Global Mining Review May 2022 by PalladianPublications

MAY 2022 VOLUME 5 ISSUE 4

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CONTENTS 03

Editor’s Comment

World News

Screening News

Gold Mining And The Evolving ESG

Terry Heymann, World Gold Council, UK, discusses the importance of addressing both the risks and positive ESG impacts of the gold mining sector.

Giant Tyres For A Growing Need

The Need To Adapt

Rock-Solid Communications For The Underground Mine

Giant tyres are designed to withstand the most demanding activities and environments. Piero Torassa, BKT Europe, identifies why giant tyres are therefore fundamental for machine performance and company productivity. Goodyear UK, explores the role tyre systems are set to play in the connected mine of the future.

Jaime Laguna, Nokia, USA, evaluates the benefits of private wireless networks as mines go deeper underground.

Slashing Cycle Times

Uwe Wyink, Hugo Bras, and Precious Jere, Master Builders Solutions, consider why new demands and new technology in hard rock mining mean that cementitious grouts are under more pressure to perform than ever.

Shining A Spotlight On Shotcrete Spraying

Rick Kraft, Getman, USA, outlines the development process involved in making the latest evolution of shotcrete spraying solutions a reality.

Energy Transition Opportunities In Mining

Making Automation And Control A Reality

Double Down On Data

Better Safety Through Simulation

Rod Saffy, Aggreko, provides insights on how embracing renewables into a mining operation’s energy mix creates positive impacts on cost and emission savings. Johnny Wang, Baraja, China, examines how automation can help mining operations boost employee safety, improve productivity time, and increase profit margins. Phillip McBride, I4 Mining and Rayven, Australia, reviews how the way to achieving emissions, ESG, or any Industry 4.0 and automation goals starts with data. Andre Mendes, ThoroughTec Simulation, Canada, explains how interactive training solutions can improve operator safety and efficiency.

GLOBAL MINING REVIEW MAY 2022

MAY 2022 VOLUME 5 ISSUE 4

ON THE COVER

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Pervasive and reliable connectivity is key to making mining automation work. Nokia believes that building a state-of-the-art private wireless network is the foundation for agile and automated operations – above and underground. It enhances critical communications and enables digital applications to make mines safer, more sustainable, productive, and efficient. Learn more at nokia.ly/mining

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Editor’s Comment T

WILL OWEN (EDITOR) Global Mining Review MANAGING EDITOR James Little james.little@globalminingreview.com SENIOR EDITOR Callum O’Reilly callum.oreilly@globalminingreview.com EDITOR Will Owen will.owen@globalminingreview.com ASSISTANT EDITOR Jessica Casey jessica.casey@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 EVENTS MANAGER Louise Cameron louise.cameron@globalminingreview.com DIGITAL ADMINISTRATOR Leah Jones leah.jones@globalminingreview.com VIDEO CONTENT ASSISTANT Molly Bryant molly.bryant@globalminingreview.com GLOBAL MINING REVIEW (ISSN No: 2515-2777) is published by Palladian Publications Ltd. Annual subscription (nine 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.

here is truly something special about the month of May. Here in the UK, and across much of the Northern Hemisphere, May marks the height of Spring and the start of Summer. A time for optimism and new beginnings. To quote Nicholas Breton, poet and prose writer of the English Renaissance, “it is now May… It is the month wherein Nature hath her fill of mirth, and the senses are filled with delights. I conclude, it is from the Heavens a grace, and to Earth a gladness.” Likewise, Edwin Way Teale, American naturalist, photographer and writer, once wrote: “The world’s favourite season is the spring. All things seem possible in May.” This sentiment of optimism and endless possibilities can not only be found in the words of writers of times gone by, it can be seen in the world all around us, and especially in the mining industry, for which the year is off to a strong start. With the gauntlet of fast-tracking the green transition, post-haste, laid down by the COP26 Climate Change Conference back in November 2021, battery materials demand continues to hit new highs – for example, McKinsey is projecting rapid growth in global demand for lithium alone between 2025 and 2030.1 Furthermore, with the shadow and disruption of the COVID-19 pandemic seemingly starting to lift, projects around the world have begun resuming normal operations. Both of these trends have contributed significantly to a growing sense of sanguinity, which has been spreading across the mining industry. I had the privilege of experiencing this optimism first-hand back in March, when I attended MINEXCHANGE 2022 SME Annual Conference & Expo in Salt Lake City, Utah. With over a greater-than-expected 5000 attendees in attendance, 480 exhibitors, and 430 presentations/papers delivered over 88 different technical sessions, the atmosphere was fantastic. Moreover, with all the new technologies on display and ideas being discussed, there was plenty to be excited about. With trade-shows and exhibitions evidently back to business as near normal as possible, there is much for the mining industry to look forward to this Summer. Indeed, don’t miss the chance to grab a print copy of this issue of Global Mining Review at Elko Mining Expo in Nevada (6 – 10 June), and upcoming our June issue at the PDAC 2022 Convention in Toronto (13 – 15 June in person, 28 – 29 June online). In the meantime, make sure to check out the rest of this issue next. In particular, on pages 10 – 12, The World Gold Council provides our latest special report on gold; discussing the importance of addressing both the risks and positive ESG impacts of the gold mining sector. Likewise, don’t miss the latest insights from this month’s cover advertiser, Nokia, on pages 30 – 33, which include an evaluation of the benefits of private wireless networks as mines go deeper underground. Optimism does by no means diminish the necessity of hard work, and there is certainly plenty of that in store for the mining industry, but it can make all the difference in sustaining efforts along the road to breakthroughs and eventual success. This all being said, one cannot ignore the gravity of the events playing out before our eyes in Ukraine. Not only does the scale of the humanitarian crisis continue to grow, but the fallout of the Russian invasion has caused a ripple effect that continues to have significant implications for markets and industries all over the world, and not least the mining industry. As Reuters has reported, while on one hand mining companies have benefitted from soaring commodity prices, they are also faced with the threat of high inflation that could follow, with the potential for a significant blow to be struck to short-term demand and a slowdown in growth.2 To conclude, clearly there is a lot for the mining industry to feel good about this May, but, of course, it does not exist in isolation from the rest of the world. The impacts of the ongoing Ukraine-Russia conflict cannot be ignored, and will require us all to carefully re-asses our plans and expectations for the rest of the year. 1. 2.

AZEVEDO, M., BACZYŃSKA, M., HOFFMAN, K., and KRAUZE, A., ‘Lithium mining: How new production technologies could fuel the global EV revolution’, McKinsey & Company, (12 April 2022). DENINA, C., and MENON, P., ‘Mining companies may pause growth plans amid Ukraine war, inflation’, Reuters, (3 March 2022). Palladian Publications Ltd, 15 South Street, Farnham, Surrey, GU9 7QU, UK t: +44 (0)1252 718999 // w: www.globalminingreview.com

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WORLD NEWS AUSTRALIA Greatland Gold awarded a drilling grant for Paterson province exploration project

reatland Gold plc, a mining development and exploration company with a focus on precious and base metals, has been awarded a grant from the Western Australian government to co-fund exploration drilling and mobilisation costs at its 100% owned Rudall licence in the Paterson province. The Rudall licence covers an area of approximately 65 km2

approximately 20 km south-southeast of Greatland’s Havieron gold-copper resource. The grant awarded is the result of a successful application under the exploration incentive scheme. Greatland is eligible to receive a grant up to AUS$200 000 to co-fund drilling and mobilisation costs, within 12 months of the grant.

AUSTRALIA Omniflex and AMOG receives funding from METS Ignited

mniflex and AMOG Consulting, who have collaboratively developed Industrial Internet of Things (IIoT) oversize detection instrumentation for the global mining industry, have received new funding from METS Ignited as part of an AUS$2.5 million funding initiative. The funding is aimed at backing companies that have successfully commercialised technologies under previous METS Ignited funded projects in the mining equipment, technology, and services sector. Mines often operate by blasting mine and pit faces with explosives, producing rubble of various shapes and sizes. This is then loaded onto large haul trucks and transported to an ore crusher. When oversized rubble reaches the crusher, it can block and damage it, halting production while blockages are removed, or parts are replaced.

Omniflex and AMOG have collaboratively developed IIoT instrumentation to boost oversize detection capabilities for the global mining industry. The system uses sensors to detect the size of ore rubble as it is loaded into haul trucks to be carried from the blast site to the crushing plant. This information is wirelessly communicated in real time to the driver, mine operations, and/or remote data storage for later analysis. The initial technology creation was possible due to METS Ignited Collaborative Project funds. This new project aims to accelerate the scaling up of the business to meet global industry demand. This includes expanding production, testing capabilities, certification, enabling rapid adoption of this innovative digital technology.

USA Rio Tinto starts tellurium production at Kennecott

io Tinto has started producing tellurium at its Kennecott copper operation in Utah, becoming one of only two US producers of the critical mineral used in advanced thin film photovoltaic solar panels. The tellurium will be refined in North America by 5N Plus, a leading global producer of specialty semiconductors and performance materials, under a commercial agreement between 5N Plus and Rio Tinto. The refined tellurium will primarily be supplied to First Solar, the only American company among the world’s 10 largest solar manufacturers, under an existing supply contract between 5N Plus and First Solar. 5N Plus will also use the tellurium to manufacture ultra-high purity semiconductor materials at its facility

in St. George, Utah, to serve the security and medical imaging markets. Approximately 20 tpy of tellurium will be produced through a new US$2.9 million circuit built at the Kennecott refinery. This valuable material is recovered from by-product streams generated during the copper refining process, reducing the amount of waste that needs to be treated and discarded as mine tailings. Tellurium is listed as a critical mineral by the US government due to its importance to the economy and energy security. Tellurium is one of 10 metals and products recovered from ore extracted at Kennecott, which produces nearly 15% of US copper with the country’s lowest carbon footprint. GLOBal mining review // May 2022

WORLD NEWS Diary Dates Elko Mining Expo 2022 06 – 10 June 2022 Elko, USA https://exploreelko.com/ event/36th-annual-elko-miningexpo/2022-06-09/ PDAC 2022 Convention 13 – 15 & 28 – 29 June 2022 Toronto, Canada & Online www.pdac.ca/convention Euro Mine Expo 2022 14 – 16 June 2022 Skellefteå, Sweden www.euromineexpo.com Electra Mining Africa 05 – 09 September 2022 Johannesburg, South Africa www.electramining.co.za International Fair EXPO KATOWICE 2022 06 – 09 September 2022 Katowice, Poland www.expo-katowice.com Mining Indonesia 14 – 17 September 2022 Jakarta, Indonesia www.mining-indonesia.com CONEXPO-CON/AGG 2023 14 – 18 March 2023 Las Vegas, USA www.conexpoconagg.com/conexpo-conagg-construction-trade-show To stay informed about the status of industry events and any potential cancellations of events due to COVID-19, visit Global Mining Review’s events page: www.globalminingreview.com/events

May 2022 // global mining review

CANADA Pacific Ridge acquires Chuchi porphyry copper-gold

project

acific Ridge Exploration Ltd has entered into an agreement with AuRico Metals Inc., a wholly owned subsidiary of Centerra Gold Inc., to acquire up to a 75% interest in the Chuchi porphyry copper-gold project, located in the prolific Quesnel Trough, north-central British Columbia. Over 6100 ha. in size, the road accessible Chuchi is located 90 km north of Fort St. James and 35 km northwest of Centerra’s Mount Milligan mine. The project is in the Quesnel terrane and is underlain by lower Jurassic volcanic and sedimentary rocks of the Takla Group (Chuchi Lake succession). Porphyry copper-gold mineralisation at the BP and Rio Algom Zones is associated with a cluster of early Jurassic monzodiorite to syenite porphyry intrusions, dated at 188.5 Ma ± 2.5 Ma. The main BP Zone is defined by 4 x 3 km halo of outer propylitic alteration surrounding a central 1.5 x 1.5 km area of copper-gold mineralisation, which is open to depth and potentially to the east across the north-south trending Valley Fault. Chuchi has a long history of exploration by companies such as Noranda, BP, Rio Algom, Kiska Metals and AuRico, including 8886 m of drilling in 48 holes, of which 39 holes have targeted the main BP Zone. An additional 27 holes were drilled in 1991, but the records for this drilling have been lost. Most of the drilling was shallow, less than 150 m in depth, with many of the drill holes ending in mineralisation. Grades within the mineralised portion of the BP Zone range from 0.21 – 0.4% copper and from 0.21 – 0.44 g/t gold. Pacific Ridge believes that the core of the porphyry system has yet to be identified. The project also contains other targets that could represent porphyry centres. Pacific Ridge is planning an airborne ZTEM resistivity survey and a surface exploration program consisting of mapping, sampling and core re-logging this summer, with the objective of defining drill targets for the 2023 field season.

GLOBAL Glencore and Li-Cycle announce partnership

lencore has established a strategic partnership with Li-Cycle Holdings Corp., a leading lithium-ion battery recycler in North America. Glencore will subscribe for convertible debt in Li-Cycle and Li-Cycle will become a preferred partner for Glencore in the lithium-ion battery recycling sector. With the addition of this strategic partnership with Li-Cycle, Glencore will seek to combine primary and recycled battery raw materials to produce battery grade end products. This will enable auto manufacturers to meet their EV ambitions, while also being able to meet key regulatory directives related to battery raw materials. Subject to the satisfaction of customary conditions precedent and entry into the key commercial agreements, which is expected in 2Q22, Glencore will subscribe for US$200 million of convertible debt in Li-Cycle. If Glencore elects to convert during the conversion option period, Glencore would hold an approximate 10% equity stake in Li-Cycle. Upon closing, Glencore will have the right to nominate one board member to the Li-Cycle board. Kunal Sinha will be nominated by Glencore.

TR-2000 ROADHEADER The TR-2000 type roadheader is a self-propelled machine with cutting boom and hydraulic drive intended for drivage of gallery excavations (tunnels) in rocks with unconfined compressive strength below 80 MPa.

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Screening NEWS MAJOR offers on-site technical services to maximise screening performance

AJOR, a leading global manufacturer of high-performance wire screening media, works closely with its dealer network to offer complimentary on-site technical services for end users. Each programme is designed to help producers and contractors in the aggregates, mining, construction and recycling industries, to maximise uptime with their screen media and includes local screening performance assessments, technical assistance, training workshops, and more. MAJOR certified dealers offer screening performance assessments to identify opportunities and offer solutions for improvement to increase plant uptime and screening efficiency. A MAJOR screening expert will visit the operation and collaborate with producers to collect data and operational parameters. Upon reviewing the data, the screening expert will provide a report that includes recommendations for improvement and outlines opportunities for growth.

Technical assistance is also available through MAJOR’s dealer network. This involves a personalised plant visit where a local screening expert can address issues and make recommendations on optimal screening solutions. Each plant visit will include a vibration analysis test with MAJOR’s signature FLEX-MAT Sensor. The app-controlled vibration analysis sensor enables readings of screen box vibrations within seconds and generates a report, allowing MAJOR certified technicians to review results and fine tune an operation’s screen box without shutting down the equipment. Additionally, MAJOR and its dealer network offer aggregate and mining producers on-site training opportunities to optimise efficiency. The seminars educate plant managers, operators, and maintenance crews on best practices for screen media usage and how to prevent inefficiencies. Operations can also request custom training sessions focused on specific challenges or applications.

FLSMIDTH supplies full equipment flowsheet to Sabina Gold & Silver

LSmidth has been chosen to supply the full equipment and processing flowsheet for Sabina Gold & Silver Corp.’s Goose gold mine in the West Kitikmeot region of Nunavut, Canada. The order is valued at approximately DKK 270 million and was booked in 2Q22. The equipment is due to be delivered in the middle of 2023, ahead of the mine start-up date in 1Q25.

FLSmidth will supply the jaw crusher, Raptor® Cone Crushers, ball mill, VXP-Stirred Mill (secondary grinding) and KREBS® cyclones, pumps as well as screens, feeders, and KnelsonTM gravity concentrators. The order also includes equipment for pre-oxidation and leaching; carbon in pulp extraction; absorption, desorption, and refining; and detoxification.

ANDRITZ develops new screen roll centrifuge

NDRITZ has developed a new screen scroll centrifuge with innovative features that reduce wear, enable the rapid exchange of parts, and increase maintainability. The new ANDRITZ screen scroll centrifuge HX can process bulk chemicals, minerals, agrochemicals and food, even under difficult feeding conditions. It is designed for improved product quality and maintainability. New features include a Gentle FeederTM feeding system, a modular scroll, and a rotating assembly that can be removed and replaced in one piece (express cartridge). The express cartridge design enables the entire rotating assembly to be replaced without dismantling any process piping, reducing downtime to less than 8 hrs, even for major maintenance

8 May 2022 // global mining review

work. Minor maintenance work can be done without removing the cartridge as the scroll and screens are easily accessible and removable. The scroll itself is a modular unit designed specifically for cost efficiency and rapid repairs – worn parts can be replaced separately using standard tools. These new features minimise maintenance costs and maximise uptime. The screen scroll centrifuge HX is also equipped with ANDRITZ’s proven Gentle Feeder feeding system. It gently accelerates the solids, thus reducing particle breakage and screen wear. An automated cleaning-in-place system, a cake washing feature and optional additional wear protection round off this innovative solution.

85 YEARS OF SOLUTIONS. Since 1937, Fletcher has been answering some of underground mining’s toughest questions. At Fletcher we provide more than solutions, we provide an atmosphere for an open dialogue with customers to ensure their operations are reaching maximum efficiency. Fletcher provides lifetime support through an experienced, knowledgable team of sales staff, engineers and field service technicans. Is your operation facing obstacles that mass produced equipment isn’t addressing? Get your custom solution started today. Learn more at www.jhfletcher.com

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10 May 2022 // global mining review

Terry Heymann, World Gold Council, UK, discusses the importance of addressing both the risks and positive ESG impacts of the gold mining sector.

ver recent years, investors have increasingly been considering how to integrate environmental, social, and governance (ESG) considerations into their investment decision processes. Similarly, consumers have become more mindful of the need to ensure the gold they purchase has been responsibly sourced. This has implications for the whole gold supply chain, but it often starts with an examination of the nature of mining operations and need to validate whether companies and the wider sector can demonstrate responsible and sustainable business practices. And, as for all sectors, investor, regulatory, and societal expectations are broadening. Business leaders are increasingly asked to look beyond the objective of creating shareholder value, and exhibit an understanding of the wider social and environmental impacts of their companies and products. Recently, Blackrock’s Evy Hambro, a leading mining-focused fund manager, publicly stressed the importance of miners being able to explain the positive impact they have on the economies and communities in their host countries. He noted that the majority of miners’ ESG reports focus primarily on the negatives – the downside risks – rather than the opportunities. Hambro is right; the gold mining sector needs to better communicate the societal and environmental positive impacts it brings, as well as the steps it is taking to address risks. It is important to note that the gold industry has clear standards in place, across the supply chain, including the World Gold Council’s Responsible Gold Mining Principles (RGMPs) and the LBMA’s Responsible Gold Guidance. The RGMPs were developed to address all the material ESG risks associated with gold mining; and the Responsible Gold Guidance is followed by all LBMA-accredited refiners, in order to ensure that they have appropriate responsible sourcing procedures in place. These complementary frameworks should give all stakeholders confidence that the gold they invest in has been mined and processed in a responsible manner. In addition, the industry also plays an important role in delivering wider positive impacts that help advance the UN Sustainable Development Goals (SDGs). Responsible gold mining supports sustained socio-economic development in many of the countries and communities where gold is mined. It creates well-paid jobs for local workers, stimulates local economies, provides valuable tax revenues for host governments, and generates sustained benefits for local

global mining review // May 2022

communities through infrastructure provision and supporting health and educational provision. Furthermore, the gold mining sector has credible plans to decarbonise and, if the industry continues on its current path, its emissions reduction will broadly be in line with the climate targets set by the Paris Agreement. Looking downstream, at gold as an investment asset, it offers a number of benefits to investors which suggest it might play a positive role to play in reducing exposure to climate-related risks within a multi-asset portfolio.

Value distribution and wider socio-economic impacts

The World Gold Council’s members, 32 of the world’s leading gold mining companies, are committed to responsible and sustainable business and operational practices. In 2019, it launched the RGMPs – a framework that sets out clear expectations for consumers, investors, and industry stakeholders as to what constitutes responsible gold mining. Developed with its members, and through extensive stakeholder consultation, the RGMPs comprise 51 principles that address all material environmental, social, and governance issues for the sector. All of the World Gold Council’s members are committed to implementing the RGMPs, which requires publicly-disclosed external assurance by a third-party. The hope is that the RGMPs will be adopted across the entire gold mining sector, and the council has seen a number of non-World Gold Council members commit to implementation. In addition to committing to responsible mining, the members are also committed to supporting social and economic development in the countries and communities where they operate. Gold mining is a major economic driver for many countries across the world. Well-managed, transparent, and accountable resource extraction can be a major contributor to economic growth, due to the creation of employment and business opportunities for local people. In 2021, the World Gold Council released a report – the Social and Economic Contribution of Gold Mining – which examined the value contributed by its members in the countries in which they operate. This report, covering 31 member companies, operating in 38 countries and producing 34.5 million of oz of gold, found that, collectively, these companies contributed close to US$38 billion to the GDPs of host countries. This represented 63% of the total revenue they received from gold sales, and equates to almost US$1100 in value added locally for every ounce of gold produced. It also highlighted the positive impacts on stimulating wider employment, including job creation beyond the mine site; for every job at a mine, a further six are supported in the broader economy. Furthermore, in contrast to historical trends, the vast majority of the mine’s workers – over 95% – are employees from that country. Members also support their host communities by investing in infrastructure, proving education opportunities, and healthcare facilities and services, including, for example, COVID-19 relief and tackling malaria.

Gold and climate risk mitigation

The World Gold Council and its members recognise that climate change imposes very substantial risks to the global

12 May 2022 // global mining review

economy and socio-economic development. Policy makers, industry participants, investors, and wider society are eager to develop a greater understanding of these risks and their potential consequences, and how they might be mitigated or managed in future. To contribute to a clearer, more consistent appreciation of how climate-related risks and opportunities might impact the future prospects of the gold industry and its many stakeholders, it has undertaken a programme of research, in collaboration with leading climate and sustainability experts. Substantive research has looked in detail at the gold industry’s carbon footprint and led to the conclusion that there is a credible way for the entire supply chain to reach net-zero by 2050. The research also evaluates the impacts of reducing gold mining’s power emissions by 2030 to assess what would be required to be consistent with the Paris-aligned climate targets. Based on the industry’s current status and known plans, coupled with analysts’ estimations of future trends, the World Gold Council calculates the primary cause of sectoral emissions – the carbon intensity of power used in gold production – is estimated to fall by approximately 35% by 2030. This reduction is based on the growing decarbonisation of grid-sourced electricity, and gold mining company actions to replace direct site-generated electricity from fossil fuels with the increased use of renewable energy sources, alongside substantially reduced production from higher emission mines. Furthermore, as gold miners decarbonise their energy sources at mine sites, they can also bring cleaner power to local communities and, in some locations, will be a key factor in bringing low carbon electricity to the region, with potential development benefits well beyond the mine. Building on a better understanding of gold’s carbon profile and potential decarbonisation pathway, the World Gold Council’s latest research on gold and climate change examines the implications of holding physical gold (or a gold-backed asset) on the climate-related risk and performance profile of diversified portfolios. Its analysis, conducted in collaboration with financial climate risk experts at Urgentem, found that including gold as part of a portfolio of equities and bonds can increase the portfolio’s alignment to climate targets while reducing the portfolio’s overall carbon footprint, and reduce the vulnerability of the portfolios to climate transition risks and shocks, such as the imposition of carbon taxes and the rising cost of carbon more generally.

Carving out a path for future progress

From implementing the RGMPs to, more recently, committing to reporting their positions and progress on climate-related risks in line with the recommendations of the Taskforce for Climate-related Financial Disclosures (TCFD), companies have shown they are committed to taking action and creating real change. While there is still a great deal of work to do and further progress to be made, a vibrant gold sector, with responsible mining at its heart, can make substantial contributions to advancing sustainable development and to supporting the transition to a decarbonised economy.

he most commonly used grout for cable bolts in hard rock mines is ordinary portland cement (OPC). It is tried and tested, well understood by those working with it, and widely available. However, some mines are turning their backs on tradition to work with pre-formulated grouts that behave differently. This change is partly driven by a switch to automated bolting and grouting machines, which perform more efficiently with engineered grouting systems. Productivity gains and a reduction in failures and rework mean that the increase in material costs for pre-formulated grouts is more than offset by savings made elsewhere.

Why bolts fail

The role of a rock bolt is to help take loads from the ground which are no longer supported by the rock that has been removed in the mining process. They are not needed everywhere; it depends on the type of rock and on the stresses and strains in the strata. Geologists and engineers set parameters which determine the type of rock support that is needed at different points in the mine. Grout is installed to fill the gap between the bolt and the rock, as well as any fissures that run from the bolt hole. It is a vital part of the system because it transfers the load from the rock to the bolt. If the gap around the bolt is not properly filled for any reason, the loading on the bolt will not be uniform, which could mean that an overloaded section of bolt will fail at some point. One problem with OPC grouts is that they shrink as they cure, creating space between bolt and rock. This can also allow water to run through the bolt holes, increasing the pace of corrosion of the rock bolt and bringing more water into the mine, weakening the installed ground support.

global mining review // May 2022

Ground water in mines can sometimes be very aggressive, leading to relatively fast failures due to bolt corrosion. For instance, if the water contains sulfates, it is not uncommon for friction bolts to fail within six months. Even where a bolt is fully encapsulated by OPC grout, the water can make its way through the material to corrode the bolt. The outcomes from bolt failures are delays during the mine development process and mining at best, and loss of human

Case study: comparing re-entry times in Australia The time it takes for the grout around a rock bolt to reach the required strength has a huge impact on cycle times, and hence on the productivity of the mine. A hard rock mine in Australia carried out a comparison of the time taken to create an intersection, using three different types of grout: standard OPC grout, a pre-formulated fast-setting grout, and a pre-formulated ultra-fast setting grout. One of the challenges when creating an intersection is that it requires two phases of bolting and grouting. While the grout is curing each time, it is not safe for plant or people to pass through that junction point. This can mean that mining activity in the original drive, as well as in the branch drive, is halted. With the OPC grout taking around 12 hrs to reach a safe strength, the high-strength grout taking 8 hrs, and the ultra-high grout taking just 2 hrs, the difference in cycle times over two phases is significant. A cycle using high-strength grout takes 40 hrs rather than 48 hrs, effectively saving one whole shift. The ultra-fast, high-strength grout cycle takes 28 hrs, saving 20 hrs.

Figure 1. Three-way intersection: Phase 1.

life at worst. Any safety-related incidents must be reported and possibly investigated by the authorities, depending on the region and its legal requirements. Fatal accidents may well involve the police and even the closure of a section or the entire mine for a period. Even where accidents are avoided, slips require significant amounts of remedial work. If the incident has taken place at an important location strategically, the cost of delays will be even greater. As resources, such as lithium, nickel and copper, become scarcer, deposits in challenging ground become more attractive. This also means that bolts will be required more often to provide additional support – and that their failure could be even more costly and dangerous.

Move to automation

When more bolts are required, it can make economic sense for mines to invest in automated processes – e.g. switching to one machine that can drill the bolt hole, as well as install the cable from a roll mounted on the machine that also contains a pump for injecting the grout around the bolt. However, using OPC with these machines increases the risk of breakdowns and delays. When the temperature underground is high, the open time for OPC grouts tends to fall dramatically. This can mean that the grout hardens inside the machine, resulting in clogging and downtime while mechanics are called to repair and restart these expensive pieces of kit. To avoid clogging, operators must spend significant amounts of time on cleaning and maintenance, which prolongs cycle times. Another challenge – which can apply to grout installed traditionally too – is ensuring that OPC grout is pumpable. In practice, this means that water is added until the consistency looks correct, but this increases the water-cement ratio, which in turn leads to bleeding, lower strength grout, and shrinkage. The other tension between using automatic bolting machines and OPC grout is that, while the aim of automation is to increase productivity, traditional grouts generally require a 24 hr wait before re-entry is possible. It is not safe to work in an area that has just been bolted until the grout has reached a predetermined unconfined stress – usually 25 MPa. There can be other repercussions from a grout that takes 24 hrs to gain a safe strength. The ground can keep moving until the grout is hard enough, particularly in situations where there are high stresses and strains in the rock mass, which could lead to problems.

Doing it differently

Figure 2. Three-way intersection: Phase 2.

14 May 2022 // global mining review

Pre-formulated grouts are engineered to overcome the problems that can come with OPC grout. The goal is to provide a grout with a much faster re-entry time and, at the same time, a sufficiently long open time to prevent damage to automated bolting and grouting machines. Rather than a re-entry time of 24 hrs for OPC grout, pre-formulated grouts can provide a

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Figure 3. Rock bolt performance depends on the gap around a rock bolt being fully filled – achieved here with pre-formulated grout. If there are voids, the load from the rocks will be unevenly transferred, and the bolt could fail.

re-entry time of 8 hrs, which has significant implications for cycle times and productivity. Even faster re-entry times can be achieved with pre-formulated grouts (as low as 2 hrs), although these are at the cost of a shorter open time; lower than 1 hr. Typically, pre-formulated grouts contain high-performance additives, which aim to shorten or prolong the open and curing time of the grout. They can also incorporate additives to protect against corrosion and viscosity modifying agents to improve the rheology for better flow during the pumping process. Finally, the grout could also contain additives to make the grout thixotropic – so that it does not run out of overhead bolt holes. From a safety perspective, the addition of the plasticiser to improve flowability means that bolts are more likely to be fully encapsulated, removing the risk of uneven loading and failure. Easily pumpable grout also reduces the wear and maintenance requirements for the pump and lines. Less resistance in the pumping lines also means that lower pumping pressures are needed, and hence less energy is expended. Where aggressive conditions such as sulfates in the ground water exist, pre-formulated grouts can be engineering to guard against corrosion. The addition of a corrosion inhibitor prevents water migrating through the grout to corrode the bolt.

Environmental considerations

Figure 4. When grout made with OPC cures, it shrinks and cracks. That crack becomes a weak point, making loading on the bolt uneven and allowing water to get to the bolt and into the mine.

Figure 5. The choice of grout for rock bolting in mines has a profound impact on cycle times. Whereas traditional OPC take 24 hrs to cure, pre-formulated ones take 8 hrs or less.

16 May 2022 // global mining review

There are three major environmental benefits from switching from OPC to pre-formulated grouts: savings on materials, savings on energy, and the reduction of water inflows into the mine. All of these gains will ultimately reduce the whole-life carbon footprint of the mining operation. It is well-established that the manufacture of cement is one of the biggest emitters of carbon. So, reducing the volume of cement in the grout, and reducing the quantity of grout used over the lifetime of a mine, have a positive impact on the embodied carbon of a support system. Pre-formulated grouts reduce the volume of grout used in two ways. First, because there will be fewer rehabilitations needed due to rock bolt failures, the overall demand for grout will be reduced. Second, because it is supplied in water-resistant paper sacks, there will be no loss of grout due to moisture; contrast this with OPC grouts, where between 5 – 10% of material could be lost when bags stored at the bottom or top of a pile get wet and are unusable. Better encapsulation of the bolts will reduce the amount of groundwater that drips into the mine. This means that less energy is required to pump water from the mines, fewer resources are needed to treat it, and the risk of contamination of local water bodies with mine water is reduced. Although pre-formulated grouts have been available for many years, their use is still limited, especially in hard rock mines. Current research and development programmes aim to improve the technology further. For instance, Master Builders Solutions is creating a new generation of pre-formulated grouts which will deliver the same performance in terms of re-entry time and open time, whatever the rock type or temperature. With these new developments in hand, mine owners and operators have the opportunity to boost productivity, while delivering lower whole life costs, less whole life carbon, and safer working environments.

Rick Kraft, Getman, USA, outlines the development process involved in making the latest evolution of shotcrete spraying solutions a reality.

ot long ago, the underground mining industry relied on a pool of very skilled and experienced shotcrete operators. Today, there is a shortage of skilled operators for spraying concrete, and equipment must evolve to fit the skills of a new generation. After years of development, Getman Corp’s new ProShotTM Concrete Sprayer was introduced in the summer of 2021, with a prototype working in a western-based US mine. The ProShot has been specially designed to use available technology to compensate for a deficit in operator experience. Extensive resources were dedicated to

global mining review // May 2022

its development, including process screen capabilities that allow complete and accurate shotcrete process information to assist operators in applying quality sprayed layers.

Application benefits

The ProShot is user friendly and uncomplicated. New operators are comfortable using touch screen technology in daily life, and thus can easily move through screens and options with minimal shotcrete experience. ProShot uses numerous control area network (CAN) modules, which minimise the number of wires laid out across the machine. Instead of large multiplex bundles passing across the articulation and through the cab,

Essential facts n Key specifications: § Telescopic boom extension: 2.6 m (8.4 ft). § Coverage envelope with telescoping boom parallel (H x W x D): 5.4 m x 8.5 m x 3 m (17.7 ft x 27.9 ft x 9.8 ft). § Stainless steel chemical tank: 1040 l (275 gal.) capacity. § Fuel tank with self-closing cap: 227 l (60 gal.) capacity. n Boom mounted on centreline of chassis. Boom strength allows for effective concrete spraying at full kinematic boom coverage using 2 ½ in. hose. n Modular engine compartment permits ease of access for engine maintenance. n Easy to access operator cabin mounted mid-frame to reduce exposure to rebound and provide good operator visibility. n Nozzle assembly easily disassembles for cleaning without special tools. n ProShot’s innovative in-cab 10 in. touch screen provides real-time information about the machine. With Bluetooth and Wi-Fi capabilities, software revisions are available and accessible via a customer’s smartphone. n The Getman dosing management system provides live spray process information and data acquisition, visible on three 7 in. exterior displays. n Chemical additive dose may be changed via remote, with five preset rates and changes visible on process displays. n An optional OptiME Lidar Scanner is available with the ProShot. The OptiME scans the surface and creates a digital map to determine the thickness of the sprayed layer. The process includes the following steps: boom unfolding, pre-spray scan, nozzleman sprays area, nozzleman performs post-spray scan, then reviews the coverage of the area. Software produces an overlay of both scans in a real-time report for the operator to review and adjust spraying accordingly. n The ProShot features the Schwing 301 concrete pump, designed for pumping low slump material.

18 May 2022 // global mining review

Getman’s design eliminates excessive wires. While CAN is not new technology (over 20 years old), it is proven as particularly effective in this application. ProShot was designed by operators and for operators – with emphasis on it being intuitive, safe, and easy to maintain. An example of the ProShot’s intelligent control layout and fluid operation is a button in the machine’s dosing enclosure to turn rear driving lights on/off so operators may eliminate climbing in and out of the cab. Additionally, forward and reverse lights may be flashed from the steering joystick trigger control while driving to alert other vehicles at crosscuts and intersections.

Mine operations and method1

The ProShot pilot unit now works in New Afton mine, located approximately 346 km (215 miles) northeast of Vancouver, British Columbia. New Afton is the underground extension of the original Afton Mine, which served as an opencast mine from 1977 – 1997. Development of the underground workings, including the construction of a new mill and other infrastructure began in 2009, with production starting in June 2012. The New Afton deposit is mined using the block-caving method. Ore is transported by a load haul dump (LHD) loader from the drawpoints on the extraction level to an ore pass that directs the ore to the haulage level down below. The ore is then loaded onto an LHD loader and into a haul truck that transports the ore to an underground gyratory crusher. From there, the crushed ore is conveyed to surface. Owned and operated by New Gold Inc., New Afton currently processes approximately 13 000 tpd. It produced 98 000 oz of gold and 87 million lbs of copper in 2016. Based on current production rates, proven and probable reserves will allow mining to continue through 2024.

Case study

Current production levels at New Afton are at a depth of over 1 mile. During the summer of 2021, the operation was using three sprayers in various working conditions. A development contractor brought a ProShot to the mine and when New Gold saw it, they wanted to test the machine. Testing began with large-volume rehabilitation sprays. Existing machines were assigned to shoot production levels, as production level sprayers must be certified to meet a certain compressive strength. Criteria level must be met before a sprayer can be certified to spray in production areas. As the ProShot began rehab spraying, all three existing machines went down. Consequently, New Gold took the ProShot down to the production area to try ‘test’ sprays as primary ground support. Concurrently, the ProShot sprayed test panels which normally take 28 days to cure. 2 hr beam test panels were also sprayed and successfully passed the initial test, allowing ProShot to spray primary ground support. The Getman ProShot now sprays production levels two shifts a day, every day. ProShot passed the tryout and met the challenge.

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To appreciate the challenge in full, it is important to understand that concrete transporters are filled at the surface and then travel down a long ramp system in the mine to get to the bottom. With a set number of transporters to travel the distance, it is a long process. Additional product differentiators of ProShot include: nn It is easy to learn and operate; operators recognise it as ‘intuitive’.

n Ease of maintenance (adjustable components are easily accessible). n Clear visibility from the cab. n Equipped with informative diagnostic screens for machine analysis. n Electrical harnesses and connectors are carefully routed to eliminate water ingress. n Strength of design – the purpose-built design features the hose mounted in an easy-to-access area, running alongside the chassis, making it to remove and disconnect. n Longer uptime. n Impressive serviceability/reliability. A second ProShot began work at New Afton in April 2022. Both machines now serve in a primary production ground support role. Following these successful results, New Gold is considering the purchase of additional ProShot machines to support their operations.

Thinking about the future

Figure 1. ProShot spraying in a rehab area to prevent further fall of ground.

Operators often ask how the ProShot spraying solution could be developed further and what is next for shotcrete machines in the mining industry. In truth there are several possibilities: n Alternative power solutions – diesel electric over hydraulic and battery electric. n Awareness of what operators need to understand about the spray process, by making it easier with special tools (such as providing real-time information for successful spraying). Getman’s goal is to provide a machine that communicates all the key variables. Thus, ProShot was designed with maximum utility for inexperienced operators. n Laser scanning systems – now in use, with software continuing to advance. n Machine reliability – robust, user friendly, smart technology. The more complex the machine, the more difficult it is to operate. Recording data related to spraying volume and dosage, and then supplying that data to the operator is realistic. Using that data to help the operator make smart decisions could help product development evolve to remote operation.

Conclusion

Getman dedicated extensive resources over several years to the development of its ProShot technology. The development of previous iterations of shotcrete sprayers led to new ideas and ongoing progress towards the goal of developing the best machine on the market. Increased automation is emerging as the roadmap for future development.

References 1.

Figure 2. The ProShot applied 60 m3 of shotcrete to stabilise a large

remuck gallery inside the New Afton mine.

20 May 2022 // global mining review

Information courtesy of the Mineral Resources Education Program of British Columbia – https://mineralsed.ca/learningresources/bc-mineral-resources-map/bc-operating-mineprofiles/new-afton-mine/

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Figure 1. In the mining sector, modern machinery is larger and more powerful, and requires increasingly outstanding performance from its tyres.

22 May 2022 // global mining review

esearch and the mega-trends of production efficiency and sustainability drive tyre development. In particular, the support of digital technology over the past 10 years has exponentially increased the possible scope of application without any creative limits, but above all by having available data and feasibility and investment forecasts. The tyre market is growing together with the development of the work vehicle segment. Today, the better the machines perform, the more sophisticated the tyres that equip them must be, requiring a unique tool that is available to operators. Perhaps the biggest revolution in recent years is a growth in company awareness that tyres are no longer an accessory component for the vehicle, but that they can be the keystone to ensuring its optimal performance.

What are the challenges of the mining sector and the demands from operators? For a company working in the mining segment, the cost of vehicles can have major impacts on financial statements. These are imposing machines that can withstand heavy loads and which must work in environments where the daily variables in their use are unpredictable, either due to the type of load or soil, or due to climate change. This is why performance needs to be calibrated and planned as precisely as possible; any vehicle downtime represents serious economic damage. Not to mention, a vehicle could remain idle precisely because a tyre is damaged or, even worse, is not the right one. On the other hand, the mining sector, out of all segments, is the one that puts the most strain on tyres; they are at risk of being damaged every day and are quickly worn down in any case. That is why operators are very careful during the purchase phase for each tyre: it is a strategic choice.

Tyres are born from dialogue

BKT, one of the leading manufacturers of off-highway tyres, has invested in research into what technology can be made available to companies today. For the company, dialogue with its users is becoming the driving force for this research. When designing a tyre, there are numerous parameters to satisfy, such as safety, traction, durability, and efficiency. For each type of operation and application, there is a suitable design, compound, structure, inflation, pressure, and, of course, size. As with other manufacturing sectors, the tyre market too is data-drive by indicators which have been increasingly perfected since the start of the digital transformation. Nevertheless, the company has developed its own data organisation by focusing on cases it has collected over the years to transform them into precise feasibility projects, through virtual simulations, tests, and cataloguing of information. This is an asset to which user experience is added as necessary, as well as technical meetings often held with machinery manufacturers. But it is not just technology. In fact, dialogue is born and is possible only through people: users with their needs and

valuable feedback; the BKT staff from the R&D centre; the field engineering team which checks the tyres in the field; and experts who follow customers throughout the whole life cycle of the tyre they have bought, to advise on a possible choice of renewed equipment or to provide solutions and training that may help their daily routine. Investment in the purchase of tyres, especially those used for mining work, is a significant item in customers' budgets. So, how can the investment be optimised? How can the right tyre be matched to the right machine?

Each application corresponds to a particular tyre

BKT recommends having direct and constant contact with the technicians because not all variables can be catalogued, such as working habits and the conditions of the soil, load, and transport. However, the consequences of making the wrong choice are not limited to the tyre. The cost of a bad investment affects many other factors, such as the impacts of vehicle downtime on work schedules, as well as how much such a waste of resources weighs on the sustainability principles of modern businesses. An expert is able to take every detail from the user in order to get an indication of the best solution. This can be useful as today’s tyres are technologically advanced products and can be extremely specific depending on the type of use, machinery, model, conditions, load, and much more. The service must also be continuous and constant in the after-sales service, not just during the tyre selection phase. It is essential that there is always an expert available to solve important or momentary tyre-related problems. A question or doubt is never out of place if raised in good time – in this way, it is possible to correct any problems.

The answer: Giant tyres

In the mining and quarrying sector in particular, modern machinery is very powerful and large and requires tyres capable of dealing with treacherous terrain and heavy loads. Hence the need for ever larger and more resistant tyres. The company offers various products in the giant tyre range. The first is EARTHMAX SR 46, a tyre designed for rigid dump trucks. The second is the EARTHMAX SR 468, the largest tyre ever made by the company, which is also intended for rigid dumpers. Suitable for rough and muddy terrain, this tyre range is particularly resistant to attacks and punctures as a result of the ‘all steel’ structure, which provides resistance to the casing and an E-4 depth tread, which offers resistance in very difficult conditions. Finally, different tread compounds have been specifically developed for different track distances, to reduce heat build-in without compromising cut and wear resistance. These two products are part of BKT’s EARTHMAX line, designed for better distribution of loads on the ground for dumpers, and which today includes 40 different tyres for the OTR sector, available in numerous sizes and compound variants. In addition, BKT has developed another tyre that is particularly suitable for handling mining operations in

global mining review // May 2022

difficult conditions, due to its large size. The EARTHMAX SR 45, designed for rigid dump trucks, features a specific design, and deep tread provide the product with an extended life cycle. Thanks to a particular lug design, the tyre can ensure the best traction under any usage condition. It features a deeper tread, increasing the tyre life-cycle without compromising its performance over time. The special tread compound has been designed for the purpose of providing resistance against cuts, abrasion and impacts – all risks which can be frequently found in extreme usage conditions. By operating in this way, machine downtime is significantly reduced, maximising productivity at the same time.

The EARTHMAX range is produced in the Bhuj plant, the BKT model site where the Indian multinational invested structurally in 2021 in order to expand the production area; with 40% more space, today the site hosts a new plant for the Super Giant OTR line for tyres up to 63 in., one for Super Solid and one for Agri-radial tyres. The modernisation of Bhuj and the subsequent inclusion of new machinery to produce the latest tyres in the Giant range was a challenging process for the company, which found itself having to briefly interrupt the work due to the pandemic. This partially slowed down the project but, since Spring 2021 (after the implementation of all the new safety-related parameters), the machinery has been installed and production could commence.

Case study: India

Figure 2. BKT’s EARTHMAX range of tyres is entirely produced in the Bhuj plant, a model production site equipped with advanced technology.

During the pandemic, EARTHMAX SR 468 came into being. The new machinery that was needed to make the giant tyre reached the Indian plant in Bhuj in January 2020, just before the lockdown which affected – at various levels and at different times – the Asian continent. Initially, owing to the emergency situation created by the COVID-19 pandemic, the machinery at Bhuj was not immediately installed. It was only after a temporary shutdown of the company’s manufacturing facilities, which was necessary to finalise a rigorous safety plan for all staff, did activities finally return to full operation. This included the installation of the new 57 in. giant tyre machinery, which was installed with the remote help of the manufacturer and BKT engineers on site. This is how the first prototype was presented in September 2020 and, after the relevant tests, was put into production in the first few months of 2021. Immediately after its creation, BKT was awarded a supply contract for giant tyres by South Eastern Coalfields Ltd (SECL), a mining company owned by the government of India's Ministry of Coal. The operation involved the supply of 42 EARTHMAX SR 468 tyres in the 40.00 R 57 size, intended to equip the machines present in the quarries distributed around the country and managed by the Ministry; the first batches have already been manufactured and delivered, while others will follow during 2022.

Towards an ever-greater future Figure 3. EARTHMAX SR 468 in the 40.00 R 57 size is the largest tyre ever made by BKT, intended for rigid dumpers.

Figure 4. Three BKT’s EARTHMAX SR 468 tyres in the 40.00 R 57 size are ready to be delivered to the South Eastern Coalfields Ltd mining company.

24 May 2022 // global mining review

There are numerous important issues which are influencing the development of the mining sector and related machinery and components. Among them are automation, data digitalisation, alternative energy, and innovative materials. Given the growing need for productivity, machinery will be increasingly powerful and will need even larger tyres that transform their power into traction and which are above all resistant. BKT is currently working on all of these fronts, with a particular focus on new compounds that have high cut and chip resistance, i.e. against cuts and abrasions, as well as ultra-heat resistant compounds, able to carry large loads and at the same time to maintain an excellent TKPH, that is the average ratio between the weight transported by the machinery and km/h. Some ‘revolutions’ in the tyre world may be invisible to most, but they are no less important.

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BS-F SERIES BACKSTOPS

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Goodyear UK, explores the role tyre systems are set to play in the connected mine of the future.

ver the past few years, there has been a real focus in the mining industry on working smarter. The machines have become more powerful, with higher load capacities; a development which has, naturally, prompted a host of new requirements across the supply chain. One area that has seen a particular need to adapt is tyres. With higher load capacity inevitably comes a conversation about what the tyres in use are capable of, and how they interact with the environment in which they are operating. Sector experts also say that digitialisation has caused the industry to look again at the efficiency of tyres, and the wider benefit that they can offer. There has been a

26 May 2022 // global mining review

particular focus on how tyres are monitored, with new technologies developing in tandem with ground-breaking new products. In short, there is a lot that tyre manufacturers are bringing to the mining industry, all in the name of meeting new challenges and ensuring the most efficient operations possible.

Product innovation

Choosing the right tyre is vitally important, and one of the ways that Goodyear has responded to the challenges facing the mining industry is with a new advanced range of 3*marked tyres for wheel loaders, graders, and underground

global mining review // May 2022

mining machines. Compared to the 2*marked range, these tyres feature a stronger radial carcass with a larger bead section and stronger ply wires. This allows for up to an 18% higher load-carrying capacity, helping to improve efficiencies through a reduction in cost-per-hour and minimising downtime, by standing up to the tough conditions faced in applications, such as underground mining. The company’s Hi-Stability Technology, which consists of a radial sidewall construction, provides greater stability to reduce bucket sway and increase driver confidence in loading operations. Likewise, the improved stability and control help to extend the tyre’s life by minimising deflection and making it more resistant to impact. Besides the 3*marked product, Goodyear’s full line of OTR tyres for quarry and aggregate operations provide a range of options. From the newest off-highway large haulage product line, the Goodyear RH-4A+ helps to deliver a lower operating cost per hour and high productivity in hard rock underfoot conditions. For loaders and articulated dump trucks, the Goodyear TL-3A+ has enhanced traction that makes it efficient for soft underfoot conditions. Beyond this, for specific needs, it may be beneficial to add reinforcements to the sidewall construction which supports increased vehicle loads. Altering the rubber compounds is another adjustment that will help to enhance cut protection and even help better manage heat generation to fit different types of operational journeys, such as short load and unload trajectories or loading and unloading a couple of miles further.

Smart solutions for demanding operations

It is not just the tyres themselves that have continuously improved in recent years. Tyre-monitoring technologies have also advanced dramatically. The industry has come a long way from dusty drivers checking air pressure with a kick, and operators scrawling mileages by pencil in a logbook. Today, Goodyear's heavy-duty tyre pressure monitoring system (TPMS Heavy Duty) can be used to support automated checks of pressure, temperature to detect under inflated tyres, air leaks and mechanical issues. This wealth of data is actually playing a much larger role in mining than originally envisioned, with a tangible impact not only on the life and performance of tyres, but also a mine’s overall productivity and profitability. Unlike many other pieces of mining equipment, tyres travel to every part of a mine and are exposed to almost all of its terrain, weather, temperature, and light conditions. When sensors featuring GPS and accelerometers are added, and the data is analysed, there is potential for enormous impact. After all, proactive maintenance or changing a tyre if necessary before its full end-of-life can help to avoid downtime and contribute to more sustainable operations. The data can do more than just report back on tyres, though. When Goodyear gave four months’ worth of tyre performance statistics to data scientists, in order to help improve performance, the team was able to correlate the tyre data with the GPS data collected from vehicles at a project and found that drivers would often accelerate to higher speeds, ride approximately three miles at that speed, then rapidly decelerate, only to sit in a queue to get loaded or to dump. Previously, the focus had been solely on how that speed, load, and GPS data related to tyre wear. However, the data scientists were able to identify something that was potentially just as valuable. The team eventually concluded that the fleet in question could save between 9 – 12% in fuel consumption if the vehicles were driven at a lower speed, and drivers were trained to not accelerate or brake harshly.

Tyre pressure monitoring system Figure 1. Goodyear's TL-3A+ in action.

Figure 2. Close up of Goodyear's RH4A+.

28 May 2022 // global mining review

Goodyear’s own offering in the tyre-monitoring space arrived in 2018, with the launch of the TPMS Heavy Duty. Having seen the impact that such technology could have on tyres in the transportation sector, Goodyear studies show that having the right pressure at all times and carrying out proactive maintenance can result in increased uptime and working hours, and even extend the lifecycle of the tyre. It made a great deal of sense, therefore, to introduce a heavy-duty option for larger vehicles. In one example of a fleet using four-wheel loaders, Goodyear estimated savings of over €71 000 over a five year period, using its technology. The savings in this particular case comprised: nn €1100/yr from eliminating bi-monthly inflation checks. nn €9700/yr by eliminating tyre disablements (historically one disablement per year). nn €17 600 as a result of increased tyre life of between 10 – 15%.1

Goodyear’s TPMS Heavy Duty includes predictive capability software, which uses machine learning to perform predictive maintenance. This system uses a series of intelligent predictive algorithms, developed by Goodyear engineers, to flag potential issues before they even happen. Combined and derived from Goodyear’s Commercial Tyre and Service business, the system aims to help operators precisely identify and resolve tyre-related issues. The main benefits of using such solutions for tyre maintenance are the potential to minimise downtime, increase tyre mileage, monitor for hazards, and improve fuel savings. There have been cases where the air pressure has slowly dropped due to a spike embedded in a mining truck’s tyre and it was spotted by the algorithm, even though the tyre pressure was well above the thresholds set by the customer. The algorithm can detect when something is slightly off with the tyre’s behaviour, in some cases as far in advance as 42 days before it would have been caught by typical processes. The system then texts the client a slow leak warning, preventing expensive downtime. The company’s EMTrack Off-The-Road tyre performance management system is linked to a mobile phone application for easy and instant data entry with cloud-based data storage which makes information available immediately and from anywhere. EMTrack can be used by operators to manage their fleets’ tyres and rims through key metrics data management and improved maintenance to optimise their tyre investment. Global and local miners can now use the system to compare performance data from projects in, say, Nordics and Newfoundland, and the ability to complete surveys on tablets or phones that can be instantly synced with databases can have a huge impact.

What is next?

As methods of gathering and monitoring tyre data continue to become more established in the mining industry, new technologies are constantly finding their way into the process. For fleets that are looking to make better use of their tyres, there is Goodyear’s Total Mobility value proposition, an all-encompassing service that provides operators with a tailored package of hi-quality tyres, innovative tyre monitoring and management tools, and support with tyre-related maintenance or breakdowns from specialist staff. Having products, solutions, and support available all under one umbrella with databased decision-making often proves to be ideal for operations managers who want to keep their vehicles on the move and their tyres in the best possible shape. It is difficult to know where the industry will go, and what challenges it may find itself facing over the coming years. What is certain, however, is that tyre systems are set to play an even larger role in the connected mine of the future.

Reference 1.

Benefits verified through a real-condition test conducted by Goodyear. Benefits can be achieved by consistently following up on pressure and temperature alerts and reports. Actual results may vary depending on utilisation conditions of the tyres, how often the tyres are replaced, driving conditions, and proper tyre maintenance.

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Jaime Laguna, Nokia, USA, evaluates the benefits of private wireless networks as mines go deeper underground.

smart mining research study published in 2021 showed, the market is projected to reach US$23 055.4 million by 2028, up from US$9614.5 million in 2021.1 The reason for this is clear, as more companies realise the benefit of connecting people, machinery, and even the structure of their mines in order to digitally transform operations. Mine operators have high expectations for these future operations. They want to increase the safety of their workers and protect local communities; maximise utilisation and extend the lifespan of their equipment; optimise processes and workflows to enhance productivity and become more competitive. Operators are also dedicated to managing and using resources more efficiently, in order to meet stringent regulatory requirements and sustainability goals. By accessing operational data and performing intelligent data analytics, they can better support decision-making to achieve all these goals. They will be able to benefit from a mix of old and new services, from simple voice and video person-to-person communications to more complex capabilities. Remote environmental and equipment monitoring, drilling and blasting control, as well as autonomous and tele-remote-controlled vehicles and machinery, are all within their grasp in the connected mine. All of these innovations have one thing in common: they rely on mission-critical wireless communication capabilities.

Ultra-connectivity requires reliable and ubiquitous coverage

To support these use cases, companies need reliable, pervasive network coverage; massive capacity; and low latency – all qualities

30 May 2022 // global mining review

global mining review // May 2022

beyond the reach of many legacy communication technologies. While TETRA and P25-based radio networks overcame the limitations of using fixed telephony, they were never built for broadband data and video communications. Wi-Fi networks replaced inflexible cables that were prone to damage by heavy machinery, but they are not able to provide the heartbeat accuracy required to reliably connect many business-critical and mission-critical applications. Wi-Fi has limitations, even in opencast mining. Access points have limited reach and blasts can impair configurations, making them unusable for continuous operations. Additionally, Wi-Fi networks do not have the quality-of-service features required to prioritise critical network traffic. As extractions move underground, the thick rock walls, steep inclines and networks of tunnels, galleries, enclosed spaces, and ventilation shafts create even greater challenges. Underground, Wi-Fi signals can be weakened and distorted by the structure of the mine itself. In the ultra-connected mine, there can be no tolerance for patchy coverage.

Networks must perform predictably, maintaining ubiquitous connectivity at all times, even as autonomous vehicles and other machinery navigate uneven surfaces and rough terrain. They must be able to support a mix of services and latency needs, and they need to meet strict regulatory standards. Harsh production environments and a continuously changing geography provide challenges for any network, but it is vital to be able to connect people, vehicles and equipment, in addition to digitally monitoring environmental conditions to enhance safety and productivity in today’s mines.

Meeting the challenge of the connected digital mine

Thankfully, industrial-grade private 4G/LTE and 5G wireless networks are more than up to the challenge. Delivering high bandwidth, robust connectivity, pervasive coverage and flexible capacity, they allow companies to reliably connect people and machines, while supporting thousands of sensors and the big data demands of Industry 4.0 use cases and mission-critical applications. Mine operators can leverage the Industrial Internet of Things (IIoT), artificial intelligence (AI) and machine learning, as well as augmented, virtual, and extended reality (AR/VR/XR) to enhance operations over a single network infrastructure. This single network infrastructure is vital as it allows companies to create synergies between applications and gain real-time transparency and insight into their operations. With the ability to support high-speed mobility and predictable quality of service, as well as low-power sensor IoT connectivity, and traditional communications, virtually any underground application can run over private 4G and 5G wireless networks. Autonomous vehicles, drones, remotely operated robots, smart sensors, and even those applications that traditionally required cable connections, such as high-definition CCTV feeds, as Figure 1. Industrial-grade private 4G and 5G delivers the ubiquitous well as mission-critical push-to-talk and push-to-video connectivity needed to monitor environmental conditions communications, are supported. and provide mission-critical communications for enhanced Equipment can be connected and monitored as well worker safety. as the environmental conditions within and around the mine, using IoT sensors, CCTV feeds, and drones to enhance maintenance and safety practices. Geolocation capabilities enable high-precision tracking of people and equipment, and the health of miners can be monitored via wearable PPE devices. Teams can leverage automated workflows, autonomous vehicles, and machinery to optimise operations. At the same time, alerts can be implemented to notify of unusual activity, or if a worker is entering a hazardous area. Even training can be enhanced using AR overlays and VR goggles to deliver risk-free instruction on working in unsafe environments and on expensive equipment.

Figure 2. A private wireless network ensures an underground mine has optimised coverage and no dark spots; so people, vehicles, and equipment can be connected safely at all times.

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A unique network design comprising a mix of radios

Network architecture design, antenna technology selection, and radio planning are key to

successful implementation. Even operational factors create challenges in coverage. Sequential extraction procedures, operational restrictions, and the availability of specialised staff define how work is managed from week to week. While separate teams work concurrently in different sections of a mine, or periodically rotate locations, it can be as important to monitor the environment in the unmanned areas as it is in the locations being mined. Delivering a private wireless network for underground mining means thinking around corners, through walls and along blind spaces. Telecom engineers must consider how to optimise coverage across every point of the mine – there can be no dark spots. Careful consideration must also be given to coverage distance to ensure that the signal from one autonomous vehicle cannot be blocked by another, or by the structure and incline of the mine itself, and that different radio systems do not interfere with each other. While coverage of a single antenna is often limited to a section or gallery, the power of the 4.9G/LTE or 5G signal makes it convenient for supporting caving, room-and-pillar and longwall mining methods, as well as in-mine mission-critical and emergency voice and video communications. A unique design, comprising a mix of radio technologies, including small cells, micro remote radio heads, distributed antenna arrays and radiating cables (also known as leaky feeders), will allow engineers to design a solution that will overcome these issues and meet the unique needs of each mine site – above and underground.

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An end-to-end wireless network

Operators looking to implement private wireless networks should investigate solutions with end-to-end capabilities. Dust, moisture, extreme temperatures, changing topology and pressure waves, as well as seismic activity from explosions, put infrastructure and equipment to the test. By adopting a solution that incorporates ruggedised user equipment, teams can benefit from workpads and handheld devices designed to withstand the harsh environments in and around mines, as well as industrial routers and dongles that simplify the connectivity of mining equipment to the network. Whether mining operators are looking to enhance operations and safety or achieve sustainability goals, private 4.9G/LTE and 5G wireless networks can handle everything. With reliability as rock-solid as the walls of the mines they operate within, as the network of tunnels expands and excavations move deeper underground, the private wireless network will follow, allowing mining operators to enhance capabilities in myriad ways.

References 1.

‘Smart Mining Market Worth US$23 055.4 Million by 2028 at a CAGR of 13.3% Globally, COVID-19 Impact and Analysis’, The Insight Partners, https://www.prnewswire.com/news-releases/ smart-mining-market-worth-us-23-055-4-million-by-2028-at-acagr-of-13-3-globally-covid-19-impact-and-analysis-by-the-insightpartners-301364231.html

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Figure 1. Aggreko Granny Smith solar farm and gas power station from afar.

Rod Saffy, Aggreko, provides insights on how embracing renewables into a mining operation’s energy mix creates positive impacts on cost and emission savings.

hile some miners are embracing decarbonisation and taking steps to lower emissions, others are not sure how to begin their transition to renewable energy. Fortunately, power generation companies are taking significant steps to support miners on their respective paths to net-zero emissions. For those who are yet to introduce renewables, it is not from a lack of desire to change or from not wanting to

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achieve a net-zero emission future. It is because with so much information – or in some cases, too little information when it comes to emerging or future technologies – it can be hard to know where to start. They also express concern about whether new innovations are a wise purchase, given that technology could change further down the line. Luckily, technology is not in the same place as it was five years ago, or even two years ago. Some of the renewable

power technologies available today, combined with thermal generation in a hybrid solution, offer the same – if not better – levels of reliability and competitiveness than traditional thermal technology. While it is of course important that miners weigh up the cost, risks and threat of future new technology, an ideal option to start the renewables journey is to consider a hybrid power solution.

Benefits of hybrid models

If miners are to start with a hybrid power solution – where they can switch in renewables to their power mix, alongside fossil fuels – then their operation is afforded more flexibility to integrate new innovations as they become available, and the power plant can be scaled up and down as needed. There are also ways to de-risk the threat of future innovation. For example, Aggreko’s approach enables miners to partner with the company for the life of their mine. The company’s engineers design an efficient and cost-effective hybrid power plant, meaning miners are not tied down to one fuel type for their power source. Maintenance is also taken care of, and new technology is introduced as it becomes viable. Simply put, integrating renewables with a hybrid power plant can result in greater cost-savings and efficiencies for the project, when done correctly.

Case study: Africa

To gain an understanding of cost and emissions savings, one solar and thermal hybrid solution Aggreko delivered for a remote gold mine in Africa resulted in more than 12% savings in fuel (approximately 10 000 l/d) and the contract offered meant the miner did not have to come up with capital to invest in the solar plant.

Case study: Chile

In another project, a hybrid solar and thermal power solution the company is working on for the Salares Norte opencast mine in Chile, at an altitude of 4500 m, is expected to achieve US$7.4 million of energy cost savings over the next decade, as well as a further US$1.1 million in carbon tax offset over the life of the mine. This project is also expected to achieve 104 000 t of carbon emissions savings. The system will surpass the Chilean government’s current environmental standards, as well as Gold Fields’ requirement for a minimum of 20% renewable power generation for mining operations.

Options other than renewables

There are times when renewable power options in a hybrid model is not possible for miners due to site space constraints or weather unpredictability. Aggreko’s engineers have pioneered a new power system that will clean up to 99% of all controlled emissions (carbon monoxide, nitrous oxide, and hydrocarbon) from generator exhaust streams. The 1300 kW ultra-low emissions package is the world’s lowest-emitting temporary power generation system – exceeding the most stringent environmental requirements and ensuring vital business operations can proceed swiftly through the permitting process. The package works by providing 1300 kW of continuous power output. It features a selective catalyst reducer (SCR)

that separates harmful nitrous oxide into nitrogen and an oxygen catalyst that converts carbon monoxide into carbon dioxide in a highly efficient combination. Emission levels are 90% lower than the next best available technology on the market. The company expects the new technology to revolutionise the way air quality is managed in mining and related sectors, greatly assisting projects on the journey to net-zero.

Decarbonisation pathways – in summary

Decarbonisation energy pathways available to miners currently include:

Hybrid power plants

Hybrid power plants combine renewables (for example solar and wind power) with thermal generation and battery storage, benefiting areas with limited or no access to permanent power. These are generally cost-competitive; once solar or wind plants are installed, their generation running costs are relatively low and at zero emissions.

Virtual gas pipelines

Gas power generation offers a greener and more cost-effective alternative to diesel and heavy fuel oil. A virtual pipeline is a substitute, and an alternative, for a physical pipeline. Gas is instead transported as LNG or CNG to the point of use by sea, road, or rail. For mines not connected to a physical pipeline and looking to switch to gas from diesel, a virtual pipeline model simply imitates their current supply solution. For users who are connected to a gas pipeline but are looking to supplement insufficient or unreliable pipeline capacity, the virtual power plant solution has several advantages over diesel.

Renewable energy

Renewable energy power systems are an effective way of tapping into natural resources to provide power, such as: wind farms, hydro power, and solar. The challenge is their reliability on weather, hence why, if power is interrupted for any reason, it is important to ensure they are backed by batteries or a temporary thermal power solution. A significant future fuel in this space will be hydrogen. Investment in hydrogen is on the rise too because of the role it can play in supporting a global transition to net-zero. Its versatility and compatibility with existing furnaces, engines and generators make it particularly appealing for the mining industry. Businesses around the world are at the beginning of their hydrogen journeys and need to be supported to find the best ways of integrating it into their operations.

Ultra-low emissions package

When space constraints prevent miners from implementing renewables, another option to consider would be a low-emitting thermal power solution. Aggreko’s solution offers an ultra-low-emitting temporary power generation system, which cleans up to 99% of all controlled emissions (carbon monoxide, nitrous oxide, and hydrocarbon) from generator exhaust streams. Emissions levels are 90% lower than other technologies available on the market.

global mining review // May 2022

Future energy pathways

Figure 2. Aggreko Renewables Project at Bisha Mine in Africa.

Figure 3. Aggreko hybrid power plants combining renewables with battery storage and other sources.

Energy sources likely to become more prevalent in mining during the next decade include biofuels (as they become less expensive), hydropower, energy storage (such as pumped, mechanical flywheels), and gas generation which runs with a hybrid renewable system. While they are already increasingly used as power sources now, wind and solar power are expected to gain more momentum. Aggreko is also experimenting with mobile wind solutions, re-deployable solar panels, and tidal wave power (though tidal wave power might not be for the mining industry yet). Energy providers are also committing to emissions targets and incorporating environmental strategies into their corporate strategies. Aggreko is committed to operating as a net-zero business across all services it provides by 2050. The company will also reduce the amount of fossil diesel fuel used in customer solutions by at least 50%, reduce local air quality emissions of its solutions by 50%, and achieve net-zero across its own business operations by 2030. To achieve these goals, Aggreko is increasingly offering clean technologies, such as battery storage and solar power, as well as prioritising the use of alternative fuels. It will be fantastic to see the innovations presented in the next few years as collaboration evolves further between miners and energy companies to lower emissions. The key now though is to embrace renewables into the energy mix because, done correctly, cost and emission savings can be greatly reduced without compromising reliability.

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Johnny Wang, Baraja, China, examines how automation can help mining operations boost employee safety, improve productivity time, and increase profit margins.

n an industry that is challenged by extreme environments, countless hazards and a need for uninterrupted or continuous production, fully-autonomous machinery is a dream. Taking humans out of the driver’s seat will help drastically increase workplace safety and lead to improved productivity, reduction of errors, increased lifespan of machinery and overall cost savings. This vision is now becming a reality. Hitachi Construction Machinery Co. Ltd, one of the world’s most well-known industrial machinery manufacturers, is partnering with Baraja, a global LiDAR technology company with headquarters in Australia, and putting automation for its ultra-large hydraulic excavators into practice at its Japan testing site, making it possible for miners to remotely

operate multiple machines all at the same time from the safety of a distant control room.

Mining automation in practice

Hitachi has begun developing and testing remote control and driving support systems for its ultra-large hydraulic excavators, helping to improve the safety and productivity of mines around the world, and launching the mining industry, as a whole, into the future of autonomy and virtually human-free excavations. This remote-control system enables machine operators to step away from the machine and control the massive mining equipment from a safe distance, by relying on a combination of LiDAR, radar, camera, GPS, radio, and a perception algorithm.

global mining review // May 2022

This level of autonomy is massive for the mining industry, which currently depends largely on each individual operator’s skill, experience and ability to repeatedly perform complex operations for extended periods of time, while maintaining the stability of the vehicle and avoiding collision with any surrounding equipment. Many mining sites require machines to operate 24 hrs a day, 365 days a year, so this amount of autonomy can decrease the stress on the human operator by reducing the workload and thus the demand for long shifts. By equipping vehicles with autonomous features, such as a collision avoidance system, operators no longer need to remain vigilant of potential crashes. Instead, the sensors on the machine can sense and detect objects, providing the

perception algorithm with the necessary data to make accurate, split-second decisions on how to respond – be that stopping or moving to avoid a potential crash or accident. By essentially eliminating the possibility of accidents, operators are free to concentrate solely on achieving their excavation task, thereby increasing the accuracy and productivity of each machine. Pair this with the ability to operate the machine remotely, and a single operator can completely remove themselves from the dangers of the site and operate multiple ultra-large hydraulic excavators simultaneously, further reducing site costs. Overall, a collision avoidance system provides better accuracy, helping to reduce accidents that can create workplace hazards, costly equipment damage and stalled production time.

Transitioning mining fleets

Figure 1. Ultra-large hydraulic excavator using Baraja’s LiDAR.

Aside from the technology itself, achieving full mining automation requires changes in staffing, training and operations, along with other adjustments. Some mining companies also fear the expensive investment costs of upgrading their machinery. In addition to the technology, the automation solution Hitachi is creating is also easily scalable. The remote-control systems are designed to be retrofittable on to the entire EX-7 series of ultra-large hydraulic excavators, making the technology easy to add on to existing mining vehicle fleets that are already in operation. This will enable mining site customers to utilise their current equipment while gradually integrating autonomous capabilities in a feasible timeline, without high investment costs.

LiDAR: the key to enabling automated mining equipment is in the sensors

Figure 2. Baraja Spectrum-ScanTM LiDAR in use.

LiDAR sensors are often considered the missing piece to solving higher levels of autonomous driving in any form – from the highway to the mining site. This is largely due to the type of measurements that LiDAR sensors are capable of achieving. Cameras are great for accurate object classification but are nearly useless in low light or fog, and cannot measure distance or velocity. Radar is great for detecting objects in various weather conditions, including their distance and speed, but cannot differentiate one object from the next, making it hard for perception algorithms to differentiate, say, a large rock from another piece of machinery. LiDAR sensors, on the other hand, are capable of collecting data that is detailed enough to enable perception algorithms to make accurate split-second operating decisions. The problem has been finding LiDAR sensors that can achieve this level of accuracy and precision in practice, and also withstand the extreme conditions of mining sites.

Finding a LiDAR system with high-resolution Figure 3. By essentially eliminating the possibility of accidents, operators are free to concentrate solely on achieving their excavation task, thereby increasing the accuracy and productivity of each machine.

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The Baraja LiDAR system has advanced high-resolution capabilities and is extremely durable, meeting two of the key LiDAR requirements for mining application. Previously, legacy LiDAR sensors used in mining had very limited resolution, which made it difficult to detect smaller

hazards and obstacles. Now, with the Baraja Spectrum Off-Road LiDAR and its ability to detect very small objects, the Hitachi automated ultra-large hydraulic excavators are enabled with more precise data. Furthermore, the Baraja Spectrum-ScanTM platform can dynamically increase pointcloud resolution to where it is needed most, providing highly detailed data for superior object classification and avoidance. This is similar to how the human eye works when presented with a potential obstacle. Spectrum-Scan LiDAR is a flexible steering mechanism that gives the user complete control, and enables effectively instant changes to resolution within the scene.

Holding up to the tough environments of mining

In addition to meeting high technical requirements, a LiDAR system must also be able to endure the realities of a mining site, such as heavy hits from rock and debris, strong vibrations from the machinery, constant 24/7 operation, and extreme weather conditions; including rain, fog, and extreme heat. Legacy LiDAR systems rely on rapid mechanical components for steering, which reduces their durability in such conditions. Continuous operational needs, flying rocks and debris, and intense vibrations from the machines themselves can all easily cause moving pieces to break, slide out of place or reduce their lifespan, rendering the LiDAR virtually useless for mining.

Baraja has taken a revolutionary approach to its LiDAR design, replacing spinning lasers and oscillating mirrors with prism-like optics, creating a truly solid-state, high-performance LiDAR. This not only makes the LiDAR extremely durable, but also helps to solve many of the reliability issues that are inherent to legacy LiDAR designs, such as LiDAR interference, shock, and vibration.

Conclusion

The future of mining is here. Soon, operators will abandon the driver’s seat and the hazards of the mining site, and sit themselves safely in a remote office where they will be able to effectively control and plan multiple machines at once. Transitioning to a fully-automated fleet of mining equipment will help mining customers around the world boost employee safety, improve productivity time, and increase their profit margins. Mining sites will operate 24/7, virtually uninterrupted with no shift changes and fewer maintenance needs. Mining customers will also benefit from a longer lifespan of equipment. In addition to remote control and driving support systems for its ultra-large hydraulic excavators, Hitachi is also using Baraja’s LiDAR for its autonomous haulage system (AHS). Hitachi’s AHS is currently conducting demonstration tests in the Australian Outback. Mining customers will soon be capable of implementing these automated machines on their mining sites, bringing the industry a step closer to the future of AI-operated mining sites.

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Phillip McBride, I4 Mining and Rayven, Australia, reviews how the way to achieving emissions, ESG, or any Industry 4.0 and automation goals starts with data.

hite & Case’s recent ‘Mining & Metals 2022’ report found that – low and behold – environmental, social, and governance (ESG) concerns topped the risks that senior executives in the mining sector see for the coming year.1 As the same report did last year. As did Deloitte’s latest ‘Tracking the trends 2022’ report,2 and EY’s ‘Top 10 Business Risks and Opportunities for Mining and Metals in 2022’.3 These reports all also found that there were significant benefits for miners in investing in solving ESG challenges – not just through grasping the nettle and beginning their work on emissions reductions ahead of 2050 – but in also delivering efficiencies on costly inputs (such as by reducing energy usage), finding new sources of capital, seizing optimisations in real time before potential gains are lost, and proving stakeholder credentials to unlock new sites and extend the lifespans (or scope) of existing ones.

global mining review // May 2022

The data is in: ESG is not just the zeitgeist, but the organisational imperative. So how can automation and artificial intelligence (AI)-led intervention play a significant role in helping mining and metals companies achieve their ESG objectives? The answer(s) can be simple, but only if the right foundational pieces are in place and businesses are looking to solve challenges now, not tomorrow.

The data (and execution) challenge

A lot of the issues that relate to tackling many ESG or transformation challenges, but emissions in particular, begin with data. More specifically: nn There is a lack of access to credible, accurate data of what is or is not happening. nn These data points are not being effectively analysed or made available in a timely manner. nn Businesses do not have the technological ability to do something about the data they are seeing in real time on the ground (i.e. before optimisations are lost or a failure leads to a much bigger problem). Not only does this lead to general inaction (‘where’s the evidence?’/‘I don’t believe the data’/‘these are only estimates rather than actual measures’) and a disjointed approach to achieving strategic goals, but it prevents organisation’s from leveraging Industry 3.0 (automation) and Industry 4.0 (AI-led interventions) to tackle the challenges that they face. The Internet of Things (IoT) and AI revolution of recent years, however, has created an answer to the aforementioned problems. It comes through the adoption of a foundational piece of technology that is critical if businesses are to create a true digital mine and find answers to the difficulties that they are facing with ESG.

Getting a complete, credible, real-time picture from existing sources

Businesses in every sector have significant data problems at present. Not only are key measures missing because organisations simply are not leveraging the IoT in-field technology needed to collect them, but key data exists in different IT systems or software as a service (SaaS) suites, is stuck in operational and physical technology (think SCADA or other machinery software), and cannot be linked and looked at alongside relevant third party data (such as weather forecasts) that are being used on sites and in HQ. Fundamentally, interoperability is a massive challenge, but so is the merging of data sets and the analysis of them in context with each other to provide a complete picture of what is going on in real time; the forming of predictive insights as to what is (or is not) about to occur based on that picture using machine learning; and the development of the functionality to take action, execute, or programme actions based on what the data is showing then and there. To connect these silos and make use of real-time data via automations, as well as AI and human-led intervention, what is required is a single piece of technology that is capable of 100% interoperability, connecting to every system and data source. It should have the functionality to

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analyse all of the data that is coming from them (plus other systems or data sources inside and outside an organisation), in order to identify trends, relationships, and insights hidden in the ‘Big Data’ that is being accumulated in real time. It should then also be programmed to take direct action based on custom business logic (automations), or via AI-led intervention, to improve and optimise processes, work schedules or anything else on an ongoing basis, based on changing variables and performance. What is being described here is a new generation of technology platform called a real-time data consolidation and AI + IoT solution delivery platform. It is critical because it is the one place in an organisation where all of its data (both historical and real-time, from any system, sensor, or data lake) can flow and be standardised for analysis in real time, where machine learning algorithms can be leveraged, and where cross-functional decisions can be orchestrated and executed: it is a Mining 4.0 brain for every business.

Real-world automation and Industry 4.0 ESG applications

The creation of a reliable, credible real-time view of organisational performance unlocks numerous applications for enhancing ESG performance across the entire mining lifecycle and operational lifetime, which can all be tailored to individual site and business needs. The following is an outline of just some: nn Accurate carbon accounting: By accurately monitoring and tracking carbon emissions by integrating data from in-field devices, advanced plant and business systems, it is easy to create a real-time view of SDGs, TCFDs, or any other key environmental metrics at a moment’s notice. Taking it further, it makes it possible for businesses to compare current performance to benchmarks and, through the use of machine learning, predict and model future performance based on asset, personnel, sites, and entire operational changes (digital twin). nn Real-time environmental monitoring: An Industry 4.0 consolidated data and AI + IoT platform enables miners to unite real-time data feeds from sensors on site, with internal systems and third-party data sources to deliver readily accessible, accurate, real-time environmental metrics. This can be used at all stages of a mine’s lifetime, establishing better baseline values and tracking post-close remediation success. It also unlocks the potential for many other benefits, such as: fault and leak detection, geo-fencing, reduced energy consumption, operator environmental and safety scoring, proximity real-time alerts, compliance guidance, remote tracking, plant class comparisons, pinpoint environmental areas of concern, improved maintenance regimes, and much more. nn Improved environmental and social impact assessments (EIAs and SIAs): The collection of accurate data from sites and the real-time monitoring of environmental performance over time, based on different operational factors, enables miners to establish baselines more accurately for future EIAs and SIAs, as well as better

plan operations and post-closure remediation efforts at an individual site level. Aggregated risk profiling: The platform enables the creation of algorithms that can better explore the impact of certain activities on others to establish true risks via aggregated profiling. For example, the impact that atmospheric conditions can have on a tailings dam and when that becomes a problem. Cross organisational analysis: With accurate, standardised analysis of asset, function and site performance in different mines and facilities, it is possible to uncover best practices, identify superior plant, as well as identify areas for improvement based on large data sets. This improves short-term site level metrics, but also improves the environmental results via longer-term optimisations (e.g. better staff training) and takes away barriers that exist between departments and units. Immediate, automated mitigation and remediation: Real-time data can provide miners with rapid, effective direction (plus automated interventions) should an unexpected environmental incident occur (or be about to). Learning from modelling and previous performance, the platform can leverage situational data and find ways to better mitigate unwanted outcomes or, better still, monitor critical environmental measures in real time to prevent breaches and harm from ever occurring. Better waste management: Spill, tailings, and other waste, if improperly handled, can have serious environmental impacts. A data consolidation and AI + IoT platform can enable miners to monitor how it is being handled in real time, accurately scrutinise process adherence, plant and personnel performance, and be used to reconcile tonnage across supply chains and track whether waste is being treated/incinerated/stored correctly. Establish real-time employee safety and environmental scores: Through the analysis of real-time data monitoring, via technologies such as drones, wearables or other in-field sensors, it is possible to monitor employee performance based on individual aspects of their role, such as how safe they are being within operational norms. This could help identify when, for example, an employee is distracted, regularly following

rules, or could be about to make a mistake that would lead to serious environmental consequences.

Do not wait for the grass to grow

The path to true digital transformation and achieving ESG (or any other) business objective will be lined with lots of use case-specific technologies that improve the abilities of individual elements of mining operations, whether it is better water pumps, electrified forklifts, or better risk analysis of environmental threats. All of these technologies, including existing and legacy ones, need a place where the data that they are using and creating can come together and be put to use to work together and achieve the same goals – it is the difference between improving a single measure or metric vs delivering holistic change that can achieve tangible, measurable business objectives. What is so beneficial about a real-time data consolidation and AI + IoT solution delivery platform is that it is not necessary to be chasing ‘transformation nirvana’ and have huge resources to get started with it – in fact, it works better if this is not the objective. Start with something small that can be measured and improvements assessed, such as forecasting when critical machinery that is needed to prevent polluted material from entering groundwater systems will break down or fail at a particular site. From there, build in rainfall data and predict when challenges may occur and/or leverage wearables to inform those on site when a failure is going to happen, so that they can do something about it. Next, copy it across sites, and then build a similar system for dust, noise, carbon dioxide and methane emissions, and anything else. Start small, prove return on investment and then scale, but most importantly: start, because the future is not that far away.

References 1.

2. 3.

‘Mining & metals 2022: ESG and energy transition – the sector’s biggest opportunity’, White & Case, (3 February 2022), https://www.whitecase.com/publications/insight/mining-metals-2022esg-and-energy-transition-sectors-biggest-opportunity ‘Tracking the trends 2022: Redefining mining’, Deloitte, (3 February 2022), https://www2.deloitte.com/au/en/pages/energy-and-resources/articles/ tracking-the-trends.html ‘Top 10 Business Risks and Opportunities for Mining and Metals in 2022’, EY, (7 October 2021), https://www.ey.com/en_gl/mining-metals/top-10business-risks-and-opportunities-for-mining-and-metals-in-2022

ver the last few decades, pressure on training has intensified greatly in order to keep pace with the increasing complexity of heavy equipment, occupational health and safety requirements, and the constant drive to push productivity up and costs down. Consequently, the most progressive mines are looking for partners who can provide comprehensive, end-to-end training solutions, using the latest training technologies to both attract young talent and develop more efficient and effective equipment operators. ThoroughTec Simulation is meeting this demand by offering interactive e-learning systems, virtual-reality pre-trip inspection trainers and high-fidelity equipment simulators, all integrated under the company’s Workforce Excellence (WX) Training and Performance Management system, and augmented by a comprehensive range of managed training and support services.

Benefits of simulation Increasing training efficiency and safety

Simulators allow trainee operators to familiarise themselves with a vehicle’s controls, functions and operating procedures, along with the site on which they will one day operate, in a safe and controlled manner. Mine personnel and mining equipment are not exposed to risk or unnecessary wear and tear, while, at the touch of a button, trainees can be exposed to risky operating conditions and various emergency situations, which could never be safely recreated using traditional training methods in real equipment. This unique capability better prepares the operators to adapt to and excel in the real world, boosting productivity, preventing accidents, and reducing downtime.

44 May 2022 // global mining review

Andre Mendes, ThoroughTec Simulation, Canada, explains how interactive training solutions can improve operator safety and efficiency.

global mining review // May 2022

Reducing training and maintenance costs

In principal, a huge proportion of an operator’s practical training (in some instances up to 80%) can be completed on hi-fidelity simulators. This represents a significant potential saving in training-related fuel-burn and maintenance, by eliminating absolute-rookie time in the mining equipment. This same equipment is also then released for production tasking to positively influence mine bottom lines, when margin is everything.

Hi-fidelity simulator systems

Not to be confused with the many low-fidelity simulator systems in the market, which might answer for basic or induction training, hi-fidelity simulators integrate and leverage a range of unique features to unlock the ultimate potential of virtual-interactive training. For example, CYBERMINE Simulator Systems feature fully replicated cabins; original equipment manufacturer (OEM) controls; military-grade six degree-of-freedom motion platforms; contactless head and body tracking; ultra-high resolution; laser-projected panoramic displays; digital 3D surround sound; and interactive, multi-player modes to completely immerse the trainee in the virtual scenario. In doing so, knowledge is more readily taken in and retained, while skills and experience transfer almost seamlessly to the real world. Equally critical to such systems are the simulated mining worlds, and ‘under-the-hood’ computational models which bring the simulation to life and make it relevant as a training tool – the digital twins of the mine environment and mining machines. Simulated vehicles need to function and operate exactly as they do in the real world, a world which needs to be intricately modelled in virtual reality so

Figure 1. Instructor and operator in simulator training session.

as to represent every possible feature to the student. When this is done right, trainees will quickly forget they are not in ‘the real thing’ and the training will become ‘real’. ThoroughTec’s experience in this field has recently received a boost in the form of closer collaboration with some of the world’s largest mining equipment providers, an example being Caterpillar, which now works exclusively with ThoroughTec to develop the best possible hi-fidelity training solutions for their customers around the world. Without detracting from the technology, essential as it is to facilitate such modern training, the power and influence of good human instructors must not be overlooked. Whether planning simulation exercises or coaching students through them, instructors underscore and embellish the students experiences in the simulator, drawing connections between the theory and the practice of mining equipment operation. Recognising this, CYBERMINE Simulators come equipped with a set of instructor tools, supporting the creation of myriad scenarios to test the student’s abilities under almost any circumstances. Exercises can focus on productivity enhancements, such as reducing spotting times in haul trucks or improving drilling accuracy and speed in underground drill rigs, or they can emphasis machine care through the application of mechanically sensitive operating practices and early identification of fault conditions. And then there is emergency scenario training, almost the unique preserve of simulator-based training. Burst tyres, engine and wheel fires, run-away conditions and loss of control, each one as dangerous and challenging as the other, can be practiced again and again, without cost or risk, until operator response becomes second nature. And what good would any of this be if each and every input or action made by the student was not monitored and recorded? To this end, the simulators offer a comprehensive range of reports delivering metrics and analysis of both operator competence and proficiency. The company also offers a range of supporting technologies to enrich and complete the holistic training solution. Two of these are the company’s in-house developed CYBERMINE E-learning courses and virtual-reality Pre-Trip Inspection Trainer. Both technologies help to lay down a critical foundation of theoretical knowledge through modern digital mediums, paving the way toward downstream simulator training activities and beyond.

E-learning systems

Figure 2. CYBERMINE Cat 793F simulator.

46 May 2022 // global mining review

The use of e-learning systems has grown exponentially in recent years. Assessments, training material, and employee records are moved online which reduces paper consumption and drastically simplifies the creation, management, and delivery of training content. They have also been proven to increase the learning rate and retention by combining audio, 3D models, video, and interactive content to keep students interested and engaged. E-learning also delivers greater consistency and uniformity, both when delivering content and testing. CYBERMINE e-learning modules are developed to be

equipment and site specific, educating students on almost any topic; from the basics of personal protective equipment (PPE) use, through to site operating procedures and principles of mining, as well as more complex vehicle operating procedures.

Virtual pre-trip inspection trainers

Pre-trip or walk-around inspection training has also been brought into the digital age, as students can now learn to perform these safety-critical tasks using an interactive touch screen. The virtual mining machine is completely and accurately modelled in 3D and placed into a virtual space where the student can, by way of the touch screen or other interface, move around and inspect every aspect and component of the machine. The taught inspection procedures are developed according to OEM recommendations and tailored, where necessary, to include site-specific nuances. Potential faults and defects are realistically modelled and randomised during the tests so that the students learn to identify such issues and take appropriate action before operating the equipment.

Figure 3. CYBERMINE e-learning.

Digitising mine training

Traditional mine training organisations are beset by a number of challenges, ranging from the incompatibility of various training tools and excessive reliance on paper-based assessments and record keeping, to the complexity of optimally scheduling students and resources. Learner management systems have historically been used to some effect in the e-learning environment, but their

Figure 4. Operator on a CYBERMINE Sandvik DD422i simulator.

usefulness across the broader sweep of mine training systems and processes has been very limited.

To address this problem, ThoroughTec has developed a Training Management System (TMS) as part of the broader WX Platform. This system has been specifically designed to cater to the challenges faced by the mining industry. WX TMS is an online system that digitises and centralises the creation, planning, control, reporting and record keeping of all mine training activities, replacing most, if not all the functions of traditional LMS/HRD/ERP implementations. While naturally optimised for use with ThoroughTec’s CYBERMINE range of products, the system is both technology and process agnostic, allowing it to adapt and meet virtually any organisational need. Such a system acts as the training department’s central nervous system, cohesively linking everything from classroom training through to simulators, and even in-pit training and practical evaluations, while providing hitherto unheard-of insight to all mine stakeholders.

skills and weaknesses vary, and each require a tailored response to optimally improve. WX Analytics has been developed specifically to address this problem. WX Analytics uses artificial intelligence (AI) to automatically and continuously monitor individual operator behaviours, analyse the resultant data, and then intelligently recommend tailored simulator-based training interventions to address and correct any identified performance deficiencies. When training is needed, what training is required, and how it should be presented is thus determined by science, and the resultant interruption of operator work-time kept to an absolute minimum. Once the operator returns to the pit, the AI will also be responsible for determining whether or not the intervention was successful, and, if necessary, schedule additional training.

Closing the loop between training and the pit

With access to this new array of digital training technologies, and enjoying a reinvigorated mandate to advance health, safety and environment in the industry, the training of mining equipment operators is entering an exciting new era. Essential to harnessing the potential of this moment are the training management tools and systems which integrate and channel this (at times intimidating) spectrum of technology into a cohesive and effective system. Through such an orchestrated approach, mines will be able to attract new talent to address the prevailing skills shortage and sustain a highly proficient, safe workforce in the long-term.

The historical and largely persistent problem is that mining training is locked in an eternal conflict with mining operations, competition for the man hours either spent training or working. The paradox is that effective time spent training should naturally result in more efficient time spent working, however, in reality, commercial and operational pressures rarely yield. Invariably, this makes most mine operator training infrequent and sporadic, possibly even solely incident-based, which is too late. In addition, people do not necessarily learn at the same rates; experience,

Conclusion

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Global Mining Review May 2022

Articles inside

Better Safety Through Simulation

Double Down On Data

Energy Transition Opportunities In Mining

Making Automation And Control A Reality

Rock-Solid Communications For The Underground Mine

World News

Gold Mining And The Evolving ESG

Slashing Cycle Times

Giant Tyres For A Growing Need

The Need To Adapt

Editor’s Comment

Shining A Spotlight On Shotcrete Spraying

Screening News