New Report Identifies Major Carbon Reduction Opportunities in Global Mining
by Philippine Resources - May 11, 2021
- New analysis lays out the scale of the mining industry’s energy use and identifies ways it can be reduced using currently available technologies
- Materials such as copper, lithium and nickel play an essential role in the technologies like electric vehicles and renewables that will help the world meet its decarbonisation targets
- As demand for these metals increases, the mining industry must itself become more efficient and environmentally sustainable
The global mining industry must move away from legacy systems and processes if it is to meet the challenge of decarbonisation, according to a new report released today which calculates mining’s share of global energy consumption and identifies ways the industry can aid the transition to net zero emissions needed to limit temperatures in line with the Paris Agreement.
The report, commissioned by the Weir Group plc, analyses mine energy data from over 40 published studies to give a comprehensive understanding of where energy is consumed in mining and minerals processing. It shows that the total amount of power used by the mining industry – which plays an essential role providing the metals used at the heart of the modern economy – is equal to c.3.5% of global energy use.
The metals produced by mining are critical for enabling the global transition to low-carbon infrastructure. But without action, energy use in mining itself is set to trend higher in the coming years as demand increases for metals like copper, nickel and zinc. The report suggests there are technologies available today that could make a significant difference to this trend. For example, it highlights that comminution – i.e. crushing and grinding processes – is the single biggest user of energy at mine sites, typically accounting for 25% of mining’s final energy consumption. This is equivalent to the power used by 221 million typical UK homes, or c.1% of total consumption globally. Comminution is therefore a natural target for the most impactful energy savings opportunities.
Small improvements in comminution technologies can lead to relatively large savings in both energy consumption and greenhouse gas emissions. For example, a 5% incremental improvement in energy efficiency across comminution could result in greenhouse gas emissions reductions of more than 30m tonnes of CO2-e. The replacement of traditional comminution equipment with new grinding technology also reduces indirect emissions in the mining value chain, for example by removing the need for the manufacture of emission-intensive steel grinding balls.
Of the remaining energy consumption by the mining industry, diesel in varied forms of mobile equipment accounts for 46%, electricity in mining (ventilation) 15% and “other electricity” 14%.
Other significant opportunities identified by the report for reducing mining’s energy consumption include optimisation, big data and artificial intelligence. In addition, if zero emissions energy sources are deployed for mining equipment – e.g., renewable energy, energy storage and alternative fuels – then the industry may well be able to achieve zero emissions, leaving a relatively small role for offsets and carbon credits to play.
The report comes as the mining industry is under ever-greater pressure to produce essential minerals that
support some of the biggest global structural trends, from population growth to urbanisation and decarbonisation. Copper, nickel, steel and lithium are core components of electricity transmission and storage, electric vehicles and renewable energy infrastructure. The move to a decarbonised economy will result in increased primary consumption of these mined commodities, even after factoring for recycling, so it is important that mining itself becomes more sustainable.
Download the independent Mining Energy Consumption 2021 report here: www.energysavingsinmining.com
Commenting, Weir Group Chief Executive Jon Stanton said:
“The mining industry is central to economic development globally, with critical minerals enabling the low-carbon transition required in the rest of the economy. But the environment in which it will operate in future will be very different from the past, requiring comprehensive change and investment. In short: mining needs to become more sustainable and efficient if it is to provide essential resources the world needs for decarbonisation while reducing its own environmental impact.This report is an important contribution to that debate which we hope will spark thoughtful conversations around the world on the way forward.”
Alison Keogh, Chief Executive of the Coalition for Energy Efficient Comminution, said:
“This report highlights both a challenge and an opportunity to revitalize cross-industry discussion and actions on decarbonisation and ESG solutions. We invite industry leaders to actively contribute and collaborate through mining-vendor-research partnerships and share knowledge. Together, we can accelerate improved energy, emissions and water footprint across industry faster.”
Ricardo Garib, Weir Minerals Divisional President commented:
“Weir Minerals is focused on making mining more efficient and sustainable by leading technology change in the industry. Our Enduron HPGRs are increasingly replacing conventional milling systems in comminution (crushing, screening and grinding) circuits because of their substantially lower energy consumption, finer rock reduction requiring less water downstream and potential for significant total cost of ownership reductions.”
Stuart Hayton, Managing Director of Weir Minerals Netherlands, where the Enduron® HPGRs are designed and manufactured, added: “Not only do Enduron HPGRs require as much as 40% less energy than traditional alternatives, their wearable components last much longer and the maintenance time required to replace worn out parts is significantly lower. The estimated carbon saving of each Enduron HPGR in operation is equivalent to taking more than 3,600 petrol fuelled cars off the roads each year.”
- The report quantifies energy use in five commodities: copper, gold, iron ore, nickel and lithium. Bringing together mine energy use data from more than 40 published studies (each of which references dozens more studies) from 2007 to 2020 into a single narrative, the report aims to build a more comprehensive understanding of energy use in the mining industry.
- Using the current production rates of the commodities in question, and the energy intensities for each of the commodities, a total of 1,68 EJ/a (1,680,000,000,000,000,000 joules per year) has been calculated. This is approximately 0.5% of total final energy consumption globally. Published information indicates that the entire mining industry consumes approximately 12 EJ per year – or 3.5% of total final energy consumption globally.
- Assuming that present trends continue, there will be 250m electric vehicles on the road by 2030. To meet this demand, production of cobalt, lithium, graphite and nickel will need to be scaled up significantly.
- Current projections show that the current rate of decarbonisation globally is far below what is required to meet the goals of the Paris Agreement. A sustained decarbonisation rate of up to 7% per year, year on year should be sufficient to achieve the goal of a temperature increase of well below 2°C by 2100. For the mining industry, there are multiple ways to achieve decarbonisation including energy efficiency and fuel/energy switching. Many of these opportunities are starting to be explored by both the mining companies and the mining services providers, who see decarbonisation and energy reduction as a key way to reduce exposure to the risks of climate change.
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Philippine Resources - July 01, 2021
Weir Minerals Launches Multiflo® Mudflorm Submersible Pump for Large Particle Handling
Weir Minerals, global leader in the provision of mill circuit technology, dewatering solutions and services, has launched the new Multiflo® MudfloTM hydraulic submersible slurry pump. Engineered for abrasive applications and large particle handling, the Multiflo® MudfloTM pump features a hydraulically driven wet-end specifically designed to efficiently and safely reprocess and relocate tailings ponds, maintain water retention dams and manage slimes and sludge ponds. The innovative solution combines the Warman® MGS pump-end, Multiflo® CB32 hydraulic cutters and ESCO® excavation teeth to provide efficient pumping of highly charged and abrasive slurries. Weir Minerals' unique Ultrachrome® A05 chrome alloy impeller ensures high wear resistance and the specially engineered suction strainer minimises the risk of clogging by preventing large solids & debris from entering the pump. Drawing on decades of Warman® pump design experience, the Multiflo® Mudflo™ pump is capable of pumping between 150 and 1,200m3/h, up to 82m head. The Multiflo® CB32 hydraulic cutters feature market-leading ESCO® Ultralok® tooth system to prevent premature breakage, avoid tooth loss and protect the integral locking system to ensure the continuous operation of the pump. Engineered by the Weir Minerals dewatering pump experts in Australia, it is available for global customers from July 2021. “The Multiflo brand is synonymous with high quality and long-lasting equipment. In designing the Mudflo pump, our dewatering experts drew from the very best Multiflo, Warman and ESCO technology and used advanced hydraulics to create an innovative and cost-effective new solution for mine dredging applications,” Cameron Murphy, Director of Dewatering Weir Minerals APAC said. Weir Minerals understands that success is built from enduring partnerships based on close collaboration and a mutual commitment to safety and technical excellence. “It is not uncommon for sites to use a combination of pumps, shovels, excavators and trucks for dredging applications. When one of our long-time partners in Indonesia contacted us about developing a custom solution for the slurry build-up in their sumps, we knew we could provide a better solution,” Geoff Way, Weir Minerals Dewatering Specialist said. “We’re problem solvers. We considered our customer’s pain points and engineered a new solution to efficiently and safely manage their site processes,” he said. The Multiflo® MudfloTM pump can also be retrofitted to competitor OEM equipment; the quick-hitch plate attachment ensures convenient installation and removal from hydraulic excavators. The Multiflo® Mudflo™ pump can be assembled on land, eliminating the safety risks associated with assembling pumps over water. Furthermore, the new hydraulic hose management system reduces the risk of hose entanglement and trip hazards, all the while providing a reliable hose bend radius to ensure smooth oil flow. The Multiflo® MudfloTM pump will be available globally from July 2021. Discover more at https://info.global.weir/mudflo
Philippine Resources - August 23, 2021
Using dewatering systems to improve site efficiency
Photo: Multiflo® mega barges on site in Brazil Dewatering is critical to a mine’s operations and more resources are being allocated to its optimisation. Traditionally, there’s been a tendency among some mine and quarry operations to view dewatering as something to be avoided at all costs – until it can’t be. Therefore, cost minimisation has been the primary focus when it comes to implementing a dewatering or fluid management solution. However, with dewatering becoming increasingly necessary, operators are approaching these challenges in more sophisticated and methodical ways. The trends informing dewatering practices mirror many of those that are observable across all mining processes: a focus on sustainability and the efficient use of energy and other resources; customised, holistic solutions based on each sites unique geological and climatic conditions; and the emergence of new technologies, with a particular focus on real-time monitoring. Dewatering solutions that are carefully designed and implemented have the potential to reduce energy usage, CO2 emissions and significantly lower OPEX over the life of the mine. The overall efficiency is affected by individual elements, but also by how these elements interact and operate with one another. The renewed focus on pumping efficiency requires a significant shift in how many operators have previously approached dewatering and fluid management on site. Because most dewatering programs have been designed with the singular focus of lowering groundwater levels as quickly as possible, they often have excess pumping capacity and oversized pipes and pumps operating at only a fraction of their capacity – a process that’s inherently inefficient. This needs to change to accommodate the increased focus on efficient use of energy and water, which is critical to maintaining a social licence to operate. Multiflo® MF pump unit on site in Indonesia Improving pump efficiency begins with effective monitoring. There have been enormous improvements in electronic control and communication systems in the last few decades. Real time reporting and control of pumping systems can now be an economic reality for almost any mine site. The more visibility you have over your fluid management on site – flow rates, operating pressures, groundwater level, water quality, system relocations, alternate drive solutions, equipment selections to reduce maintenance and repair cycles, etc. – the better placed you will be to install the most appropriate equipment. The industry is moving towards customised solutions and there’s a growing awareness that no two sites are the same, which means a one-size-fits-all approach to dewatering is neither cost effective nor sustainable. Weir Minerals has a global team of dewatering experts who partner with mine operators to assess their specific requirements and provide integrated solutions. With a long and proud history of innovative engineering, Weir Minerals has a team of process and design engineers armed with the latest technology, specific process knowledge and site experience to optimise your dewatering management processes. We take advantage of our global capabilities and engineering skills to provide our customers with the best solution as quickly as possible. With an extensive global network and the ability to service on-site or at one of our 130 dedicated service centres, we are always there when you need us - no matter how remote your operation is.
Philippine Resources - May 24, 2021
Weir Minerals announces major order of Enduron® HPGR with IAMGOLD
Weir Minerals is proud to announce another major order of Enduron® HPGR in Gold application with our valued Customer IAMGOLD. An Enduron® HPGR with rolls measuring 2.4 m x 2.4 m (length : diameter) will be installed at IAMGOLD's Côté Gold Project. This will be the largest HPGR in Canada and the largest in the world in a gold hard rock application. Weir Minerals’ Enduron® HPGR unique design is perfectly suited to IAMGOLD’s Côté Gold operations to achieve industry-leading particle size reduction and with the lowest total operating costs. Enduron® HPGR is the market proven HPGR with the mechanical design to support efficient and durable skewing thanks to its unique bearing arrangement and control philosophy Enduron® HPGR has a unique roll diameter-width ratio which maximizes throughput at the desired product grind Enduron® HPGR self-adjusting cheek plates provide equal sealing distance as flanges at minimum costs Enduron® HPGR is the market leader in large format, high tonnage hard rock HPGR Tim Lundquist, HPGR Regional Sales Manager North America: “Our Enduron® HPGR design will create energy savings of up to 40% compared to an equivalent SABC comminution circuit, while also significantly reducing the need for downstream grinding media. This power and grinding media savings will optimize total ownership cost and also account for a significant reduction in carbon emissions”. Weir Minerals prides itself in being close to its customers at all times. Our Weir Minerals Canada team and purpose-built facilities will be providing full HPGR service for the Côté Gold operations. For more information about Enduron® HPGR please visit enduronhpgr.weir
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Philippine Resources - May 23, 2023
MEMORANDUM OF AGREEMENT SIGNED WITH TVI RESOURCE DEVELOPMENT (PHILS.) INC.
Photo credit: TVI Resource Development The Board of RTG Mining Inc. is pleased to announce that a comprehensive settlement of all outstanding issues with the Villar Family controlled Sage Capital and TVI Resource Development (Phils.) Inc. (“TVIRD”) has been reached and a binding Memorandum of Agreement signed. On execution of the final documents, expected in the next month, all litigation that RTG had launched will be withdrawn as part of an agreed restructuring of the Mabilo Project. The Villar Family is one of the most prominent families in the Philippines and RTG is pleased to partner with them in the development of the Mabilo Project, which is a significant mining project for the country. The key terms of the agreement for RTG include the following: RTG (through SRM Gold Limited) will retain a 40% interest in Mt. Labo Exploration and Development Corporation (“Mt. Labo”) with the project also developed by Mt. Labo, in line with Philippine regulatory requirements, with Sage Capital (which is owned by TVIRD) holding the remaining 60%; RTG will have a 2% net smelter royalty (“NSR”); RTG’s debt together with interest, currently in the order of US$27M (subject to audit) will be repaid out of the proceeds of Stage 1 of the project, the Direct Shipping Operation subject to customary requirements to address liquidity and ongoing operations of Mt. Labo; Funding arrangements for the project as between the major shareholders of Mt. Labo have been successfully renegotiated, (relieving RTG of a sole funding obligation) and replaced with a pro-rata funding obligation, together with a disproportionate funding obligation of Sage Capital, as set out below; With debt repayments in full and the NSR, RTG will be entitled to approximately 57% of the proceeds of Stage 1, the Direct Shipping Operation; RTG will be entitled to 40% of the operating cashflow of the project, together with the 2% NSR and repayment of its debt, which is currently in the order of US$27M; The first US$5M of expenditure for Mt. Labo (or 12 months of expenditure, whichever occurs the earlier), will be funded pro-rata between the two shareholders (ie RTG will provide 40%) and thereafter, Sage Capital/TVIRD will sole fund the next US$5M of expenditure, with all additional funding thereafter to be provided on a pro-rata basis; All parties are required to act in the best interests of the project and not compete; A shareholders’ agreement will be finalised which will provide typical minority interest protection clauses including reserve matters for voting including annual budgets and appointments of key personnel; Any disputes will be resolved by the Singapore International Arbitration Centre; and On completion of final signed documents, all litigation matters will be withdrawn and settled in full. With the restructuring of the Mabilo Project now agreed, over the balance of this year, the remaining permitting matters and financing plans will be finalised, a review of the 2016 Feasibility Study will be completed, together with finalising the acquisition of surface rights, following which, a commitment to development will be formalised by the Board of Mt. Labo. RTG is pleased with the outcome of the discussions and the co-operative and constructive approach adopted by the Villar Family representatives. RTG believes they can be a strong and positive partner to work with to take the Mabilo Project forward, with both a near term development and future exploration activities to expand the project, which will start to unlock the value of the project for all stakeholders, not only the local communities but for the country as a whole.
Philippine Resources - May 22, 2023
Mining Operational Excellence Through Digital Transformation
Part 1: Mining Operation Challenges and Mine Operations Management Domains 1 & 2. By Mae Ann Cabasag, EM Mining companies encounter numerous challenges throughout their operations. However, initiatives to mitigate these challenges and improve efficiency are often limited. Most of these limitations emanated from a common factor: the challenge of “poor visibility” in mining operations. A viable solution is to adopt digital transformation in mining operations by incorporating available real-time data into an integrated system— capable of ensuring automatic updates and reliable source of information. Through this, mining companies not only understand simulations and plans developed but also anticipate potential outcomes. Various mining industry analysts have found that using non-digital methods in the mining operations can lead to a 27% reduction in production time and 25% increase in data inaccuracy. For a mining company to remain competitive in an industry susceptible to operation challenges, i.e. production processes, workers’ and equipment performances, ore quality and quantity, compliance to regulations, and inter-departmental collaboration, it needs to embrace digital transformation. Dassault Systèmes Mine Operations Management provides transformative digital solution for mining companies to achieve excellence in their operations. Mine Operations Management (MOM) equips mining companies with an integrated system for their mining operations, enabling them to achieve efficient plan and schedule. This system integrates entire operation data into a single repository source of information, known as the “single source of truth”, ensuring complete transparency of the company’s processes from mine to port. By leveraging MOM, we can address the following global mining industry challenges: Maintaining competitiveness amidst market volatility. Eliminating waste materials, poor communication, and error duplication. Improving site productivity and efficiency. Utilizing assets and sharing best practices across the value chain. Ensuring an utmost level of safety. Reducing environmental impacts and achieving sustainable operations. The transformative digital solution, Mine Operations Management, is composed of eight work packages, split across four domains, namely: Data Management, Material Reconciliation, Operational Control, and Assets Performance. These domains help generate valuable insights from integrated operational data for rapid and informed strategic decision-making. The Data Management consists of Master Data Model and Integration Framework packages essential for material tracking, stockpile management, task and workforce management, machine performance, and asset maintenance. It enables users to manage master data objects such as Site, Material, Location, Equipment, and Operator through manual data entry or third-party source systems. With this, mining companies can ensure efficient and integrated management of critical data required for seamless operations. Material Reconciliation, on the other hand, consists of Material Tracking and Stockpile Management packages. Material Tracking enables us to track material movements across different stages, i.e. from the least accurate grade estimated in geological model to the most precise information on shipped material quantity and quality, to account for any inaccuracies. While in the Stockpile Management, users not only can calculate daily stockpile balance, add Survey or Sampling data, analyze inventory levels and trends, create graphical representation of the stockpile balances and movements, calibrate stockpile using volumetric survey and sampling, enables comparison of different models, track movement genealogy and review stockpile slices for stockpiles with LIFO and FIFO calculation type but can create a different type of analysis such as actual vs plan vs model. In the upcoming article, we will explore the two remaining domains of Mine Operations Management to where assigning operational tasks, tracking compliance to plan, monitoring equipment down to workers’ performance are feasible in the mining operations. To know more about MOM, mining innovations and solutions, contact Dassault Systèmes Value Solutions Partner: Paramina Earth Technologies Inc. through email@example.com References: Make it happen for mine execution excellence: Dassault Systèmes®. MEGATrends. (n.d.). https://events.3ds.com/make-it-happen-for-mine-execution-excellence Dassault Systèmes. (2021, August 12). Digging deeper: The virtual solution for Mining Operational Excellence. Dassault Systèmes. https://discover.3ds.com/virtual-mining-operational excellence dassault3ds. (2022, June 16). The mining industry needs to adapt, but how? Dassault Systèmes blog. https://blog.3ds.com/brands/delmia/the-mining-industry-needs-to-adapt-but-how/
Philippine Resources - May 22, 2023
Customer’s First Choice: Sandvik Philippines Delivers 11th and 12th Pantera DP1500i Drills to Filminera Resources Corporation
Sandvik Philippines has successfully commissioned and delivered to loyal customer Filminera Resources Corporation (“Filminera”) their 11th and 12th Pantera DP1500i Top-hammer Surface Drills last 25 January 2023 at the Masbate Gold Project (MGP) located in Masbate Island, Philippines. Photo shows Sandvik Technician Larry Lugnas (second from left) and Service Operations Manager Jorge Cabello (third from left) handing over the drills to MGP representatives. Located 360 km southeast of Manila, the Masbate Mine is operated by Filminera, the Philippine subsidiary of TSX- and NYSE-listed B2Gold with headquarters in Vancouver. In 2022, the mine produced a record-setting 212,728 oz of gold out of 7.93M tonnes of ore milled at an average grade of 1.11 g/t. B2Gold also operates the Fekola Mine in Mali and the Otjikoto Mine in Namibia. Their projects under development include the Anaconda Area in Mali and the Gramalote JV Project in Colombia. The Masbate Mine started operating in 2008 initially using 4 x Atlas Copco ECM660 Drills owned and operated by the erstwhile mining contractor, Leighton. When the opportunity for re-fleeting came about in 2012, Sandvik succeeded in winning the tender which came packaged with a full maintenance contract for 24,000 service meter hours of five years. Ironically, the said maintenance contract almost led to the cancellation of the order for the first 4 x DP1500i due to a dispute with the rates. Eventually, both Leighton and Sandvik were able to arrive at a mutually acceptable arrangement, and Sandvik ran the service contract for five years without incurring penalties in the availability guarantees. The contract was so profitable, Sandvik even had to share some of the residual profit at the end with Filminera under the pain-and-gain proviso of the contract. The next re-fleeting opportunity came in 2017, with the Masbate Mine. This time, there was no service contract attached to the equipment and Leighton was no longer the mining contractor; the mine has shifted to owner-miner operation. Sandvik managed to secure the repeat order for another batch of 4x DP1500i, banking on the proven performance and reliability of the first four. That brings the total to 8 units. Drill numbers 9 and 10 were ordered in July 2020 and delivered in 2021. Numbers 11 and 12 in the photo above were ordered in January 2022 and are now handed over to the customer. Filminera ordered two more DP1500i’s in November 2022; these machines are now awaiting completion in Tampere, for delivery later this year. That should bring the total to 14 x DP1500i units spread over 11 years for our most loyal Pantera DP1500i customer in the Philippines – Filminera Resources Corporation!
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