Global Mining Review September Issue 2022

CONTENTS

03

05 World News

10 A Bump In The Road

David Kurtz, GlobalData, Australia, explores the prospects for the global iron ore market.

15 Uncovering Hidden Potential

Nadia Haseeb, Shell, explains how combining premium fuel and lubrication could be an efficient solution for an evolving sector.

19 Get More For Less

John McNulty, Weir Minerals, Australia, reviews how pumps and valves can help mining customers produce more for less.

24 The A To Z Of IPCC

Boris Frankenreiter, thyssenkrupp Mining Technologies GmbH, Germany, outlines some of the best operational practices for in-pit crushing and conveying (IPCC) operations.

30 Carving A Path To Zero Emissions

John Schellenberg, Hitachi Construction Machinery, Canada, emphasises the importance of energy management to zero-emissions technologies and describes how mines can implement such advancements, particularly in relation to loading and haulage.

34 Purpose-Built Power Sources

Jess Stephen, Komatsu, discusses haul truck power sources that are purpose-built for a sustainable future.

40 Composing An Automation Symphony

Dmitry Lukovkin, Zyfra Robotics, Finland, answers the question, ‘how do you make a dump truck autonomous?’, and explores what the future might hold for automation in opencast mining.

44 Stay Safe, Stay Connected

Marnus Kruger, Rajant Corporation, South Africa, provides an overview of some of the latest advancements that are bringing high-bandwidth, flexible, reliable, self-healing networks to mining.

48 Transforming Daily Drill Reporting

Colleagues Matrixx, Australia and North America, considers how cloud-based platforms can help resource and drilling companies better communicate.

53 Remote No More

John Geasa, Speedcast, USA, evaluates how IoT and connectivity are changing modern mining.

56 Bauma Preview 2022

Ahead of bauma 2022 in October, Global Mining Review previews some of the companies that will be exhibiting at the Trade Fair Center Messe München.

ON

Guest Comment

For the last 20 months, the global pandemic has rocked every single sector globally, and Australia’s mining, oil, and gas sectors have not been immune from this. From Australia’s international border closure to several state lockdowns impacting the sector’s fly-in fly-out working arrangements, the industry has been challenged in more ways than one. And this is on top of other key issues, including the nation’s productivity crisis, as well as the ongoing push for decarbonisation and a ‘greener’ and more socially conscious approach to mining.

Despite ongoing pressures faced by the sector, the future for the mining, oil, and gas industries is very bright. However, there are several challenges keeping mining leaders up at night, including: CAPEX squeezes; rising environmental, social, and governance (ESG) concerns; and the need for robust digital architecture to facilitate automation and data analytics.

According to the Equinix Mining Technology Report 2021 – 2022, 93% of mining leaders plan to ramp up their digitalisation efforts in 2022, with almost 44% saying they will significantly increase technology investments. More importantly, technology has been identified as crucial to overcoming critical challenges in mining, including driving the ESG agenda and CAPEX management.

Digitalisation is making mines safer for miners by reducing the need for human input in high-risk processes. More advanced data analytics and artificial intelligence (AI) are also providing increasingly sophisticated insights to improve efficiency, safety, and compliance.

However, in order for these benefits to be realised, miners need fast, reliable connectivity. This is partially due to the highly remote nature of mining sites, and partially because the majority of projects today require co-operation and collaboration between multiple parties, who are often distributed geographically. Robust digital architecture is vital to successful automation and real-time data analysis, as mine sites generate and capture significant volumes of data daily.

According to Equinix’s research, Australia’s mine expansions are being fuelled by collaboration. Partnerships – whether in the form of acquisitions, joint ventures, or other forms of collaboration –are expected to contribute 25% of projected growth in 2022.

The adoption of hybrid and multi-cloud services has been critical to enabling increased local and cross-border collaborations for Australian miners. The Industrial Internet of Things (IIoT), digital twins, and other collaborative technologies that deliver greater visibility to mining partnerships benefit from the flexibility and scalability of hybrid and multi-cloud environments. In today’s cloud environment, mining, oil, and gas companies can easily connect, transfer and share data, whether with headquarters, remote operating centres or partners, in order to facilitate smoother collaboration.

This is a huge boon to companies facing ore replacement challenges and ESG concerns. Increased collaboration means Australian miners can look forward to the discovery and development of new ore bodies to meet surging demand. Furthermore, with regard to ESG goals, strategic partnerships with providers of cutting-edge green technologies have helped Australia’s resources sector accelerate decarbonisation efforts and meet community and investor expectations for sustainability.

For the Australian mining industry to continue to move forward and grow, mining, oil, and gas companies need to ensure they are in the best place possible to make the most of emerging market opportunities through better connectivity, smart adoption and implementation of technology, and collaboration with partners. This way, miners can hone a competitive edge by taking a digital-first approach to the future.

WORLD NEWS

CHILE BHP, Caterpillar, and Finning to replace Escondida haul truck fleet

BHP Group Ltd, Caterpillar Inc., and Finning International Inc. have announced an agreement to replace BHP’s entire haul truck fleet at the Escondida mine, the world’s largest copper producer, located in the Antofagasta Region, northern Chile.

This agreement is part of the strategic equipment renewal process developed by Escondida. The new Caterpillar 798 AC electric drive trucks will feature technology that delivers significant improvements in material-moving capacity, efficiency, reliability and safety, and generate a positive impact in key initiatives for the future; such as decarbonisation, diversity and inclusion, autonomous technologies, and the development of local capabilities.

The first trucks are expected to arrive at the mine in 2H23, with delivery of the remaining trucks to extend over the next 10 years as the three companies work to replace one of the largest fleets in the

industry worldwide, currently comprised of over 160 haul trucks. Maintenance and support services provided under the agreement advance BHP’s local employment and gender balance strategies. Finning’s Integrated Knowledge Center, located in Antofagasta, will provide top of the line industry technical support for the fleet.

The agreement also allows Escondida | BHP to accelerate the implementation of its autonomy plans by transitioning the fleet to include technology that enables autonomous operation. In addition, the agreements set forth a technological path that helps Escondida | BHP meet its decarbonisation goals, through the progressive implementation of zero-emission trucks.

BHP, Caterpillar, and Finning uphold their commitment of contributing to the economic and social development of Antofagasta, through the generation of local capabilities related to the development of mining equipment technologies.

SOUTH AFRICA Epiroc to acquire AARD Mining Equipment

Epiroc, a leading productivity and sustainability partner for the mining and infrastructure industries, has signed an agreement to acquire AARD Mining Equipment, a South African mining equipment manufacturer.

AARD, based near Johannesburg, South Africa, designs, manufactures, services and supports a wide range of mining

equipment, specialising in low-profile underground machines for mines with low mining heights. The high-quality products include drill rigs, bolters, loaders, scalers, and more. The company’s customers are mainly in the Southern Africa region. AARD has approximately 200 employees and had revenues in the fiscal year ending 30 June 30 2022 of approximately SEK 650 million.

GREENLAND ABD Solutions signs MOU with Amaroq Minerals

Leading vehicle automation provider, ABD Solutions, has signed a memorandum of understanding (MOU) with AIM and TSX listed Amaroq Minerals Ltd to investigate the potential for the introduction of vehicle autonomy systems for various mining vehicles at the Nalunaq site in Greenland.

The long-term goal of the MOU is to provide a framework for ABD Solutions to deliver the support, software, and hardware solutions needed for the company to operate a diverse range of automation equipment and retrofittable mining vehicles on the Nalunaq site in Greenland. These vehicles would be operated autonomously and supervised from a central control room, therefore, improving safety and streamlining the mining process, both operationally and financially.

ABD Solutions offers a modular technology eco-system to build the various elements required for vehicle automation; including vehicle management, vehicle control actuation, communication, sense and detect, health and diagnostics, and third-party integration. This provides a flexible autonomy solution that can be tailored to a specific vehicle, environment or operational scenario, and then fully integrated into any existing operational and fleet management system.

Vehicle automation can bring significant improvements to safety by removing people from high-risk areas, as well as providing increased operational efficiency, resulting in a reduction in fuel consumption and vehicle emissions. A retrofittable solution also maximises the investment of existing high-value assets by significantly extending their usable life.

Diary Dates

Mining Indonesia

14 – 17 September 2022 Jakarta, Indonesia www.mining-indonesia.com

Discoveries

04 – 06 October 2022 Hermosillo, Mexico www.discoveriesconference.com

China Mining Expo 2022 18 – 21 October 2022 Xi’an, China www.chinaminingexpo.com

International Mining and Resources Conference (IMARC) 2022

02 – 04 November 2022 Sydney, Australia www.imarcglobal.com

Mines and Money @ IMARC

02 – 04 November 2022 Sydney, Australia www.minesandmoney.com/imarc

Resourcing Tomorrow, brought to you by Mines and Money

29 – 01 December 2022 London, UK www.minesandmoney.com/london

CONEXPO-CON/AGG 2023

14 – 18 March 2023 Las Vegas, USA www.conexpoconagg.com/conexpo-conagg-construction-trade-show

China Coal & Mining Expo 2023 25 – 28 October 2023 Beijing, China www.chinaminingcoal.com

To stay informed about upcoming industry events, visit Global Mining Review’s events page: www.globalminingreview.com/events

NEWS

GUINEA Nordgold launches new power plant at its Lefa Gold Mine

N

ordgold Group, an internationally diversified gold producer, has launched a new 33 MW power plant at its Lefa mine – one of the largest gold mines in Guinea. The US$30 million project was designed and constructed by China’s leading manufacturing service group, SUMEC, a key member of China National Machinery Industry Corp. (SINOMACH).

The new heavy fuel oil (HFO) power plant has replaced the old facility, in turn reducing both fuel consumption for electricity production by 15% and engine oil by 30%. This will result in a 17 000 tpy reduction of greenhouse gas emissions, which is in line with Nordgold’s climate change objectives, as well as its commitments to the United Nations’ Sustainable Development Goals.

Hyundai Heavy Industries, the world’s largest shipbuilding company and leading manufacture of heavy industry machinery, provided the power plant’s main generating equipment. The power plant will enable a significant reduction in operating costs, in addition to enhancing the stability of the electricity supply for over 15 years of Lefa’s life of mine. Moreover, the installation of the latest fire detection systems will increase employee safety.

During construction, hundreds of additional jobs were created and main essential construction materials including sand, cement and gravel, amongst others, were sourced locally from Guinean suppliers.

AUSTRALIA Australia’s critical minerals to drive the US’ EV battery programme

Australia’s critical minerals will drive the US’ electric vehicle battery programme, following the announcement by the US to grant Australia preferred status.

The Inflation Reduction Act is a major step forward for the Australian government’s manufacturing agenda and will help underpin the demand for high quality Australian battery minerals.

Under the Act, 40% of the value of the critical minerals in the battery must be sourced from a country that has a free-trade agreement with the US, increasing to 80% by 2027.

Driving investment in local processing and manufacturing will also ensure the demand for Australian mined minerals including lithium, cobalt, nickel, and copper.

Importantly, it will also strengthen the case for investment capital into mining. Australian mining needs approximately US$20 billion/yr to sustain current production. If it is going to increase the capacity of existing mines, or open new mines – including in the commodities needed for the global transition to net zero emissions – capital investment will need to be increased by an order of magnitude.

The Bank of America estimates that US$150 billion/yr will be needed in global mining to produce the minerals needed to achieve the global transition to net zero.

Australia needs to position itself as a competitive destination for this capital in order to realise its full potential.

World NEWS

CHILE Sandvik secures equipment order from Movitec

Sandvik Mining and Rock Solutions has received a large order in Chile for surface mining equipment and its AutoMine® Surface Drilling solution from Movitec, a contractor on Codelco’s Rajo Inca opencast project. The order includes two LeopardTM DI650i down-the-hole (DTH) drill rigs and two Sandvik DR412i rotary blasthole drill rigs, including AutoMine Surface Drilling systems for fully autonomous operations.

AutoMine Surface Drilling is an autonomous solution for a wide range of Sandvik iSeries surface drill rigs, designed to improve safety, reduce costs, and increase productivity. It enables an operator to control multiple rigs remotely from a comfortable location in line-of-sight or a distant control room – improving working conditions and safety.

Sandvik iSeries drill rigs are equipped with iDrill technology, a scaleable automation platform that provides automation options

and digital services designed to speed up the production process and support mining operations. Performance and navigation iDrill technologies work together to produce accurately placed, consistently clean, and precision-drilled holes – delivering improved fragmentation, downstream throughput, and asset utilisation.

The new order also includes one Sandvik D75KX rotary blasthole drill rig with added intelligence and improved operator ergonomics. Delivery will take place in two phases before year-end 2022, with fully autonomous operations ramping up in 2023.

In addition, Sandvik Mining and Rock Solutions will also provide contractor Movitec with remote operation training and six months’ on-site service to ramp up support as they transition to autonomous operations.

GREENLAND Hudson Resources and Neo Performance Materials sign agreement for Sarfartoq REE Project

Hudson Resources Inc. and Neo Performance Materials Inc. have executed a binding agreement whereby Neo will acquire from Hudson an exploration license covering the Sarfartoq Carbonatite Complex in southwest Greenland. The project hosts a mineral deposit that is enriched in neodymium (Nd) and praseodymium (Pr), two essential elements for rare earth permanent magnets used in electric vehicles, wind turbines, and high-efficiency electric motors and pumps that help reduce greenhouse gas emissions.

The project is close to tidewater and a major port facility and is directly adjacent to some of the best hydroelectric potential in Greenland.

Neo, through a special purpose entity, plans to explore and develop the Sarfartoq Project to further diversify its global sourcing of rare earth ore, and to expand the rare earth supply chains that feed Neo’s rare earth separation facility in Estonia. That facility was recently awarded a Gold Medal for its sustainable practices by EcoVadis, the well-respected global sustainability auditor.

Neo is also pursuing plans to break ground on a greenfield rare earth permanent magnet manufacturing plant in Estonia that is intended to provide European manufacturers with the permanent magnets needed for electric and hybrid vehicles, wind turbines, and energy-saving electric motors

and pumps. The Sarfartoq Project also is a key element of Neo’s ‘Magnets-to-Mine’ vertical integration strategy.

Completion of the sale of the license is subject to various conditions, including approval from the Government of Greenland for the transfer of the license, expected to take approximately six months, and approval of the TSXV on the part of Hudson.

Neo intends to assign its rights under the agreement to an SPE controlled by Neo that would hold the license and continue exploration and ultimately extraction of the rare earth elements on the project.

The license covers the large Sarfartoq carbonatite complex that hosts Hudson’s ST1 REE project and the Nukittooq Niobium-Tantalum project. The REEs on the property have a high ratio of Nd and Pr at 25 – 40% of total rare earth oxides (TREO). Hudson completed a preliminary economic assessment on the ST1 project in November 2011, which outlined a National Instrument 43-101 compliant resource containing 27 million kg Nd oxide and 8 million kg of Pr oxide.

Neo and the SPE expect to conduct additional exploratory drilling and other work to move the project forward to eventual commercial operation. Neo also intends to enter into an offtake agreement with the SPE with rights to purchase 60% of the ore or mineral concentrate produced from the project.

PROVEN IPSC SOLUTIONS

MMD remains at the forefront of In-Pit Sizing and Conveying (IPSC) technology, developing bespoke mobile and semi mobile sizing solutions large and small for many types of applications around the world.

Our latest relocatable IPSC stations have successfully been combined with ore diverting solutions and new ore sensor technologies, to enable separation of ore from waste in the pit whilst uplifting ore grades through fines recovery. Introducing an automated ore sorting solution into your existing system ensures only the pay material is hauled to the process plant – meaning your mine can improve production whilst reducing energy usage, water consumption and tailings requirements.

Whether you have an underground or open pit operation, our network of technical experts can help develop a tailor-made in-pit sizing and sorting solution to boost productivity and deliver a leaner, greener mine.

Typical Bulk Ore Sorting Solution

After recording output growth of 6.4% in 2021, iron ore production is expected to decline by 2% in 2022; falling to 2.4 billion t. This is despite marginal growth in Brazil, whose production is expected to reach 427 million t; and in Australia, whose output is forecast to rise to 932 million t – helped by the opening of Rio Tinto’s Gudai-Darri mine in June 2022, and the ramp up of Fortescue Metals Group’s Eliwana mine and BHP Billiton’s South Flank mine. However, steep declines in production

in Russia and Ukraine will lead to an overall fall in total global output, with a drop also forecast in China. At the same time, declining steel demand and slower economic growth in China will keep prices lower than in the previous year, while rising input costs, from fuel to manpower, will place further pressures on margins.

Through to 2026, however, GlobalData expects production to recover, helped by the ramp up of recently opened mines and additional production

coming onstream, with total global production rising by a compound annual growth rate (CAGR) of 2.8% to reach 2.7 billion t.

Impact of COVID-19

The COVID-19 outbreak in 2020 had a mixed impact on iron ore, with output flattened for the year. In many major steel-producing countries, demand fell due to lower steel production, with output in Japan and the US falling

by 16.2% and 17.2% respectively, according to the World Steel Association. However, crude steel output in China, which accounts for more than 60% of the global consumption of iron ore, grew by 5.2% in 2020, with high growth in the second half of the year, helped by the government’s investments in infrastructure to stimulate the economy. While output fell elsewhere, the growth in China limited the overall annual decline in steel production to only 0.9% to 1864 million t in 2020. In China,

David Kurtz, GlobalData, Australia, explores the prospects for the global iron ore market.

steel production rose to over 1.05 billion t, 56.5% of the global total.

At the same time, supply constraints, due not just to COVID-19-related impacts, but also operational disruption caused by tropical cyclones in Australia and tailings dam restrictions and bad weather in Brazil, led to a steep rise in the iron ore price. Having been just US$78/t in February 2020, the price rose to US$156/t by the end of 2020, spurred on by China’s push for higher steel output.

In 2021, production recovered, rising by 6.4% to 2.4 billion t. Production from Australia rose by 0.4% to 922 million t, helped by an increase of 18% from Fortescue, whose Eliwana mine opened in December 2020, although output from Rio Tinto fell by 3% and BHP’s production was flat. Output from Brazil was up by 8.1% to 423 million t.

The iron ore price continued to rise as well, peaking at US$219.77/t in July 2021. Seasonal weather disruption in the early part of 2021 led to underwhelming output from the large producers and a consequent increase in prices, which were also pushed up by rising demand from steel mills and infrastructure growth in China. However, in 2H22, the Chinese government enforced curbs on steel production in order to reduce greenhouse gas emissions, with mills in many regions cutting production based on their emissions levels as part of a winter air pollution campaign, from October to March. After rising in the first part of the year, steel production in China fell by 9.4% in July and 13.2% in August, with the Chinese government looking to maintain steel production in 2021 at the same

Table 1. Iron ore production by company (million t), 2020 – 2021 Company 2020 2021 Change

Vale SA 300.4 315.6 5.1%

Rio Tinto 285.9 276.6 -3.3%

BHP 245.1 245.4 0.1%

Fortescue Metals Group Ltd 207.5 236.5 14.0%

Anglo American plc 61.1 63.9 4.6%

Mitsui & Co. Ltd 57.8 58.2 0.7%

ArcelorMittal SA 58.0 50.9 -12.2%

Companhia Siderurgica Nacional 30.7 36.3 18.2%

NMDC Ltd 31.2 34.5 10.6%

Metinvest BV 30.4 31.3 3.0%

Company reports, GlobalData

level as in 2020, in part to help reduce emissions. Economic activity in China was also impacted by lower construction activity amidst a reducing government stimulus and property market concerns, with the country’s second-largest property developer, Evergrande, struggling to service its debts. Overall, in 2021 steel production in China fell by 3% to 1.03 billion t, the first decline since 2016. Having risen by 12% in 1H21, production in 2H21 was 16% lower, helped by tighter government controls as well as a rise in power costs. Linked to this, the iron ore price fell to US$92/t in November 2021, but recovered to US$112/t by the end of the year.

Prospects for 2022 and beyond

Global iron ore production is predicted to decline by 2% in 2022. The ongoing Russia-Ukraine war is expected to reduce Russia’s iron ore output, with only slight (1%) growth in Brazil and Australia unable to offset this fall, while production from China is also expected to decline.

Of the major producers, as of July 2022, Rio Tinto’s guidance was for shipments of 320 – 335 million t vs 322 million t in 2021 (100% owned basis) for the calendar year. BHP, whose fiscal year (FY) runs from July to June, has provided iron ore production guidance for FY23 of 249 – 260 million t, the mid-point of which would be growth of less than 1% vs FY22. Vale, meanwhile, lowered its initial guidance for 2022 from 320 – 335 million t to 310 – 320 million t, partly due to the sale of its Midwestern System to J&F Mineração Ltda, which produced 2.7 million t of iron ore in 2021. The sale is being made in order to focus on value over volume, and includes iron ore, manganese, and logistics companies.

Demand for iron ore will be negatively impacted by declining steel production in China. From January – May, output from China fell by 8.1% y/y, dragging the overall global production down by 5.5%, according to the World Steel Association.

As a result, the iron ore price, which was US$130/t at the end of June 2022, is expected to remain subdued over the remainder of the year. With costs increasing, this will in turn put pressure on margins for miners.

Through to 2026, global iron ore production is forecast to reach 2.7 billion t, a CAGR of 2.8% from 2022. Growth is expected to average 3.4% annually in Australia and 3.8% in Brazil, with output reaching 1.06 billion t and 496 million t, respectively.

Contributing to output from 2023 onwards will be Fortescue’s US$3.6 – 3.8 billion, 22 million tpy Iron Bridge, which is due to see production in the March 2023 quarter. Meanwhile, commercial production is due to commence at the end of 2022 at Champion Iron Ltd’s Bloom Lake Phase II expansion project, with an increase in capacity from 7.4 million tpy to 15 million tpy of 66.2% iron ore concentrate.

Other major developments may be a few years away, only impacting output in the middle to latter part of the decade. Rio Tinto has the potential to develop the 20 – 25 million t Western Range project, for example, as well as having a share in two of the tenements in the huge Simandou iron ore mine in Guinea. There have been challenges at the latter in 2022, however, with the country’s mines minister ordering for construction work to be stopped, requesting a solution to the development of a 670 km-long rail line and port between Rio Tinto and China-backed SMB-Winning Consortium. Rio Tinto has a 45% share in a consortium that owns two of Simandou’s iron ore tenements, with Chinalco owning 39.95%, while the SMB-Winning Consortium owns the other two. In 2020, the SMB-Winning consortium announced plans to start production at blocks 1 and 2 by 2025, but this could slip now given these delays.

Iron ore miners lead in technology and emissions reduction

The newly-opened Gudai-Darri mine will continue the trend towards the use of autonomous trucks in iron ore mines. The mine will have 23 CAT 793F autonomous haul trucks, as well as three CAT MD6310 autonomous drills, autonomous water trucks and autonomous trains, and will also employ digital twin technology.

As of May 2022, GlobalData was tracking over 1000 autonomous haul trucks in operation globally, of which 544 were at iron ore mines, 495 of which were in Australia. The increasing use of autonomous equipment has led to rising productivity amongst iron ore miners, which will prove critical as rising inflation begins to impact costs for all inputs, from fuel and consumables to maintenance and manpower.

As well as being amongst the most technically advanced mining companies, iron ore producers such as BHP, Rio Tinto, Vale and Fortescue are also some of the most ambitious when it comes to decarbonisation and a shift to net zero mining. They are also supporting a reduction in carbon emissions further down the value chain in steel production, helping to improve the environmental impact of the overall iron and steel sector, which, according to the International Energy Agency, accounts for approximately 6.7% of global carbon dioxide (CO2) emissions, with 1.9 t of CO2 emitted per tonne of steel produced.

Fortescue is aiming to be carbon neutral by 2030, as well as achieving net zero Scope 3 emissions by 2040. The company is connecting its mine sites with renewable power and battery storage, replacing stationary diesel and gas-fired power. Of its emissions, 26% are from haul trucks, which will be abated using battery and hydrogen power, while green ammonia and battery storage is used to remove diesel from locomotives (11% of emissions), and electric motors and hydrogen fuel cells are used for other heavy mining equipment (36% of emissions). In June 2022, the company announced a partnership with Liebherr for the development and supply of 120 green mining haul trucks, to be integrated with its zero emission power system technologies being developed by its subsidiary

Fortescue Future Industries (FFI) and Williams Advanced Engineering. FFI is a global green energy and product company focused on producing zero-emission green hydrogen, acting as a developer, financier, and operator. It is in the process of building a global portfolio of renewable green hydrogen and green ammonia operations, and is targeting the supply over 15 million tpy of green hydrogen by 2030.

Rio Tinto, meanwhile, is targeting a 15% reduction in Scope 1 and 2 emissions by 2025, a 50% reduction by 2030 (vs a 2020 base year), and to be carbon neutral by 2050. Renewables are key to the company achieving its 2025 targets, and will make a substantial impact on reducing emissions from 2020 – 2035. Mobile diesel represents 16% of emissions on a managed basis and the company is targeting diesel displacement between 2030 and 2045, phasing out the purchase of diesel haul trucks and locomotives by 2030. Meanwhile, it is aiming to decarbonise process heat between 2025 and 2050, with the development of low-emission process heat technology, including the trialing of plasma torches at its iron ore business in Canada.

Like Rio Tinto, BHP has made 2050 its target year for net zero, although it has a more moderate short-term target to reduce operational Scope 1 and 2 emissions by 30% by 2030 (2020 base year).

Electricity represents approximately 40% of baseline emissions, with the company looking to secure renewable energy through PPAs, or installing renewable power generation where grid connectivity is limited, as well as optimising demand side energy use. Similar to electricity, diesel accounts for 40% of emissions, with the timeframe for diesel displacement ranging from 2025 to 2040.

Lastly, Vale is targeting a 33% reduction in Scope 1 and 2 emissions by 2030 (base year 2017), and a 15% reduction in Scope 3 net emissions by 2035 (base year 2018). A key driver for their emissions reductions will be renewable power. In 2020, 87% of Vale’s power was sourced from renewable power and the company is targeting 100% renewable electricity consumption in all operations by 2030, and in Brazil by 2025. To achieve its Scope 1 and 2 emission reduction commitment (33% by 2030), the company announced in 2021 that it would invest US$4 – 6 billion until 2030. In 2020, US$81 million was invested in projects to reduce emissions, including pilots for bio-oil and biocarbon use in pelletising furnaces, underground battery electric vehicles, and electric locomotive pilots.

Conclusion

After record iron ore prices helped deliver a collective 40% rise in revenues and 136% increase in net income for the four major iron ore producers in 2021, 2022 will inevitably be more challenging; with cooler demand from China, rising costs, and a shortage of workers. While there will be short term impacts for the iron ore market, in the medium term, growth in infrastructure spending will support further investment in production, while continued investment in automation and other technology will help deliver increasingly efficient and safe operations.

Mining businesses need to maximise equipment utilisation, boost their output, and decrease costs – all while advancing their decarbonisation efforts. Offering improved productivity and reduced operational costs, premium fuels and lubricants are solutions that operators cannot afford to overlook as they work to meet shifting global demand and disruption to supply chains.

Global disruption shapes mining output

With the mining industry facing extreme global disruption, operational efficiency has become even more vital than ever. Current geopolitical events mean that some nations are swiftly switching to alternative sources for commodities.1

And, where this has not been possible, it is causing a slowdown in production across many industries and sectors.

While rising energy costs have been front and centre in the minds of most people, the disruption has also led to sharp price increases in several metals – such as gold, nickel, and palladium – due to fears of shortages.1 In fact, nickel prices more than doubled in the two weeks following the beginning of the war in Ukraine.2

In the short term, these price rises will likely drive growth in the mining industry. However, businesses will still need to address the challenges facing them as they look to meet the shifting demands of countries trying to maintain the fluidity of their supply chains.

Nadia Haseeb, Shell, explains how combining premium fuel and lubrication could be an efficient solution for an evolving sector.

This makes it essential to enhance productivity across every area of operations by reducing equipment downtime and increasing system efficiency as much as possible.

What is driving industry change?

Maximising equipment utilisation in the demanding mining environment is a difficult job at the best of times, but with the impact of COVID-19 and geopolitical pressures resulting in further cost pressures and tighter margins, there is now a much greater need for mining site managers to unlock efficiencies wherever possible.

That is in addition to some important emerging trends that are shaping approaches to operations across the sector, including:

n Alternative fuels: As mining looks to transition towards a net-zero future, alternative fuels are a means of maintaining operational efficiency while meeting sustainability targets. However, they will place different demands on equipment and require effective management to reach their potential.

n Changing equipment designs: To meet output needs, mining equipment is becoming bigger, which means unplanned downtime can have an increasingly detrimental impact. New original equipment manufacturer (OEM) designs also mean higher loads, increased temperatures and smaller oil sumps, raising the pressure even further on maintenance programmes to keep machines running smoothly.

n Tightening regulation: Equipment emissions standards increased with the advent of Tier 4 diesel engine requirements, and more recently, industry-wide targets have emerged. For example, the International Council on Mining and Metals has committed its members to net-zero Scope 1 and Scope 2 greenhouse gas emissions by 2050.

Businesses will need to adapt quickly to these trends to avoid the potential for disruption and, instead, unlock new opportunities for growth.

Driving efficiency with premium consumables

Improving efficiency and profitability while adapting to changing trends and global disruption might seem like a

near impossible task, but it can be achieved by going back to basics and focusing on the variables that are in one’s control, such as consumables.

It is vital that businesses do not lose sight of some of the most significant inputs (such as fuel and lubrication) when it comes to protecting operational fundamentals. Ultimately, it is these fundamentals – equipment health, uptime, and efficiency – that will dictate the strength of the bottom line for years to come.

After all, the fuels and lubricants selected can have a big impact on equipment and, in turn, business performance, with studies showing better fuel economy and improved fuel system technology can deliver up to a 5.5% reduction in fuel consumption.3

The right combination of fuels and lubricants has the power to drive efficiency across equipment operations and help reduce running costs. This has been demonstrated by professional experts putting consumables to the test under real-world conditions, making sure they can meet evolving industry requirements.

For example, Shell collaborated with Deutsche Landwirtschafts-Gesellschaft (DLG) to measure the total cost of ownership (TCO) savings and efficiency gains that can be achieved when using premium fuel and lubricants together.

Shell and DLG: A case study in product testing

Situated in Gross-Umstadt, Germany, DLG has a rich history of promoting the technical and scientific progress of off-highway equipment. Engaging a facility at the standard of DLG allows precise testing and close monitoring of test conditions.

Over the course of more than four months, and across nearly 600 hrs, the DLG team tested Shell FuelSave Diesel (known as Shell Diesel Extra in some countries) in combined use with Premium Shell Rimula Lubricants, against regular diesel and standard lubricants. The premium consumables were first put through DLG’s PowerMix test procedure using test frames and parameters designed by an independent expert commission, a format regularly used by leading global manufacturers to assess the quality of their machines.

Next, the two companies designed a new power take off (PTO) testing programme, combinining a series of assessments to verify the quality of premium fuels compared to standard ones. The result was a real-world measurement of how the tested fuels can impact the overall performance of an engine.

While there is a growing awareness across the mining sector of the benefits that either a premium fuel or a premium lubricant can have on equipment performance, the DLG test demonstrates the additional efficiencies that can be unlocked by combining the two.

The testing showed that, when used together, Shell’s premium diesel and premium lubricants can deliver up to 472 more operating hours as a combined efficiency benefit,4 a figure that could have significant cost-saving potential for the 24/7 schedules that are not uncommon for mining projects.

Mining haul truck at work.

The results also highlight the increased productivity that these fuels can offer, with DLG measuring up to 2.7% better fuel economy5 and 5.6% more load-pulling power when compared with regular diesel.6

Why fuel is an investment, not a cost

Turning back to fuel, this idea of an interlinked value chain is in full view, since fuel represents an important share of operating costs for mining businesses, with the average large mine hauling truck using 900 000 l/yr of diesel.7 Therefore, any improvement in fuel economy can have a significant impact on the bottom line, releasing savings that can be redirected to other parts of the business or used to protect financial health during periods of extended uncertainty.

A key factor in this is the ability to maintain engine efficiency while operating with heavy loads or on uneven terrain, especially with equipment that is consistently running at high capacity. And much of this comes down to the health of the injection system, particularly injector cleanliness. Shell and DLG’s test, for instance, showed that Shell FuelSave Diesel was able to achieve clean-up of up to 100% of performance-robbing deposits (linked to power) in less than three working days, which can significantly reduce downtime and maintenance costs.6

As more solutions become available to operators, being able to rely on products with performance proven under real-life conditions by independent test experts (such as DLG) will be key to ramping up operations. After all, the efficiency gains that once offered a competitive edge may now be essential for survival as mining businesses shake off the lasting effects of the COVID-19 pandemic.

The pressure is on to find a solution to sustainable growth

Another important element for a business is the ability to not only drive efficiency and growth, but also to do it sustainably. This is especially important given that mining currently accounts for 4% of total global energy consumption8 and is responsible for up to 7% of greenhouse gas emissions worldwide.9

Moreover, these factors are not just useful for contributing to the sector’s decarbonisation but can also help bring external stakeholders along on the journey too – something that holds its own significant value considering how important an operation’s license to operate (LTO) can be to the wider business.

And this has npt gone unnoticed by mining executives either, with six out of 10 citing their LTO as the biggest risk facing their business.10 Why? Because ultimately, they know that strengthening their LTO transcends societal and environmental factors, becoming critical for renewing existing business and winning new contracts as well.

In this context, any potential improvements around fuel efficiency or fuel consumption could be a massive driver of responsible growth. Even before thinking about the transition to alternative fuels, significant differences can be made by using the right combination of premium fuels and lubricants. The more efficient operations are and the less fuel is consumed, the fewer emissions are generated –helping companies take an important step towards the

decarbonisation of their business, while demonstrating to new and existing customers that they can deliver in this area.

How to connect people, purpose, and performance

Given the disruption facing global supply chains, operational efficiency is more important than ever. Which is why operators are looking across the board for opportunities to claw back marginal gains, be it through their consumables, digital technologies, or stronger collaboration.

Closing this gap will take time and investment, but once businesses are equipped with the right solutions and staff are given the correct skillsets, the potential benefits are clear. The important thing to remember, however, is that –just as the DLG testing shows – it is not always enough to have the right product, service or equipment on its own.

Rather, to deliver consistent performance when it is needed most, mining operators must connect the various dots from around their business, whether that is through: combining digital technology with staff upskilling; understanding that an LTO is a societal and business imperative; or unlocking efficiency potential by using premium fuel and lubricant in tandem.

References

1. ‘Russian invasion of Ukraine: Potential impact on supply chains of mineral commodities,’ GlobalData, (2022), www.mining-technology. com/comment/supply-mineral-commodities

2. ‘Supply of Critical Minerals Amid the Russia-Ukraine War and Possible Sanctions’, Center on Global Energy Policy, (2022), www.energypolicy. columbia.edu/research/commentary/supply-critical-minerals-amidrussia-ukraine-war-and-possible-sanctions

3. YUKSEL, A., ‘Digging Deeper: Increasing Mining Equipment’s Efficiency’, Cummins, (2021), www.cummins.com/news/2021/03/03/increasingmining-equipments-efficiency

4. For the same amount of fuel compared to regular diesel without fuel economy formula and to standard lubricant. Baseline of 100 000 l/hr and 50 l/hr fuel consumption per equipment. Based on demonstration tests with off-highway heavy-duty Tier 4 engines in collaboration with DLG Germany.

5. Shell FuelSave Diesel is designed to help provide by up to 3% fuel economy, compared to regular diesel without fuel economy formula. Actual savings may vary according to vehicle, driving conditions, and driving style. Internal Shell tests and with customers have shown a range of fuel savings depending on age of vehicle and type of operations.

6. Compared to regular diesel without fuel economy formula. Based on demonstration tests with off-highway heavy-duty Tier 4 engines in collaboration with DLG Germany. Achieved within 50 hrs of engine operations and four tankfuls.

7.

MURALIDHARAN, R., KIRK, T., and BLANK, T. K., ‘Pulling the weight of heavy truck decarbonization: Exploring pathways to decarbonize bulk material hauling in mining’, Rocky Mountain Institute, (2019), www.rmi. org/insight/pulling-the-weight-of-heavy-truck-decarbonization

8. ‘Largest end-uses of energy by sector in selected IEA countries’, International Energy Association, (2021), www.iea.org/data-andstatistics/charts/largest-end-uses-of-energy-by-sector-in-selected-ieacountries-2018

9. DELEVINGNE, L., GLAZENER, W., GRÉGOIR, L., and HENDERSON, K., ‘Climate risk and decarbonization: What every mining CEO needs to know’, McKinsey & Company, (2020), www.mckinsey.com/ business-functions/sustainability/our-insights/climate-risk-anddecarbonization-what-every-mining-ceo-needs-to-know

10. ‘Top 10 business risks and opportunities for mining and metals in 2022’, EY, (2021), www.assets.ey.com/content/dam/ey-sites/ ey-com/en_gl/topics/mining-metals/ey-final-business-risks-andopportunities-in-2022.pdf

Weir Minerals is focused on mining safely, sustainably, smarter, and more efficiently. It is not that production is any less important than it has always been; rather, by looking at processes holistically and taking time to plan, test and implement well-designed flowsheets, the company believes that it can help miners produce more for less.

Process-focused

In many instances, this requires a willingness to think differently – to be less fixated on the outcome and more focused on how to get there. Take, for instance, valves. Compared to a lot of other mining equipment, valves are lower cost, haver a shorter lead time, and, for that reason, operators often under appreciate their value.

Yet, valves enable operators to isolate and shutdown other equipment safely, preventing small problems from becoming plant-wide disasters – they are key to safe and reliable operation. However, because they are often only installed as an afterthought, poorly selected valves can end up shutting down operations instead of keeping the plant running.

Weir Minerals recently expanded its range of valves with the Isogate® WR knife gate valve. Drawing on decades of wear analysis, Weir Minerals’ engineers have optimised its body design by reinforcing the areas subjected to the harshest wear and pressure, while reducing the weight elsewhere to produce a robust, long-lasting mining valve that is significantly lighter than comparable products.

The gate has also been redesigned with stronger materials, resulting in a thinner gate that can still withstand

John McNulty, Weir Minerals, Australia, reviews how pumps and valves can help mining customers produce more for less.

the pressure of mining slurries. This combines with the valve’s unique gate guide, reducing deflection by ensuring smooth gate movement and less stress on the sleeve elastomer during blade transition.

The Isogate WR knife gate valve utilises Weir Minerals’ new Isogate WSL sleeve, which uses the proprietary Linard® HD 60 silica-reinforced natural rubber to solve the three most common problems with sleeved knife gate valves: leakage during cycling, tearing, and load distribution ring (LDR) failure due to corrosion and erosion.

Leveraging the Linard HD 60 rubber’s high resilience against cut, tear and abrasive wear to improve wear life, the new Isogate WSL sleeve fully encloses the LDR to prevent corrosion. By allowing the rubber to move with the blade cycles, the design reduces the chance of tearing while reducing slurry discharge by up to 75%.

But valves are only one piece of the puzzle, and this same commitment to innovate engineering underpins Weir Minerals’ approach more generally, including pump and pipeline design.

Pumping efficiently reduces costs

The amount of energy a pumping installation consumes depends on the pump efficiency, the drive train losses and

the motor and/or motor controller electrical efficiency. Pump efficiency is the biggest determinant of power costs. A slurry pump’s efficiency is reduced by the presence of solids, and an efficiency ratio (ER) is used to correct the published water performance curve; pump design also has an influence on the ER. The Warman® MCR® rubber-lined slurry pump features a large-diameter, low-speed, high-efficiency impeller, which reduces energy consumption.

Weir Minerals’ team of slurry pump experts work closely with operators to provide guidance on how to improve efficiency depending on their specific application. For example, at flow rates less than 60% of the standard impeller best efficiency point, utilising a reduced-eye impeller and low-flow volute will improve pump efficiency. And where pumps may be prone to cavitation, operators should consider maximising the use of low-NPSH-style impellers. Pump and component selection helps reduce wear, which, in turn, minimises additional maintenance expenses.

By extending wear life, operators can significantly lower the total cost of ownership (TCO); the Warman MCR slurry pump has a number of innovative features that have been designed with this in mind.

For instance, it features patented shrouds that extend past the periphery of the pumping vane and expelling vane, providing improved flow and reduced wear at the expelling vane tips. Its large, open internal passages reduce internal velocities and, thus, reduce wear.

Nevertheless, pump performance is not just about the equipment – close collaboration between miners and original equipment manufactures (OEMs) is an often overlooked factor.

A solutions-focused approach

Case study: Australia Weir Minerals understands that no two operations are the same, so it works closely with its customers to develop tailored solutions based on their specific requirements and conditions. Evolution Mining’s Cowal Gold Operations in New South Wales, Australia, wanted to increase production and reach a service life of 24 weeks uninterrupted production to align with major shutdowns and other equipment on site.

The Weir Minerals team installed a Warman MCR pump with R55® rubber liners, A65 full face adjustment throatbush and A61 impeller. Because of power limitations from the existing motors on site, they used rapid pattern prototyping to manufacture a custom 82% trimmed impeller for the application. The team also 3D scanned the site to ensure a trouble-free installation and finalised the custom design of connected Linatex® pipework, new cyclone feed line, and Isogate valves.

Cowal Gold Operations increased production and extended the pump’s wear life; the incumbent pump’s 12 weeks of continuous operation was significantly improved upon by the Warman MCR 550 pump, which achieved 29 weeks. Over one year, the incumbent pump’s TCO was AUS$2.2 million compared with the Warman MCR 550 pump’s AUS$1.7 million – saving Cowal Gold Operations nearly half a million dollars.

Figure 1. Weir Minerals Synertrex®-enabled Warman MCR 550 pump on site at Evolution Mining's Cowal Gold Operation, where wear life improved by 140%.

Figure 2. Weir Minerals’ Warman MCR 550 installed in a copper mine.

Regional factors

Operating costs often vary depending on where the mine and pump installation is located; local climatic and regulatory conditions have to be factored in when working out the TCO. The cost of water, for instance, varies greatly across regions.

The costs associated with the use of water to flush the gland of a slurry pump can be split into two components: the supply cost and the removal cost. The former depends on the type of pump – its size and gland type – while the latter depends on the particular process and commodity being handled.

The amount of water consumed by the pump depends on the type of seal. The mechanical seal and expeller or centrifugal seal can be operated without any water injection, but sometimes use small amounts to help reduce wear in particularly erosive duties.

The Warman MCR pump has a low flow design stuffing box that is also able to be centred. The adjustable stuffing box allows for centring of the stuffing box and lantern restrictor to the shaft sleeve, which increases packing life and decreases gland seal water consumption.

The Warman MCR slurry pump’s low flow stuffing box is made with tungsten-carbide-coated J221 shaft sleeves. The stuffing box also features close clearance split lantern restrictors with a harder non-galling coated inside diameter. The upgraded materials and design reduce gland water consumption.

The actual consumption of water also needs to be factored in. In remote areas, the supply of suitable gland water may be very costly due to the need for sinking bores and the long-distance pipeline pumping. Even when more readily available from mains supply, water can be relatively expensive to purchase in large quantities.

Case study: Latin America

At a Latin American iron ore mine, the operator wanted to increase its energy savings in all their processes, focusing particularly on reducing the consumption of process water. It had Warman MCR 250 pumps installed in one of its mills to transport slurry from the mill discharge to the hydrocyclone cluster. The installed Warman pump seals were wet seals with an average life of 3200 hrs.

Weir Minerals suggested trialling a Warman mechanical seal on the Warman MCR 250 pump; the mechanical seal requires a small amount of water to be injected to assist with lubrication and cooling of surfaces.

At the conclusion of the successful trial period, the time between maintenance intervals tripled and the customer’s water consumption costs decreased by 65% with the mechanical seal.

The importance of being close to customers

Inventory costs are something of balancing act. On the one hand, holding stock ties up capital that could

THINK

THINK

otherwise be spent on revenue-earning activity; on the other, having stock on hand ensures spare parts are available immediately in the case of an unplanned shutdown or to ensure supply in the case of extended lead times.

Weir Minerals’ team of slurry pump experts works closely with mining customers to understand their equipment’s wear performance, maintenance schedules, and inventory requirements. It has a global network of service centres in all major mining regions to support its customers with all their inventory needs.

Case study: USA

Capstone Pinto Valley Copper Mine has two spare Warman MCR pumps; when a pump needs to be repaired, it is pulled out of the line and shipped to the Tucson Service Centre. Here, Weir Minerals service technicians pull it apart, laser scan it to determine where the wear locations are, provide a wear report and recommendations, and put it back together according to OEM specifications. Weir Minerals then ships the pump back to Pinto Valley within 5 – 7 days. This reduces downtime, saves Capstone Pinto Valley money by removing the need for a full inventory of spares to be kept, and frees up its maintenance staff to carry out work on other equipment.

Case study: Australia

Reducing spare parts consumption can significantly lower the TCO. At an Australian gold mine, for instance, Weir Minerals

configured all their Warman MCR 550 pumps with composite throatbushes comprising half alloy and half rubber to address the localised recirculation wear around the eye of the throatbush. This resulted in a significant increase in the length of the Warman MCR pump life cycle.

This increase has reduced shutdowns from four per year down to a maximum of two per year, depending on tonnage throughput. This, in turn, has allowed the site to modify the maintenance plan and contributed to a reduction in spare parts consumption, which has saved the customer over AUS$2.1 million, while also increasing plant operation time.

As wear monitoring improves, so too will pumping efficiency.

Mining smarter

Weir Minerals wants to go beyond the traditional role of OEMs and become a digital end-to-end solutions provider to its customers. One important development in the realisation of this vision is the recent launch of Synertrex® IntelliWearTM digital wear monitoring system for spools and hoses in slurry pipelines.

The system is comprised of a digital sensor integrated into Weir Minerals’ Linatex and Vulco® hoses and spools. A central control panel captures information in a single location and a dashboard allows for visualisation and analysis of the equipment data via the Synertrex digital ecosystem. Digitalisation enables Weir Minerals’ customers to continue their normal operational duties, while large amounts of data are automatically analysed and interpreted in the background, via the Synertrex intelligent platform.

A conductive wire is installed in the rubber lining at various levels of thickness. As the lining wears, it activates sensors to indicate the extent to which the rubber liner has been worn and, in turn, how much life is left. An easy-to-use traffic light system has been developed which enables quick visual identification of the condition of the hose or spool. Less than 50% wear is green, between 50% and 70% wear is yellow, and greater than 75% wear is red – indicating it is time for preventative maintenance. The conductive wire is installed along the entire Linatex or Vulco spool or hose, throughout its diameter.

The central monitoring panel collects data from the sensors in the field and sends it to the Synertrex intelligent platform, which can then be viewed by operators and maintenance personnel. Information collected can also be uploaded to the cloud to be viewed on a live dashboard, which is automatically updated every two minutes. The intelligent system enables operators to view real-time wear information from any device remotely – ensuring continual monitoring and better control over their equipment.

Plant optimisation

With declining ore grades and increased regulatory pressure, miners have to increasingly rely on plant optimisation if they are going to meet the growing demand for many minerals. As a trusted OEM partner, Weir Minerals tries to understand each site’s specific challenges and develop bespoke solutions. It is something that is only possible because the company has a portfolio of products across the entire flowsheet, as well as the expertise to support them.

Figure 3. Weir Minerals Isogate WR Knife Gate Valve from the factory.

Beyond Rock Solid

Figure 1. Mobile conveyor bridge operating across benches in a coal mine in China.

Bulk materials, whether coal, ores or rock, still play a major role in the extraction of natural resources.

Today more than ever, the shortage of certain raw materials on the world market highlights the demand that is to be met.

Many deposits are located just below the earth’s surface, which makes extraction from the vicinity of an opencast mine a sensible option.

Product transport and related materials handling

In opencast mine operations, once crushed to the required size, the product must be transported to the next downstream process step. The scope of this article is focused on the crushing interface to mining, and hence only the features relating directly to the immediate transport of materials are considered.

Boris Frankenreiter, thyssenkrupp Mining Technologies GmbH, Germany, outlines some of the best operational practices for in-pit crushing and conveying (IPCC) operations.

In the case of higher throughputs and coarser particle size product, it is often a requirement to have a product vault or pocket under the crusher that has the capacity to hold approximately two to three truck payloads. Material is then drawn away from the vault by a feeder that discharges onto a main conveyor belt.

On the largest scale, the materials handling of the product requires a range of equipment, including belt wagons, bridge conveyors, and, in some cases, custom systems. Belt wagons (Figure 3) are essentially mobile transfer conveyors, mostly used to provide a connection between mobile crushing plant and a fixed bench conveyor. In most cases, belt conveyors are statically located at the mining face, but are designed to be shiftable. The utilisation of a belt wagon enhances the flexibility during operation of the crushing plant in combination with the belt conveyors and, additionally, the amount of shifting procedures can be reduced.

Flexibly bridging the gap

An even more flexible solution for the material transfer between a crushing plant and a mine face conveyor is formed by mobile conveyor bridges. Principally, they are a further development of belt wagons with the advantage

of further improved flexibility. Conveyor bridges, as shown in Figure 1, can operate across one or more mine benches, and further optimise travelling and shifting of the crushing plant and the face conveyors, in order to minimise system downtimes.

Beyond these specialised units for in-pit crushing and conveying (IPCC), conveyors in general form the arteries of the system. Although, these can be deployed as fixed installations in some instances, there is also the need to move the conveyors to optimise material movement. The main movement options for such conveyors are usually referred to as portable, shiftable, or semi-fixed. Portable conveyors are mostly wheel-based and are often designed in a traditional grasshopper style. Shiftable conveyors are designed to be moved periodically, so they are often skid-mounted and have attachment points to allow dragging via dozers. Semi-fixed conveyors are modular, mostly mounted on concrete sleepers, and relocation involves disassembly and movement of the modules.

For the extraction of various mineral resources in mining operations throughout the world, depending on the thickness of the material to be extracted, the movement of smaller or larger quantities of overburden is necessary. This becomes more lucrative the larger the deposits of natural resources are in the mine, located under layers of soil. Once the location and size of the raw material to be extracted have been determined by test drilling, it becomes necessary to remove the overburden layers before extraction of the resources. The overburden is commonly dumped at a suitable location in the mine, at a distance from the extraction site. In many smaller mine activities, the simple truck and shovel method is still useful, as this method is easily scalable. A small fleet of mine trucks, driving the overburden from the excavation face to the overburden dump, often represents the basic

Figure 3. Belt wagon application in China.

Figure 2. Spreader and tripper car in high capacity application.

equipment of a small or medium mining operation.

Mobile mining machines: the gentle giants

In the event of an increase in mine activities, for example due to the increase of production rates or to move larger quantities of overburden, the use of specialised machinery for continuous transportation and dumping becomes economically more favourable. After crushing the overburden into a product size, which can be handled by conveyors at the mine face, the material is transported by belt conveyors to the overburden dump area where tripper cars and spreaders are used in the dumping process. Often, the conveyors at the beginning and at the end of the complete conveyor line are designed as relocatable or shiftable. This way, the specific single conveyors can be moved close to the operation radius of the mining and dumping machinery, thus optimising travel and handling times of excavators and dumping equipment.

Many worldwide mining applications in medium and large scale rely on semi-mobile or fully-mobile crushing

plants at the beginning of the conveying line. The dumping equipment itself is independent from the type machinery used at the mine face. Tripper cars are the first unit of dumping machinery and are used to receive the overburden from the dump conveyors. Therefore, tripper cars are equipped with travel mechanisms either of the rail-type, or – more rarely – the crawler-type. They travel along the relocatable dump conveyor and lift off the belt to a specific transfer point, where the material is transferred to the spreaders. The spreaders form the last member of the conveying chain and dump the overburden in a controlled manner at the designated area. To achieve a maximised flexibility in operation and

Figure 4. Spreader and tripper car, with tripper car on crawlers.

minimise shifting-downtimes, spreaders are commonly designed as two-flight units with travel mechanisms consisting of crawlers. Capacities of spreaders and tripper cars may vary between 3000 m³/hr up to 18 000 m 3 /hr (Figure 2), and in special cases even more.

Especially in operations where spreaders and tripper cars are intended to drive on freshly filled ground, the crawler–based travel mechanisms of the spreaders are a proven, state of the art technology. Due to the lower weight of the tripper cars, their travel mechanism often consists of a travelling system on rails, which are attached to the dump conveyor, as they always are centred over the conveyor. Special applications with the demand of a very high flexibility also incorporate tripper cars on crawlers, combining with an additional discharge boom with a conveyor (Figure 4), while the spreader is equipped with a support car for the receiving of the conveyor boom.

For the application of continuous dumping equipment in smaller mines, a single operating tripper car on crawlers or on rails can also form a standalone solution without a spreader.

Advantages for budget and the environment

Low energy consumption and carbon dioxide reduction are becoming more and more important, even in the mining business. With this in mind, thyssenkrupp has worked to make sure its products are operated entirely electrically.

While discontinuous transport systems are based on a large number of individual transport units like haul trucks, a continuous system minimises the number of operators. While in truck transport systems, each vehicle is operated by at least one person, combined with multiple work shifts per day, a continuous system can be operated by fewer personnel during the same time. A significant increase in operational safety and economic savings is the result of the innovative control and monitoring systems. Implementing these solutions on a

large scale optimises the number of personnel needed for safe and economic operation of the transport system even further.

Casestudy: An IPCC system for overburden in an opencast coal mine

The continuous mining equipment recently installed in an opencast mine, located in Bulgaria, is the latest state-of-the-art technology designed for operations. After initial mine planning activities, conducted by thyssenkrupp Mining Technologies, the optimal combination of equipment has been installed inside the mine. The technical solutions adopted for the engineering of the specified continuous mining equipment operations have prioritised the stability and safety of the equipment, whilst maintaining a high degree of robustness to ensure easy and secure operations, as well as good accessibility to the components of the equipment in the event of maintenance.

The complete system, which is designed for a capacity of 3000 tph of overburden, consists of the following equipment: n Semi-mobile crushing plant of the type 63 x 89 in., fed by apron feeder, up to 150 t truck class. n Multiple stationary belt conveyors leading from the crushing plant to one shiftable dump conveyor in the dumping area – total length approximately 3200 m. n Tripper car on rails and spreader on crawlers –ARs 1600 50+70/17 – forming the dumping equipment with a maximum capacity of 5000 tph.

In normal operations, the system is interlocked and runs in an automatic mode, controlled by programmable logic controllers.

Since commissioning in 2011, the complete IPCC system, as shown in Figure 5, is in continuous operation and has proven to be a reliable, high-performance transport system.

Conclusion

When comparing the benefits of a continuous transport system with the characteristics of using trucks, the advantages are obvious: improved capacity, reliability, lower maintenance costs, increased safety in operation, and, not to be overlooked, better environmental prospects. The operation of mobile machines with belt conveyors becomes more economical the larger the mine grows and the larger the quantities that are transported.

Figure 1. Reducing emissions in haulage fleets is more complex than it first appears as these fleets are very diverse, with differing haul profiles being influenced by geography and environmental factors.

In the mining industry, fossil fuels are consumed in almost every process.

Loading and hauling account for around 50% of a mine’s overall usage of fossil fuels today, according to Hitachi Construction Machinery (HCM) data and other industry reviews. That number can be much higher depending on the particular application.

At first glance, it appears the loading and hauling segment is positioned as a quick win for emissions-reduction efforts. However, the reality is there are much more complex loading and hauling requirements that also represent a very broad scope of the mining segment.

Globally, surface mining haulage fleets are very diverse, with differing haul profiles being influenced by geography and environmental factors. Copper, coal, iron ore, gold, diamonds, phosphorus, and even oil are all surface mined. These mines are in climates ranging from the equator to the Arctic Circle, and from sea level to mountain tops.

Their diversity means there is no silver bullet to solve the entire issue. Currently, both traditional mining technology groups and non-traditional mining groups are striving to put solutions forward.

Bridge technologies do not solve the problem completely

This article will first look at the technologies available to help solve the problem, and then how to apply them. Some groups are pursuing e-fuels and second-generation biofuel options, but HCM views these as bridge solutions. They simply do not address the root issue of eliminating carbon from haulage activities.

Hybrid power solutions (smaller diesel engines with battery energy storage) are also a bridge technology, but they do provide advantages over simple fuel substitutions. The battery pack allows

energy-capture during braking and reduces energy loss associated with operational inefficiencies.

Traditional trolley technology available today, including from HCM, is also an effective bridge solution. Electrifying high-demand segments of the haulage route helps achieve significant carbon reductions. In some applications, more than 50% of emissions can be eliminated with current proven technology, providing significant short-term benefits with minimal impact. The ability to offer a retrofittable diesel trolley solution for battery trolley technology in the future is a viable pathway; the same infrastructure can be used for charging batteries and providing energy to power the truck.

The drive toward efficiency

For HCM, the road to zero emissions is not just about reducing a mine site’s carbon footprint; it is about increasing the efficient use of energy.

For example, a traditional 220 t haul truck will carry 4000 – 5000 l of fuel on board, which equates to roughly 40 000 – 50 000 kWh of energy. However, the diesel engine’s energy efficiency is only around 40%, at best, when compared to battery/electricity energy conversion.

It is important to note that substitute fuels do not increase these efficiencies. Hybrid systems decrease fuel usage by increasing engine fuel burn efficiency by a couple percent, as the small onboard battery energy storage systems can be used to optimise the engine’s operation.

When compared to a traditional engine configuration, the hybrid system may yield a 20% energy savings through braking regeneration and reduced operational energy losses. HCM sees this as an opportunity for improvement.

HCM has identified two key development pathways that allow more

John Schellenberg, Hitachi Construction Machinery, Canada, emphasises the importance of energy management to zero-emissions technologies and describes how mines can implement such advancements, particularly in relation to loading and hauling.

effective energy use in haulage applications: electrification and energy management.

Electrification and energy management

HCM believes mine electrification will be crucial in the early adoption of zero-emission technology. Electrification is a key segment of Hitachi’s overall business, and the company is very comfortable with it; viewing it as a solution to the haulage operation challenge.

Through electrification, energy efficiency can be increased. Energy can be captured and reused during braking, and energy use can be limited when the vehicle is not travelling. This helps offset operational practices that consume energy but are not contributing to material movement.

A battery electric vehicle (BEV) system is capable of more than 70% efficient use of energy when calculating from ‘generation to material moved’. While electrification will increase efficiency, the technology available today has some constraints compared to diesel. This is where energy management becomes critical to success.

If that standard 220 t haul truck carries 40 000 – 50 000 kWh of energy, at 35% efficiency, that would equate to 14 000 – 17 000 kWh of energy used to actually move material.

With today’s technology, a battery-powered truck can store approximately 500 – 1000 kWh. If the best battery option is compared against the worst diesel option, there is still 14-times more energy on the conventional diesel vehicle.

This is where energy management becomes critical to success. The ability to move electrical energy quickly from the grid to mobile vehicles is required if electrified haulage is to be competitive with current technology. Couple that with the increased volatility in the renewable energy supply, and energy management moves to the forefront.

Exploring the hydrogen option

Hydrogen is another option on the electrification pathway. Hydrogen has an on-board kilowatt-hour energy storage capacity similar to batteries, so refuelling is just as important for hydrogen as it is for batteries. Hydrogen infrastructure is not as developed as electrification systems, so technology maturity will limit short-term adoption rates.

One challenge with hydrogen is its efficiency compared to BEV technology. An automotive industry study conducted in Europe compared hydrogen and BEV technology. It was found that with battery-powered e-cars, only 8% of the energy is lost during transport before the electricity is stored in the vehicle’s batteries. In the case of a hydrogen-powered e-car, the losses are much greater: 45% of the energy is already lost during the production of green hydrogen –through electrolysis – and another 55% is lost when converting hydrogen into electricity within the vehicle. This means that the hydrogen-powered e-car only achieves an efficiency of between 25 – 35%, depending on the model. A hydrogen car consumes two to three times more electricity for the same distance travelled compared to a battery car.

Accounting for the variables

The efficiency argument is quite compelling, but it does not cover all the variables faced in the mining sector. The complexity of the global haulage environment makes energy management a key focus. In some applications, a round trip will be less than 4 km with elevation variances of less than 50 m. In other applications, a haul cycle may be more than 20 km with an elevation variance of close to 1 km. Depending on the commodity, there may be a centralised loading and dumping point with little change annually, or shallow loading faces that are continually moving. These different conditions provide a variety of challenges for onsite electrification.

In some cases, the in-pit and main haulage routes are static. Electrification of these routes is the best choice. In other applications, in-pit and main haulage routes are dynamic. Here, electrification infrastructure would need to be more flexible and more mobile. The question is: at what point does the mobility of in-pit/main haulage route electrification outweigh the efficiency losses observed in hydrogen ecosystems?

A combination of these technologies will likely be required to solve most haulage and energy-storage issues when combined with renewable energy and energy storage.

By comparing off-site energy generation to onsite energy management, companies can choose a preferred pathway.

For HCM, the development of the haulage unit is the easiest part of the equation. The company already has a solid

Figure 2. Electrifying high-demand segments of the haulage route helps achieve significant carbon reductions. In some applications, more than 50% of emissions can be eliminated.

Figure 3. The road to zero emissions is not just about reducing a mine site’s carbon footprint; it is about increasing the efficient use of energy.

modern electrified platform. Its development challenge consists of re-powering the current product. To help overcome this challenge, HCM has entered into an agreement with ABB Ltd to develop a battery-powered model for its current product line. The company is also monitoring developments with hydrogen, as it feels that this technology will form part of future mining requirements.

How can customers transition?

The first steps any mining organisation should take when considering a transition away from diesel are education and evaluation.

This article has outlined several technologies in the decarbonisation space, but not all of them. Traditional technology will continue to dominate the industry for some time to come, but alternatives are gaining ground. In some cases, they provide a better economic outcome than conventional practices.

HCM would like to see more customers investigate the alternatives because it is possible that currently available options will provide improved economic and environmental outcomes quickly.

Understanding what potential ‘green’ energy supply is available would be a first step. Energy availability and cost will drive the decision-making process and dictate which technology pathway is most suited to a customer’s needs.

participating in activities sponsored by the International Council on Mining and Metals (ICMM). ICMM is using its broad membership to collect information globally and store it online in a ‘knowledge hub’ dedicated to decarbonisation.

Contributors are not only end-users, but also mining equipment original equipment manufacturers, so there is information from both sides of the industry.

HCM’s technology pathway is based on the evaluation of its own core company strengths, however this does not mean that it ignores other solutions. One of the company’s social commitments is to achieve both a higher quality of life and a sustainable society in collaboration with stakeholders. HCM’s unique industry conditions need to be communicated to investment stakeholders and governments, so that informed decisions can be made based on industry needs, rather than the perceived needs based on unrelated applications.

Conclusion

Renewable energy will increase volatility in the power supply. Coupling this with increased electrification on the mine site and the supply vs demand equation can be very chaotic. Therefore, Hitachi feels electrification, mine plan designs, and, specifically, energy-management tools will be critical for successful green energy implementation.

Figure 1. Komatsu's autonomous trucks operate leveraging the FrontRunner system.

Jess Stephen, Komatsu, discusses haul truck power sources that are purpose-built for a sustainable future.

Agrowing sense of urgency now drives equipment planners as they work toward their 2030 emissions reduction targets. In a departure from past development programmes, some original equipment manufacturers (OEMs) offer engagement and collaboration

to mining professionals overloaded with many questions, inspirational product developments and new operational challenges, where prolonged machine lives extend the carbon impact of today’s choices out to their corporate 2050 net-zero emissions goals.

Many questions haunt leaders and the planners charged with achieving emission reductions: How are these goals reached? What equipment and operational changes are necessary? What will this cost? How does the mining industry answer those questions?

International expectations help create a clear vision of the long-term future: the technologies are under development, but specifications for practical solutions remain elusive.

And, as one report from McKinsey says: “Within the space of heavy machinery and equipment, there is still a very limited share of battery-electric vehicles (BEVs), even though electric propulsion (with cable) is not uncommon in some equipment.” 1

Thankfully, industry innovators are closer than ever to practical prototypes which convert diesel-powered equipment to 100% battery powered. They are also on the verge of what some considered theoretical just a decade or two ago: power-agnostic drive systems that allow individual sites to choose different power sources for their off-highway mining haul trucks, based on the mine’s physical application, environment, and economic needs.

Increasingly optimistic studies reinforce what industry experts are coming to accept: changing to zero-emission mining is not only necessary for the planet, it is also essential for profit.

Moving more material at lower cost

In another recent analysis, a global mining company weighed diesel-based equipment against a fleet powered by alternative energies. It determined that it could remove more than 6 megatons of carbon dioxide (CO 2 ) per year, 20 years earlier than planned – equal to eliminating nearly 1.5 million passenger cars. 2

Based on testing and analysis by Komatsu’s Greenhouse Gas (GHG) Alliance and Sustainability for mining, mining companies can move more material at lower cost by switching to electric power for mining equipment. A step-by-step transition of mining haulage delivers incremental returns that drive continued investment through each phase of the journey to

zero emissions. These economic benefits remain well after the transition to 100% electric power.

Komatsu has run thousands of simulations with major mining companies and together is finding 5 – 15% cost per tonne reductions across a variety of applications. The analytics teams are not using a bunch of future assumptions – they are evaluating current battery technology, trolley infrastructure, change management, and operational impact. It is still early, but the simulations are very encouraging.

Two strategies toward a green transition

But how do companies get from today’s profits with diesel to expanding them with electric?

Getting there requires carefully crafting a unique strategy for each organisation and its needs. There is no one-size-fits-all solution: each organisation and site must carefully investigate, analyse, and develop their plans.

That conclusion is echoed in the fleet study, which found that companies ready to embrace the complexities of the diesel-to-alternative energy transition had a ‘clear competitive advantage’. They may be able to charge a price premium to customers for products that are truly green. 2

However, the report adds, first is not always best. Analysts offered two paths toward a green transition: Move quickly away from diesel but pay more upfront; or migrate more gradually to alternative fuel sources, but deal with more complexity.

In an example of a zero-emission transition strategy developed within the Komatsu GHG Alliance using an iterative analytic process, one mine plans on first utilising a truck fleet powered with diesel trolley for increased production, reduced fuel consumption, and lower emissions. Planning for an autonomous haulage solution takes place during this trolley deployment. Once the trolley is integrated into daily operations, then autonomous haul solution (AHS) deployment begins, delivering additional production from fleet optimisation gains. With the AHS trolley in place, the plan calls for strategic replacement of diesel engine power modules with 100% battery power modules at engine rebuild, eventually converting the entire fleet to zero-emissions.

With a plan, companies know where they are going. The investments become self-funding from production improvements and cost savings, and they have a timeline for when they are going to do it. However, this plan is not for everyone and does not work where new licensing and regulatory requirements call for zero-emissions from day one.

Start with people

So, developing customised strategies now can help companies reach their equipment-based net-zero goals into 2030 and beyond. But what are the risks? What about the technological limitations? And what is the upside – beyond going green?

Figure

Komatsu’s power agnostic development truck undergoes testing at a Komatsu facility in the US.

The biggest risk to this mining transition might involve people. With autonomous haulage, the industry has learned that people are the primary limiting factor to deployment.

Any company considering a transition from diesel to electric vehicles and beyond should start looking for personnel long before deploying equipment.

The time to start looking for planners, thought leaders, and drivers of change management – is now. The benefits from recent advancements in workforce diversity show a clear advantage to those organisations willing to make the long-term investments in their people. This broader, more diverse talent pool is crucial to the future success of the transition to zero-emission mining.

These working teams will develop more than an individual organisation’s plan for EV or power-agnostic rollout. They will also help shape industry standards and regulations for everything from battery manufacturing to mining operations, and risk management to shipping.

The real risk to successfully achieving a zero-emission transition lies in not having the right people who create and drive the right plans.

Working together to rapidly innovate

That spirit of collaboration led to Komatsu’s GHG Alliance, which brought together mining leaders

from Rio Tinto, BHP, Codelco, and Boliden to work together on product planning, development, testing, and deployment of the next generation of zero-emission mining equipment and infrastructure. 3 The goal is to rapidly innovate in support of carbon reduction targets. Komatsu GHG Alliance membership has grown rapidly since its founding.

The alliance’s initial aim is to advance Komatsu’s power-agnostic truck concept for a haulage vehicle that can run on a variety of power sources – including diesel electric, electric, trolley (wired), battery power, and even hydrogen fuel cells.

The first step toward that goal should come later in 2022, when Komatsu completes the installation of a trolley line at its Arizona Proving Grounds (AZPG) near Tucson, Arizona. This 1.2 km line establishes the backbone for development of zero-emissions haulage, AHS trolley, and trolley power research. Initially the line will power Komatsu’s EVX, a 100% battery-powered, zero-emission haul truck, currently used for testing and research.

Historically, the company shares very little information about development projects – the industry only hears about the final product release. With these new products, the complexities of the zero-emission transition and dramatic infrastructure changes drive a need for deeper collaboration with equipment stakeholders much earlier in the process. This is the first

time Komatsu has ever collaborated so closely with its customers in so many stages of development.

The innovative approach will give the GHG team insight into the development, testing, and rollout of not only an EVX concept battery test platform – which debuted in September 2021 at MINExpo in Las Vegas –but also the 930E power-agnostic diesel haul truck, which is envisioned as a diesel-powered vehicle that can be fitted for battery-power and future energy options.

Power source flexibility

The concept is based on a ‘plug-and-play’ model: Komatsu will provide space within the power agnostic trucks where the engine module usually fits. Over the long life of the truck, customers can adapt the power module with different power generation and storage solutions that meet their strategic needs. At first, that might mean diesel. Then, in a first or second phase engine rebuild, customers could outfit the power-agnostic haul trucks for battery operations.

Converting from diesel to battery is largely a matter of mechanics. Replacing the diesel engine with battery trolley power reduces the already low number of moving parts on Komatsu equipment, further reducing service costs. Eliminating all those little valves, moving parts and troublesome fluids, such as engine oil, reduces maintenance interventions. Service personnel will not touch the machine as often, which is a huge benefit in TCO modelling. Less time in the shop means more time in the dirt moving tonnes – reduced maintenance time and increased production makes a big difference economically.

Trolley system installation can be cumbersome, but also provides many advantages.

For example, with trolley lines, trucks can charge their batteries while hauling; customers can charge the

battery while the truck is moving uphill; and, with the added power available from trolley segments, the batteries are fully charged without interrupting production.

For example, a diesel engine is limited to 2700 hp (2000 kW). With trolley lines, the truck can access up to 6.5 MW, which increases propulsion and charging opportunities. It is efficient, low-cost energy available to the truck’s power management system and drive motors.

Of course, batteries do have some limitations. Unlike car batteries, battery swapping with power-agnostic haul trucks will not likely be an option because of the degree of difficulty and high potential for damage.

Komatsu has looked very seriously at in-circuit battery swapping strategies, but the risk/benefit value is challenging for the large, opencast mining trucks.

Battery technology is a source of optimism for equipment manufacturers where continued innovation, performance, and cost improvements expand the range of economic viability and applications.

Only now is battery technology reaching toward the performance, cost, and durability requirements for the mining industry. Advancements in battery production and packaging make reliable operation possible. Strong manufacturing and global support is the real magic ingredient.

Transitioning profitably to zero-emission mining

This is where Komatsu is counting on its decades of battery research and strong collaboration with GHG Alliance members.

Komatsu has been testing battery power for mining trucks since the mid 2000s. Its equipment strategy takes advantage of currently available technology while provisioning for future innovations. This means collaborating closely with customers and understanding their needs and challenges, which is where the company has spent a lot of time. It is working one-on-one with mining customers to better understand: Where are they today? Where do they need to go? What changes need to be made to machines for them to fit the future of mining?

Collaboration is critical because it entrusts mutual understanding. This engagement drives successful deployment planning and operation of new technology.

Expanding collaboration across the industry will be key for developing standards that will manage the many manufacturing, logistics, and operational questions that will arise with battery powered mining equipment.

Figure 3. Komatsu’s GHG Alliance is working toward the development of a power agnostic truck concept for a haulage vehicle that can run on a variety of power sources.

The takeaway is that GHG Alliance members are helping each other develop the entire power agnostic ecosystem. For their cooperation, alliance members get early access to developments within Komatsu, which could give a competitive advantage as products come on market.

There is nobody today using fleets of 240 t or 320 t fully-electric battery-operated trucks, and many logistical questions remain. Frankly, there are few standards in place for managing this process. How will the world ship giant battery modules across the ocean? What impact will regional energy or industrial policy decisions have on importing, service, or remanufacturing battery modules? Many things that require input and guidance continue to evolvie rapidly. The company is therefore going to work with its customers closely and approach these opportunities together.

Komatsu meets with GHG Alliance members on a regular cadence for working sessions. This process offers group time for planning and reporting, as well as management of working teams engaged with subject matter experts resolving specific challenges. This effort drives toward preparation for strategy development and power-agnostic fleet deployment.

One of the looming questions for asset managers and emission strategists has been the impact of longer economic life expectancies from trucks, such as the 930E, but this is a question Komatsu cannot answer for everyone.

As a result, this is is why the GHG Alliance team engages in extensive analysis and strategy development, as customers evaluate upcoming fleet replacements and upgrade path to their ultimate 2050

zero-emission targets. The power agnostic truck series will make this transition much easier.

In addition, Komatsu has zero-emission plans for the ‘-5’ truck models currently available today. These projects will use technology derived from the power agnostic development programme.

Conclusion

As discussed in this article, diesel-to-battery transition remains more about people and planning than equipment. Technologically, a profitable transition to zero-emission mining is possible. Practical success depends on people making an early start, collaborating openly, and creating innovation from the challenges of their first planning attempt. Companies should start small, but start. And start now.

References

1. ‘Harnessing momentum for electrification in heavy machinery and equipment’, McKinsey & Company, (2019), www.mckinsey.com/industries/automotive-and-assembly/ our-insights/harnessing-momentum-for-electrification-in-heavymachinery-and-equipment

2. RUSSELL, R., ABEL, M., FERNANDEZ, D., HARWOOD, K., LEACH, M., and MCCABE, G., ‘Net-Zero Trucks? Yes, It’s Possible’, BCG, (2021), www.bcg.com/publications/2021/alternative-fuels-for-trucksfactors-to-consider

3. ‘Komatsu announces collaborative customer alliance to advance zero-emission equipment solutions - New offerings to leverage electrification for next generation’, Komatsu, (2021), www.komatsu.jp/en/newsroom/2021/20210802

To turn a conventional dump truck into an autonomous one, two things are needed. First, to enable electronic control of the truck’s actuating mechanisms – such as front (steering) wheels, transmission, brake system, retarder, etc. – control of the truck by sending the appropriate electronic signals and receiving feedback, rather than by mechanical actions on the steering wheel or pedals, must be made possible.

Secondly, it is necessary to ‘teach’ it to determine its position in space and perceive the surrounding environment. To do this, it needs a set of sensors: lidars, radars, digital video cameras, IMU sensors, communication equipment, and a high-precision satellite navigation system – for example: GPS, GLONASS, or Galileo.

This being said, ‘brains’ are also needed on the truck to operate it all. High-performance on-board computers, network, and communication equipment need to be installed on the truck, as well as a reliable power source for all this equipment. Since the design of the dump truck does not

Dmitry Lukovkin, Zyfra Robotics, Finland, answers the question, ‘how do you make a dump truck autonomous?’, and explores what the future might hold for automation in opencast mining.

provide power for the sensors or additional electronic units, a significant part of the whole complex is providing power. A dump truck is not a device with a reliable 220 V power supply. Therefore, the essential part of making a dump truck autonomous is not just the work of software developers, but also engineers who will develop a whole range of hardware solutions – from brackets, housings and cabinets with environmental protection, to the power system and even on-board computing units of the required configuration.

Why is making a dump truck autonomous less than half of the problem?

It is important to understand that, unlike passenger cars, automating a standalone dump truck at a mine site makes no sense. A quarry or a mining site is an orchestra, and it needs a conductor to control it as a whole.

To make an autonomous operations zone productive and efficient, consideration not only has to be put into the trucks, but also the loading equipment and auxiliary vehicles. Loaders will have to be equipped with a high-precision navigation system and a touchscreen panel to allow loading tool operators to interact with autonomous trucks. In some cases, loaders could be used in a tele-operations mode to further enhance safety. Auxiliary vehicles that routinely work in the autonomous operations zone side-by-side with autonomous haul trucks should be also equipped with high-precision navigation and communication systems.

Who rules them all, and how?

When an orchestra is tuned, ready and waiting in its pit, how is its performance directed? A conductor of course.

Obviously, when it comes to conducting an automated dump truck symphony, there should be software that fills this role. However, as the whole area is still very new, there is no unified name for this software. In the closed-stack, vertically integrated implementation of an automated haulage system (AHS), it is a part of, or an add-on to, the vendor’s fleet management system (FMS). In the ‘Open Autonomy’ initiative by Wenco International Mining Systems, it was called an ‘autonomy controller’.1 Sometimes it is referred to as AHS, though the ‘AHS’ term generally refers to the wider scope. Zyfra Robotics uses the internal term ‘Robot of Robots’.

So, what should this piece of software do exactly? Unfortunately, this is also not clearly defined yet.

In Zyfra Robotics’ vision, it comes down to the following main functions:

n Tracking of the location and the state of all autonomous and connected vehicles, as well as provision of information about nearby vehicles to the autonomous trucks.

n Planning of actions performed by autonomous trucks. As a striking difference from passenger cars, haul truck have many things to perform, in addition to driving by the trajectory itself.

n Calculation and management of routes and trajectories, in addition to speed limits.

n Calculation of dynamic manoeuvers (cloud could also be implemented onboard).

n Management of loading and unloading operations, including facilitating the interaction between loading tool operators and haul trucks.

On top of this, Zyfra utilises an autonomous operations management software with the following functions:

n Autonomous operations zone configuration.

n ‘Bird-eye view’ and human interface for AOZ operator, providing a visual representation of the connected vehicles on the map, and the ability to assign vehicles to different tasks and routes, allowing them to drive and send them to maintenance.

n Data analysis and reporting, especially in terms of reports that are specific for autonomous operations.

n Implementation of APIs to high-level mine-wide FMS and other information systems.

Martin Politick, Director of System Engineering and Architecture at Wenco, splits Open Autonomy services the following ways:

n Spot – manages loading and unloading zones and queues.

n Path – path planning.

n Map service provides map engine and localisation functions in the same manner for each of the other components.

n Dispatching service provides the FMS with the means to tell each truck where it should go and what to do.

n Global traffic – traffic management service in terms of handling intersection priorities, segment permissions, and general speed limits.

In this concept, the AHS component provides path and map services to other components of the system. ISO is working on the FMS to autonomous haulage interface standard, ISO 23725; unfortunately it is not published yet.

All this is to say that the design and development of an autonomy controller represents a tremendous challenge.

Developing an autonomy controller

From the architectural point of view, an autonomy controller should combine two approaches: to be event-driven to efficiently react to constantly changing and unpredictable environment changes and changes in vehicles’ states; but also to be able to execute fixed sequences of actions, representing tasks of each dump truck and other vehicles. It should be capable of ‘mapping’ the pre-defined and rigid task execution actions sequence to a very fluid spatiotemporal space representing the state of an autonomous operations zone. Moreover, though at this level the system should not adhere to real-time constraints, it is still critical to limit latencies and ensure that the correct order of sequential events is maintained.

There are no ready-made best practices, architecture guidelines, or frameworks for the development of such services. That being said, and keeping in mind that autonomous hauls trucks are already in operation,

the problem is being solved in different ways by different vendors.

One of the approaches is to use open source software frameworks and libraries as building bricks, though it will require significant efforts to develop an autonomy controller that will comply with functional and non-functional requirements.

Considering that this is the autonomy domain that is being discussed, robot operating system (ROS) and ROS 2 frameworks could look like a natural match for the job. For the sake of the design of the autonomy controller, an ROS provides a communication infrastructure for the distributed set of worker processes, called nodes. Different nodes are responsible for different functions and can exchange messages via a publish/subscribe paradigm, thus naturally enabling an event-driven approach. ROS 2 provides further improvements, being more suitable for real-time, or near real-time, applications.

Another interesting take on the problem was proposed by GAIA with their GAIA Platform. The GAIA Platform’s goal was to accelerate autonomous development, including the development of software for mobile robots and cars. The GAIA Platform offers a breakthrough solution to many questions by using the rule-based, declarative approach to software design. GAIA’s developers defined sets of rules (rulesets) in Declarative C++, that would be invoked in the case of changes in a specific GAIA database field. According to GAIA, their approach allowed developers to write 10x less code to implement the same functionality, in comparison with more traditional approaches. Unfortunately, it seems that GAIA have wound down commercial and development activities, however the GAIA Platform has been made available as an open source.2

Looking to the future

What does the future hold for autonomous vehicles in mining and how could the software and artificial intelligence (AI) community facilitate further development?

There are two twists in how robots in the industry will evolve in the coming years. First, not all machines are easy to make autonomous. For example, in the case of loaders and bulldozers, the bucket operation is poorly amenable to be controlled by deterministic algorithms. That is to say, a person works with them intuitively, but a machine cannot do that yet. Thus, for the time being at least, the

industry is left hoping for a breakthrough in simulation and machine learning. A lot of recent developments in AI, such as zero and few-shot learning, reinforcement learning, and generative-adversarial networks hardly found their way to the application in autonomous mining vehicles.

The second breakthrough has to do with the fact that the unit of autonomy in mining is the pit, not the vehicle itself. Right now, robotic dump trucks are like the first cars, which were like carriages, only without horses. Accordingly, quarries and mines are now being designed for manually operated vehicles. This should change, as well as the dump truck designs themselves. For example, the cab should be removed because it is not needed for an autonomous vehicle. Perhaps the concept of reversing will disappear: robotic dump trucks will not care which way they go.

At this point, it will be the right time to change the configuration of opencast mines: reduce safety berms, reduce haul road width, and remove edge kerbs and other elements that are only necessary for people to work.

The challenge for a software and AI development community here is to radically improve the speed of the delivery of new functionality to the vehicles and systems in mines and quarries, without sacrificing safety or productivity. Software and AI developers working in the mining industry should adopt the best engineering practices – such as continuous integration and continuous delivery and machine learning operations – and adapt them to the requirements and realities of the mining industry.

Conclusion

Only mutual efforts of the mining industry, software and AI engineering communities, shaped as collaborations on different aspects of autonomous systems for mining and open interfaces between them and other information systems, as well as software engineering practice, will allow unlocking the full potential of autonomous technologies in mining. As of now, the industry has barely scratched the surface.

Reference:

Autonomy' initiative’, Wenco International Mining Systems,

Gaia Platform’, GitHub, www.github.com/gaia-platform/

Figure 1. Mines are constantly changing and evolving, requiring a network solution that is flexible, not rigid or reliant on cumbersome infrastructure.

Accurate statistics for occupational accidents and fatalities in mining are hard to come by, as different countries and companies use different reporting methods and standards. Nevertheless, there is a consensus that mining operations are dangerous environments. When significant disasters with multiple fatalities occur, such as the Brumadinho tailings dam collapse in 2019, or the Wai Khar Jade Mine in Myanmar last year, they hit the headlines worldwide. But, every year, there are fatalities and injuries. Indeed, the International Council on Mining and Metals (ICMM) has been keeping injury and fatality records since 2012.

The 26 members of the ICMM, representing one-third of the global industry, have committed to “improving their health and safety performance to eliminate all fatalities towards achieving our ultimate goal of zero harm.” While the general trend is in the right direction – total recordable injury (TRI) frequency rate (number of injuries per million hours worked) declined to 2.94 in 2020 from 5.07 in 2012,1 and the fatality rate (number of deaths per million hours worked) declined to 0.018 from 0.033 over the same period – there is still some way to go to meet the goal.

Miners are exposed to more occupational hazards than those employed in many other industries. At the extreme, they may have to deal with explosions and cave-ins. Fortunately, those are relatively rare occurrences. However, regularly, they may be exposed to high temperatures, toxic fumes, noise, vibration, and dust. These are very stressful conditions, particularly for underground miners, which may lead to accidents. These can be due to improper use of machinery or vehicles. Or, by a simple, momentary lapse in attention that results in a fall, burns, or other accident. In addition, the speed with which conditions can change in a mine make them inherently dangerous places to be.

It, therefore, makes sense that anything that can help keep workers out of harm’s way will be very beneficial; not only for the workers, but also for the industry as a whole, and mine owners in particular. As well as the human cost, injuries and death carry a financial expense in terms of loss of productivity and higher insurance costs. In addition, downtime for any reason – be it mechanical, environmental, or human – also causes loss of income. Without autonomy and a reliable communications network, even a minor issue may mean that a miner has to return to base to report the problem and receive instructions, which can cause operational delays.

Marnus Kruger, Rajant Corporation, South Africa, provides an overview of some of the latest advancements that are bringing high-bandwidth, flexible, reliable, self-healing networks to mining.

Technology – connecting devices and people

Technology, specifically the Industrial Internet of Things (IIoT), is already playing a significant role in helping to reduce mining accidents and downtime. When machinery, sensors and people are interconnected, the whole environment changes. Autonomous vehicles and machinery improve efficiency and keep miners out of harm’s way. Sensors can monitor temperature and air quality to ensure adequate ventilation. Wearable devices in combination with sensors will alert workers when they are entering an unsafe area. In 2017, a World Economic Forum investigation reported that digitisation in mining and metals could result in 1000 lives saved, as well as 44 000 accidents being avoided over the following 10 years.2

As more and more devices get interconnected, the volume of data transmitted grows exponentially. When processed using artificial intelligence (AI) and machine learning (ML), management gains greater insight into the conditions and operations of the mine. In addition, real-time telemetry enables them to monitor and control autonomous and remote-controlled vehicles, machinery and processes, leading to more efficient use of resources and better adherence to safety standards. As risks are mitigated, workers are moved out of harm’s way and fatigue is reduced, leading to fewer accidents.

Dynamic wireless networks

While digitalisation and the IIoT bring improvements to mines, the actual functionality of connected devices, autonomous vehicles, and machinery is entirely dependent on the robustness, reliability, and flexibility of the network that they are connected to. This is where wireless mesh networks stand out.

Setting up a wireless network anywhere presents challenges. Transmission may be blocked in some locations, connections may be dropped, and in a traditional WiFi or point-to-multi-point (P2MP) or LTE network, a single point of failure presents a real risk. This risk is simply not tolerable in mines. Autonomous vehicles and machinery need the network to be constantly up; even a momentary pause will mean that operations have to stop. The ability to transmit

video is also a prime requirement for mining as robots and cameras are used to provide visibility into underground locations, so high bandwidth for the upload is also a necessity. Most networking technology is asymmetrical, meaning that the upload is much slower than the download, and thus not well suited to mining applications. As more and more devices are connected, the need for bandwidth increases, so the network has to be able to expand easily without interruption to existing connectivity. Underground, the network has to overcome uneven surfaces and thick walls and be impervious to changing temperatures and dusty environments, all of which present various propagation challenges. On the surface, the network also faces propagation issues primarily due to changing topography and weather. Therefore, it also has to be capable of extending over many miles and being easily redeployed as the mine moves. Traditional wireless networks rely on fixed transmission points, so they cannot be easily reconfigured and expanded. Furthermore, when they are able to be upgraded, it often means service interruptions. Frequently, there is no built-in redundancy, so they cannot provide the crucial reliability needed for autonomous machinery, where even momentary loss of connection is unacceptable.

Decentralised wireless mesh networks

Decentralised wireless mesh networks are an answer to these problems. In a true mesh network, there is no single point of failure, as each node acts independently, forming connections to other nodes. If one node becomes temporarily unavailable or goes down it has no impact on the network as a whole. The network is self-healing – if the next node becomes unavailable, the transmitting node simply reorganises to find another efficient path and transmits the data to the next node in that routing. Nodes are installed on machinery, vehicles, wearables and drones, as well as in fixed locations. This means that the network is incredibly flexible; as vehicles and people move around, so too does the network. As operations expand, involving more people and equipment, more nodes are added, so the network grows in sync with the operation. Similarly, if the mining moves to a new location, so does the network. With few or no fixed nodes, the network is essentially portable.

This means that wireless mesh networks are far easier to set up than traditional fixed networks, and they are inherently more versatile, reliable, and flexible. Both on the surface and underground, some mines are incredibly dynamic. In longwall mining, for example, the mine is constantly being reconfigured as the mine face moves forwards and the rear sections are allowed to collapse. A mesh network can move with the mine; as new areas open up, the nodes are redeployed to these new locations, retaining constant connectivity for the mine with no interruption of service.

Autonomous inspections

One of the key benefits of automation is the ability to keep personnel safe and send machines in to do the dangerous work. Work, in many cases, would not be possible without robots and the best

Figure

Wireless mesh provides a solution for dynamic, real-time data, video, and voice communications underground with full mobility from autonomous systems and staff on the go.

wireless mesh networks. Nowhere has this been more clearly illustrated than in two mine inspections carried out by Rajant and Australian Drone + Robot (ADR) in Australia and the US.

Case study: Australia

The first inspection took place at an abandoned mine in Queensland, where it was necessary to determine the state of the bulkhead, but too risky to send people in to do so. So, ADR robots were sent in. However, without superior communications not only would it not have been possible to control the robots, no findings would have been transmitted. Rajant set up its Kinetic Mesh® Network, which enabled the transmission of live-stream 4K video and light detection and ranging (LiDAR) data – LiDAR is a remote sensing technique that uses laser to create a 3D map of surfaces.

Case study: USA

Following their success in Australia, Rajant and ADR collaborated to conduct the deepest remote underground inspection ever recorded. In summer 2021, this occurred at a collapsed limestone mine in the Southeastern US. The existing two-way radio system that ran over a leaky feeder had been destroyed, but regardless would not have had the bandwidth necessary to perform the inspection. Rajant’s Kinetic Mesh network provided low-latency, high-bandwidth connectivity to control a fleet of 10 robots. The robots were equipped with Rajant BreadCrumb radio nodes and created the network from scratch, daisy-chaining communications between them.

LiDAR and video at 80 Mbps were transmitted from 1.7 km underground.

Without robots and a wireless mesh network that could be installed without any existing infrastructure, this mine may have remained closed for a long time. As it was, within a week of the inspection, the Mining Safety and Health Administration (MSHA) had cleared the mine to start remediation work and put employees back in a safe working environment.

Conclusion

The mining industry continues to invest in various technologies, ranging from standard fleet monitoring to advanced teleoperation and collision avoidance solutions. It has become abundantly clear that digitalisation and IIoT will have a considerable part to play in the coming years.

Operators require a network that not only keeps operations running smoothly but one that seamlessly keeps staff, equipment, and applications functioning 24/7, 365 days a year. The sector needs to foster innovation as a matter of urgency. A reliable network at the forefront empowers a bright future for the mining industry.

References

1. ‘Safety Performance: Benchmarking progress of ICMM company members in 2020’, International Council on Mining and Metals (ICMM), (June 2021), www.icmm.com/website/publications/pdfs/ health-and-safety/2021/benchmarking-safety-data-2020.pdf

2. ‘Digital Transformation Initiative: Mining and Metals Industry’, World Economic Forum, (January 2017), https://reports.weforum.org/ digital-transformation/wp-content/blogs.dir/94/mp/files/pages/files/ wef-dti-mining-and-metals-white-paper.pdf

MINE

Uptime is everything. The industry-first modified A-frame stabilizer on Stellar® Large OTR Service Trucks ensures reliable servicing of differing widths. The TM28 Tire Manipulator is built for heavy-duty mining work with a rated capacity of 28,000 pounds, 110-degree body rotation, 360-degree pad rotation and an optional side shift for perfect alignment with the hub.

LARGE

Colleagues Matrixx, Australia and North America, considers how cloud-based platforms can help resource and drilling companies better communicate.

One of the industry’s longest standing and pervasive problems is companies working together using disparate systems that cannot communicate. The history of stalemates between resource companies and drillers, each beholden to their chosen business software, has left geologists and drill supervisors bridging the divide themselves through custom data exports, data manipulation, and replicate data entry in multiple systems – all of which is manual, and all of which sees experienced and expensive resources sitting behind a desk instead of being out in the field contributing value to the business.

The challenge of daily drill reports – a well-known source of frustration and data inefficiency

Despite the technological advancements driving efficiency gains and operational improvements across nearly every aspect of mining, data entry in the field remains a page out of the 1970s for some drillers. Many drilling companies are still completing their daily reporting on paper. These crumpled sheets are gathered up, reviewed, and then –best-case scenario – they are entered one-by-one into the driller’s software package. However, more often than not they live on in a multitude of unwieldy spreadsheets,

which are manually updated and manipulated to make sense of the data and passed back and forth in email chains between individuals, before finally being uploaded to shared data drives where version management and conflicting edits are everyday pain-points. This gives rise to a range of issues including inconsistency of collected data, delays in data processing, mistakes interpreting sometimes illegible hand-written reports, and of course the ever-present threat of human error.

Even as digital daily drill report (DDR) mobile applications emerge, drilling companies often seek a

customised export template from mobile application providers enabling data exports according to each resource client’s specific requirements: a process that is both costly and time-consuming.

Resource companies load drilling data into their own geological or financial database. If not provided from a customised export template, this requires the drillers’ data to be manipulated into a bespoke format that is compatible for import, while creating a potential point of failure by populating unnoticed data compilation errors into the database – assuming the data makes it there at all.

A digital DDR alone is not the silver bullet it seems, bringing with it a new set of problems for those attempting to bring their operations into step with today’s technology. As early mobile phone users learned that each manufacturer had its own proprietary charging cable, the mining industry is struggling with siloed data-clouds created by individual mobile application vendors, each with its own sign-in, discrete dataset, and varied functionality. These clouds are not integrating with resource companies or each other, and, from a data-integrity perspective, are not offering significant gains on the triplicate books of years gone by.

Figure 1. Drilling companies who use the Matrixx Mobile application in the field are able to view and manage their drilling data in real time.

To date, a resource company’s only resort for combatting data compilation inefficiencies has been to request all contracted drillers use the same mobile application, in order to standardise the data being submitted and facilitate the DDR data import into its internal systems. This practice means that drill crews need to enter daily reports twice, into two different systems: once, for the drilling company’s purposes; and a second time to meet the contractual and operational requirements of the resource company. This method is unsustainable – populating the same data in two independent, unconnected systems creates a divergence in the data which cannot be undone, and inevitably leads to conflicting records, undermining the veracity of the data. This ultimately makes end-to-end data comparability and timely invoicing virtually impossible.

These practices can be found on any drilling site to varying degrees. They can break the data chain-of-custody, as well as create instances of non-compliance when data is compiled and moved between systems.

The solution – DDR chain of custody

Digital and data software developer, Colleagues Matrixx, is tackling this problem with the release of MatrixXchange back in November 2021; a single sign-on, cloud-based viewing, approval, and reporting platform. Since arriving on the market, MatrixXchange has amassed the support of major resource companies and drillers alike, and has become a ‘go to’ link between resource and drilling companies.

MatrixXchange delivers a solution to the collaboration problem, automatically collating and standardising data formats from all DDR or progress log of drilling (PLOD) submissions, regardless of the number of drilling companies or the software system they use; giving resource companies a single, cohesive interface to manage

Figure 2. The Matrixx Mobile application is used by drillers in the field to capture and upload their daily drilling reports (DDR’s or PLOD’s).

all daily drilling reports, and present that data to any other internal systems that need it.

In releasing this platform, the company is helping to solve the collaboration problem by providing an end-to-end solution, integrating directly from drilling companies’ data capture systems into resource company geological and/or financial databases, and any other systems using the drilling data. The platform is accessed securely, presenting all DDR submissions across all drilling contractors in one cohesive interface, where they can be reviewed for approval and analysed using integrated reports, all while negating data double-handling for drilling companies at the rig.

The platform tackles siloed data clouds by bringing all drilling data together in one place, regardless of the original mobile application that collected it. Its single-sign-on web platform means one login to see every submission, for every driller, for every project.

When a submission has been rejected or approved, notifications are automatically sent to relevant parties carrying the DDR’s status update along with, in the case of a rejection, any additional information the resource company provides. Drillers using Matrixx Mobile will also see the updated DDR status when they login to the Matrixx Portal. The approved DDR data seamlessly integrates into resource company corporate databases, eliminating compilation, data manipulation, CSV exports, and manual intervention. Enabling efficient collaboration and data transfer between companies, whilst also improving data quality and preserving the chain of custody of data from rig to database.

MatrixXchange alone does not fix the paper problem, but for the hold-out analogue drillers still using paper, it prevents the headaches, inefficiencies, and expense that usually follow the paper data once it hits a spreadsheet. The data from the driller can go straight into MatrixXchange; no more compiling, no more data modification, no more hassle.

Changing the game using technology

It is about working smarter, using state-of-the-art technology with field-to-office applications that ensures teams are making the most efficient use of their time.

MatrixXchange provides all data in a consistent format, regardless of the mobile application source. Resource companies no longer need to worry about data formatting and standards for contractors, as it will handle any DDR mobile application or CSV file drillers choose to use, eliminating hassle and failure points in the flow of data. This provides a chain of custody for drillers and resource companies, providing consistent and reliable data for geological databases and financial systems.

For drilling companies who choose to use Matrixx Mobile, they can record drilling activities in the field and use the online Matrixx Portal to manage their schedule of rates, invoicing, and timesheets. Drilling companies can generate invoices quickly and resource companies validate those invoices using the exact same data as the driller, meaning invoices are paid faster.

The extent of benefits for the resource company become clear after the drilling information has been integrated into a geological database, giving geologists valuable information about geological rock properties based on the drilling conditions and rig behaviour at the project drill site. Planned drill holes can be assigned through to all drilling companies without the need to email or create paper lists for drilling companies to follow on site.

The solution provides additional modules for reporting with robust data analytics and dashboard capabilities such as PowerBi. MatrixXchange is also not limited by the type of form or DDR and can collect data to integrate from multiple sources including reverse circulation, diamond drilling, hydro, geotechnical drilling, as well as environmental and earth moving equipment daily forms.

Conclusion

MatrixXchange delivers operational and economic benefits by streamlining workflows and increasing transparency across every aspect of the drilling process for both drilling and resource companies. It takes data from many separate sources, makes it available through a single online interface, and integrates that data with other systems.

Figure 3. Mining companies can view real time analytical data through MatrixXchange reporting dashboards.

Figure 4. Geologists approve or reject data drilling data from all disparate drillers systems from a single sign on in the office.

coverage

technology and

coverage

Global coverage

John Geasa, Speedcast, USA, evaluates how the Internet of Things and connectivity are changing modern mining.

While the majority of mines remain physically remote, vastly improved communications, coupled with ever-increasing digitalisation of processes and devices, means that the modern mine of today is far from remote. It is, in fact, quite the reverse; a closely connected network of devices and automated processes, much of which takes place offsite. Three things have combined to facilitate this: the Internet of Things (IoT), significant improvements in broadband connectivity, and cloud processing.

Mining is a very competitive business. Resources are finite and companies are being forced to mine deeper and in more remote locations. The industry is quickly realising how IoT can be used for competitive advantage. Research conducted by market research firm, Vanson Bourne, found that only 2% of

mines worldwide had fully implemented at least one IoT project. 1 When this research was repeated just two years later in 2020, the figure had risen to 65%. 2 This research was corroborated by other research carried out by GlobalData at the beginning of this year, which showed overall investment in new technology for mining continues to grow, with almost every application showing increased investment compared to two years ago. Investment is particularly high for communication systems and networks with over 60% of mines either

making ‘considerable investment’ in, or having fully implemented new systems. 3

Drivers and benefits

There is no one thing that drives a mine owner to embrace IoT, upgraded processes, and communication networks. Motivators, like benefits, are multiple. Indeed, research from Vanson Bourne has revealed a long list of benefits already achieved or expected to be attained. Topping the list was “improved health and safety of staff.” Given the intrinsically hazardous nature of mining, it is not surprising that this is one of the key drivers, and benefits, of the digitalisation of mines. IoT contributes to this in several ways. For example, data from cameras and sensors can be used for remote detonation, removing the need for miners to be in close proximity to a blast. Furthermore, wearable technology, which monitors biometric and environmental data, can be combined with proximity sensors to provide alerts when workers are in danger from changes in the environment, such as rising gas levels or a change in the stability of the rock face.

Other attained or expected benefits mentioned by over 90% of respondents in the Vanson Bourne report include improvements in productivity, processing throughput, reduced costs, and better return on investment (ROI). 2 These are all intertwined. Even improvements in health and safety contribute to cost reduction. Fewer accidents mean improved productivity, as well as adherence to safety standards. An additional benefit is that the improved processes also lead to better fuel consumption and reduced emissions; reducing the environmental impact of mining and helping companies meet their environmental, social, and governance (ESG) goals.

Mines are often physically remote,

There are multiple other ways that IoT contributes to the bottom line to improve a company’s competitiveness. Real-time information is used to facilitate automated or remote operation of vehicles and equipment, geofencing and to deliver an immediate response to a problem, reducing the need for skilled workers to be on site. In addition, and very importantly, data from all the different sensors, cameras, drones, and monitoring equipment is combined and processed in a public or private cloud, utilising augmented intelligence (AI) and machine learning (ML) to provide valuable insights into the conditions at a site.

External data, such as weather forecasts and maintenance procedures from equipment manufacturers, can also be incorporated, as well as data from other similar mines. From this, a mine owner will learn the best time for preventative maintenance of equipment and vehicles, reducing failures and downtime. Equally, if not more importantly, the mine owner will have far greater

Figure

of mines worldwide had fully implemented at least one IoT project in 2020.

Figure

The benefits of digitalisation in the mining industry are vast.

Figure

ever-increasing digitalisation means the modern mine is more connected than ever.

visibility into the conditions at a site, enabling them to pinpoint the ideal time and place to start mining, to determine the optimal location for blasting and to identify changing conditions in time to prevent problems, such as: erosion, flooding, and even the collapse of an unstable shaft.

The more data that an owner can access, the faster decisions can be made that will lead to both increased margins and improved working conditions. While many mines are investing in digitalisation and automation, very few are fully automated. Resolute Mining in Mali is a good example of where a mining company has embraced full automation for operations: the entire production operation – drilling, charging, blasting, loading, and trucking – is carried out via an autonomous system. This has reduced the cost of gold production by US$135/oz and cut mining costs by 30%. 4

Connectivity

The backbone of these remote site IoT and XYZ systems is a comprehensive managed connectivity solution, delivering the critical applications that enable ABC. Reliable connectivity is the key to successful implementation. To achieve this, there are two stages. Firstly, there has to be a robust wireless network on site. Historically, this has often been Wi-Fi or 3G, both of which have now largely been superseded by private LTE networks. LTE offers several advantages: it provides more bandwidth than 3G, it is a more stable network, and it provides wider and deeper inside coverage than Wi-Fi. Private 5G networks are now also being installed in some mines. As the amount of data generated on site increases, so too will the necessity for 5G. It offers significantly greater bandwidth than LTE and provides lower latency, which is essential for real-time connectivity for remote vehicle and machine operation.

Secondly, there has to be a reliable broadband connection that seamlessly interconnects with the local network, in order to move all this data offsite. Since the majority of mines are in remote locations, satellite is the technology of choice for this part of the hybrid network. 85% of mines that have successfully implemented at least one IoT project use satellite for data transport between the site and the control centre. 2 A few have been able to install a fibre connection, but even that depends on satellite for backup.

Historically, geostationary satellites (GEOs) were the only option. GEOs are positioned 36 000 km from the earth, so latency is introduced. For much of the data, this is not an issue, but there are always exceptions. And, as two-way video, remote operation of vehicles and machinery and offsite problem resolution become more common, the need for virtual real-time communications will increase. That is why it is important to have a partner that, amongst other things, can offer multi-orbit connectivity. Medium earth orbit satellites (MEOs) operate closer to earth than their GEO counterparts, providing fibre-like speeds and latency. Low earth orbit satellites (LEOs) are located even closer to the earth. Mine owners are already starting to take

advantage of these newer, non-geosynchronous constellations and capabilities. In Western Australia, for example, an iron mine’s existing GEO connectivity was supplemented with a MEO constellation. This enabled the site to meet its increasing need for real-time data, to optimise its operations, and also to support the welfare of more than 300 staff with voice, data, and video services. 5

Multi-orbit connectivity is important and will become even more so in the next few years. However, there is more to the hybrid network than satellite orbits. Multi-frequency is also a key factor, and a communications partner should be able to provide access to C, Ku, Ka, and L-Band. Seamless integration to other technologies, including MPLS, LTE, Wi-Fi, 5G and microwave, should also be expected. The network must be flexible enough to handle occasional low data-rate transmissions as well as two-way HD video, and to assign appropriate traffic priorities and routing. It must also be scaleable so that as the volume of data from a site changes, it can effortlessly scale up or down as needed.

Fully managed networks

To realise digital transformation benefits and accelerate remote mine operations, a single-threaded connectivity solution alone is not sufficient. A fully managed, end-to-end service must be leveraged for optimisation of operations – one that includes multi-mode terminals that seamlessly interface with all communication modalities. Any service used must be intelligent and flexible to allow the automatic switching of data to the most cost-efficient path when required, while a cloud-based solution will help to process large amounts of data and allow access from anywhere. Reliability is of course essential, so any system implemented must guarantee at least 99.95% availability.

Thanks to the ability of satellite communications to deliver at-home levels of connectivity to even the remotest of locations seamlessly, the digital revolution of mining becomes more of a reality with every passing day.

References

1. ‘Research Programme Mining 2018: Mining’, Inmarsat, www.inmarsat.com/en/insights/enterprise/2018/researchprogramme-2018-mining.html

2. ‘The Rise of IoT in Mining’, Inmarsat Research Programme, (2020), www.inmarsat.com/content/dam/inmarsat/corporate/ documents/enterprise/insights/Inmarsat_WP_The_Rise_of_IoT_ in_Mining.pdf.coredownload.inline.pdf

3. ‘Technology adoption rates: results of surveys of global minesites’, GlobalData, (March 2022), www.mining-technology. com/wp-content/uploads/sites/19/2022/03/Global-Mine-SiteTechnology-Adoption-Rates-2022.pdf

4. ‘Mind Over Matter: The Not-Too-Distant Future of Autonomous Operations’, Accenture, (March 2020), www.accenture.com/_ acnmedia/PDF-120/Accenture-Autonomou-Operations-MiningReport.pdf#zoom=40

5. 'Speedcast Delivers Connectivity to Mining Site in Western Australia for Leading Iron Ore Producer’, Speedcast, (2019), www.speedcast.com/newsroom/press-releases/2019/speedcastdelivers-connectivity-to-mining-site-in-western-australia-forleading-iron-ore-producer-2/

Ahead of bauma 2022 in October, Global Mining Review previews some of the companies that will be exhibiting at the Trade Fair Center Messe München.

ABB

C2.413

A trusted partner to the mining industry globally, ABB will present its industry specific portfolio at bauma. Mining technology experts will take visitors on a journey across grinding, motors, drives, electrification, conveying, material handling, automotive wiring harness protection, and traction.

In line with the exhibition’s main themes, ABB continues to deliver seamlessly integrated electrification, automation and digital solutions, products, and services from mine to port.

ABB will showcase its digital portfolio, including ABB AbilityTM MineOptimize solutions and the ABB Ability eMineTM suite of electrification and digital systems, designed to accelerate the decarbonisation of the mining sector.

eMine comprises ABB Ability eMine FastCharge, which is set to become the world’s fastest and only fully automated charging system for haul trucks, offering up to 600 kW of power. It also includes ABB Ability eMine Trolley System technology, which can reduce diesel consumption by up to 90%.

Also designed and manufactured by ABB, Harnessflex® Specialist Conduit Systems include flexible conduit systems and connector interfaces, protecting critical electrical and electronic wiring assemblies on automotive machinery from mechanical abrasion, liquid ingress, dust, and salts.

BEUMER Group

B2.413

The BEUMER Group will showcase its expertise in economical transport solutions for the mining industry. Among other things, the system provider will provide information on the conveying, loading, palletising, and packaging of building materials and cement. With the BEUMER Group’s overland conveyors and pipe conveyor, users can transport different bulk materials even over long distances and over rough terrain, enabling large gradient angles and tight curve radii.

A highlight in Munich is the joint trade show appearance with the FAM Group. With the acquisition, the BEUMER Group has strengthened its market position in the minerals and mining sectors. FAM plans, designs, and manufactures turnkey plants and systems for the extraction, conveying, loading, storage, and processing of various raw materials. The business areas of the two companies complement each other ideally. In addition to planning and engineering, FAM brings the complete value chain, including after-sales service, to the BEUMER Group.

Boart Longyear

C2.414

Established in 1890, Boart Longyear is in its 132 nd year as one of the world’s leading providers of drilling services, orebody-data-collection technology, and innovative, safe, and productivity-driven drilling equipment. With its main focus in mining and exploration activities, spanning a wide range of commodities (including: copper, gold, nickel, zinc, uranium, and other metals and minerals), the company also holds a substantial presence in the energy, oil sands exploration, and environmental sectors.

The Global Products division offers sophisticated research and development and holds hundreds of patented designs to manufacture, market, and service reliable drill rigs, innovative drill string products, rugged performance tooling, durable drilling consumables, and quality parts for customers worldwide.

The Geological Data Services division utilises innovative scanning technology and down-hole instrumentation tools to capture detailed geological data from drilled core and chip samples. This valuable

orebody knowledge gives mining companies the ability to make timely decisions for more efficient exploration activities.

The Global Drilling Services division operates for a diverse mining customer base with drilling methods, including: diamond coring exploration, reverse circulation, large diameter rotary, mine dewatering, water supply drilling, pump services, production, and sonic drilling services.

Brokk

A1.451 & FM.711/4

Brokk is a world-leading manufacturer of remote-controlled demolition robots. Since 1976, the company has produced small but powerful robots, developed for demolition solutions for the construction, cement, mining, metal processing, tunnelling, and nuclear industries.

At Brokk, demolition robots is what the company does. It dedicates 100% of its time, resources, and passion to remote-controlled demolition robots, and nothing else. That is why Brokk has the widest range of demolition robots, with unique characteristics and countless options. From the Brokk 70, small enough to fit through narrow doorways, to the Brokk 900 with a weight of 11.4 t and a 9 m reach. The range consists of demolition robots in different sizes with one thing in common: compact power.

At Brokk, the company continue’s to innovate and push the development of new technology forward. Pushing the limits of what is possible with remote-controlled demolition robots and finding new applications, all while staying true to the same commitments made in 1976 – safe, efficient, and profitable demolition.

Derrick Corporation

B2.137

For over 70 years, Derrick® Corporation has been leading the industry in the design and manufacture of high frequency vibrating machines and screen surfaces. With a pioneering spirit driving innovative solutions, Derrick is continuously at the forefront, advancing the field of fine particle separation technology. Known globally for its high-capacity and superior separation efficiency, Derrick products are used successfully around the world. Its advanced technology allows processors to screen a wide variety of wet or dry fine materials in the range of 10 mm to 38 μ m.

Derrick has success stories in nearly every mining application that requires fine screening. Its proven fine particle separation technology has been beneficial in coal, copper ore, gold, industrial minerals, fertilizers, iron ore, plastics, silica sand, potash, and many other fine screening applications – creating more efficient processes, saving energy, and increasing profits for the processors. In addition, structural requirements for Derrick screens are considerably less than other types of

vibrating screens, since Derrick screens transmit virtually no dynamic load to the support structure.

Derrick has also offered premium slurry separation and desanding equipment to the worldwide microtunnelling, large diameter tunnelling, slurry wall/foundation drilling, horizontal directional drilling, hydrovac mud processing, water well drilling, dredging, and other civil construction industries for over 30 years.

DSI Underground

C2.143

DSI Underground is a leading supplier of ground support products, systems, and solutions for underground mining and tunnelling. The company is present in 70 countries and employs over 2500 people, including engineers and technical specialists with in-depth experience in the underground industry.

With market-leading brands covering everything from bolting systems to injection chemicals and resin capsules, it reinforces mines, tunnels and underground structures, helping customers advance underground and towards their objectives – faster and more efficiently.

At bauma 2022, DSI will showcase its latest ground control solutions for underground structures. Experience its virtual reality-based training with the AT – Pipe Umbrella Simulator, powered by Edvirt, allowing operators to get familiar with the AT – Pipe Umbrella System. Learn more about the range

of dynamic anchors, including POSIMIX Anchors, OneStep Bolts, and the Mechanical Dynamic Rock Bolts for hard-rock mines, developed by Sandvik in Australia. The MD Bolts set a new standard for seismic ground support, and the MDX Bolts offer a unique design for effective anchorage. DSI will also display its chemical injection simulator and the complete product range of injection chemicals for mining and tunnelling, with two-component foam or organic mineral adhesive.

Dunlop Conveyor Belting (Fenner Dunlop Group)

B2.238

Netherlands-based Dunlop Conveyor Belting will be a particularly strong presence at this year’s bauma exhibition. Despite the disruptions caused by COVID and, more recently, the troubles in Ukraine, the company continues to exceed even its own ambitious expectations. The company is especially looking forward to bauma this year because of the portfolio of well-proven, top performing products, as well as some genuinely new innovations.

The Ultra X range of single-ply belts beat conventional multi-ply belts by being particularly rip and tear resistant, yet really cost competitive at the same time.

Although the company is planning to unleash new additions to their X range, Dunlop’s overall market strategy will definitely not be changing. Ever since the

company was first born over 100 years ago, the foundation of the business has always been quality and producing belts that are as close to ‘fit and forget’ as possible, and which carry on running many times longer.

FLSmidth

B2.203

FLSmidth will again, proudly, be one of the more active participants at bauma, with a top-level delegation of product and industry experts. FLSmidth’s delegation will be covering everything from pit to plant; including state-of-the-art equipment, digital solutions, and sustainability-enhancing mining technology and services.

Present at the booth will be a Raptor® Cone Crusher (designed for the aggregates industry), the LoadIQ smart solution that ensures easy-to-implement mill optimisation, and KREBS® pumps. The company will also feature the REFLUXTM Flotation Cell (RFCTM ) technology that is pushing the boundaries on concentrate grade, recovery, and throughput well beyond the performance of conventional open tank systems. Meanwhile, the ever-popular MissionZero Mine interactive 3D model will allow visitors to the booth to interact with the sustainable mining flowsheets of the future.

As part of FLSmidth’s participation, Josh Meyer, Global Service Business Line President, will give an official event presentation examining the productivity and sustainability challenges facing the mining and aggregates industries and how auditing, digital solutions, upgrades, and expert service can provide fast, easy-to-implement gains. Meyer will look at how operators can meet their sustainability targets by optimising existing sites and aggregates plants.

Maschinenfrabrik Köppern GmbH & Co. KG

C2.238

The Köppern Group is a modern, high-tech German group of companies at the forefront of plant and machinery manufacturing for various processes related to the fertilizer, cement, minerals, and metalworking industries.

Köppern high-pressure grinding rolls (HPGR) have proven successful throughout the world, in plants specialising in the cost-saving high pressure comminution of cement clinker as well as other highly abrasive feed materials, including slag and various ores (such as: iron, copper, gold, diamond, molybdenum, and lithium ore), with pilot HPGR testing capabilities in Australia, Canada, and Germany.

The Köppern Hexadur® and Hybridur® tyres feature an extremely wear-resistant surface that provides enhanced roller protection and ensure substantially extended, uninterrupted service life when grinding highly abrasive feed materials.

Köppern – quality made in Germany: n State-of-the-art HPGRs and wear protection. n Process technology know-how. n High plant availability. n Low maintenance cost.

Magotteaux

B2.338

Part of Sigdo Koppers, listed in Santiago, Chile, Magotteaux is a world leader in process optimisation solutions for abrasive and impact applications in the mining, cement, aggregates, quarrying, power stations, and recycling industries.

Magotteaux employs over 3000 individuals and has a market footprint of above 1 million t of grinding media and castings through its 22 specialised production units, sales offices, and technical centres worldwide. Its team of 200+ technical and sales experts are located close to customers’ operations, in order to help them with much more than just grinding optimisation and milling efficiency. Working continuously to reduce their environmental impact, Magotteaux provides innovative solutions to help all of its customers to do the same.

The company notably produces the Mag’Impact, a vertical shaft impact crusher that can also help meet the market demand for high quality crushed sand, and all of its associated wear parts, as well as horizontal shaft impact crushers wear parts, such as crusher blow bars.

Meet Magotteaux’s experts to discover the company’s unique expertise in crushing processes.

Mincon

C2.415

Ireland’s Mincon Group will be at bauma 2022 with its latest hard rock drilling systems for the construction and mining industries.

The Group will also use the show to launch its next-generation MP-series DTH hammers, which promise to deliver uncompromised performance and real-world fuel savings to help businesses lower costs and reduce carbon emissions.

Mincon experts will be on hand to discuss the latest projects that have successfully used Mincon solutions to raise the bar for what can be achieved using DTH systems.

MLT Group

B2.414

Since 1947, MLT has been a French manufacturer whose core business is the splicing of conveyor belts, the manufacture of technical belts, and equipment for conveyors.

MLT is a precursor in quick and easy-to-install solutions with the objective of meeting the needs of the market.

Innovation has always been the link in the company’s DNA. It invests heavily each year in its three research

and development departments within the group.

MLT’s innovative solutions deliver significant reduction in plant downtime, and consequently in maintenance costs and repairs.

The company operates in many sectors of activity, such as: cement plants, quarries, construction and concrete plants, surface mines, recycling plants, wire and cable factories, and much more.

MLT is the original inventor and manufacturer of the SUPER-SCREW®, the only flexible screw splice, created in 1994. At the beginning of 2022, the MLT team completed its range of flexible splice to screw by creating new generations of SUPER-SCREW – three new exclusive and unique products to reduce conveyor downtime and improve productivity:

n SUPER-SCREW Premium: high strength splice, for very abrasive environment.

n SUPER-SCREW Security: first splice in the world with security indicator, to anticipate replacement.

n SUPER-SCREW Primary: the budget-friendly temporary solution splice.

Siemens Large Drives

C2.325

From ore to metals to rare earth elements, mining is a key industry for today’s and future technologies. Siemens is a partner for sustainable businesses that meet the needs of present and future generations.

The company offers solutions, systems, products, and services for the global mining sector. Integrating automation and drive systems, along with energy supply and distribution systems, it creates complete high-efficiency solutions for the mining industry. Siemens’ portfolio can be applied to primary tasks, such as excavation, transportation, and the processing of raw materials; as well as to secondary processes, such as service and maintenance.

Digitalisation is of crucial importance to Siemens and its customers. The company has the domain know-how to turn the data generated by various systems into economic value. Its solutions enable customers to simulate, optimise and intelligently automate their mine operations, aiming to sustainably boost efficiency throughout the entire value chain.

SKF

FM.709/4

As mining applications face some of the toughest and most remote working conditions on earth, it is easy to see that costly unplanned downtime can easily occur. But what if operators could extend service life, improve performance, and reduce the total cost of ownership of hard-to-maintain mining machinery?

SKF provides proven bearing, sealing, lubrication and maintenance solutions, as well as condition monitoring and a range of consulting services to improve machine reliability to help:

Grind down your maintenance costs

Köppern roller presses have been proven successful throughout the world in plants specializing in the cost-saving high pressure comminution of various ores like iron, copper, gold, diamond, molybdenum and lithium ore. The Köppern Hybridur® tires feature an extremely wear resistant surface that provides enhanced roller protection when grinding abrasive ores.

Köppern – Quality made in Germany.

» State of the art HPGRs and wear protection

Process technology know-how

High plant availability

Low maintenance cost

Pilot HPGR testing capabilities in Australia, Canada, Germany

For further information please contact

n Improve productivity.

n Reduce downtime.

n Reduce operating costs.

n Improve worker safety.

n Safeguard the environment.

SSAB

A6.439

Visit SSAB at bauma to discover how Hardox® wear plate and Strenx® performance steel can help companies reach their mining needs. SSAB is presenting its top-of-the-line steel products: Hardox 500 Tuf, Hardox HiAce, and Strenx Plus grades.

Hardox 500 Tuf is a breakthrough steel when designing wear resistant and durable equipment for mining and many other wear-challenged industries. It has a unique combination of hardness and toughness, ensuring high productivity and low maintenance in operations. Hardox HiAce adds an extra dimension to wear resistance, since it can resist corrosive wear and give longer service life in humid and acidic conditions.

Strenx Plus grades provide an extra edge to structural and advanced load-bearing applications. Strenx 700MC Plus has an extreme toughness of 40 J at -60˚C, making it highly suitable for bending, punching, and shearing. Strenx 900 Plus and Strenx 960 Plus have all the performance properties of Strenx steel in the 900 and 960 MPa range, with excellent welding and forming properties.

THIELE GmbH & Co. KG

B2.103

THIELE is one of the world’s leading chain manufacturers. THIELE’s product line includes round-link chains, bush conveyor chains, forged conveyor chains, and a full range of fittings and accessories. THIELE’s know-how has been built up over many years of designing and producing complete chain systems for conveying and lifting. THIELE engineers provide an on-site consulting service and work alongside the client to analyse the technical requirements before planning and sizing up the chain assembly. Customised solutions are worked out in detail in THIELE’s own design department.

TotalEnergies

A5.238

TotalEnergies Lubrifiants is a leading global manufacturer and marketer of lubricants, with 42 production sites around the world and direct presence 160 countries, delivering to more than 600 mines per day.

TotalEnergies’ Lubricants division offers innovative, high-performance, and environmentally-friendly products and services to help its mining customers to reduce carbon footprints and ensuring lowest total cost of ownership.

Meet the company’s experts to learn about TotalEnergies’ Lubrifiants products and services for the mining industry.

Weber Mining and Tunnelling

C2.538

Weber Mining and Tunnelling is a global supplier of ground support and stabilisation resin products to the coal mining, hard rock mining, and tunnelling industries. Weber has been developing innovative products for over 60 years, working closely with our customers, distributors, and channel partners to identify and deliver targeted solutions. Today, Weber has a global presence and boasts a full range of products and associated specialised engineering application equipment to meet the most difficult challenges underground.

Weir Minerals

B2.212

Weir Minerals engineers, designs, supplies, and services market-leading products and bespoke integrated solutions for the mining, quarrying, and minerals processing industries. A global leader with a history of innovative engineering, it provides trusted technology and services that make industrial operations more productive, safe, and sustainable.

With a portfolio of products spanning the entire flowsheet – from extraction to comminution, mill circuit and tailings management solutions –Weir Minerals partners with businesses to provide them with all their equipment needs.

The booth at bauma will feature a number of Weir Minerals’ market-leading products and solutions.

LINATEX® LOCTITE® – LINA 88 TM is a mining-industry-first solvent-free adhesive range for rubber lining applications with zero volatile organic compounds (VOCs), delivering multiple environmental and safety benefits, as well as best-in-class bond strength.

The Synertrex® Intelligence Ecosystem continuously monitors and assesses equipment condition and performance. This information is then converted into actionable insights and recommendations, providing operators with unrivalled real-time decision support.

There will be a sand wash plant solution on display. Designed to remove excess fines or coarse material, they provide exceptional washing results while delivering a clean, low moisture product for conveying or stockpiling.

Wirtgen Group

FS.1011

At bauma, the Wirtgen Group will be presenting sustainable – and therefore pioneering – solutions for the construction industry, once more demonstrating its outstanding powers of innovation.

One of the industry’s trendsetting technology leaders, and the second-largest exhibitor, is again appearing at the event together with John Deere. Visitors will find more than 90 exhibits and 33 world premieres on a 13 000 m 2 exhibition space

One of the world premieres includes the new Wirtgen Surface Miner SM 280(i). The 280 SM(i) is a high-performance surface miner designed for the reliable and selective extraction of primary resources by direct loading, sidecasting, or cut-to-ground. Raw materials are extracted in purest quality and crushed in situ in a single operation – without drilling and blasting, and with minimal environmental impact. Thanks to the reduction of carbon emissions, an efficient water management system and minimisation dust pollution, the 280 SM(i) shows that ecological and economic considerations can be compatible. This surface miner is the tool of choice for cost-efficient mining processes in the 120-t class.

Zeppelin Baumaschinen GmbH (exhibiting Cat Construction Industries equipment)

B6.106

Cat® construction equipment will be displayed by Cat dealer, Zeppelin. Under the theme ‘Let’s Do The

WorkTM ,’ the overarching messages will expand beyond the equipment to highlight Caterpillar’s broad range of technology, services and sustainability solutions.

The exhibit will feature more than 70 pieces of Cat equipment and attachments from Caterpillar Construction Industries.

Among the multiple technologies on display at bauma 2022, the Cat Command Station enables operators to work remotely and safely, nearby the site or many kilometres away, seated in a virtual cab with familiar controls and display. Attendees will be able to sit in the Command Station and operate a machine remotely.

bauma 2022 attendees will also learn about the hundreds of new Cat Reman and Rebuild product offerings, as well as the range of repair options that lower equipment owning costs.

In the future, certain models of Cat equipment will also include battery-electric with zero-exhaust emissions, while still delivering superior productivity. Caterpillar will unveil to bauma 2022 attendees several electric models currently under development. Additionally, the modified tethered electric Cat MH3024 material handler excels in indoor applications where less mobility is needed and no exhaust emissions are required.

JENNMAR designs and manufactures a wide range of dependable ground control products, from bolts and beams to channels and trusses, resin, rebar, and more. We’re proud to make products that make the mining, tunneling, civil, and construction industries safer and more efficient.

Because we understand the ever-changing and demanding conditions above and below ground we have built the richest portfolio of diverse and complementary brands. JENNMAR sets the bar in every industry we serve and as we continue to grow, our focus will always be on the customer.

We feel it is essential to develop a close working relationship with every customer so we can understand their unique challenges and ensure superior customer service. Our commitment to the customer is guided by three words: SAFETY, SERVICE, and INNOVATION. It’s these words that form the foundation of our business. It’s who we are.

For a complete list of our products and services, visit us at www.jennmar.com.

SAFETY,