increased transfer of tailings around sites; that is to say, once the sand is produced, it has to then be pumped to the perimeter of the dam wall via a pipeline reticulation system.

Conclusion

The mining industry is acutely aware of the tailings-related challenges it is facing. There is an understanding that if it is going to meet the growing demand for the minerals required to facilitate the transition to a low carbon economy at a time when ore grades are declining, the ability of miners to manage their tailings effectively will directly impact whether or not they can continue production.

In the face of these challenges, the industry seems to be going through a period of unprecedented collaboration. In many ways, the WTC epitomises this commitment, with miners, EPCs, and OEMs all working towards the shared goal of making mining more sustainable.

www.euromineexpo.com

EURO MINE EXPO Cutting edge innovations & the latest methods in mining 28 -30 MAY 2024 | SK ELLEF TE Å , S W EDEN

Register today!

Book tickets and hotel rooms at our website for best availability. euromineexpo.com

200

EXHIBITORS

>50% MANAGERS

>40

NATIONS

>30

LEARNING SESSIONS

GOLD SPONSORS: SILVER SPONSORS:

Euro Mine Expo is organized by Nolia AB

Sam Abbaszadeh and Amanda Adams, Stantec, USA, assess the opportunities to attract the next generation of tailings engineers in a Q&A with Will Owen, Editor of Global Mining Review.

Figure 1. Tailings storage facility (TSF) in Peru.

E

ngineers of Record (EORs) oversee all aspects of a tailings storage facility (TSF) and need a varied and specialised skillset. Adoption of the role has increased in recent years, thanks in part to the Global Industry Standard on Tailings Management (GITSM), which requires EORs on certain tailings projects. Will Owen (WO), Editor of Global Mining Review, recently sat down with Stantec’s Sam Abbaszadeh (SA), Tailings and Waste Technical Practice Lead, and Amanda Adams (AA), Principal, Mining, Minerals, and Metals, to discuss how they are guiding the next generation of tailings practitioners into EOR roles for TSFs.

WO

Sam, you are an Engineer of Record (EOR). Why did you choose EOR as a career path?

SA

To be more accurate, I’d say EOR chose me. An opportunity arose where I was asked to be the deputy EOR for an

inactive site in Arizona and I said yes. At the time, I didn’t really think that far ahead, and I was just curious about the opportunity to learn. The challenge sounded exciting, so I said yes to the opportunity and started getting into the EOR role.

WO

What did the learning process look like?

SA

It was a long journey (about 8 years now) and involved many site visits, inspections, preparing, and presenting to Independent Technical Review Boards (ITRBs) and Tailings Stewardship Teams (TSTs). The highlight of it is how much more beyond your specific discipline (in my case, geotechnical) you have to absorb to be ready for the EOR role. You can’t just stay in your comfort zone or area of expertise and ignore the other areas. You must develop at least a basic understanding of other disciplines, such as

global mining review // January/February 2024 53

hydrology, hydraulics, water management, water balance, material balance, geochemistry, geology, and mine operation and closure. There are a lot of other things, and you must stay curious, ask questions, and grow. I was very lucky to have the opportunity to learn from some of the best in the industry.

WO

How will you modify that learning process to train your Deputy EOR?

SA

With the global gap in that type of skillset and knowledge, we know we need to accelerate the process to train more EORs. Ideally, a TSF has a lead EOR and a Deputy EOR. This helps with institutional knowledge and general transfer of skills. On my first site visit it took me a while to understand the importance of the multidisciplinary knowledge. If I went back to do it again, I’d be more intentional in transitioning from a geotechnical engineer to someone with a basic understanding of all the aspects of the TSF. That would be my main focus when it comes to training a Deputy: to emphasise the importance of multidisciplinary knowledge that is required for this role.

WO

How do you think the industry at large is addressing the EOR workforce issue?

SA

TSFs are getting more attention today compared to any other time in the history of mining. We are seeing a lot of collaboration globally to share knowledge and accelerate tailings education. As an example, this year I went to the International Commission on Large Dams (ICOLD) conference in Sweden, and I think for the first time one of the two keynotes focused on tailings and three of the four short courses focused on tailings. Historically, this is not a conference devoted to tailings. So, globally the industry is sharing knowledge and contributing to the growth of these initiatives. And as far as the EOR workforce issue is concerned, this is a great step forward to help accelerate gaining the multidisciplinary knowledge required. Another, and perhaps more challenging, component is the practical knowledge which only comes when you are willing to put your boots on the ground and spend time at various TSFs.

WO

What does the next generation of tailings engineers need to do differently?

SA

I have thought about this a lot because I am in the ‘middle’ generation. I think one of the things the next generation needs to focus on more is proactive succession planning and training. This is particularly important because it was probably not a major issue for the previous generation of tailings engineers and EORs. The current legends in the industry, who are nearing their retirement now, may have trained a few disciples throughout their careers who are

54 January/February 2024 // global mining review

becoming the new leaders of our era. This was probably sufficient, given the industry needs at the time. However, for us to meet the needs of today and the future, each of these new legends must train another dozen disciples in the industry. So, if you consider yourself a next generation tailings engineer, make sure that you identify the tailings legends in your organisation and express your interest to be trained. And if you are one of those legends, make it your mission to train a dozen of the next generation engineers before you retire. That will be your legacy that will live long after you leave the industry, and that is how we continue to grow and improve.

WO

What challenges and opportunities is the industry facing?

SA

We’re seeing a global shift in the workforce. Today, people seek more work-life balance and workplace flexibility. This can be difficult when much of our work happens at a project site. To me, this is one of the biggest challenges, and a learning process across generations as we all work together.

I believe both employers and employees need to think creatively and flexibly to apply modern solutions when appropriate. And as with any challenge, we’re also presented with new opportunities we didn’t have even 10 years ago. We’re seeing huge advances in technologies to allow for remote data sensing. As an example, we worked on a cool tailings project recently where we increased confidence in data integrity of dam inspection observations by implementing GIS-based remote data collection.

Another great opportunity is elevating industry-wide collaboration. For example, it would be very beneficial to the industry if the mining companies and consulting firms would create a job-sharing framework where they could easily exchange employees for a certain period of time. This would benefit the employees, as well as their employers.

WO

What needs to be done to attract people to these roles?

SA

We should start with the multidisciplinary aspect of this role, the challenges it brings, and the nature of problem-solving. I think that is how we should advertise it – a multidisciplinary opportunity to grow almost endlessly, form teams, and solve problems for the benefit of our environment and communities. And, by the way, it is also paid very well, but the conversation needs to go in that order. You need to have the passion first, to be successful in this role.

For example, some tech companies are successful in attracting the next generation of talent not only because of their high pay, but also because they provide opportunities to learn new things and take on new challenges. We need to take this approach with the next generation of EORs.

WO

Now Amanda, let me ask you a question – I know you haven’t been in an EOR role, but you have been involved extensively, what’s your opinion on how to attract this next generation?

AA

In order to attract a new generation of EORs we have to promise – and deliver – mentorship. The people who take on these roles need to know they have the tools and support in place to be successful. I am really invested in the success of our EORs, and in the future of the EOR workforce. That’s why I am involved with the tailings committees for organisations like SME and USSD, and I work with USSD and CDA’s joint working group on EOR. It’s also why I spend time teaching short courses through the Tailings Center, and why Stantec is a committed industry partner of TAILENG. Tailings engineering is a fascinating career that I love, and I want to introduce the next generation to it, because it has provided me with many unique and interesting opportunities.

RIEGL VZ-i SERIES LASER SCANNERS

FOR MINING & MONITORING

WO

What do you think about the pressure we put on young professionals; how do we allow them to fail safely? A lot of people are almost scared of this role because they think, “if this facility fails tomorrow, I will go to prison”.

Realistically, how can we keep people protected?

NEW WHITE PAPER RIEGL V-Line Scanners for Permanent Monitoring Applications

AA

We (Stantec) must do work for owners that we trust to safely manage their tailings facilities. We take on EOR roles when we are a partner with the owners, when we know our recommendations will be valued, and when we know the owner is committed to doing the right thing.

We protect our EORs by taking on EOR assignments where we are confident we will be successful, where we have the data we need to make the right decisions, and where we are involved for the long-term.

WO

Thank you both for providing your opinions on this important topic, any closing thoughts?

AA

I am excited to see where the industry is going, because there is so much collaboration between tailings practitioners. Sam and I recently attended the Tailings & Mine Waste 2023 Conference in Vancouver, and it was astonishing and motivating to see how openly owners, consultants, academics, and vendors were sharing their successes (and struggles). The people in this industry want to do what is right, and they know that we do not have the luxury of spending the next 20 years figuring it out. In order to advance the industry, we need to share lessons learned and build on our collective experience – we don’t have time for everyone to experience the same mistakes on their own. I am so optimistic about the future because we aren’t doing things the same way we always have.

We are adopting technology faster, in newer, better ways, solving problems with more diverse teams, and seeing more collaboration than ever before. We have a big challenge ahead of us, but we also have the right people to figure it out.

RIEGL APPS FOR REAL TIME ANALYSIS, PROCESSING, AND VISUALIZATION

RIEGL VZ-i Series for highest accuracy and optimal performance • ranges up to 2500 m, accuracy 5 mm • customized apps written in Python programming language • cloud connectivity for remote operation and data transfer via LAN, Wi-Fi, and 3G/4G LTE

RIEGL Monitoring Apps for highest efficiency in the field • flexible scan data acquisition scheduling • flexible threshold value setting

• no extra software required – webserver on scanner for browser-based data and result publication NEW Monitor+ App permanent, periodic, and sporadic monitoring solution, monitoring of surface and targets/prisms in one Monitoring App data comparison and visualization of differences to a reference data set Design Compare App data comparison to a given 3D design model, visualization of undercut and overcut Slope Angle App calculation and visualization of local slope angles and the areas above the critical slope angle

Explore the full portfolio of proven RIEGL LiDAR sensors and systems www.riegl.com Austria | USA | Japan | China | RIEGL WORLDWIDE | Australia | Canada | United Kingdom

Bibhrajit Halder, SafeAI, USA, details how generative AI can enhance a wide range of functions in the mining industry.

T

he mining industry is no stranger to artificial intelligence (AI) and automation.

It was one of the first industries to experiment with autonomous vehicles (AVs), dating back almost 30 years. Recently, this technology has gained serious traction; the mining AV market is projected to hit a staggering US$12.6 billion by 2031.1 At the same time, the number of new use cases for AI and automation has exploded, from leveraging AI-powered tools for resource estimation to testing autonomous drones designed to anticipate and prevent underground roof collapses.

Implementations have accelerated as AI and autonomy emerged as a business imperative. Then, about a year ago, generative AI entered the scene, promising a seismic shift in AI deployment and impact.

This technology has been brewing for some time, dating back to a 2017 paper called ‘Attention is All You Need’.2 However, in 2023, it hit the mainstream conversation, taking the business world by storm. A third of business leaders already say their companies are using generative AI.3 40% say they intend to increase their investment in AI because of advances in generative AI. Everywhere, people are discussing ChatGPT and its counterparts – how will it disrupt industries, from healthcare to transportation? How much more efficient can it make companies? How can they get started?

56 January/February 2024 // global mining review

It is high time the mining industry enters the conversation. With various challenges that AI and automation are well-suited to address and troves of domain-specific data, mining companies are uniquely positioned to benefit from this technological revolution. Here is why and how the industry should embrace the opportunity.

Dig into the impact of AI and automation to date

Before digging into the revolutionary impact expected from generative AI, it is necessary to set the scene on where the industry stands today through an overview of the areas where AI and automation are already improving operations. Mining companies grapple with a range of challenges that these technologies are already tackling head-on, including: n Safety: Mining is a hazardous industry. From incidents with machinery to cave-ins, it is considered one of the most dangerous jobs in the US.4 The industry employs approximately 1% of global labour, but generates 8% of fatal accidents.5 Companies can use autonomous solutions to remove employees from harm’s way. n Workforce support: There is a growing labour crunch in the industry. 71% of mining leaders say the talent shortage makes it difficult to hit production targets. 86% say it is harder to fill the roles they need today, compared to two

global mining review // January/February 2024 57

years ago.6 This challenge is acute and expected to worsen as half of the workforce retires, interest from young talent declines, and the need for mined resources skyrockets.7 Technology can help augment the existing workforce and plug gaps where they exist. n Productivity: The resource-intensive energy transition is driving rapidly increasing demand for mined minerals.

The need for some mined materials, including graphite, cobalt, and lithium, could grow by as much as 500% by 2050.8 This offers an enormous opportunity for mining companies to grow, but also creates a lot of pressure to operate more efficiently. AV operators say this technology improves their productivity by 15 – 30%.9 n Emissions: Climate change is considered a top concern for mining companies today.10 Companies have a clear vision not only to provide more minerals for the energy transition through enhanced productivity, but also to curb their greenhouse gas emissions as they do. Fully addressing this challenge requires a comprehensive, multi-faceted strategy, and autonomy can play a role.

From streamlining operations to reducing downtime and operating vehicles more efficiently, AVs can help mining companies curb emissions.

Figure 1. SafeAI worked with Australian mining company MACA to retrofit this 180 t Hitachi haul truck.

Figure 2. The autonomous vehicle is pictured here at a gold mine in Karlawinda, Australia.

58 January/February 2024 // global mining review

It is important to understand where companies already see substantial value from AI and automation. Generative AI can build on these successes by optimising these use cases and adding value in other ways.

Accelerate transformation with generative AI

The mining industry has incredible data from geological surveys, drilling reports, equipment telemetry, environmental impact assessments, and more. This data is invaluable, but also complex and difficult to analyse. As a result, it has historically been severely underutilised because companies did not have the capabilities or resources to make sense of it. Generative AI models are poised to change that.

These models can analyse vast amounts of data, understand complex patterns, create actionable insights, and make intelligent decisions. This will enable the mining industry to take decades of industry data and put it to use for smarter, safer, and more productive operations.

For one, it can create significant additional value in the areas where AI and automation are already being leveraged, including: n Safety: Generative AI can analyse real-time sensor and video feeds to identify safety hazards before they happen, alert workers, and prevent incidents. n Productivity: Generative AI optimises resource allocation, such as fine-tuning energy consumption patterns of autonomous machinery or distributing materials across a worksite. These models can predict and adjust for operational variables to help minimise waste and maximise efficiency, improving environmental and economic performance. These models can also analyse operational data to identify inefficiencies and propose alternate workflows to boost productivity. n Workforce support: Generative AI can be used to improve autonomous equipment operation, making these vehicles more independent and precise.

However, there is also a variety of additional use cases where generative AI holds immense potential, including: n Material discovery and predicting metal deposits in mining: The mining industry is experiencing a massive spike in demand for many resources. Copper is a great example of this. An exceptional conductor of electricity and heat, it sits at the heart of the renewable energy revolution. While green applications consumed 4% of copper in 2020, forecasts suggest this demand will surge to 17% by 2030. This steep rise underscores the need for efficient copper mining practices. n The story is the same for other metals and minerals.

Pinpointing where valuable metals and minerals are located is a complex challenge critical to planning and development for mining operations. Generative AI can process the abundance of geological data available – from satellite imagery to seismic surveys – and extract actionable insights. It can transform the data into a precise map, leading to rich, undiscovered deposits.

These insights can make mining operations more

efficient and environmentally friendly by reducing unnecessary exploratory drilling. n Predictive maintenance: Generative AI can analyse sensor data and historical maintenance records to predict equipment failures, enabling proactive maintenance and minimising downtime. This is critical to keep projects on time and within budget – it is estimated that an hour of equipment downtime costs companies an average of US$260 000.11 n Quality control: Generative AI models can analyse data from sensors and image recognition systems to detect defects in real-time, ensuring a high-quality output. n Project management: Generative AI can assist in project planning, scheduling, and risk analysis, enabling better decision-making and resource management.

n Take stock of your company’s AI readiness. With this technology, it is impossible to go from zero to sixty; the right data and infrastructure is needed. Evaluate what data you already capture and what data you can access to train a model. Understand how and where it is being stored, and assess what technology infrastructure is in place to support AI deployments. If there are gaps, now is the time to address them. n Then, determine where AI can have the greatest impact.

What pain points are most pressing for your company?

Where can it augment existing workstreams? Focus your initial strategy there, instead of trying to boil the ocean. n Set specific, measurable goals to evaluate success.

For example, your goal may be to improve mineral estimates by 20%. This will ensure your strategy delivers tangible improvements to your overall operations.

In short, there are myriad ways generative AI can enhance efficiency, productivity, cost-effectiveness, safety, and environmental impact across the mining industry.

It is time for the mining industry to grab the bull by the horns on generative AI. The mining industry is well-positioned to benefit from this technology with a wealth of data and a wide range of functions, through which AI and autonomy can deliver meaningful impact. The companies that take action will gain a meaningful competitive edge and set themselves up for long-term success.

Create a roadmap before beginning the journey

Generative AI is still in its infancy in mining. However, companies that want to take a proactive stance and get ahead of the curve can and should begin laying the groundwork for these applications. The most important step at this juncture is to plan how to move forward:

References

Available upon request.

A

s the world looks to make the transition to a sustainable future, the transformation of essential sectors – such as transport, construction, and manufacturing – will be key. In order to facilitate the scale of change needed, however, vast quantities of raw materials will still be required.

From lithium and cobalt for electric vehicle batteries, to bauxite and cadmium for solar panels, mining will

60 January/February 2024 // global mining review

continue to play an integral role in securing the resources needed to transform society. It is critical that the mining industry itself is equipped with the tools to decarbonise as rapidly as possible, allowing it to lead the way in enabling a more sustainable future for us all.

When looking for the best solution, there is often little need to attempt to reinvent the wheel. In working to help accelerate the decarbonisation of the mining industry,

Will Owen, Editor of Global Mining Review, conducts a Q&A with Gonzalo Otegui and David Rogers, McLaren Applied, to learn about the benefits provided by technologies brought over from motorsport to the mining industry.

McLaren Applied has been implementing new products and technologies based on its existing knowledge and expertise gained from other industries, such as motorsport.

Will Owen (WO), Editor of Global Mining Review, recently spoke with Gonzalo Otegui (GO), Data Science Product Owner, and David Rogers (DR), VP Mining Sales, at McLaren Applied’s office in Woking, UK, to find out more.

WO

What does a company known for motorsport bring to the mining industry?

GO

At face value it does sound like a weird match, but when you look at it in more detail, it makes quite a lot of sense.

In motorsports, the performance and efficiency of the cars

global mining review // January/February 2024 61

are of paramount importance, not to mention the critical nature of energy deployment strategies. In mining it’s exactly the same, the purpose is just slightly different. In motorsports, we look to enable a car to go round a circuit as fast as possible, while in the mining industry, the aim is to make the truck and track as productive and efficient as possible, in order to reduce fuel usage and emissions. In the end, both share a very common thread, just with a slightly different perspective. Thus, we are leveraging all the know-how that we have accumulated from many years working in the motorsport space and are applying it to mining.

quantities of data being generated on the track, providing operators with recommendations in real time.

Cloud software engineers are critically important to maintaining a high-quality infrastructure that delivers.

The team that fills these roles come from a variety of diverse backgrounds. The McLaren Applied team has people from the automotive world, motorsports, and even an award-winning physicist from the space research world.

We try to bring as many perspectives as possible that really enhance and improve our reactivity when it comes to tackling the different challenges that we face.

DR

McLaren Applied is packed full of high calibre engineers, probably 95% of the workforce, and it starts at the very top. To give a few examples, our Chairman Nick Fry was behind Brawn GP’s success in 2009, and prior to that was responsible for the rejuvenation of Aston Martin with the DB7 model – the first Aston Martin to sell in higher volumes. Furthermore, Samir Maha, our COO, was a leader in his previous roles dealing with the quarrying industry and at the consultancy McKinsey. Finally, one of our Directors, Pablo Garcia, brings a very deep well of knowledge and experience to the table, covering lots of different fields, but transport in particular. It’s a really great bunch of engineers generally, as well as myself and several others supporting them with our own knowledge and expertise.

I think there are a lot of synergies between an opencast mine and a motor circuit. For one, both share the same need for high-speed connectivity to facilitate real-time decision-making. Another example is the shared desire to optimise energy-efficiency to get around. Mining may operate at a ‘slightly’ slower speed than motorsport, but the aim remains the same: to not only save fuel and reduce CO2 emissions, but to improve productivity as well.

GO

Adding to David’s point on connectivity, I’d like to emphasise again its critical importance. Being connected to all of the high-value pieces of equipment involved in mining is critical to the success of operations – data from any part of a track should be accessible at any time for analysis. This is another thing that McLaren brings over from motorsports to mining: advanced analytics.

WO

What is the makeup of the McLaren Applied team working on this, and what type of backgrounds do they have?

GO

It’s a pretty diverse team, possessing a broad variety of skills from quite different backgrounds. We have data scientists, simulation engineers, cloud software engineers, etc., each of them adding different perspectives and skill sets to the mix. This helps to ensure that we are delivering the best quality product possible.

The data scientists, of course, are experts in analysing vast amounts of data. They take all the data collected from mining operations and extract insights gained from that applied advanced machine learning. Algorithms, predictive algorithms, etc., allow us to identify what decisions we can make in real time to help the mining operations.

Then we have the simulation engineers, mostly coming from the motorsports world. Through simulation, we can run very advanced models to exercise how a track would behave in various specific conditions during mine operations. This allows us to further gain confidence in the algorithms that we are using to generate these recommendations for the track operators, and also to tweak the algorithm further.

This is a solution that relies on a lot of data being collected. The advanced models are trained using the large

62 January/February 2024 // global mining review

DR

WO

How does the McLaren fuel analytics service work?

GO

At its core, it is an analytics cloud solution which works in the different stages. One of the most important steps is accessing the data. All of the data that is being generated by the dump trucks during the operation is a treasure trove of valuable information. By analysing this data, we can understand what the performance efficiencies are, and the kind of gaps that might exist. First though, we need to collect that vast amount of data. This is where constant connectivity plays a pivotal role, facilitated by our product Halo 300.

Once we have collected all the data, we need to make sense of it. As I said, it is a treasure trove in terms of what it can contain and what insights can be extracted. Our data scientists have developed a model that analyses how different truck operators behave (i.e. how they drive). We are able to automatically identify what the most efficient driving behaviours are for dump truck operators. With this information, we are building a model for the ‘ideal driver’.

At the end of the day, this is very much like in Formula 1 (F1) when we try to distil what the ideal driver would do, in order to help real drivers train to be as fast as possible.

Here, we do the same, but with mining and truck operators.

This automated process of collecting all the data and training this really advanced model that will create the ideal driver allows us to work in really challenging conditions. Mines are very dynamic, ever-changing places,

and this is where the beauty of these solutions shines through. They are highly adaptive, and keep learning from all the data that is collected in real time. This allows us to always ensure that we are delivering the best possible recommendations that we can to the mining truck operators, again in real time. The operators would be relayed these recommendations on a screen within the cab, and from this they will know in real time exactly what speed they need to be driving to be super-efficient. This has a wide range of benefits. The most obvious one is the reduction in fuel consumption that comes with efficient driving. Through this, we are really striving to help our mining customers tackle OPEX issues, as well as helping them with their environmental concerns and decarbonisation targets – a top priority for mine operators.

Another key benefit of our real-time recommendations is a boost to productivity.

These are the core benefits that customers receive from our service, but of course there are many others that can come along with it. For example, in relation to operator training. Mine managers expend a significant amount of time and effort training their operators to be as efficient as possible. Our solution takes an activity that traditionally has been asynchronous – based on post-shift analysis of the performance of the operators – and streamlines the process, as the operators receive real-time feedback on how they are performing and where they need to improve.

This really reduces the time that mine managers need to

Rely on

spend on training, and produces proven results.

Furthermore, our recommendations to customers for maximum-efficiency truck operation really help with the lifespan and the maintenance needs of the vehicles in question.

DR

Just to add to what Gonzalo has already said, I believe the way we relay the recommendations to the operators in very simple terms, so it’s nice and easy to follow, is very valuable. All that is required to review our recommendations is a quick glance at the head-up display in the cabin right in front of an operator. We don’t add a whole range of other screens around the cabin, creating what can sometimes feel like a spaceship; we make everything very user-friendly.

We can gamify the experience to make it more enjoyable.

Operators can lean in to the competitive edge of league tables, which adds some fun to the task of maximising productivity and makes the work enjoyable to carry out.

Read more online

Enjoying this Q&A? The full version is available online at www.globalminingreview.com/special-reports here:

W

ith electric vehicle (EV) manufacturers planning to ramp up production, demand for lithium for these automotive batteries continues to outstrip supply in North America. Bypassing traditional mining methods, Volt Lithium Corp. has used its extensive oil and gas industry experience to find a solution.

Volt has expedited test production to demonstrate the commercial viability of its proprietary direct lithium extraction (DLE) technology. It directly extracts lithium from oilfield brines, leveraging existing infrastructure and regulations in Alberta’s oil and gas sector. This approach reduces the time and development work required to achieve production versus conventional mining. Volt is now advancing towards commercialisation and pursuing the opportunity across the continent.

Background

Volt is aiming to be North America’s first commercial producer of lithium from oilfield brine from existing hydrocarbon wells.

This includes the production of lithium hydroxide monohydrate (LHM) and lithium carbonates. The company’s

64 January/February 2024 // global mining review

flagship project – Rainbow Lake in Northwest Alberta, Canada – spans approximately 430 000 acres and has more than 1300 fully permitted oil-producing wells with lithium-infused brine.

A successful pilot programme and technical report estimate a lithium production life of approximately 100 years.

Volt’s DLE solution creates a new category for lithium production within the resource sector. The approach offers an alternative to conventional lithium exploration and mine development, which, even after proving economical, still takes years to bring into production.

Looking to Canada’s oil and gas industry

Volt enters the lithium space with a perspective informed by hands-on experiences in hydrocarbons. The company is led by President and CEO Alex Wylie, a serial entrepreneur with years of experience in Alberta’s energy sector. Wylie and his team identified the potential for a technology-driven solution to address the supply-demand imbalance for lithium, and this coincided with a petroleum market movement favouring a technological shift towards industry modernisation,

Alberta’s Volt Lithium profiles its direct lithium extraction technology and outlines its course to commercial production across North America.

innovation, and increased involvement in the global clean energy transition.

Bridging mining and energy, lithium gave Volt an opportunity to take part in this shift. The metal exists in brines as a by-product of oil production, but was previously unextractable in commercial quantities. In Alberta, stringent oil and gas industry regulations significantly streamline the permitting process for lithium projects. Existing hydrocarbon wells with production infrastructure eliminate the need for new drilling, reducing capital costs and mitigating enterprise risks.

Commercialisation strategy

Introducing DLE technology and its commercialisation plans, Volt has outlined four distinct production ‘pillars’ to reach its end goal.

The process starts with Volt’s two-stage DLE extraction, the Proprietary IES-300 Technology. Stage 1 removes up to 99% of contaminants from lithium-infused brine, including water treatment and filtration systems. Stage 2 extracts up to 90% of the lithium from brine. This is achieved using a

specialised compound that differs from traditional extraction media. Volt’s 5-micron compounds have 800 times the surface area of conventional extraction media used for lithium extraction. This boosts extraction efficiency, lowering capital costs.

The second pillar is the company’s agreement with privately held oil producer Cabot Energy Inc., which produces lithium-infused brine at Rainbow Lake. Volt management’s background is key to this project’s development. This deal also creates a foundation for Volt to secure similar agreements with other oil and gas producers.

Next in the production strategy is the quality of the lithium reservoir at Rainbow Lake. The reservoir is estimated to contain 99 billion bbl of lithium-infused brine, with the Hay River Basin’s highest reported lithium concentration at 121 mg/l. This presents a veritable ‘ocean’ of brine for long-term production.

Lastly, regulatory advantages and Volt’s DLE approach provide a more immediate production path. A conventional North American lithium mine would take 17 years to enter production, following the typical stages.

global mining review // January/February 2024 65

Volt’s leadership decided to proceed with DLE test work on oilfields without conducting preliminary economic report studies. The company concluded that current regulations and reporting on the target oilfields would provide sufficient data to proceed to pilot testing.

and scale. Analysis revealed the property has an estimated 99.0 billion bbl, or 15.7 billion m3, of brine, exceeding previous estimates by over 20 billion bbl.

Company asset

Volt’s DLE technology success stems from several strategic technology partnerships and collaborations with governments, labs, and academia. For example, Alberta’s Nanotechnology Research Centre undertakes critical lab work for Volt’s DLE. One of the world’s largest nanotech facilities, the centre is a partnership of the National Research Council of Canada, the University of Alberta and the Government of Alberta. The Canadian government provides core funding for the work.

Volt has also partnered with Alberta’s Camber Technology Corp. (CTC) for lab testing. The CTC lab continuously tests and improves the proprietary DLE process for Volt. Additionally, Volt leverages CTC’s subsidiary Sterling Chemicals for its supply chain, obtaining essential substances for operations.

The information gained from the partnership provides Volt with valuable insights into cost efficiencies in field execution.

Moreover, Volt has secured strategic technology collaborations with two University of Alberta research labs.

These collaborations aim to leverage nanotechnology and water processing expertise to remove contaminants from oilfield brine for the DLE. Volt considers these to be integral to its efforts to advance the commercial and economic extraction of lithium from water produced during extraction.

In March 2023, the company commenced pilot operations at the Rainbow Lake Project to test its proprietary DLE process in a simulated commercial environment. The approximately 430 000 acres contain more than 1300 producing wells, substantial equipment and infrastructure, and access to road and rail transportation for commercial export. Volt has focused on project areas featuring the highest lithium concentrations to optimise returns and cash flow. It initially targeted regions with known concentrations of up to 121 mg/l in the Muskeg Formation of Alberta.

Outcomes

Volt succeeded to extract lithium from oilfield brine at scale, processing up to 50 000 l during its pilot operations through 2Q23.

Following full analysis, Volt reported in May 2023 that testing had exceeded management’s expectations. Results confirmed a breakthrough in commercial lithium extraction at low concentrations from the infused brines with robust economics. Volt’s DLE technology achieved 90% Li recoveries at 34 mg/l. This opens numerous North American oilfield reservoirs for potential development using Volt’s IES-300 technology. Additionally, 97% Li recoveries at 120 mg/l concentrations were achieved under simulated operating conditions.

Operating costs were under US$4000/t (at 120 mg/l) assuming a sustained average annual production of 20 000 tpy. This outcome justified proceeding to a preliminary economic assessment (PEA) to support future commercial economics.

Volt’s technical report, published in 2Q23, revealed an inferred mineral resource of 4.3 million t of lithium carbonate equivalent (LCE) at Rainbow Lake. The inferred mineral resource is 215 times the estimated peak annual production of 20 000 t, demonstrating this lithium asset’s sheer size

Building technology partnerships and collaborations

Sustainability upside

Utilising Alberta’s existing infrastructure, wells, and regulated processes creates upsides for environmental stewardship and promotes responsible corporate citizenship. Volt’s proprietary DLE process does not require hard rock mining, which foregoes conventional exploration, development, and mine construction. This reduces Volt’s environmental footprint with 94% fewer emissions. As an added benefit, Volt captures natural gas emitted at the project to power its operations.

Volt has implemented strong governance policies and mandates for its groundwork to support its production process. Alongside best practices for corporate and ESG accountability, Volt is dedicated to continually refining and improving these processes. Furthermore, the Rainbow Lake Project allows Volt to leverage existing community engagement.

This is highlighted by Indigenous relations and an employee training programme.

Looking to the future

Figure 1. Volt Lithium’s pilot plant operations in Regina, Saskatchewan, Canada, May 2023. Testing facility equipment was utilised to treat Volt’s brine prior to entering into the DLE process.

66 January/February 2024 // global mining review

Volt is drawing interest from the mining and energy sectors while advancing toward full-scale production. Volt’s Rainbow Lake Project is estimated to generate a rate of return of 45% on a US$1.5 billion project valuation. The company is accelerating towards commercial lithium extraction from oilfield brines across North America by 2025.

In December 2023, Volt completed its PEA, now publicly filed. It is based on the capital and operating costs for a 20 000 tpy lithium plant at Rainbow Lake. The PEA targets production growth in three phases: n Phase 1: Production is targeted at 1000 tpy focused on the Muskeg Formation, with an average lithium grade of 92 mg/l. n Phase 2: Volt intends to expand production to 5000 tpy of LHM, primarily focused on Muskeg. n Phase 3: Production aimed to expand to an average of approximately 23 000 tpy of LHM, focused on the Muskeg and Keg River formations.

Figure 2. Volt Lithium’s two-stage DLE extraction process undertaken at the

Technological improvements to Volt’s Rainbow Lake Project, Alberta, Canada. proprietary DLE process have driven down conditions for extracting lithium from oilfield brines and operating costs at Rainbow Lake. At the converting it into lithium hydroxide and lithium carbonates. time of publishing the PEA, operating costs were projected to This plant will integrate technological improvements from be US$3276/t from the Muskeg Formation, with an average the proven pilot operation used for Rainbow Lake. The lithium concentration of 92 mg/l (previously US$4000/t at demonstration plant’s proximity to Volt’s corporate 120 mg/l), and US$4545/t from the Keg River Formation, with headquarters will enhance administrative efficiencies, address an average concentration of 49 mg/l. a single set of provincial regulations for test analysis, and Volt has also commissioned a permanent demonstration streamline business development initiatives. This will aid in plant for real-time testing. The plant in Calgary, Alberta, will evaluating commercialisation opportunities. serve as Volt’s anchor processing facility. It will simulate field

Toughest conditions, coarsest materials – time for EFFICIENT PROCESSES

SAM Semi-autogenous and Autogenous Mills Christian Pfeiffer specializes in producing customized AG/SAG mills and ball mills that are designed to meet the specific requirements.

We also offer the flexibility to adapt the design to existing foundations making it easier to replace existing mills.

Contact us today for more information on our tailored mill solutions.

www.christianpfeiffer.com

68 January/February 2024 // global mining review

Figure 1. Intelsat FlexMove: Connecting industrial operations on-the-go everywhere.

Joel Schroeder, Intelsat, explains the benefits of implementing satellite communications in digital mining operations.

W

ith automation and remote management capabilities, the adoption of cloud computing and artificial intelligence, and the continued emergence of a host of industry-specific enterprise applications, the mining industry continues to evolve to become smarter and more technologically advanced seemingly by the day.

Across all phases of the industry, from site exploration to extraction, mining organisations are relying more heavily on digital and connected solutions to optimise operations, explore new sites, and meet ever-expanding sustainability mandates, while enhancing safety and quality of life for workers. Technology solutions are being deployed and utilised, both by operations management at their headquarters and miners operating in remote sites. However, reliance on these technology solutions also presents some new challenges for mining operators, specifically as it relates to the need for connectivity.

Mining sites are often situated in some of the most remote locations around the world. In these places, access to traditional terrestrial connectivity, such as cellular, is either unavailable or unreliable. Even in areas where some form of terrestrial connectivity might be available, reach and quality can be severely compromised. The quality of the signal can be vulnerable to outages caused by weather

conditions, surrounding geography, or other external factors.

While slow connections or intermittent downtime might be acceptable for some activities, such as personal internet browsing, connectivity limitations are not tolerable for certain mining applications. For example, OTA file transfers and software upgrades, as well as the ability to remotely control or autonomously operate heavy mining equipment, have the potential to improve safety, increase productivity, and reduce costs dramatically. However, capitalising on this capability depends on the presence of ubiquitous and uninterrupted connectivity.

As mining organisations continue to recognise the value of digitising mines and mining activities, more solutions and applications will require a non-negotiable level of ever-present connection.

With the increasing reliance on technology to connect and automate, the demand for a premium and ultra-reliable level of connectivity will only accelerate.

Finding reliable connectivity sources to meet these demands requires looking beyond cellular and terrestrial options. With the ability to reach far-flung locations and deliver connectivity unencumbered by events on the ground, satellite communications networks have a significant role to play as the mining industry continues to speed towards digitisation.

global mining review // January/February 2024 69

Whereas satellites once were thought of as expensive and only accessible via heavy, complex, and immobile equipment, advances have made satellite communications technology ideal for mining organisations looking for either a primary or redundant connectivity option.

In a recent study conducted by Harbor Research, mining operators cited the difficulty of network setup as being one of the biggest drawbacks to adopting a satellite solution. Latency and cost were also cited as concerns.

Today’s satellite networks more than address these concerns.

Networks are robust enough to meet rising bandwidth requirements. They can be accessed via portable, lightweight terminals and antennas that are easy to set up and manage, even by technical novices in the field.

Software-defined satellite networks and smart antenna technology can allocate bandwidth to the locations and applications in need, ensuring that the mining user pays only for the connectivity they require. Soon, multi-orbit capabilities will allow mining companies to access low-earth orbit connectivity, along geostationary, to support specific applications where zero latency is required. Satellite networks also meet the security and data protection needs of mining organisations.

Among today’s networks that are purpose-built to meet the evolving needs of the mining industry is Intelsat FlexMove, a high throughput satellite network solution (HTS) that effectively fills the communications gaps and delivers the connectivity modern and digitised mining companies need to power complex and integrated applications.

Powered by a fleet of more than 50 satellites, FlexMove is a globally available, secure, fully managed connectivity solution designed specifically for the needs of mining organisations. With high-quality, high data throughput coverage and ubiquitous enterprise-grade availability even in the most remote locations, FlexMove offers vast upgrades in connectivity speed compared to terrestrial and even the traditional low-data, narrowband satellite solutions usually deployed at mining sites.

FlexMove removes the complexity of dealing with bandwidth availability, configuration, and network infrastructure management, giving mining operators and workers peace of mind.

Figure 2. Reliable mobile connectivity for mining.

70 January/February 2024 // global mining review

Optimising, automating, and remotely managing heavy equipment fleets

According to Harbor Research, the market for mining equipment will grow from nearly US$34 billion in 2022 to over US$100 billion by 2032. As mining operators increasingly rely on fleets of connected heavy equipment, FlexMove can combine with other technologies, including cellular and non-geostationary satellite networks, to provide complementary connectivity that will help optimise efficiency, improve safety, maximise performance, and protect investments.

By adding satellite connectivity to the complement of networks, mining operators can monitor heavy equipment, measure risk, and receive real-time alerts, should any mechanical or performance issue arise, reducing the risk of equipment breakdowns and addressing issues before they become catastrophic.

Additionally, as remote equipment and semi-autonomous technologies emerge to help mining companies address worker shortages, increase safety records, and significantly improve output, FlexMove enables long-distance remote operators to control equipment located in areas beyond the reach of cellular connectivity.

Finally, satellite-powered Wi-Fi in the cab will allow mining companies to connect field operators and headquarters in real-time. Voice connectivity, video streaming, and high data transfer enable the relaying of information that can inform operational changes, while at the same time enhancing safe driving practices across fleets.

As mining companies continue to explore the use of applications that enable the remote monitoring of machinery and heavy equipment in real-time, FlexMove delivers reliable connectivity that enables miners to take full advantage of remote monitoring solutions and always have complete visibility of their assets, no matter the location of the mine.

Powering connectivity during remote exploration

As miners head into dangerous and hostile locations to explore and identify new sites, they need to establish temporary offices quickly and have the necessary network connectivity for sharing high-quality pictures, videos, and site samples, as well as receiving feedback in near real-time. Moreover, workers engaging in dangerous remote exploration work need and want connectivity for crucial health and safety purposes. No matter the core purpose, any digital applications that might be used during remote site exploration will require significant bandwidth to be most effective. FlexMove offers HTS communications-on-the-pause (COTP) solutions that are small enough to be carried in a backpack and simple to set up and use by remote teams, enabling high-quality, highly reliable communication hotspots.

Leveraging data for operations and sustainability

The ability to capture data from mining operations can have a significantly positive impact on business. Heavy equipment fleet management platforms can yield a trove of valuable data. However, this data is only valuable if it can be effectively transmitted and shared.

Harbor Research’s recent study revealed that mining companies leave as much as US$20 billion in additional monetisation opportunities on the table by not capturing and leveraging critical data that can assist in and increase the overall value of operations.

Intelsat FlexMove enables mining companies to continuously derive value from critical data collected by connected solutions, through ensuring heavy equipment stays connected anywhere. FlexMove allows miners to collect and transmit data related to vehicle usage, engine idling, and refuelling. Additionally, FlexMove can play a vital role in helping eco-conscious mining companies achieve their environmental, social, and governance (ESG) goals by cutting carbon emissions and conducting operations more sustainably.

SEPARATION EXPERTISE FOR MORE SUCCESS IN THE MINING AND MINERALS INDUSTRY? AS K YO U R S E PAR ATI O N S PECIALI ST

Premium connectivity experiences on-the-move and on-the-pause

The connectivity needs of mining operators are both unique and varied. As mentioned, during site exploration, miners need a connectivity solution while ‘on the pause’, to quickly establish a temporary intelligent remote office, connect and share insights with headquarters, and support employee health and welfare. On the other hand, miners also require ‘on the move’ connectivity capabilities for remote monitoring and predictive maintenance of heavy equipment and service vehicles. FlexMove offers both connected mobility and portable connectivity to meet all diverse mining industry use cases.

Network innovations on the way

Today, FlexMove already offers multi-layered satellite coverage across 99% of the Earth’s populated regions, with 99.99% network uptime. To ensure miners always have network access needed at the most critical moments, Intelsat continues to make significant investments in network innovation. This includes a new constellation of software-defined satellites that can communicate with smart edge antennas to dynamically allocate bandwidth to where it is needed most at a given moment in time. Intelsat is also introducing multi-orbit capabilities to meet the specific coverage and latency needs of different applications and use cases. By delivering access to both geostationary and low-earth orbits via a singular terminal, multi-orbit will also offer yet another layer of redundancy and failover.

As robust, always-available connectivity continues to emerge as a critical requirement in the mining industry, satellite communications networks can deliver connectivity anywhere mining activities are happening in a matter of seconds, powering the connected mines of the future and creating a safer, more sustainable world.

Increasing throughput while preserving product quality, minimizing energy consumption and operating costs or increasing water recovery: Efficient separation technology backed by innovative automation and digitalization is a crucial competitive advantage.

Our current portfolio covers the full solid/liquid separation process from sedimentation and dewatering to drying, and ensures excellent throughput of high-quality products – all with low operating costs and maximum reliability.

The variety of different thickening, dewatering and drying technologies combined with the opportunity to analyze your processing requirements and conduct tests in a state-of-the-art laboratory means, that you get the right equipment or individualized line solution for your specific need.

ANDRITZ AG ⁄ Stattegger Strasse 18 ⁄ 8045 Graz ⁄ Austria ⁄ andritz.com/separation

5-8 February 2024

CTICC, Cape Town, South Africa

C E L E B R AT E

30

YEARS OF PROGRESS I N A F R I CA N MINING

Join us to celebrate the 30th anniversary of Investing in African Mining Indaba.

Register now to be part of the landmark event.

REGISTER NOW

@miningindaba | #MI24 | miningindaba.com

Glenn Barlow and Ross Milne, Dassault Systèmes, France, consider how companies can adopt strategic mine planning and parametric design to improve flexibility and revenue.

M

ining, like many industries, can be slow to change. Companies often stick to traditional processes far longer than needed, primarily because they are comfortable with them and do not want to take the risk of trying out something new.

However, this means they may also miss significant opportunities both to improve profits and increase sustainability.

A common refrain from mine planners is that they do not have enough time to look at all the possible options for a solution space, which leaves them worrying about questions such as: How much value was left in the last untested cut-off grade or mining capacity limit? Which direction and sequence would

global mining review // January/February 2024 73

have created the best schedule? Have the pit optimisation angles been followed closely enough?

The fact is, however, that this situation can be solved, and these important questions can be answered, if companies adopt a different approach to strategic mine planning.

Strategic mine planning

Mine planning concentrates on long-range production planning aimed at maximising the value derived from exploiting an ore deposit. However, by its very nature, because it is long-term, a mine plan can be affected by a variety of internal and external forces, including: increased knowledge of the orebody, unexpected staffing issues, technical advancements, and changes in legislation, economy, and market.

Strategic mine planning attempts to de-risk a mine plan and to make it flexible enough to adapt to changes as and when they rise.

Traditional approach

The traditional approach to developing a mine plan is to assess a mine project based on the net present value (NPV).

That means the NPV, which is calculated by applying a rate to progressively discount cash flows based both on how much profit the mine project must make and on its risks, becomes the primary KPI for the mine plan and drives decisions about where to start the extraction and how to orient the sequence.

For opencast mines, mine planners traditionally define reserves using the Lerchs-Grossmann (LG) algorithm, which identifies an economic envelope (pit shell), constrained to maximum slope angles, that will boost the total

undiscounted cash flow. With that final pit identified, the planner builds a sequence to reach it, often by creating nested pit shells using the same algorithm but constraining the volume of the output envelopes or adjusting the block model valuation using revenue factors (RFs). To select a subset of the nested pits to serve as pushback expansions toward the final pit, the mine planner then calculates the preliminary schedules.

Issue with this approach

The issue with this traditional approach is that, most of the time, the nested shells available for the planner to select as pushbacks are not operationally feasible, and that may in turn require: n Mining multiple satellite pits in earlier periods of the life of the mine. n Having a large starter pit, even for small revenue factor increments. n Following a concentric sequence, which requires multiple mining fronts. n Awkward pushback shapes and sizes, which may be difficult to implement.

Often, the planner will try to override these issues by building some feasible pushback designs loosely based on a set of nested pit shells and by splitting and merging different envelopes. However, this often seals the decision to use a pushback sequence based on the RF-limited pit shells, instead of looking for other possible sequences towards the same final envelope. Moreover, as a side effect, because the traditional approach is based on maximising undiscounted cash flow for simulated price-levels through different RFs, there is no guarantee that the sequence obtained will maximise NPV and could be out of alignment with other feasibility-focused KPIs.

A more flexible approach

Figure 1. Optimised pit phases.

Figure 2. Strategic mine planning vision.

74 January/February 2024 // global mining review

Using process-automation tools with mine planning software allows mine planners to better appraise the optimisation solution space, delivering a workflow such as this: 1. Generate a ‘value map’ based on a modified pit optimisation algorithm that allows the planner to easily: § Identify the best starting region and corresponding directions, based on an assessment of preliminary strategic schedules for each combination.

§ Compare directional approaches, while taking into account other vital components of a mine plan, such as spatial constraints, sinking rate, and other feasibility KPIs, as well as NPV. 2. Run thousands of possible scenarios based on mining rate and production capacity, their corresponding CAPEX and OPEX (making both the mine and the processing plant, and their corresponding costs, the right size), and cut-off grade, with each scenario producing its own mine plan and production schedule.

3. Optimise the schedule to maximise NPV by identifying what material to mine from each pushback and when, since this will affect the mine’s order of revenues and costs (i.e. cashflow).

For example, the traditional approach has been to optimise the material sent to the processing plant, based purely on the mining and processing capacity.

This can lead to low-grade material taking up vital plant capacity in the early periods and reducing NPV, among other KPIs. A better approach would be to stockpile lower-grade ore in the early years of production in order to prioritise higher-grade processing early on, and then use the remainder of the viable ore later, increasing NPV over the life of the mine. Even better still would be to not only optimise the processing capacity, cut-off grades, and stockpile usage, but to do this at the same time as choosing the sequence and the pit shells. This would free the optimisation to look at a wider solution space and not lock it in to decisions that were made in the previous step.

Strategic mine design

It is important to remember that optimisation and scheduling is only one side of the coin that is mine planning, and that it takes a design to make a schedule actionable. In a process which creates large numbers of scenarios for optimisations and schedules, it is critical to establish a living design model with an intelligent workflow that updates as objects and inputs change.

Traditional CAD-based mine design works well, but because it requires a designer to modify the entire shape of a design in response to a change, it is often slow, manual work that is prone to mistakes. This slowness can mean that a designer is able to produce just one or maybe two design options by the deadline, with no time left for engineers to evaluate the integrity of the design.

Adding an automated parametric capability to the traditional design process not only ensures faster execution, it does so with improved accuracy and flexibility over traditional mine design.

LENSER Filtration

CUSTOMIZED FILTER PLATES MADE IN GERMANY

Chemicals

Food

Mining

Minerals

Environment

KMZ RUD

LENSER Filtration is one of the world‘s leading manufacturers of filter elements for industrial solid/liquid separation in filter presses.

For over 50 years, our filter plates have been successfully used in the chemicals, food, mining, minerals and environment sectors.

Good filter elements are built by many.

LENSER goes one step further: we produce customized products according to your individual requests in formats up to 2450 x 2450 mm.

We offer particularly strong solutions in the mining sector: due to the combination of years of experience and high-quality materials, LENSER filter plates are designed to meet very high requirements.

Scan the QR code and contact your personal #FiltrationExpert now

Parametric design fundamentals

Parametric design does not produce a solution as much as generate a family of possible outcomes through dynamic automation.

LENSER Filtration GmbH | info@lenser.de | lenser.de/en

Parametric modelling can use a propagation-based system, where algorithms produce final shapes that are not predetermined by initial parametric inputs. Alternatively, it can use a constraint system, where final constraints are set and algorithms define fundamentals (structures, material use, etc.) that satisfy these constraints.

Propagation-based systems often include ‘form-finding’ processes that optimise specific design goals against a set of design constraints, so that the final form of the designed object is ‘found’ based on these constraints.

Both types of parametric modelling have been used for years in other industries, such as civil construction, aviation, and manufacturing, as a replacement for traditional 3D CAD-based design.

Creating a living model

The parametric model-based approach incorporates traditional CAD functions, but differs by adding links between objects and parameters.

This associativity preserves the connection between reference data – such as terrains and geology or resource models – and existing infrastructure models. This in turn allows the mine designer to update designs automatically every time there is new input data because, while the input data may have changed, the parameters of the design may not. The designer can also create templates by searching a series of functions and parameters, to speed up the time needed to design repetitive tasks and deploy them manually or automatically through scripting.

Figure 3. Optimised pit and haul road design.

The result is a ‘living’ model, where design changes made in a localised area will update the global mine design, and designs are ready for review days or even weeks faster than traditional practice allows.

Running limitless simulations

Mining projects are complicated, expensive, and extremely risky ventures. Being able to simulate everything in advance, from the mine design to the material movement, is critical to de-risking a project.

By automating the manual and iterative work done by the mine designer, parametric simulation enables the designer to compare the original design configuration with a larger spectrum of data. Regression models are first trained on simulation data and then progressively calibrated on measured data during a set monitoring period, in order to evaluate the robustness of design-phase performance and detect potentially critical assumptions. These models also maintain a continuity with operation-phase performance using feedback from measured data.

Applying simulations in real life

Parametric simulations can be used to design mining phases that consider unexpected variations and uncertainties, such as the metal content available in a mineral deposit and shifting commodity prices.

For example, Dassault Systèmes used a Design of Experiments (DoE) to perform a wide range of input modifications to a pit optimisation run. This allowed them to calculate tens of thousands of scenarios and explore the entire solution space, with the output being a dynamic set of pit shells linked to and associated with a set of pit design parameters. This associativity, coupled with parametric design, created the design shown in Figure 3.

The design now maintains a constant link with the optimisation results. As alternative scenarios are selected, new designs are automatically created and stored with their own revision and life cycle. It is also possible to choose to link and associate them with other restriction criteria not made available to optimisation, such as pit crusher locations that require their own areas for infrastructure, flat areas in the ramp for regulatory purposes, or sump locations for pumping requirements. A template can be assigned to each of these criteria, which is associated with the design and will be used to automatically update it.

Finally, each design can be used again within the life-of-mine scheduling, closing the planning loop and confirming the assumptions taken previously in the optimisation step.

Conclusion

Figure 4. Whittle and Process Composer Design of Experiments.

76 January/February 2024 // global mining review

Strategic mine planning and parametric design are critical innovations at a point where mining companies are looking to reduce time to market and address marginal economic deposits and ESG challenges.

By reducing reliance on traditional mine planning tools and embracing new and innovative technologies, companies can find the opportunities they need to move forward into a secure and responsible future.

Thiago Henrique Buoso, Haver & Boecker Niagara, Brazil, discusses how choosing the right condition monitoring system can minimise downtime and maximise ROI.

A

s the saying goes, a watched pot never boils. Rather than idling by the stove, gathering the meal’s ingredients first can yield a bubbling pot upon your return and enhance efficiency.

While the idea of leaving things alone applies to many activities beyond cooking, it is not an effective approach to the screening process within mineral processing environments.

Undetected issues with vibrating screens can allow out-of-spec material to pass through, as well as cause further damage over time. In addition, any downtime for repairs can lead to production losses.

It is not viable for operators to monitor vibrating screens all the time. Fortunately, using a condition monitoring system takes this task off their hands, ensuring screens stay healthy without constant attention.

global mining review // January/February 2024 77

Proactive performance over reactionary repairs

Any mineral production plant faces the challenges of maintaining the uptime of its equipment, while reducing the cost of corrective maintenance. The information that condition monitoring systems provide can therefore be an invaluable asset to mine managers. However, not all systems are made equally.

Figure 1. Condition monitoring systems use modern algorithms and artificial intelligence to monitor the health of the vibrating screens on site by forecasting the equipment’s dynamic condition, predicting necessary maintenance, and providing critical downtime alerts.

Most of the available options on the market are reactive and unable to prevent unscheduled shutdowns and costly reduction in output. This is typically because these systems send only very specific information, and often in a format that is difficult for operators to understand.

Condition monitoring systems that stand out from the pack are those that use modern algorithms and artificial intelligence to monitor the health of the vibrating screens on site. These condition monitoring systems use their advanced technology to forecast the equipment’s dynamic condition, as well as predict necessary maintenance and provide critical downtime alerts. They can identify common types of failures such as lubrication faults, contamination, and bearing damage, as well as loose or broken structural parts of the vibrating screen body.

Over time, a condition monitoring system should be getting ‘smarter’ by using its artificial intelligence to improve the accuracy of the alerts it sends.

Understandably, purchasing any monitoring system can seem like an additional cost on top of other operational expenses. However, it is important to note that a well-chosen condition monitoring system almost eliminates unscheduled downtimes, significantly reduces corrective maintenance hours, and consequently increases equipment performance.

Typically, most operations encounter an average of one significant issue each month, with a total of 10 – 12 per year. In some cases, just one critical alert effectively pays for an entire three years of a condition monitoring system. When considering that certain condition monitoring systems prevent critical failure for just US$22 per day, it is hard to refute that the investment is worth the reward.

Diagraming the diagnostics

Figure 2. Condition monitoring systems offer 24/7 equipment surveillance through permanently installed sensors that can be installed at any time on the equipment.

Figure 3. The best manufacturer will not just sell you the system, but will partner with you to offer a comprehensive evaluation experience for your production plant. Diagnostics are often the first step, which can involve impact tests, vibration analysis, and condition monitoring.

78 January/February 2024 // global mining review

While monitoring systems for vibrating screen bearings are common in the market, more advanced options offer 24/7 equipment condition monitoring through permanently installed sensors on both the bearings and the body of the vibrating screens. Although the sensor configurations are customisable, the typical setup involves four body sensors placed on each corner of the vibrating screen, with the addition of two bearing sensors. For larger screens, eight body sensors and six bearing sensors are used. In just one day, it is possible to install sensors on multiple machines in case of a plant stoppage. Since receptors do not require the screen to be stopped, they can be installed at any time. Condition monitoring can be installed at any point on the equipment, but the sooner the better is the optimal time for quick dividends from the service.

Once installed, condition monitoring quickly gets to work scanning the vibrating screen for deviations that may lead to damage or loss of production. From there, artificial intelligence is used to predict the dynamic conditions of the equipment.

For many operations, maintenance time is optimised by noting probable causes of potential failure of the equipment, such as loss of stiffness or uneven spreading of material feed on the screen media. Last but not least, customer focus is central to high-quality condition monitoring by providing easily interpreted information every five minutes.

Not only can information be provided continuously, but it can be accessed online and remotely. While these systems are compatible with any Wi-Fi network, integrating data via cable or an application programming interface is a good backup in case

of any outages. Other benefits of high-tier condition monitoring systems include quality hardware such as industry-leading sensors, as well as a long battery life of more than two years, which is noteworthy given the daily use of vibrating screens.

Condition monitoring is most effective for 24/7 operations, as well as those which process high-priced materials, work in aggressive or hazardous environments, or only have a small maintenance team. Partnering with an OEM-certified technician is a cost-effective first step towards identifying whether such a system is the best fit for an operation.

All-inclusive inspection

Countless companies have thrown their hat in the ring with a condition monitoring system to gain the business of producers.

Some of these companies specialise only in technology with no direct aggregate or mining connections. Others are OEMs that serve the industries but have limited coverage or service capabilities after initial installation. Those who rise above are manufacturers with the complete package – the equipment and extensive industry knowledge, an experienced team that offers insight and service to customers, and a condition monitoring system with the features those customers need to stay competitive.

Part of the value of condition monitoring systems lies in the service that producers receive from the OEM. Even the best systems require a human element when questions arise, training is required, or upon new installation. Considering the history and experience level of a manufacturer when selecting a condition monitoring system will undoubtedly save time and

Figure 4. A good manufacturer provides a skilled technician who evaluates screening equipment through a detailed checklist, trains personnel on proper installation and operation of condition monitoring systems, and works with the customer to develop a preventative maintenance plan.

YOUR NEW CONTACT FOR HIGH-QUALITY TRACK SHOES

, 2024, L 23-26 I R P A , &T EXPO ISIT US! T THE M . COME AND V A T N E S BE PRE AT BOOTH I33 K WILL BS TRAC PAULO BRAZIL SAO

prevent future headaches. Start by looking at whether the company has dedicated experience in the mining and aggregates industries. Then, determine how long they have been involved in the industry, what their customer service commitment is like, and their territory coverage. A global company that has an expansive service team is much more likely to be able to send someone for a consult, to troubleshoot, or to install sensors on a new screen than a regional company without that depth of personnel.

Having a deep bench and industry expertise is half of the equation, but the technology and condition monitoring system itself play a vital role as well. The best manufacturer will not just sell you the system, but will partner with you to offer a comprehensive evaluation experience for your production plant. In these cases, an in-depth, eight-point inspection can be provided that thoroughly assesses the efficiency of an operation. Diagnostics are often the first step, which can involve impact tests, vibration analysis, and condition monitoring. Impact tests ensure that each machine is properly calibrated to avoid operating in resonance, which can diminish productivity, incur damage to vibrating screens, and pose safety risks. Vibration analysis examines the real-time health of vibrating screens by detecting irregularities. Condition monitoring elevates these results by not just identifying and fixing current issues, but emergent ones. The remaining steps of the inspection can involve using the manufacturer’s expertise in processing

equipment, engineered screen media, original parts, rebuilds and upgrades, services, plants, and process engineering to inspect customers’ screening processes and recommend best practices for processing proficiency.

Reputable manufacturers will ensure that all information to install the condition monitoring system is available before the components are shipped, so that the customer’s personnel can install the system themselves. However, it is always good to consider the presence of an OEM technician to help during that process, not only for troubleshooting reasons, but also to register personnel and make certain they all have training and proper access to the system, so that they know where to find necessary information.

Do not let production problems boil over

While a pot on the stove does require an occasional glance, mineral processing equipment needs more immediate attention. Smaller issues, such as wear or damage to the vibrating screen that are not caught quickly, can lead to bigger production headaches – and losses – later on. This is why monitoring systems in line with the latest industry advancements in smart technology are vital for the health of any efficient operation. Finding the right system and manufacturer to partner with can provide the strongest ROI and ensures keeping up with – or beating out – the competition.

Advert Index 47 Alimak

15 Komatsu

71 Andritz

75 LENSER Filtration GmbH

29 Becker Mining Systems

IFC Maestro Digital Mine

79 BS Track

09 MMD GPHC

67 Christian Pfeiffer

06 Orica

48 CIM Connect Convention + Expo

18 PDAC 2024

17 Cincinnati Mine Machinery Co.

IBC Regal Rexnord

33 Denso Inc.

63 Richwood

02 Dyno Nobel

55 RIEGL

52 Euro Mine Expo

59 SafeAI

39 Fenner Dunlop Conveyor Belting

04 SSAB Hardox

33 & 40 Global Mining Review 11 Hägglunds OFC & 21 Innovative Wireless Technology 72 Investing in African Mining Indaba 2024 27 J.H. Fletcher 23 Jennmar

80 January/February 2024 // global mining review

43 Stantec 35

TerraSource Global / Elgin Separation Solutions

51 Weber Mining and Tunnelling OBC Weir Minerals 35 World Coal

Powertrain Solutions

Bearings Bearings

Bearings

Belt & Chain Drives

Belt & Chain Belt & Chain Drives Drives Belt & Chain Drives

Bearings

Clutches & Clutches & Backstops Backstops Clutches & Backstops

Clutches & Conveying Backstops Conveying Conveying Conveying

Stop seeing individual parts.

Start seeing unlimited possibilities.

Regardless of your objectives or the challenges with your application, Powertrain Solutions can help you achieve your Monitoring & Disc & Gear Speedtogether.

Reducers unique goals. No matter what your application looks like, it Gear relies on many components, allSpeed working But not Monitoring & Motors Disc & Conveying Reducers Belt & Chain Clutches Clutches &Conveying Diagnostics Belt & Chain Clutches & Conveying Monitoring & Belt & Chain Clutches & Couplings & Gearboxes Disc & GearConveying Speed Reducers Motors & Bearings Belt & Chain BearingsBearings Motors Couplings & Gearboxes Bearings Monitoring Diagnostics & Disc & Gear Speed Reducers Backstops Backstops Diagnostics Backstops Couplings & Gearboxes Drives Drives Drives Drives Backstops Motors all components are made to work together reliably and efficiently. Powertrain Solutions has the insight,Diagnostics experience Couplings & Gearboxes and expertise to engineer your collection of components into a fully optimized system — giving you solutions that boost efficiency, improve reliability and performance, lower costs and simplify ordering and logistics.

W H E R E O T H E R S S E E PA R T S , W E S E E A S Y S T E M

Bearings

Belt & Chain Drives

Clutches & Backstops

Conveying

Disc & Gear Couplings

Motors

Speed Reducers & Gearboxes

Monitoring & Diagnostics

Monitoring & Monitoring & & Disc & Gear Speed Reducers Disc & Gear Speed Reducers Disc & Gear Speed Reducers Monitoring & Monitoring Disc & Gear Motors Motors MotorsSpeed Reducers Diagnostics Diagnostics Diagnostics Couplings Motors & Gearboxes Couplings & Gearboxes Couplings & Gearboxes Diagnostics Couplings & Gearboxes

It’s time to see the bigger picture.

Get started at RegalRexnord.com/Powertrain

Regal Rexnord is a trademark of Regal Rexnord Corporation or one of its affiliated companies.

© 2023 Regal Rexnord Corporation, All Rights Reserved.

MCAD23009E • Form# MB0122E

Don’t spend more on tailings than you have to.

Weir Minerals’ unmatched technology and expertise means you can find a solution that’s built to your operational and site requirements. We’ve reduced customer energy consumption by 51%, average water usage by 76% and lowered TCO all while safely improving the stability of tailings and reducing the tailings footprint. Plus, we can even help re-purpose waste into useful materials for dam wall construction and backfill that saves valuable resources and increases efficiency.

Now it’s your turn to re-think tailings with a Weir Minerals tailored solution.

global.weir/rethink_tailings Copyright© 2023, Weir Minerals Australia Ltd. All rights reserved.