Engineering firm Worley has been awarded a contract for program management services and engineering, procurement and construction management (EPCM) to support Anglo American’s Woodsmith project in the UK, the mining company has confirmed.
Worley, in tandem with other contractors, is being tasked with delivering a polyhalite mine for its client Anglo American.
The project includes the sinking of production and service shafts with 6.75-m diameters – having depths of 1,594 m and 1,565 m, respectively – and a 37-km-long concrete-lined tunnel containing a conveyor belt, which transports the polyhalite ore from Woodsmith mine, near Whitby, to the Mineral Handling Facility, on Teesside, for processing and shipping.
In Anglo American’s half-year results, released earlier this year, the company outlined that major critical path components had continued to progress to its updated plan at Woodsmith.
“[Our] ongoing technical review confirmed there are several improvements to modify design to bring it up to Anglo American’s safety and operating integrity standards and optimise value for the long term,” it said.
Mining companies around the world rely on Kal Tire’s Mining Tire Group for mining tyre management and supply. Over the last five decades, Kal Tire has grown to a team of more than 2,700 people serving more than 150 mine sites across five continents. With that breadth of expertise across commodities and conditions, and innovation in tooling, processes and safety, Kal Tire focuses on helping customers achieve their goals and maximise their tyre investment. By investing in tyre management technology, sustainable solutions and highly skilled teams, Kal Tire helps solve miners’ evolving challenges and provides measurable value at every stage of tyre life. Some unique Kal Tire solutions making an impact include its Tire Operations Management System (TOMS), Ultra Repair, a thermal conversion recycling facility, six world-class retreading facilities, and a new Maple Program and verified carbon calculator so customers can earn recognition for the emissions saved by retreading.
MTGMarketing@kaltire.com
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Solving the environmental challenge of scrap mining tyres
Kal Tire’s Mining Tire Group has a new partner to help scale and grow access to its thermal conversion recycling technology. How can mines best prepare for a new way of handling end-of-life tyres?
Several years ago, Kal Tire’s Mining Tire Group began to imagine a new way to recycle ultra-class tyres that would lead to the best and highest use of a recycled rubber product. Today, Kal Tire’s thermal conversion recycling facility in Antofagasta can process five 63 inch tyres (20,000 kg) every day – creating 6,500 litres of alternative fuel, 4,000 kg of steel and 8,000 kg of carbon black as well as enough synthetic gas to fuel the plant itself for seven hours.
It’s the only operating facility of its kind that Kal Tire is aware of and, now that it’s been operating successfully for a year, the company was ready to embark on a partnership to scale the solution and reach many more mines much more quickly. In September, Kal Tire and Mitsui & Co., a global corporate group focusing on innovation and sustainability, announced a joint venture that will support growing demand for OTR recycling solutions, and the collaboration will start by commercialising the Chilean plant in 2023.
How did Kal Tire develop this unique technology at the top of the recycling hierarchy and what does the new partnership mean for the mining industry? At a time when mining companies are pursuing ESG and sustainability solutions with greater attention than ever, why is thermal conversion a much-discussed option and what can mines that are determined to reduce their carbon footprint learn about paving the way for bold solutions?
Until recently, Chile was like most mining countries in that it was without a viable option for its stockpiles of scrap tyres. Chile is home to six of the 10 largest copper mines in the world and nearly 500,000 t of scrap tyres. Recognising the need for a solution was great, several years ago Chile became one of the first countries to develop mining tyre disposal legislation.
At the same time, Kal Tire began to consider its role in providing a solution to customers at every stage in the life of a mining tyre, and the company could see the demand for a sustainable solution on the horizon. A project team was tasked with exploring not just a practical way to recycle ultra-class tyres (tyres can weigh 4 t and many mines are far from major centres) but also the most sustainable way to recycle tyres – an option that could do more for mines and communities than traditional shredding. While shredding gives a second life to recycled rubber crumb as garden mulch, asphalt aggregate and playground surfaces, that recycled rubber product will eventually end up at the landfill. The phrase ‘circular economy’ was less common then, and it was one the project team aspired to achieve.
Kal Tire has been serving customers in Chile for decades, and so the legislation discussions became the impetus for Kal Tire to develop a mining tyre recycling solution that would first be implemented in northern Chile.
Significant research led the project team to thermal conversion recycling. It’s a unique process that uses heat and friction to induce a reaction that converts tyres to their base elements. After the tyres are cut into smaller pieces, they’re heated in a vacuum with no oxygen. That also means there’s no combustion and no smoke – a very clean, environmentally friendly process. After about five hours in the reactor, the process emits a gas that fuels the entire process. The external fuel is turned off and the tyres themselves provide the energy for the process to continue.
When the process has completed, what’s left is carbon black, alternative fuel and steel – the original components used to manufacture a tyre, and virtually 100% of the tyre can be reused as high value chemical feedstock. Carbon black can be reused in batteries, plastics, pigments and paints. High quality tensile steel can be recycled in numerous ways. Oil can fuel generators, or it can be refined into alternative fuel for reuse in mine site equipment – creating that circular economy and a greater impact.
Back in 2015, however, the technology didn’t exist to support the recycling of mining tyres. If Kal Tire wanted to pursue thermal conversion, it would have to develop the technology.
What followed was the arduous process of making thermal conversion a viable and effective solution for ultra-class tyres and building the 20,000 sq.m facility in the heart of Chile’s mining region. During that process, Kal Tire was also participating in dozens of conversations with customers and the Chilean government to ensure the plant would meet the needs of government and industry, and exceed environmental and safety requirements.
Throughout, Kal Tire commended the leadership of the government and the involvement of the mining industry, keen to operate in a way that’s more environmentally responsible.
A few years later, as the facility’s wet testing approached, one of Kal Tire’s longstanding Chilean customers invested in having 2,300 t of its scrap tyres recycled. In the spring of 2021, the first reactor’s full load tests were successful and, later that year, the facility reached the end of commissioning. The progress followed a groundswell of interest in the mining industry to support a circular economy and ESG, but how would the output quality compare with expectations, and how could Kal Tire share these learnings to help other regions take action?
Kal Tire has built a 20,000 sq.m facility in Chile leveraging its thermal conversion process to provide a viable and effective recycling solution for ultra-class tyres
As Kal Tire begins to recycle some of the thousands of scrap tyres in Chile, the potential opportunities for reuse of the materials are growing, as is the appetite for an approach that creates this kind of circular economy.
Over the last year, the facility has seen consistently high-quality outputs and, with that, more opportunities for them to become high value chemical feedstocks or fuels. For example, the project team imagines a future where the carbon output could be reused in conveyor belts on mine sites (and the belts could be recycled time and again), or in the manufacture of plastic piping that transports water on mine sites. Mines have the potential to use a tyre once for its intended purpose, and then reuse a portion of a tyre’s original material in a form such as fuels. This is the chance to have an even greater impact for customers and communities that Kal Tire sought to achieve.
The technology is effective. The outputs are of high quality. The circularity is proven and exciting. What now? How can this solution be used in other countries?
Many plants have to evaluate whether to do major component replacements in-house or take advantage of OEM service teams to complement their site personnel’s efforts. Baden Parker, Senior Manager, Global Field Services with Metso Outotec, shares his thoughts on what needs to be considered when dealing with these major service events.
When it comes to replacing major components for gyratory, cone and jaw crushers, finding the right personnel who are trained for these specialised tasks can be a challenge. Bottom shells, mainshafts or gears eventually need replacement or even an upgrade to take advantage of product improvements. Large and heavy parts often require specialised handling and installation procedures, as well as specialised tools to ensure safety.
When replacing an eccentric, a pitman, a pinion or any other major crusher component, many questions can come up. Has the site planned this type of work before, and does it have all the right tools? Are all the service steps perfectly understood to do the work safely and efficiently? Are there experienced personnel available to execute the part change-out? Does the site service team know what to look for to make sure the parts come together properly? Are new parts to be used or are the existing parts that are going to be re-used in good condition?
Crusher component replacement work involves dealing with large parts which can pose safety, maintenance and handling challenges
Using in-house expertise, OEM support or both
Many mine sites and plants try to tackle these types of crusher component change-outs with their in-house capabilities. However, even with sites that have strong maintenance teams, there are many challenges that may not be considered. Some sites may have to deal with high turnover in key service positions, leading to uncertainty in how to perform these major and non-routine maintenance tasks. Other plants need to service many models and brands of equipment and may not have the specialised knowledge that comes from performing complicated parts’ change-outs on a regular basis. There is also the constant struggle between production and maintenance aims and goals. When the pressure is on to increase production, there can be the temptation to shortcut maintenance times, which can lead to equipment problems or safety concerns that outweigh the time saved doing the actual work.
Having served at mine sites for 10 years, holding roles such as Shift Mechanical Fitter, Leading Hand, Supervisor, Senior Supervisor & Maintenance Planner before joining Metso Outotec as a crusher maintenance expert, has given me a broad view when it comes to service operations. I gained considerable knowledge on the life cycle of a site’s crushing assets and the maintenance required to ensure equipment reliability and, in turn, plant availability. I can say with confidence that if the on-site crews are well trained, many routine tasks can be handled safely and competently. However, a typical maintenance mentality that I observed (and personally held for some time) is ‘We can fix anything ourselves’ and that calling in the OEM was not needed, as we could work out the best ways of working ourselves. For many routine component replacements, this was indeed true enough.
However, over time I changed my view and realised that, in many cases, OEM support complemented a site team’s strengths and led to a far better result in terms of efficiently maintaining a site’s crushing equipment. I would like to share just a couple of examples that I have seen first-hand, relating to gyratory crusher component replacement work, that display how not pulling in needed know-how can be detrimental and potentially costly.
SOUTH32 said sales of aluminium and manganese from its South African operations declined in the first quarter of its 2023 financial year owing to port congestion and reduced third party rail availability.
Aluminium sales fell 18% quarter-on-quarter to 162,000 tons while manganese sales totalled 473,000 tons, a decline of 8% on the previous quarter.
South Africa’s state-owned rail and port operator Transnet has struggled to maintain volumes owing to Covid-19 absenteeism, a lack of parts and equipment, and persistent theft and sabotage perpetrated by criminal gangs.
Previously, South32 has resorted to trucking manganese from its mines in the Northern Cape. However, a decline in the manganese price means this route is less effective. And there may be more sales disruption to come.
Said South32: “We continue to closely monitor the situation and will seek to mitigate the potential impact on our aluminium sales during the December 2022 quarter”.
Including the strike, and Transnet logjams, annualised revenue losses of some R50bn were expected this year, 43% more than R35bn last year. This covers losses on revenue of iron ore, coal, chrome, ferrochrome and manganese exports, the council said.
South32 said it had finalised “a new collective employment agreement” for three years to 2025 at Hillside Aluminium post the quarter end. It did not provide additional details, but the National Union of Metalworkers of SA said on September 5 South32 had offered a 3.1% increase across the board and a 4% once off cash payment for the month.
South32 had a strong production quarter, however. Guidance was unchanged at all operations except Illawarra metallurgical coal. The group forecast 13% copper equivalent production growth in 2023 following the first quarter.
South32 returned $50m to shareholders via its share buy-back programme and closed the first quarter with net cash of $446m. Some $784m was also returned in October through its previously announced ordinary and special dividends.
The Konongo-Odumase Township was thrown into mourning in the early hours of Sunday when a toilet caved in, swallowing a 24-year-old woman who was attending to nature’s call.
Rescue efforts by personnel from the Ghana National Fire Service and residents could not save the young lady who was pulled out from the pit after almost three hours.
With the aid of an excavator, the rescue team removed heaps of sand from the caved pit before locating the lifeless body of the deceased amid anxiety and uncontrolled wailing.
Some residents blamed the incident on an abandoned in-house mining pit close to the toilet but would not speak openly about it for fear of intimidation.
Residents who attempted to narrate the circumstance leading to the disaster to the media were visibly threatened others believed to be involved in the practice.
Some of them who spoke to GNA on condition of anonymity, said the landlord of the house had cautioned tenants not to use the toilet facility due to the precarious nature of the pit.
In-house mining is a common phenomenon in Konongo-Odumase where most houses are known to be having mining pits some of which are dug in bedrooms.
In 2016, the Municipal Security Council banned in-house mining in Konongo-Odumase following incessant complaints by residents who envisaged the danger that the practice posed to both the environment and humans.
Prior to the ban, the Assembly had arrested and arraigned some of the perpetrators following the identification of about 70 in-house mining pits in the same area where the incident happened.
The GNA gathered that despite the ban, some recalcitrant miners continued to engage in the illegal activity, but the expectation is that authorities would step up efforts to tackle the problem following the latest incident.
The Federal Government has stressed the need to computerise the nation ‘s mining sector , saying it will enhance development and efficiency of the sub -sector of the economy.
Sensitising primary stakeholders on the adoption of the Electronic Mining Cadastre System, (eMC+), in Ibadan, Director General/ CEO, Nigeria Mining Cadastre Office, under the Ministry of Mines and Steel Development, South West region, Engr. Obadiah Simon Nkom, said the new system was designed to cater for the entire process of Mineral Title administration; from application submission, payment of fees, granting (refusing) up to the issuance of certificate.
According to him, the efforts towards the computerization of the Mining Cadastre Office picked up with development focused on enhancing development.
“EMC+ is simply like the word, Electronic Mining in Cadastre and like i said, somebody will say what is the +, we will have to be able to put the + looking at the global trend; what are the attributes you need to add and that is the +, to make it effective, efficient, transparent and we will be able to adapt it to the whole word and things that are coming.
“One needs to now put those attributes in place. so Electronic Mining Cadastre will be able to now access the system from anywhere in the world, you dont need to come, you don’t need to leave Ibadan, even with your phone you will just see and have access to the status of the mineral titles, you will be able to have email send to you, stages of your licencing proceedings.
In his goodwill message, Commissioner for Environment, Oyo State, Abiodun Oni lauded the initiative, saying it will go a long way in the effectiveness and efficiency of the mining cadastre processes.
The commissioner who represented the state governor, Seyi Makinde, therefore urged all relevant stakeholders to take maximum advantage of the programme, stressing it will benefit the mining sector tremendously.
“I dare submit how easy my job will become with this innovation. Technology they say is the bedrock of modern civilization, without technology the mother of modern technology will not grow.
“I am particularly inspired by some of the hurdles this innovation will address. This will set the pace for the mining sector to work and deliver more efficiently and effectively.
Komatsu and Cummins have signed a memorandum of understanding to collaborate on the development of zero-emissions haulage equipment. Building on a legacy of diesel engine partnership across a wide variety of mining and construction equipment, Cummins and Komatsu will initially focus on zero emissions power technologies including hydrogen fuel cell solutions for large mining haul truck applications.
In August 2021, Komatsu announced its power agnostic truck concept for a haulage vehicle that can run on a variety of power sources, including diesel-electric, trolley, battery power, and hydrogen fuel cells. Working with Cummins is complementary to Komatsu’s development of this technology.
“Komatsu’s deep expertise in mining and equipment design and integration paired with our advanced power technologies including hydrogen fuel cells will accelerate decarbonization of mining equipment,” said Amy Davis, vice-president and president of new power at Cummins. “The mining industry has great potential to lead in adopting renewable solutions.”
As a leading independent power provider in the mining segment, Cummins provides unique application understanding that is critical to introducing reliable, quality products that can withstand the harshest environments. Cummins has a broad portfolio of batteries, fuel cell systems and electrolyzers (for generating hydrogen), that are key building blocks for decarbonization. Together, the two companies have a long history in the global mining market and strong technical capabilities necessary to develop these new solutions.
As a company, Komatsu is committed to minimizing environmental impact through its business, targeting a 50% reduction in carbon dioxide emissions from use of its products and production of its equipment by 2030 (compared to 2010 levels) and a challenge target of achieving carbon neutrality by 2050.
Komatsu also announced in 2021 the creation of its greenhouse gas (GHG) alliance with customers to actively collaborate on product planning, development, testing and deployment of the next generation of zero-emission mining equipment and infrastructure. The alliance’s initial target is advancing Komatsu’s power-agnostic truck concept, with a goal of commercial offering in 2030.
The collaboration with Cummins is part of Komatsu’s efforts to provide zero emissions solutions for its global customers. Moving forward, Komatsu intends to explore further possibilities in zero emissions mining haul truck development.
Epiroc has won a large order from Glencore in Canada for battery-electric equipment and automation solutions that will be used at what will be one of the world’s first all-electric mines.
Glencore’s Sudbury Integrated Nickel Operations has ordered a full fleet of battery-electric equipment for the Onaping Depth project in Ontario, Canada. The nickel and copper mine is located below the existing Craig mine and is being developed to start production in 2024. The order also includes the capability for advanced automation solutions, including remote control.
“Glencore is taking a major leap forward in the mining industry by going all-electric with its Onaping Depth project,” says Helena Hedblom, Epiroc’s president and CEO. “We are excited to collaborate with Glencore and deliver battery-electric vehicles and automation features on their journey to build a mine of the future.”
The benefits with battery electrification are significant, including eliminating emissions underground, reducing noise pollution, and lowering costs by lessening the need for ventilation and cooling when required; this is especially important as underground mines keep getting deeper.
“Epiroc scored high on safety, design and testing of the entire battery system,” says Peter Xavier, VP of Glencore’s Sudbury Integrated Nickel Operations. “Epiroc also offers large capacity batteries, uses a standard CCS charging protocol, has a battery swap system, and the designs are universal and compatible. Also, the batteries have integrated cooling systems and safety systems built into the design.”
The ordered battery-electric equipment is manufactured in Örebro, Sweden. The 23 machines ordered include Scooptram loaders, Minetruck haulers, Boomer face drilling rigs, Boltec and Cabletec rock reinforcement rigs, and Simba production drill rigs.
The Simba rigs will be operated in part through tele-remote from the comfort of a control room. All units will be equipped with Epiroc’s Rig Control System, making them ready for automation and remote control, and will also be installed with Epiroc’s telematics system, allowing for intelligent monitoring of machine performance and productivity in real-time.
Following the launch of the Sandvik DL422i battery electric drill in 2021, Sandvik Mining and Rock Solutions has now introduced its diesel counterpart, designed for underground mass mining in 4 by 4 metre or larger production drifts. The new drill offers the same productivity, reliability and high utilization as its BEV counterpart for operations with challenging site conditions that are not optimized for a battery electric fleet.
“The new DL422i expands our i-series longhole production drill offering with a traditional diesel engine layout and begins to take over the workload of its renowned predecessor, Sandvik DL421.” says Sami Anttila, product line manager, longhole production drilling.
Sandvik DL422i prioritizes automated operations, fleet connectivity, availability of data and improved hole accuracy, supported by Sandvik’s technical support and operator training for an improved user experience. Automated operations over shift changes enable up to 20% increased productivity and up to 10% more drilled meters in a shift.
Enabling digitalization
Sandvik DL422i is a highly automated drill within Sandvik’s i-series underground drilling offering, with options for both automation and teleremote operation. It is compatible with Sandvik’s Platinum level automation package, which includes one-hole and fan automation, automatic boom repositioning to the next hole, automatic stinger control, drill plan and as-drilled data management (WLAN), plus connectivity to My Sandvik remote monitoring and Sandvik DrillConnect mobile application. Later in 2022, Sandvik DL422i will also be compatible with Sandvik’s teleremote drilling and tramming offering, expanding remote control from single to multiple units from a single console.
In operations with low or zero mine network connectivity, Sandvik DrillConnect mobile application can be utilized for easy and smooth drill plan transfer, comprehensive data collection and intelligent troubleshooting.
Sandvik DL422i is designed to provide maximum productivity and safety and has been developed with the future of mining in mind. The control system platform allows for new technology implementation during the product lifetime, while teleremote and automated drilling allows for unmanned operation through shift changes and breaks, increasing fleet utilization.
The powerful HF1560ST rock drill offers improved energy transfer and stability with high penetration rates and drilling capacity.
Sandvik’s new i-class cabin provides a safer and more comfortable working environment, with improved visibility in operation, reduced sound levels during drilling, adjustable drilling control panel and multi-purpose seat with back and head support. Swing out frames provide easy, safe and fast access to the main components from ground level.
Epiroc has won a large order for equipment, including battery-electric machines and automation solutions, from the Canadian Malartic partnership, that will be used in a major new underground gold mine currently under construction – the Odyssey mine in Malartic, Que. which will become one of Canada’s largest gold mines.
The Canadian Malartic is a 50:50 joint venture between Yamana Gold and Agnico Eagle Mines.
The Epiroc equipment includes a variety of drill rigs, loaders and mine trucks. Some of the machines will be battery powered. Automation features include Minetruck and Scooptram, which are part of Epiroc’s Sixth Sense portfolio of digital solutions. By combining these solutions with Epiroc’s traffic management system, material handling is optimized within the mine, bringing benefits such as virtually eliminating the risk of collisions. The equipment order also includes education and training using simulators.
“The Canadian Malartic partnership is taking a massive next step with the new underground mine where our battery-electric and other advanced machines with state-of-the-art automation and traffic management solutions will help optimize safety and productivity. Epiroc and the Canadian Malartic partnership have a history of successful co-operation, and we look forward to continue contributing to their success,” Helena Hedblom, Epiroc’s president and CEO, stated.
This is the second equipment order from the Canadian Malartic partnership. Epiroc also won a large order for drill rigs, loaders and mine trucks in the third quarter of 2021. Epiroc will also provide service and spare parts, as well as expertise on electrification solutions.
The Odyssey mine is located just west of the Canadian Malartic open pit gold mine, which is still in operation, and to which Epiroc in previous years has provided powerful Pit Viper surface drill rigs.
“Over the years, Epiroc has clearly demonstrated its willingness to be a leader in the technical evolution of mining equipment, whether in electrification or automation. Obviously, this transition will not happen by itself. We are privileged that Epiroc has proposed us a collaborative approach in order to effectively integrate their equipment into the Odyssey mine and actively participate in this evolution. The benefits from this collaboration will contribute to making mines even safer and jobs more accessible in the field,” Patrick Mercier, general manager of the Odyssey mine, added.
The equipment ordered during the first quarter includes battery-electric versions of the Boltec rock drill, Simba production drill and Boomer jumbo for face drilling. It also includes an Easer raise borer, Scooptram loaders and Minetruck haulers. The machines will be equipped with Epiroc’s telematics system Certiq, which allows for intelligent monitoring of machine performance and productivity in real time.
