The centerpiece of the Cat exhibit was the 789AC, which was equipped with a
retractable arm that attaches to electrified aluminum rails demonstrating the
company’s new Dynamic Energy Transfer (DET) system. (Photo: Steve Fiscor)

The wide offering of innovative products and services reinforced the fact that mining is a leading-edge industry that is rising to the challenge of meeting soaring global materials and energy demand in a safer, smarter, more environmentally responsible and more efficient manner than ever before, explained Rich Nolan, president and CEO, NMA.

“The response this year was beyond what we could have expected with unparalleled networking and dealmaking like we’ve never seen before,” Nolan said. “From the exhibitors to the new space in the convention center and our new streaming platform NMA TV, everyone stepped up their game and the results were extraordinary.”

The NMA selected Denise Johnson, group president, Resource Industries for Caterpillar to chair MINExpo 2024. This was the second time she served as chair. “It was a great honor for me and a testament to Caterpillar’s commitment to the mining industry,” Johnson said. “Cat’s MINExpo 2024 experience demonstrated that commitment in a big way. And of course, by big, I mean the big Cat mining machines that were on display and the big results that they can deliver.

“At this MINExpo, more than ever before, we are looking beyond the iron to the opportunities that we have to work together to make the mining industry better,” she said. “We have always worked hand-in hand with miners. And since the last MINExpo, those collaborations are bringing to bear some exciting new solutions that address the mining industry’s biggest challenges, like advancements in energy and electrification, innovative technology and autonomy offerings.”

Cat’s MINExpo Experience
The theme for the Cat MINExpo Experience was: Together, we’re mining better. “In the three years since the last MINExpo, we have made advancements in both our iron as well as the technology and the solutions we provide,” said Veronica Newhouse, vice president marketing and aftermarket sales, Caterpillar. “This is our opportunity to showcase how we collaborate with Cat dealers and our customers to create an exceptional experience to succeed together.”

The Cat exhibit had fewer machines at this MINExpo and a greater emphasis on technology and services. The exhibit had a maintenance bay, for example, which showcased aftermarket solutions. Specific areas addressed fleet management solutions and other customizable options to maximize uptime. They also had an area dedicated to repair and rebuild solutions, including Cat reman engines.

Caterpillar announced its Dynamic Energy Transfer (DET) system just before the show. The centerpiece of the exhibit was a 798AC haul truck equipped with retractable DET arm that reaches out to connect to set of electrified aluminum rails. The rails encircled the exhibit, which included a wheel loader, a large motor grader, two LHDs, a service bay and a rotary blasthole drill.

A Cat-developed system, the DET system can transfer energy to both diesel- electric and battery-electric haul trucks while they are working around a mine site. It can also charge a machine’s batteries while operating with increased speed on grade, improving operational efficiency and machine uptime. The rail system is a highly deployable, mobile solution that can be customized to specific mine site layouts, including high-speed and curved haul roads (See Operating Strategies, p. 52). The connecting arm can be installed on either side of a truck and on multiple truck models, providing options to fit customers’ specific operations. It can also be used on mature or developing sites, and it can be easily moved or expanded to allow maximum mine site coverage.

The 789AC has a 410-ton payload capacity. “The engineering focus for our team is on the cost per ton and how to deliver solutions for our customers,” said David Rea, vice president and general manager for Cat’s Rigid Frame Trucks. “Our trucks are built to be rebuilt. Rebuilding the components, rebuilding the frame, rebuilding the machine, whatever it may be. That’s a big part of our sustainability journey.” Most of that rebuilding activity is supported by Cat’s dealer network.

Cat performs full machine testing on the mechanical and electrical drivetrains for its trucks in Peoria and they can also do it virtually. “Our design centers in the U.S. and in India have a digital twin of the truck, which we can use to do a lot of the validation testing much more rapidly and more cost effectively as well,” Rea said.

Cat has designed the 794, 796 and 798 haul trucks on a modular platform. “It’s the most modular commonality that we have in the product line,” Rea said. “It really leverages what we learned from the 785, 789, and 793 haul trucks, which also had a lot of commonality. We took it to the next step with these models, which helps our end-to-end value chain, reducing the amount of complexity, reducing the number of parts, etc.”

“We are just approaching 500 trucks in this line that are operating in the field,” Rea said. “We now have more high altitude 798s in operation than 797s. And we have had high altitude 797s for more than 20 years. So, the market acceptance of that product has really been incredibly exciting for us.”

Autonomous hauling is an exciting part of the Cat portfolio, but the company also realizes the importance of haul truck operators and their comfort. “When it comes to operator efficiency, it all starts with the operator environment in the cab,” Rea said. “These next-gen cabs have a lot of modernization features. Some of these operators spend more time in that cab than they do anywhere else. We want to make sure that they’re comfortable and efficient. These trucks are equipped with operator assist functions. Other features provide operator feedback for coaching purposes.”

The controls and the communications systems on board the 789 AC have been updated with the latest technology, enabling better asset health and management. “We know how the machines are performing and the health of the components, and we provide warnings to the operator, the dispatcher and the maintenance team so that when the machine comes in for service, they have a list of repairs,” Rea said.

These trucks are built for the future, Rea explained. “With any new advancements that we bring forward, we make sure that there are both backward and forward compatible,” Rea said. “A mine operator may not be ready for autonomy today, but the machine is Command ready. They do not need to do a lot of disassembly or incur additional costs and downtime if they decide to move forward with those options.”

For the underground mine operators, Cat displayed the R1700 XE load-hauldump (LHD) loader with battery-electric propulsion. The company also showcased the R2900 XE LHD with a high-efficiency switch reluctance electric drive system along with a new battery, the PGS 1260 HD Energy Storage System module and the MEC500 for mobile equipment charging.

When he talks to customer, Mike Berry, vice president and general manager for Load and Haul at Cat said he repeatedly hears five things when it comes to product development. “They want help with increasing productivity, lowering operating costs, the shortage of labor, environmental/ sustainability issues, and safety, which is a top priority for all mine sites,” he said.

Berry believes the new LHDs check all the boxes. “Miners operating battery machines side-by-side with diesel machines are saying the battery machine can be as productive or more than the diesel machine,” Berry said. “As far as the charger, we are seeing more than 99% availability, which is really remarkable for something that’s that new to the field.

“When we started developing the R1700 XE in 2018, we put more than 3,400 hours at customer sites during our field follow programs. “What customers confirmed for us was the onboard battery system was the right approach,” he said. “The other thing they liked was the transmission replacement architecture and having the electrical components up off the ground. Some LHDs operate half submerged at times.”

The MEC500 charger was designed to be easy to commission and portable. The use of MEC500 started to give mine operators the insight into what they were going to need as far as supporting electrical infrastructure in an underground environment, Berry explained.

Cat now has more than 40,000 hours on the battery-powered machines in the field, including testing and charging. “Customers are achieving more than 90% availability with the R1700 XE,” Berry said. “We feel like it’s meeting our objectives, certainly from a learning standpoint and from a performance standpoint.”

Battery-electric equipment has the benefit of zero exhaust emissions needs. They also generate less heat and noise. “The operators tell us they can actually hear the tires slipping when they are mucking the face, and tire wear is a concern,” Berry said. The lack of diesel exhaust, dust and noise improves the working environment and reduces the ventilation costs.

Cat introduced the R2900 XE for miners who are not quite ready to make the battery-electric leap. “Customer acceptance has been very strong with the R2900 XE,” Berry said. “The machines that we’ve put into the field from last year to today have accumulated collectively more than 55,000 hours of operation. The R2900 XE allows mine operators to make the switch from diesel mechanical to diesel electric. It can reduce fuel consumption by 30%-35% depending on the application.”

“One of the primary reasons for the high customer acceptance on these machines is that the upper powertrain of the R2900 XE is 90% common with the 988 XE wheel loader,” Berry said. “The propulsion motor, the inverter, the generator, are all the same as the 988 XE. What that means for the mines is that the dealers know how to work on them, and they have the parts and inventory. So, we feel like we’ve hit a sweet spot with that machine.”

The future for underground mining revolves around getting the operators out of the underground environment all together. “The vision for the future is a barrierless system of equipment operating and, interacting with each other fully autonomously,” Berry said. “Today equipment operates autonomously inside barriered portions of the mine. We have a guide-assist for the R2900 XE, which keeps that machine off the wall. We have Autopilot for miners operating multiple machines from one station. The technology to operate the LHD from the full dig cycle to the dump point exists. The R1700 XE has the ability to detect and avoid collisions, which is one of the building blocks to achieving barrierless autonomous operations.”

Ultimately, Berry said he believes that zero emissions (or battery-electric) is the destination. “It’s not really a matter of ‘if,’ it’s a matter of ‘when,’” Berry said. “And as a manufacturer and an organization that designs the equipment, it’s our job to make the ‘when’ not matter.”

Cat also had an MD6310 rotary blasthole drill on the show floor. “Cat has redesigned its rotary drill product line from the MD6380 through to the MD6200, from the ground up with its design principles, and the Cat philosophy around electronics and simulators,” said Greg Heppler, senior vice president for the resource operations and products. “As an example, the drills previously had a lot of point-to-point wiring and that has been upgraded with adapters and connectors.”

Cat wanted to optimize the electronic architecture to integrate the drills with its autonomous operating solutions and it also helps as far as service on the dealer side. The entire MD product line has been optimized except the MD6640, which is a large electrically powered drill.

“We are seeing huge gains with autonomy, especially in the drilling space,” Heppler said. “We have now moved from drilling a row of holes to a pattern. Productivity is as much as four times greater than what we’ve seen under manual operation. That’s not only the location from geospatial positioning, but also the depth. It’s critical that the drills hit the exact depth or otherwise to minimize overbreak and underbreak with the blasts.

Matched power with the drilling product line was a big move forward for Cat from a performance perspective, Heppler explained. “We now have electronic compressor control that matches the motor with the power requirement,” he said. “Anytime you hear air blowing off on a drill, that is wasted energy. “We have been focused on uptime with the drills,” Heppler said. “The optimized electronic architecture gives us the ability to monitor the machine, develop algorithms, and perform predictive scenarios.”

Another important aspect of the Cat exhibit was the service bay, which displayed aftermarket solutions. It had undercarriage components, powertrain components, and hydraulic hoses and couplings. “We can’t provide that exceptional experience if we don’t have parts available when and where they are needed,” Newhouse said. “Whether it’s rebuilds, safety technology, individual components and parts, the reliability, the durability of the program depends on aftermarket.”

Technology plays a critical role for Cat in mining better, explained Sean McGinnis, vice president of technology and global sales support for Cat. “We are an industry leader in mining technology and autonomy, and we are continuing to invest in that space,” McGinnis said. “The key enabler to achieving a holistic solution is our building block approach. It could be fleet management, it could be our safety solutions, it could be our automation, but all of those combine to enable electrification and they’ll also help with our precision mining. So, site solutions are really a key part of how we’re going to unlock that next level of value proposition.”

Sandvik unveiled an advanced operator station with improved operational control, efficiency and
productivity.

The R2900 XE has Command for loading and Detect for safety. “We refer to our underground safety system as an active system, as it’s constantly pinging,” McGinnis said. “This allows you to be able to see around corners. Unless it can see the other machine, it won’t give you much warning.” “This MINExpo 2024 exhibit demonstrated what’s possible through collaboration with Caterpillar,” McGinnis said. “The results we have seen collaborating with customers is far more valuable than a typical transactional model.”

Sandvik Showcases Technology
Sandvik Mining and Rock Solutions introduced lithium iron phosphate (LFP) technology for its battery-electric underground drills at MINExpo 2024. Sandvik said the batteries are robust and purpose- built for harsh mining environments while retaining the same level of safety as Sandvik’s existing battery technology. “Sandvik has been the leader in battery- electric underground drilling since launching the industry’s first BEV — Sandvik DD422iE — in 2016,” said Marko Roivas, product line manager, underground drilling at Sandvik. “Now, we are introducing a significant development in underground drilling technology with this new LFP battery.”

During field testing at Agnico Eagle’s Kittilä mine in northern Finland, operators were able to tram 50% further and achieve 20% more speed in uphill tramming. The two onboard battery packs offered 36% more usable energy than the existing battery technology, and charging time was reduced by 55% during the testing period.

When paired with underground drills, Sandvik said miners will continue to enjoy the established benefits of battery-electric drilling, including zero-emission operations, Sandvik’s Charging While Drilling technology, off-grid drilling and bolting and reduced heat and noise generation. LFP battery technology will be available first on Sandvik DD422iE development drills, with testing underway for the DL422iE production drills and the DS412iE bolters. Sandvik expects to offer LFP batteries as standard from 2025. Sandvik will also introduce LFP battery retrofit kits for Sandvik BEV underground drill customers operating equipment with the current sodium-nickel batteries.

Sandvik also unveiled its most advanced operator station to demo the company’s latest AutoMine technologies. These concept desks mark a significant step forward in the evolution of operator stations, where automation and state-ofthe- art technology redefine operational control, efficiency and productivity. They showcase autonomous operation capabilities for underground mining, featuring the AutoMine Core platform for mass mining applications, and surface drilling operations with the AutoMine Surface for autonomous drilling product portfolio.

The AutoMine Concept Underground Operator Desk is an AutoMine Core simulator, capable of simultaneously managing up to four machines. This capacity, according to Sandvik, reflects the optimal number of machines an operator can effectively monitor and maintain in continuous operation. While the simulator is designed for this threshold, the AutoMine Fleet system can support up to 15 machines concurrently, with an expansion to 30 machines anticipated early next year.

“The AutoMine Core simulator is an enhanced adaptation of Sandvik’s established training simulator, which is extensively used by AutoMine Core customers at their sites and by Sandvik experts at our test mine facility in Finland,” said Jouni Koppanen, product line manager, automation at Sandvik. “While this technology demonstrator is not currently commercially available, Sandvik said it is committed to collaborating closely with customers through its NextGen program to develop customized solutions that meet their specific operational needs.”

The AutoMine NextGen program is a major advancement in autonomous mining, delivering solutions that significantly enhance operational flexibility, productivity and safety in self-navigating systems. It builds on more than 20 years of automation expertise, incorporating cutting-edge technologies to advance mining operations. This robust platform integrates seamlessly with modern mines, leveraging 3D sensing technologies such as LiDAR and IMU-enhanced SLAM for enhanced precision, mapping and route planning based on pre-recorded mine maps. By improving environmental awareness and optimizing performance, this technology significantly enhances efficiency in underground mining operations.

Sandvik also introduced the Sandvik DR411i rotary blasthole drill rig. The compact, mid-class drill delivers high productivity for both rotary and down-the-hole (DTH) production blast holes. The DR411i supports a hole diameter range of 170 mm to 270 mm and comes equipped with the full suite of Sandvik i-series technology, ensuring precise, clean blast holes.

“Sandvik DR411i maximizes power in an impressively compact design, helping drill-and-blast customers improve productivity and reduce cost in even the most challenging applications,” said Pat Murphy, president of rotary drilling at Sandvik. “As demand for our intelligent rotary blasthole drills continues to grow, this expansion of our range reinforces our customer-centric approach.”

Sandvik DR411i delivers an extended mast single-pass capacity of 55 feet (16.8 meters) with a total depth of 80 feet (24.4 meters) and 75,000-pound (34,020-kilogram) weight on bit. A traveling centralizer reduces pipe flex, producing cleaner, straighter holes. The rig is equipped with Sandvik’s Performance iDrill and Navigation iDrill onboard automation solutions that increase accuracy and productivity. The optional AutoMine solution extends these onboard features to enable line-ofsight or fully autonomous operation.

The Sandvik Intelligent Control System Architecture (SICA) provides the operator with real-time feedback regarding the machine’s performance, while the DRi platform ensures a consistent operating experience and improved control of rig functions across all i-series surface rotary drills. Sandvik DR411i reduces personnelto- machine contact while maximizing component life. Its maintenance-friendly design, along with compatibility for auto- pipe handling and auto-bit changing, reduces the time needed for both scheduled and unscheduled tasks, improving safety and ROI.

The new rig also supports customers’ sustainability needs. Intelligent system load management helps reduce carbon emissions and extend component life, improving operating costs. The compressor control system matches compressor volume to application, reducing fuel burn and resulting environmental impact while improving hole quality.

Sandvik Rock Processing Solutions displayed its eco-efficient rock processing solutions, designed to address the increasing demand for safe, efficient, reliable and cost-effective operations. These include the Sandvik 800i cone crusher series, featuring the new ACS-c 5 automation system, and its newly expanded range of vibrating screens and feeders equipped with the ACS-s condition monitoring system.

According to Sandvik Rock Processing Solutions President, Richard Harris, Sandvik leverages digitalization as a cornerstone of its innovation and cutting-edge technologies, which significantly enhance the efficiency and sustainability of crushing and screening operations.

“Not only is our latest equipment easier to operate, manage, maintain and service, but it also contributes to our industry’s desire to reduce its environmental impact,” Harris said. “Through our close partnerships with customers and our unwavering focus on innovation, we are shaping a future where rock processing is eco-efficient, productive and sustainable.”

Thanks to recent acquisitions, Sandvik now offers an expanded line-up of heavy-duty vibrating screens and feeders perfectly adapted to the world’s toughest mineral processing applications, with machines capable of up to 8,000 mt/h.

Komatsu Introduces First Power Agnostic Haul Truck
Komatsu used its MINExpo platform to launch its first commercialized truck in the new Power Agnostic series. The company said the Power Agnostic 930E haul truck represents a significant milestone in its decarbonization strategy, offering unparalleled flexibility for mining operations transitioning toward zero emissions. It accommodates a wide range of current and future power sources, including diesel, battery and even hydrogen fuel cells.

For the underground miners, Komatsu introduced the new Z3 series jumbo drills and bolters and the WX04B LHD.
(Photo: Komatsu)

“This truck represents a key component of our decarbonization strategy and will provide customers operational flexibility in reaching their sustainability goals when the opportunity is right for them,” said Dan Funcannon, senior vice president of Surface Haulage for Komatsu. This future-proofing capability empowers mining companies to make strategic investments in equipment that delivers strong diesel performance today and supports long-term sustainability by transitioning toward zero emissions. The truck embodies Komatsu’s commitment to delivering value and operational excellence while addressing the global demand for reduced emissions in the mining sector.

For the loading side of the business, Komatsu displayed the PC4000-11E hydraulic mining excavator. The electrically powered shovel merges the powerful digging force of high-performance diesel machines with the lower carbon footprint of an electrically powered machine. Built to endure the toughest mining operations, the PC4000-11E features robust components for exceptional durability and reliability in the harshest conditions.

Aligned with Komatsu’s sustainability focus, the electric drive is designed to reduce emissions by up to 95%. When combined with the Komatsu Trolley Truck Assist System, electrification of production can be significantly increased, promoting more sustainable mining operations. Benefits of electrically powered hydraulic mining excavators include reduced operating costs due to the elimination of diesel fuel with zero tail pipe emissions, resulting in up to 50% savings in the total cost of ownership compared to conventional Tier 4 diesel drives.

The fully automatic cable drum is designed for easier operation of the electrically driven excavator in backhoe configuration. The automatic winding of the cable makes maneuvering in the pit significantly easier and saves time. Simplified electric machine control enables fast troubleshooting and maintenance of the electrical system and contributes significantly to increasing the overall availability of the machine and helping our customers work toward achieving the highest safety standards.

“MINExpo is the perfect platform for us to connect with our global customers and those who aspire to join us. We see ourselves as partners to our customers, supporting and collaborating with them on their journey toward a more sustainable and efficient mining operation,” said Peter Buhles, vice president sales and service for Komatsu Germany GmbH – Mining Division. “We are looking forward to meeting everyone in person at our booth and showcasing our latest technical solutions for hydraulic mining excavators.”

For the underground miners, Komatsu introduced the new Z3 series of medium-size class development jumbo drills and bolters to its lineup, further broadening Komatsu’s selection of offerings for the underground mining industry. The Z3 machines are built on a universal platform and designed with a focus on modularity and efficiency. This focus offers improved productivity that can help reduce service and maintenance costs across operations. The Z3 also boasts universal operator controls, simplifying user adoption and increasing training efficiency. The new series expands Komatsu’s current underground hard rock offerings by adding the ZJ32 and ZB31 medium-size class drill and bolter.

Key features include innovative technology, such as a newly designed ground support installation system developed in collaboration with JENNMAR that utilizes their J-LOK P pumpable resin. In addition, the machines’ drilling attachments have limited moving mechanical parts and offer a simple design for smooth operability, resulting in reduced cycle times and increased drifter uptime compared to competitors in the same size class. “Our Z3 product line was designed to meet the evolving demands of our underground hard rock mining customers,” said Johan Kempe, product director, underground drills for Komatsu. “The common platform on which both machines are built enables the interchangeability of parts and service, boosting operational productivity for customer operations.”

Komatsu also rolled out its first battery-electric powered LHD, the WX04B, designed specifically for underground hard rock mining operations. Komatsu will pair this innovative LHD with its new OEM-agnostic 150kW battery charger, a robust charging solution built for the demands of hard rock mining. Together, they mark a significant milestone in Komatsu’s commitment to enhancing productivity and sustainability in underground operations.

The WX04B represents a new era in battery-electric mining equipment. Designed for narrow vein mines, this 4-tonne LHD features industry-leading battery technology with best-in-class energy density, offering up to four hours of run time on a single charge. As a result, fewer charge cycles are needed compared to competitors, maximizing operational efficiency and minimizing downtime.

Built to endure extreme-duty environments, the WX04B’s advanced design focuses on zero-harm, reliability and durability. The industry proven reinforced boom and optimized Z-link geometry, alongside Komatsu’s ROPS/FOPS-certified operator cab, increase safety and enable a productive experience. The optional fully enclosed cab with environmental controls enhances operator comfort and safety. At the same time, interlocks automatically engage brakes and turn off all functions when the cab door is open or the seatbelt is disengaged, prioritizing worker protection.

One of the standout features of the WX04B is its innovative battery swap system. Unlike many traditional systems that require extensive underground infrastructure, the WX04B’s battery swap can be performed at ground level without additional equipment or risks of rigging overhead loads. This streamlined process reduces costs and complexity, making it a more efficient and user-friendly option for underground mining operations.

“Komatsu’s WX04B delivers a powerful combination of productivity, increased safety and sustainability,” said Tyler Vien, product manager, LHD and trucks at Komatsu. “By offering ground-level battery changes and eliminating diesel emissions, we’re providing our customers with a comprehensive solution that addresses the unique challenges faced in underground mines.”

Complementing the WX04B, Komatsu’s vehicle-agnostic 150kW battery charger has been engineered specifically for underground hard rock mining. Leveraging years of experience in industrial mineral applications, the charger is designed for extreme conditions and high performance. The compact, rugged design allows the charger to be easily moved and deployed, even in the most challenging underground environments.

Key features include power efficiency, broad compatibility with mining power sources (400 VAC to 1,000 VAC) and no need for an external transformer. This design minimizes infrastructure requirements, offering mining operations greater flexibility without the need for a dedicated charging station. Additionally, the battery recharges in approximately two hours, which promotes battery health and is less than the operating time of a full charge, allowing for better scheduling and reduced downtime.

This integrated approach highlights Komatsu’s dedication to providing a complete, scalable solution for underground mining. The combination of the WX04B and the 150-kW charger addresses the demand for zero-emissions equipment while maintaining high productivity, allowing customers to meet the evolving needs of the underground hard rock market.

Komatsu announced the expansion of its hard rock crushing equipment portfolio with the introduction of the HRX800 sizer, an innovative solution designed to enhance efficiency and productivity while reducing waste. This product line extension underscores Komatsu’s commitment to providing customers with robust, high-performing machines that drive production growth and add value to their mining operations. Komatsu’s comprehensive crushing lineup includes feeder breakers, reclaim feeders, mobile crushers and sizers, all engineered to meet the demanding needs of modern mining operations.

The HRX800, launching at MINExpo 2024, represents the next step in Komatsu’s evolution of crushing technology. Designed for hard rock applications, the HRX800 is a smaller-scale alternative to the HRX1000, providing the same high capacity and efficiency in a more compact form. This sizer is ideal for both underground and surface installations, offering the benefits of fines reduction in demanding applications of hard abrasive minerals or wet and sticky material.

“We are excited to introduce the HRX800 to our customers,” said Brandon Phillips, global product manager for sizers and feederbreakers for Komatsu. “The HRX800 is designed to push the envelope on where sizers can be successfully applied, delivering the power and performance our customers expect from Komatsu while offering the flexibility needed in today’s dynamic mining environments.”

The HRX1000, a standout in Komatsu’s crushing lineup, will be on display at the upcoming MINExpo 2024 in Las Vegas. This primary crusher is designed to accept run-of-mine materials and crush them to a size suitable for conveyor transport, making it a crucial component in mining operations that demand high production capacity. The HRX1000’s innovative pick technology efficiently breaks down minerals in tension, reducing the need for multiple crushers and lowering operating costs. Its versatility makes it an invaluable asset in a wide range of mining applications.

ASI is Now LinkOA
Epiroc unveiled a new name for its line of surface mining autonomy solutions. This move follows the acquisition earlier in the year of ASI Mining, which is best known for its Mobius autonomous mining system.

As part of the rebranding, Mobius, has been renamed LinkOA – short for ‘open autonomy’. Epiroc said that, as an OEM-agnostic solution, LinkOA empowers mining operations to seamlessly integrate fleets of various makes and models, ensuring interoperability across all mining systems.

“Under Epiroc’s leadership, LinkOA will now be expanded to support a broader range of surface mining applications,” the company said. “The flagship products of LinkOA include the autonomous haulage system (LinkOA for Haulage) and autonomous drills (LinkOA for Drills).

“LinkOA marks a new era of open autonomy as Epiroc continues to lead the transformation of the mining industry by delivering flexible, future-proof automation solutions that enhance safety, productivity, and scalability.”

Fortescue and Liebherr Sign Historic Green Partnership
Liebherr and Australian iron-ore miner, Fortescue, announced an expansion of their partnership and unveiled a jointly developed autonomous battery-electric T 264 truck. Dr Andrew Forrest and Dr Willi Liebherr attended the event to seal the historic deal.

The two companies plan to further develop and validate a range of zero emission mining solutions, which will result in the supply of 475 new Liebherr machines (approximately 360 autonomous battery- electric trucks, 55 electric excavators and 60 battery-powered dozers) featuring Fortescue’s green technology to Fortescue’s operations in Western Australia. This represents about two thirds of the current mining fleet at Fortescue’s operations. Liebherr and Fortescue are committed to having a comprehensive and large scale zero emission mining ecosystem operational by 2030.

Liebherr and Fortescue expanded their partnership and unveiled a jointly developed autonomous
battery-electric T 264. (Photo: Carly Leonida)

Dr. Jörg Lukowski, executive vice president, sales and marketing, Liebherr-Mining Equipment SAS, said: “We are proud to have facilitated the single largest equipment deal in the entire 75-year history of the Liebherr Group. Especially as the expansion of our collaboration with Fortescue is an important step forward in our shared goal to decarbonize mining activities worldwide. The technology developed as part of this record-breaking deal will not only support our customers along their decarbonization journeys but also help us honor our commitment to offer completely fossil fuel free hauling, loading and dozing solutions by the end of the decade. In fact, in the coming years, Liebherr and Fortescue Zero will be able to offer more customers within the industry a proven, large scale zero emission mining ecosystem.”

Dr. Forrest added: “Partnerships with companies and people like Liebherr and Willi Liebherr — where ambition is backed by action — are critical. This is an important next step in our 2030 Real Zero target — to eliminate emissions from our Australian iron ore operations by the end of the decade. The world needs Real Zero now — it simply cannot afford to wait. The green solutions we need are here today, and Fortescue Zero is supplying them and rolling them out across our massive mining operations. Fortescue Zero developed this battery technology and jointly developed the Automated Haulage Solution, leading the way to provide green innovative solutions to eliminate emissions from heavy industry. We invite all companies in the mining, heavy industry and haulage sectors to join us. The solutions are there, and the missing ingredient is leadership. The time of others persuading you that greenwashing is a better return to shareholders and your community is over. Fortescue invites you to join us. We can together be the trailblazers who forge the world’s move away from fossil fuels.’

Liebherr and Fortescue have been working in partnership since 2022; their initial cooperation covered the supply of 120 zero emission haul trucks. The new expanded fleet announced on September 25th will ultimately be equipped with a zero-emission battery power system developed by Fortescue Zero and the jointly developed Autonomous Haulage Solution (AHS) – both of which were built to be scalable so they can be retrofitted onto existing Liebherr haul trucks. This means that trucks purchased today are already futureproofed for tomorrow.

The AHS, which was co-developed using both companies’ expertise, also includes an Energy Management System that coordinates the static recharge assignments for the trucks and ensures the charger is fully utilized without causing queuing on site.

“We wanted to design and build an intelligent, state-of-the-art AHS that not only includes the know-how from both an OEM and a mining operator generated over the last few years but will also be able to integrate with new zero emission solutions in the future,” said Oliver Weiss, executive vice president, R&D, engineering and production, Liebherr-Mining Equipment SAS. “Therefore, control and command of zero emission mining technologies were included in the AHS from the outset. The fleet management assignment engine at the core of the AHS monitors fleet energy levels so that jobs and energy replenishment tasks can be assigned efficiently within zero emission fleets equipped with this system.”

Fortescue has developed a stationary fast charging solution to support the autonomous battery-electric truck. Equipped with robotic connection options, the charger can provide up to 6 MW of power and charge the current battery- electric T 264 in 30 minutes.

“We have an enormous amount of expertise in autonomous haulage and have used that expertise to play a leading role in the development of this system,” explained Dino Otranto, chief executive officer, Fortescue Metals. “We have more than 200 autonomous trucks across our mine sites, travelling the equivalent of two trips to the moon and back each month. It is imperative that they operate efficiently and at maximum capacity. We have used our strong track record of being a first mover in autonomy and our technological know-how to derisk zero emission fleets to enable the industry to break free from the pilots and prototypes. The fully integrated AHS will be a game changer for us in reducing our carbon emissions.”

The T 264 battery-electric truck will commence onsite validation at the end of 2025. The approximately 360-strong T 264 truck fleet has already begun arriving to Fortescue’s Western Australian operations, with the first trucks delivered to Fortescue’s Eliwana mine in October 2023. The initial 240-metric-ton capacity trucks will be converted to zero emission powertrains before 2030. However, most of the fleet will be supplied in battery-electric configuration from first arrival.

Four autonomous trucks are currently in validation at Fortescue’s testing site, with the first deployment of operational autonomous trucks expected in Q1 2025. All T 264 trucks are arriving autonomy- ready and will be progressively deployed to autonomous operations across Fortescue’s sites. Validation of the full autonomous battery- electric solution is expected to be complete in early 2026.

The companies also announced that they will collaborate to jointly develop a zero-emission dozer. Fortescue’s battery power system will be integrated into an electric version of the Liebherr’s flagship mining dozer, the PR 776, which is currently in development. Once developed, Liebherr will supply Fortescue with 60 units of this zero-emission dozing solution to meet Fortescue’s Real Zero targets.

This historic deal also includes the supply of 55 R 9400 E electric excavators. This fleet will be a mix of backhoe and face shovel configurations. Fortescue first adopted Liebherr’s electric excavator technology in 2023, with the commissioning of Australia’s first operational electric excavator in December of that year. Three R 9400 E excavators are already operational across Fortescue’s sites. Fortescue is also boosting its capacity to supply the hundreds of batteries required for these machines — both trucks and dozers.

“The T 264 battery-electric truck, powered by a Fortescue Zero battery power system, will be one of the first zero emission solutions for mine haulage in operation globally,” Otranto said. “It combines Fortescue Zero’s heritage of innovation, delivering a battery power system designed for best-in-class range and durability in all mining environments, with Liebherr’s proven haul truck excellence. The zero-emission battery power system developed by Fortescue Zero also reflects Fortescue’s continued evolution into a leading technology company that is selling its innovative solutions to the world.”

All 475 machines of this deal will become part of Fortescue’s iron ore hub in the Pilbara region of Western Australia. As such, Liebherr-Australia — Liebherr’s sales and service company in the country — has already begun its preparations for supporting this enormous fleet.

New High-capacity EM Feeder
Eriez showcased the largest available of the four new B-HC electromagnetic heavy-duty vibratory feeders. An expert with the company said the availability of a bigger model is imminent. “The biggest of the units, the 120, will be released at the end of this year,” said Rob Yandrick, global vibratory product manager. “In the early part of next year we’ll be shipping them out.”

Ideal for head-load applications below a hopper, the new B-series feeders offer the widest capacity range in the industry, and can deliver up to 1,089 mt of material per hour, Eriez said. They easily handle more throughput than do competitor solutions, Yandrick said. “Compared to other similar technologies in the marketplace, some of them we are doubling those capacities, and others, even the top-level performers in the industry, we are 25% beyond those capacities as well.”

The feeders employ an “electromagnetic drive that features an exceptionally strong rare earth permanent magnetic armature assembly,” Eriez said. “This system applies power in both the forward and reverse directions of the feeder tray, ensuring precise linearity and control compared to traditional attract-release systems.” The electromagnet and permanent magnet apply opposing forces to the feed, giving optimal control, Yandrick said. “We attract it from one end and we repel it from the other, so we are always in complete control of the feeder tray.”

Electromagnetic feeders are renowned for their excellent controllability, he said. “You can stop them and start them in seconds if you need to. You can just adjust them from zero to 100% of your feed rates and anywhere in between.” An accelerometer monitors the vibrations to instantly detect buildup and direct the flow away from it. “It will keep the feeder running right on track,” Yandrick said. “It eliminates problems. It keeps capacity where you want it to be.” The design has no sliding or rotating parts, and it reduces power consumption and maintenance requirements, Eriez said.

Since magnetism is the primary acting principle, “there are no motors. There is no rotation. There are no bearings, no lubrications,” Yandrick said. That translates to “very low-maintenance, high-performance machines.” It also translates to more production in the same or a smaller footprint, offering energy savings. “They take up less space, which gives room to work around them and makes installation easier,” he said. The feeder can be retrofitted into “an existing installation and immediately and significantly increase capacity in the same envelope size.” In the same footprint, tonnage can increase “from 70% to 100%; so, much greater capability.”

The new models were developed in response to customer needs for higher throughput, he said. “We were getting asked to create machines that could deliver higher tonnages,” he said. “We’ve now far exceeded what was available on the market.”

Hitachi Zeros in on the Future
Hitachi Construction Machinery said it was zeroing in on the future with innovative technology on display at MINExpo. Forging a path toward zero emissions, zero downtime and zero-entry mines, Hitachi believes can reduce fuel consumption and interruptions for a lower cost per ton while enhancing safety by removing employees from mining operation danger zones.

The Hitachi EH4000AC-5 has a 242-ton payload, and several operating
modes to maximize power and fuel ef?ciency. (Photo: Steve Fiscor)

The company also showcased its automated haulage system (AHS), which combines advanced digital technologies and Wenco International Mining System’s fleet management system. The use of Hitachi AHS allows mixed fleet integration with manned fleets while transitioning from conventional to autonomous operations, open interoperability to optimize the entire truck fleet and the ability to retrofit existing trucks. Hitachi owns Wenco, and it recently acquired a stake in Envirosuite, an environmental intelligence company, to provide real-time data to enable responsible mining practices.

Hitachi also said it is developing a system for semi-autonomous and remote operation of ultra-large hydraulic excavators. Key features of this system are the digging assist function to support the excavation of ore, and the loading assist function to support an optimized loading cycle. Once complete, this system aims to improve operational performance, and mine sites will benefit from reduced operator burden and increased productivity.

AspenTech Addresses Maintenance Challenges
Aspen Technology featured new functionalities for Aspen Mtell, a prescriptive maintenance solution. Mtell addresses maintenance challenges within metals and mining better than ever with new asset templates that are designed specifically with mining equipment used in the Load and Haul, Comminution, Mineral Processing and Smelting processes of the mining value chain. These new asset templates will accelerate the development, implementation, and scaling of agents monitoring these pieces of equipment, deliver multiple ready-to-use asset templates for setting up agents with built in key performance indicators (KPIs) to monitor asset health, and leverage the built-in domain expertise on mining specific plant and machinery that Mtell services and supports.

FLSmidth is Now FLS
FLSmidth leadership said the company is changing its name to FLS and its identity to a pure-play mining business. “This is a really important milestone for us as we are in the process of shifting and migrating from a 140-year-old company with its roots in the cement industry that migrated into mining to today predominantly a mining business,” said Joshua Meyer, service business line president.

“FLSmidth is a mouthful. It is a very difficult name for many people to pronounce. There are a million variations of it. And many people simplified it to FLS. We said, let’s embrace it,” he said. “It also helps create a separation and a unique, new, refreshed identity around our mining presence and our focus as a pure-play mining company.”

The company is changing the brand image to one that combines a growth curve and a precision flow. “It is to highlight the precision of the highly engineered, highly sophisticated nature of the business,” Meyer said. Currently, the company is maintaining both FLSmidth.com and the new FLS.com.

FLS also announced the Oct. 29 opening of a new service center in Tucson, Arizona. “We have a large manufacturing facility in Tucson. I am stealing some space from them right now to operate,” said Todd Rooney, head of professional services, North America. “But we are building a fit-for-purpose, world-class facility in Tucson to handle the rebuild or exchange programs there.” The facility will be the third service center in the U.S. FLS service centers support field service groups that go “to sites and do advisory inspections and audits on our equipment,” Rooney said. “The idea is to try to reduce our client’s downtime and really understand our equipment better.”

Service centers enable the supplier to “get as close to our clients as possible,” Rooney said. Whereas the manufacturing centers are large, “our service centers are smaller and much more intimate,” he said. “We are teaming up with our clients to bring product back into our shops, do a teardown, and then rebuild them, usually at a fraction of the cost of a new product.”

The service centers also support the company’s exchange program. “We partner with them so we really understand their usage,” Rooney said. “When they bring their product in, we already have one ready to go on the truck for them,” he said. “We send that to them. It minimizes their downtime and lead times overall.”

The exchange program works “well for our customers if they have resource issues, but also, just from a planning perspective, in managing their inventory better,” Rooney said. “They are bringing product out and putting product in much quicker with these programs than they ever have before.”

Also, FLS announced a mill liner recycling solution. “We are going to be putting that system into North America in 2025,” said Todd Moir, global director, milling consumables. The solution answers the enduring challenge of what to do with the company’s top-shelf composite liners. “How do you separate rubber from metal instead of it going to the landfill?” Moir said.

“We’ve developed a system that is very environmentally friendly,” he said. “Our first system will be installed in Chile later this year.” FLS showcased its composite liners. “Some of the advantages of this type of product are that you get wear life, the durability of metal, but you have a much lighter product that is considerably safer to install,” Moir said. “This is one of the premium products we are producing now.”

Compact Battery-electric Loader
Aramine showcased the L140B, a battery-powered loader with roughly 1.5-metric ton (mt) capacity. Leadership at the company said the unit caps a long evolutionary process driven by customer sustainability needs.

“We now have more than 50 machines in operation,” said Marc Melkonian, managing director. “We have passed 200,000 operating hours underground in very tough mines, in very high altitude mines,” he said. “We know our solution is really proven for all the mines.” The design is available in two models. The bigger L440B “has a near-5-mt capacity but with exactly the same technology,” Melkonian said.

The rear segment of the above L440B loader is the detachable energy module, which can be replaced in 10 minutes,
Aramine said at MINExpo. (Image: Aramine)

On the L140B, the module can be replaced in 10 minutes using a 1-mt crane. The bigger model uses a 5-mt crane. The quick replacement system allows the loader to run almost continuously. A module can be charging while the machine is in operation, and installed during a 10-minute break. The module is compact, small enough to have no bearing on the machine’s center of gravity, Melkonian said. It has two plugs for the two integrated battery packs. “The reason for that is if there is a failure on one battery pack, on the charger, on the electric components, then the machine continues running on the other pack,” he said. “It doesn’t stop the operation of the mine.”

The clean-sheet design all but eliminated the need for brakes. “We have designed the system in a way that we can use the electric motor to stop the machine,” Melkonian said. “Fully charged, on a ramp, the machine does not need a brake pedal.” While the loaders do feature a brake pedal, “it is not necessary,” he said. Its redundancy means the brakes could last the life of the machine. “That is a big, big change.”

Both models come ready to adopt Industry 4.0 solutions. “All these machines are electronic and collect all of the information on the battery, the wheels, driveline, and hydraulic system,” Melkonian said. “All the data can be collected and analyzed to anticipate any possible failure of the components,” he said. “With the correct maintenance, there is no breakdown.”

Neither models have a transmission. “These machines are fully electric,” he said. “They have an electric motor for locomotion and an electric motor for driving the hydraulic system.” Thus far the units in the field have undermined the myth that battery electric loaders are burdensome compared to diesel competitors, Melkonian said. “When we provide a battery machine to a mine, they realize how simple it is compared to a diesel machine,” he said. “Bringing the fuel underground, for example.”

The success of the units in the field have also positioned Aramine for growth, said Christophe Melkonian, president. “We tend to be the best offer on the market for this small segmentation.”

Weir Displays Its Breadth of Solutions
Weir unveiled a range of new innovative technologies and solutions for mining and mineral processing. The company officially launched the ESCO NEXSYS GET Lip System for rope shovel dippers. It also showcased an new high-capacity ENDURON ELITE screen. The stand also featured a Digital Hub, which highlighted the company’s digital offering — MOTION METRICS and Weir’s new digital brand, NEXT Intelligent Solutions.

“We’ve been doing a lot of work to expand our portfolio of innovative, end-toend solutions to help our customers produce the metals and minerals required to transition to a low carbon economy and it’s exciting to be able to show that off at the world’s largest mining show,” said Jon Stanton, CEO, Weir. “It is clear the world needs more metals and minerals but there is a recognition in the industry that we need to mine them more sustainably than we have in the past. That means using less energy, using water wisely and generating less waste. And Weir — with our world-class engineering, advanced materials science and intelligent automation — is at the forefront of helping miners do that.”

Kevin Stangeland discuss the changes to tooth
geometry on the ESCO Nexsys system.
(Photo: Steve Fiscor)

“We were able to optimize the geometry to take the loads that come into the system very cleanly, which eliminates the wear,” he said. “The new geometry also offers a tight cast fit with the leading edge of the lip. Those factors combine to extend the life on the lip. In our first trial, which ran about 15 months, we pulled the system apart and found we only needed a couple of weld touchups. Typically, the mine would see about 25 hours of welding repair required after one campaign per position. And in our field trials we saw about three hours.”

Weir said the NEXT Intelligent Solutions extend and expand its current capabilities and transforms its process optimization services into real-time digital solutions. Weir has developed digital packages for much of its equipment, including pumps, cyclones, HPGRs, and screens.

“Using real time data, AI driven analytics and the latest technologies, we are delivering a solution that provides insights and recommendations for the customers so they can optimize the efficiency and operation of the machines and processes,” said King Becerra, Director Digital Product Strategy at Weir Minerals. “These digital solutions help the mining industry work smarter, more efficiently and more sustainably.”

The ENDURON ELITE screen is a high-capacity, double-deck banana screen, available in a range of sizes, the largest of which has a deck measuring 4.3- x 8.5-m and weighs nearly 50 metric tons. “This is the first machine of this size that has been driven by only two exciters,” said Corné Kleyn, global product manager - vibrating screens for Weir Minerals. “A screen building on a mine would have eight to 12 screening machines, which means 24 exciters versus 36. That’s a 33% reduction in inventory management and maintenance activities.

“This will also form an integral part of Weir’s commitment to transform flowsheets by replacing tumbling mills with high pressure grinding rolls, HPGRs, and vertical stirred mills, potentially reducing energy consumption by up to 40%,” Kleyn said. The new MOTION METRICS Shovel- Metrics Gen 3 Payload monitoring solution is designed to optimise truck loading and improve haulage efficiency by reducing both underloading and overloading. For mines operating in remote locations, the system now supports connectivity via Starlink, enabling reliable data transmission anywhere in the world.

Metso Showcases Planet Positive Technologies
Metso showcased its sustainable technologies and pit-to-port aftermarket solutions. “We have selected ‘Empowering a responsible energy transition’ as our theme at MINExpo,” explained Giuseppe Campanelli, president, North and Central America at Metso. “For Metso, this means taking an integrated approach and driving a more responsible business ecosystem.”

Among the solutions highlighted was the new FloatForce+ mixing mechanism. This is a plug-and-play solution that Metso said maximizes metallurgical recovery, boosts pumping efficiency, and reduces energy consumption, helping customers recover valuable materials and increase revenue.

Originally launched in 2006, FloatForce has set a standard for efficient flotation mixing mechanisms in the mining industry, but Metso said recent R&D breakthroughs have unveiled new ways to further enhance performance and sustainability.

Christian Cardoso, product, manager, mechanical flotation services at Metso, said: “The FloatForce+ is designed for seamless plug-and-play installation with existing FloatForce configurations. It’s also compatible with other mixing mechanisms, needing only minimal modifications for integration.”

Metso is also expanding the availability of its mill liner recycling service to the North American market. This is facilitated by an innovative technology that enables safe and efficient separation of different rubber and metal liner components, like cast inserts, wear plates, and backing plates. Composite liners, like Megaliner and Poly-Met liners, can be processed using this solution. Metso also has an existing recycling process for metallic mill liners.