International Mining

Emerson – from the ground to the cloud During MINExpo INTERNATIONAL 2024, International Mining Editorial Director Paul Moore sat down with Mike Gordon, Emerson Strategic Business Unit Director – #KnifeGateValves to discuss the uniquely broad role Emerson plays in today’s #mineralprocessing industry. Emerson is one of the few companies in the mineral processing arena that starts all the way back at the field level with #fielddevices and goes right the way through to #cloudbased monitoring & maintenance. On the ground this covers a vast array of instruments and analysers to sense all the different parameters – as well as the final control elements, including different types of valves including control and #isolationvalves. Gordon states: “Then we have the next level – including #PLCs and #edgecontrollers, and above that the #DCS and everything that comes with that. Now, with Emerson also having a controlling ownership share of Aspen Technology, our offering goes all the way up to the cloud, including cloud-based analytics for predictive maintenance and other purposes. So #Emerson brings just about everything that is in a concentrator plant from #primarycrushing onwards from an #automationsolutions perspective – so our advantage is in the breadth of our offering, but also our worldwide coverage.” He added that the Emerson technology stack and the range of flagship product lines is second to none, plus the fact that it makes these available globally through a vast and well-established network. “Our brands are very well known in mining, from #Clarkson #slurryvalves to #Rosemount #sensors and #transmitters, #MicroMotion #flowmeters, Fisher valves, actuators & regulators and #DeltaV advanced industrial automation solutions. Most mineral processing plants worldwide will use at least some of these solutions from Emerson.” Are there any particular Emerson solutions that he would single out as being differentiators? “Isolation valves have a big role to play – we have been supplying them for over 50 years and I lead the Clarkson Knife Gate Strategic Business Unit, which lies within the isolation valves portfolio. Their use starts right at the front end of the plant, or even before that if the material is being brought in via #hydrotransport of #slurry where the pipelines will have isolation valves. In the plant, as soon as you get to the comminution circuit, the valves are there & then all the way through to the back end and the tailings circuit.” What is the Emerson value proposition – quality, reliability, safety, TCO or a combination of these? “All of these, plus on big projects, which most of these process plant projects are, EPCs and owners prefer to deal with as few vendors as possible as it reduces their project costs in the early stages, as well as during start up & commissioning. But it’s also about our deep application expertise across multiple products developed over many years of experience." #futureofmining #miningautomation #mineofthefuture

TCO equation stacks up for 150-t payload battery-electric trucks: report New analysis by SRK Consulting indicates that a 150-t payload battery-electric haul truck could end up being $3 million cheaper on a total cost of ownership (TCO) basis than the equivalent diesel model. The report, titled, ‘Decarbonizing Mining: Diesel vs Electric Haul Trucks on Cost and Efficiency: Assessing Economic and Operational Trade-offs’, compares the TCO and operational efficiency of 150 t diesel and electric haul trucks. The authors, Satadru Ghosh – Mechanical Engineer (Research Intern), Somnath Gain, Principal Consultant – Mining, Sudipta De, Principal Consultant – Mining, stated: “Electric trucks, particularly those powered by lithium iron phosphate (LFP) batteries, offer substantial benefits. These batteries are cost-effective; compared to other battery types they have a longer cycle life and lower environmental impact, providing significant energy and maintenance cost savings, despite higher initial capital expenditure. “Operationally, electric haul trucks can reduce the cost per tonne of material moved by 65%, enhance operational efficiency through better torque and regenerative braking systems (which recover energy during braking and store it for reuse), and demonstrate superior performance metrics, including increased tonnes hauled and speed. Environmentally, electric trucks contribute to cleaner and quieter mining operations with significant reductions in energy costs and CO2 emissions.” Challenges such as battery technology, charging infrastructure and productivity remain; however, advances in battery technology, rapid charging systems and battery swapping are promising solutions to these issues, the authors added. Read the report in the feature below... #mineelectrification #TheElectricMine #batteryelectric

Pathways to decarbonisation – Cummins highlights the role of hybrids Cummins Inc. is globally known as a leader in #miningengines used throughout the world. But of course #Cummins, like its customers, is looking to the future and options on the route to net zero. During MINExpo INTERNATIONAL 2024, International Mining Editorial Director Paul Moore sat down with Molly Puga, Cummins #PowerSystems Executive Director of Strategy, Digital and Product Planning, to talk about just that. Cummins’ strategy is two pathways to #decarbonise: “First there is an #electrification pathway that starts ideally with an existing #dieselelectric powertrain, adding a #battery to create a #hybrid stepping stone solution, then eventually you remove the engine and have an all battery powertrain.” Cummins has already succeeded in demonstrating a hybrid step – in March a hybrid Inner Mongolia North Hauler Joint Stock Co., Ltd. NTH260, 220 t mining truck rolled off the production line in #Baotou and is running at #Baiyun Iron Mine. The Cummins optimised #hybridsystem allowed the truck engine to be downsized from the previous 2,500HP QSK60 to the current 2,000HP two-stage QSK50. Cummins also supplied power electronics, the #batterymodule and the integration across the powertrain. Cummins says #advancedhybrids have the potential to improve fuel efficiency up to 30% dependent on the mine profile and advanced battery technology and controls integration. The second Cummins pathway centres on #alternativefuels. “This depends somewhat on where you are in the world. If you are in a region with natural abundance of #ethanol or #methanol, which are carbon lowering fuels, this can mean minimal interference with the existing engine – for example you could use a dual fuel kit, which is what we are doing with Komatsu and Vale using ethanol in Brazil. And once you start using alcohol-based fuels – it puts you on a pathway towards hydrogen if that becomes a fully scaled solution.” Cummins is investing in both pathways. Puga concluded by saying that Cummins believes there is a real need out there for a bridging hybrid solution that is underestimated. While nothing beyond the NHL truck trial has been made public, Puga said a lot is happening internally and behind the scenes. “We have been quietly developing viable #aftermarket hybrid solutions that we are ready today to find customers for – we have already looked at numerous different hybrid architectures including both for diesel electric and #mechanicaldrive trucks. So we are ready, we have designs, it is more about how and when we get them out into the market – both with mining groups but also truck OEMs. And we are getting good engagements – there are a number of projects where we have already passed what you could call the sensing and discovery phase with hybrids and have moved on to full programs – watch this space.” #roadtonetzero #minedecarbonisation #MiningScope1 #futureofmining #theelectricmine

Our Earlybird delegate rates are currently active, so now is the best time to register for this event! #TheElectricMine25 #TEM25 #NetZeroMining #MiningInnovation #MiningTransformation #SustainableMining #Electrification #BatteryElectrification #FutureOfMining #Chile25

XCMG - solid to succeed At MINExpo 2024, International Mining Editorial Director Paul Moore met with Ren Hua, General Manager of XCMG Group’s Global Mining Machinery Business Division. #XCMG is today China’s leading #miningequipment supplier and a growing force in mining globally. They discussed a range of topics including the rise of wide body trucks and its unique breadth of product range and #greenenergy solutions. On XCMG’s offering to mining compared to traditional Western suppliers, he commented: "We are and have been actively responding to the global energy transformation by promoting the application of new energy technologies into mining machinery. In fact, 20% of XCMG’s products are #newenergy products. We are committed to providing clean and #smartmining solutions. Today for mining equipment we have launched #ethanol, #methanol, #LNG, #hydrogen, #hybrid & #batteryelectric powered machinery. To date we have already had significant success with our 80 t battery electric mining truck, the XD80TE, and we are already in serial production with that model, with deliveries to high profile mining customers. These trucks already have #zeroemissions so this is already a differentiator between us and Western suppliers – they may have prototypes and trials ongoing but we have fleets of these machines operating. We also took time to talk about why wide body mining trucks are increasingly being used in place of other options in mining: "When compared to conventional tipper type off highway trucks, they have a much stronger chassis plus a better and more robust suspension system. Plus they can carry a higher payload in relation to their size which means increased productivity. Then compared to the traditional two axle rigid mining truck, they are much more economical to run, with a very competitive initial cost as well as low ongoing maintenance costs. Finally on #BEV charging: "Battery technology is advancing rapidly, especially in terms of #powerdensity with #solidstate #batteries. These batteries are becoming lighter, more compact, and safer, making them increasingly suitable for mining equipment. Charging times are also decreasing, while equipment operating hours are increasing to six hours or more per charge. We are looking at solid-state batteries going to production in the next three years. At XCMG, we currently offer a range of charging solutions, including 1C and 2C, and we are moving toward even higher charging speed, such as 6C for fast charging. Our primary solution remains stationary plug-in charging, but we are also developing #dynamiccharging technologies. We have delivered a number of #batteryswapping solutions for wide-body trucks, allowing battery packs to be swapped from both sides or the top. Although battery swapping is more challenging for larger rigid trucks, we are actively conducting studies to adapt this technology for them as well." #futureofmining #mineofthefuture #ChineseOEMs #theelectricmine

We're excited to host this exclusive Weir Minerals webinar next month! Featuring Erik Vlot, Global Manager Tailings and Backfill, and Job Kruyswijk, Slurry Solutions Manager, we'll discover how Weir Minerals is redefining the industry’s approach to tailings management with its transformational flowsheets, helping miners rethink, reduce and repurpose tailings. DON'T WA$TE ON WASTE. Learn how to turn your mine’s challenges into opportunities Date: 25 November Time: 8 AM CET (UTC+1) Online: https://lnkd.in/gSSFJsTY Register now to secure your spot! #minetailings #mineralprocessing #RethinkReduceRepurpose

Voltera - helping Chilean miners begin the decarbonisation journey The #BEV surface utility or often called light vehicle market is highly competitive, with many mines seeing it as an easy first step into electrification. Some companies are taking existing successful #lightvehicle BEVs and selling them into mining – one of these, and already a highly successful one, with a large fleet of 53 of its R6 light vehicles operating with Grupo Antofagasta Minerals at Minera Centinela – is Voltera Chile. The R6 has a range of 403 kilometres and i capable of carrying up to 900 kg. It was especially tested for the mining sector, under real working conditions and at high altitudes, with excellent results. International Mining Editorial Director Paul Moore caught up with Co-Founder Andres Vergara recently and also saw two of the company’s mining BEVs up close at the EXPONOR CHILE - ¡Nos vemos en EXPONOR 2026! show in Antofagasta in June 2024 – the new R7 4×4 light vehicle and the M3 people carrier as well as its Chinese-made Iocharger(Xiamen Galaxy Camphol Technology Co., Ltd.) plug-in charging station, which is interoperable for both #CCS2 and GB/T charging ports. Vergara explained that #Voltera is already the number one seller of electric cars in Chile, with Tesla for example only having entered the Chilean market this year in 2024. And all of these sales are to different types of companies, it does not operate in the retail market. And from a company perspective its three main customers are light trucks for mining, road cars for Uber for the Uber Green platform, plus vans for last mile deliveries in food, consumer retail and other trades. Voltera represents two Chinese BEV majors in Chile – Dongfeng Automobile Co., Ltd. and GEELY. In some cases it sells them under the Voltera brand and in some cases under the OEM brand. Vergara emphasised the massive BEV potential in Chile – in 2023 their sales as a proportion of overall sales was less than 1% – this compares to China for example which in the same year was almost 40% of overall sales. “The fleet that we have at Centinela is the largest BEV fleet at any mining operation in the world. So we are pioneers and first movers in that respect. Taking the top 20 copper mines in Chile alone, each has well over 500 pick up trucks and some of them have over 1,000. We estimate in the Chilean mining industry as a whole there are 30,000 to 40,000 pick ups that will need replacing with BEV versions in the coming years. Our market share in mining BEVs is already 70% and we hope to maintain and grow that.” Global mining contractor Thiess earlier this year announced an agreement to lease two Voltera R6 BEVs, which were delivered to their #Llano #Copper Project in October 2023 – Llano being a major greenfield project that is part of the overall #Centinela operations. #miningEVs #mininglightvehicles #theelectricmine #futureofmining

Mining truck rebuilds - from Indonesia to Perth Global #miningservices company Thiess says it has successfully exported its first fleet of rebuilt trucks – five Caterpillar Inc. 789 trucks – from #Batam Island in #Indonesia to #Perth, #Australia, with more enroute to support the ongoing demand for hauling fleet. It states: “Our #Thiess #RebuildCentre team in Indonesia resets the usage clock on each truck to zero hours, extending each truck’s service life by 40,000 to 60,000 hours, with a full rebuild that includes overhauling all major components and refurbishing the chassis and electrical systems. Since opening in January 2024, the team has completed 17 trucks, with six more near completion. A total of 31 trucks are expected to be completed and exported by the end of the year.” Thiess Group Executive Chair and CEO Michael Wright said: “Our truck and component rebuilds underscore Thiess’ commitment to sustainable solutions and innovation in mining. The rebuilt equipment and components will result in improved machine productivities, incorporating product updates and technology improvements, delivering reliability and enhanced mining efficiencies at lower costs for our clients.” He adds: “The centre also serves as an incubator, allowing us to explore #decarbonisation and #alternativefuel technologies, with future opportunities to offer these services to our clients. Our rebuild team has successfully developed innovative solutions such as building diagonal stairway control boxes from piece parts, helping circumvent global supply chain issues.” Strategically located near #Singapore to service Thiess operations in Asia and Australia, the centre showcases the role Thiess can play in the future of sustainable mining, which includes creating opportunities in the communities where the company operates. Thiess Engineering Indonesia General Manager Daryl Albury said: “Thiess has invested in several local programs across the Batam region. We’ve partnered with Batam State Polytechnic and vocational schools across Batam to provide work experience programs and sponsored local youth to take part in our leading Apprentice Program at our #Balikpapan Training Centre, providing valuable skills in mechanics and auto-electrical trades. These contributions ensure we’re helping to build a robust workforce and pipeline of skilled local workers that supports economic growth and innovation across the region.” Further strengthening Thiess’ community impact, the Thiess Rebuild Centre team has also worked closely with local government on various initiatives aimed at promoting environmental #sustainability and public health. #mineofthefuture #miningrebuilds #futureofmining #theelectricmine

A ‘revolution’ for GET rope shovel dippers It is always hard to replace a tried and trusted brand, but the ESCO® NEXSYS® GET Lip System for rope shovel dippers looks to be making a strong business case for mine sites already used to working with the existing Whisler Plus™ system. Weir says the system is designed to lower lip maintenance requirements, extend tooth and adapter life and, ultimately, provide miners with longer uninterrupted shovel operation. The Weir – ESCO Group LLC Division has achieved this using field data from hundreds of Whisler Plus system installations, laboratory simulation and analysis and customer input, it says. “We’ve been serving Whisler Plus customers for 20 years. We are proud of the reputation it has within the marketplace for wear life and longevity,” Kevin Stangeland, PE, Vice President of Global Products, ESCO, told IM at the recent MINExpo 2024, in Las Vegas. “At the time of its release, Whisler Plus was seen as revolutionary; it has allowed us to capture a market share close to 50%.” Considering the machines these systems are used on are viewed as the workhorses of the open-pit sector, rope shovels, ESCO knew it would need something equally revolutionary to move existing customers onto a new product. Stangeland and the ESCO team believe they have achieved that. Read the full story below to find out more... #MiningGET #miningtheuptime #openpitmining #NEXSYS

#TheElecricMine25 is already shaping up to be a great event, with Gonzalo Ramirez Troxler the first of many speakers to be announced. Stay tuned to The Electric Mine page 👇 to ensure you don't miss a beat! #TEM25 #NetZeroMining