Mining

Two record breaking diamonds were recovered by Lucara Diamond Corp. just weeks apart. (Image Source: TOMRA) 

TOMRA X-Ray Transmission (XRT) technology at the Karowe Mine in Botswana has played a vital role in the recovery of two record-breaking diamonds

The 2,492-carat stone that was recovered by Lucara Diamond Corp. in late August is one of the largest rough diamonds in recorded history and the largest one ever recovered directly from run-of-mine ore. Then, just a few weeks later, it was followed by a 1,094-carat diamond – representing the sixth rough diamond weighing more than 1,000 carats recovered at the mine. These achievements are, in part, a testament to the transformative capabilities of TOMRA’s technology, which has been present at the mine since 2017.

“TOMRA’s XRT technology has transformed diamond recovery, achieving unprecedented results and breaking records,” remarked Corné de Jager, diamond segment manager TOMRA Mining. “Fifteen of the top 23 largest diamonds, bigger than 400 carats, recovered since TOMRA XRT bulk concentration installations commenced fully in the diamond industry in 2014, were recovered with our technology – thirteen of them at Lucara’s Karowe Mine, which holds record-breaking finds in various categories. In fact, our TOMRA XRT technology has contributed to the recovery of 7 of the top 10 largest diamonds in history at the Karowe Mine.”

Complete diamond recovery

TOMRA’s innovative high-capacity XRT technology is capable of extremely precise detection and ejection of exceptionally large and even smaller particle sizes. Proprietary image processing deliver 100% detection in the specified size range irrespective of luminescence or surface coating, with a guaranteed diamond recovery rate above 98% and remarkably low yields. In addition, the unique TOMRA COM XRT 300 / FR final recovery sorter featuring TOMRA’s proprietary ultra-high resolution sensor technology and precise ejection has revolutionised final recovery processing to efficiently deliver an ultra-high diamond-by-weight concentrate, thereby contributing to improved & focused downstream security and reduced hand sorting.

TOMRA is the only manufacturer to offer a full recovery service from 2 mm to 100 mm with a flowsheet covering the entire process – from high-capacity Concentration (+4-100mm) to Final Recovery and Sort House applications (+2-32mm), which includes a detailed analysis of customers’ requirements and the collaborative development of an XRT technology-based flowsheet.

Earlier this year, African Review spoke to Albert du Preez, head of TOMRA Mining, to understand why the company’s new AI-powered OBTAIN software heralds a new dawn in sensor-based sorting for mining operations.

The expansion unlocks the potential to transform the Lumwana mine into a long-life, high yielding, Top 25 copper producer and a Tier One copper mine, capable of contending with the volatility of the copper demand cycles. (Image source: Barrick)

Barrick’s ambitious expansion of the Lumwana mine in Zambia is moving swiftly, with the feasibility study set to be completed by the end of the year, paving the way for construction to begin in 2025

Speaking during a webinar focused on the Lumwana Super Pit Expansion Project, Barrick president and CEO Mark Bristow said the expansion, "Unlocks the potential to transform the Lumwana mine into a long-life, high yielding, Top 25 copper producer and a Tier One copper mine, capable of contending with the volatility of the copper demand cycles."

This expansion will first double throughput by twinning the existing process circuit and then significantly increasing mining volumes. Throughput will rise from the current 27Mt to 52Mt, effectively doubling the mine’s annual copper output from 120kt to an average of 240kt. Mining volumes will ramp up year-on-year, starting at 150Mt in 2024, reaching approximately 240Mt in 2028, and eventually hitting 290Mt per annum by 2030.

CEO for Africa and Middle East Sebastiaan Bock added, “The phased ramp-up will enable a competitive cost profile over the life of the mine and annual operating cash flow and free cash flow are projected to improve by as much as 85% and 60%, respectively, based on the long-term copper price consensus. These production and cost improvements will contribute to an estimated incremental net present value (NPV8) of US$1.7bn.”

At a long-term average copper price of US$4.13/lb, Barrick forecasts an incremental internal rate of return (IRR) of 20%, with a total mine IRR exceeding 50%. The project is expected to pay back its initial expansion capital within two years of completion. Following the expansion, cost of sales and C1 cash costs are projected to fall to US$2.36/lb and US$1.85/lb, respectively, placing Lumwana in the first quartile of the industry, excluding the benefit of any byproducts.

According to mineral resource management and evaluation executive Simon Bottoms, "The process plant engineering has matured to a point that has allowed Barrick to select major equipment vendors and place orders for long lead equipment, including both mills and crushers. We are starting detailed engineering works this quarter and expanding our onsite accommodation while building partnerships with key suppliers and contractors ahead of the pre-construction ground preparation works, which are scheduled to start next year."

Commissioning of the new process plant is anticipated to begin in the second half of 2027. Once the new circuit is online, the existing one will undergo planned shutdowns for upgrades, ensuring steady copper production throughout the expansion.

The permitting process is well advanced, with the Environmental and Social Impact Assessment already submitted to Zambian authorities. Approval is expected by the end of the year. Barrick’s vision for Lumwana is clear: an even greater copper powerhouse is on the horizon.

Caterpillar's Cat DET revolutionises mining energy management with groundbreaking tech for efficiency and sustainability. (Image source: Caterpillar)

Caterpillar Inc. has introduced an innovative OEM-designed solution to address one of the mining industry’s most challenging aspects of the energy transition: energy management

The Cat Dynamic Energy Transfer (DET) system is entirely developed by Caterpillar and can transfer energy to both diesel-electric and battery-electric large mining trucks while they operate on a mine site. Additionally, it can charge a machine’s batteries while operating with increased speed on grade, enhancing operational efficiency and machine uptime. The Cat DET system offers the industry options to support both near-term and long-term sustainability strategies.

Denise Johnson, Caterpillar’s resource industries group president, stated, “We believe Cat DET provides a technological leap for the mining industry. Our team of innovators designed this system to provide immediate benefit to miners who want to lower their operating costs and greenhouse gas emissions today while also creating flexibility for the future. We know customers need choices to fit their unique site objectives. We are proud to deliver an innovative, integrated solution that can support their needs of today and those of the future.”

Flexibility through innovative design

The Cat DET system consists of a series of integrated elements, including a power module that converts energy from a mine site’s power source, an electrified rail system to transmit the energy, and a machine system to transfer the energy to the truck’s powertrain.

The rail system is a highly deployable, mobile solution that can be customised to fit customers’ specific site layouts, including high-speed and curved haul roads, which boosts productivity. The connecting arm can be mounted on either side of a truck and on various truck models, offering flexibility to meet customers’ specific operations. It can be used on both mature and developing sites and is easily movable or expandable to maximise mine site coverage.

Cat DET will integrate with the Cat MineStar Command for hauling solution, combining autonomy and electrification technologies to provide a comprehensive site solution.

Marc Cameron, Caterpillar senior vice-president, explained, “We believe mine sites will benefit from enhanced efficiency with the integration of electrification and automation. When combined, these technologies will help miners achieve production targets while simultaneously managing energy demands.”

The SmartROC D65 BE is powered by a battery that drives the tramming motors and is connected via an electric cable to supply power for drilling. (Image source: Epiroc)

Epiroc has planned to debut the first-ever Down-The-Hole SmartROC D65 battery-electric drill rig at the MINExpo exhibition in Las Vegas, 24-26 September

This groundbreaking surface drill rig is a significant step towards a green transition and zero-emission drilling in surface mines.

“We are very excited to showcase this rig at this year´s MINExpo. The SmartROC D65 BE is a milestone for us and for surface drilling around the world. The fact that we are removing tailpipe emissions from the drilling process is an important step towards a better environment. This accomplishment also shows that Epiroc has a vital role to play in making our industry more sustainable,”remarked Martin Johansson, acting vice-president marketing, Epiroc Surface Division.

Green mining innovation

The SmartROC D65 BE demonstrator builds on the proven SmartROC D65 surface drill rig. Leveraging Epiroc’s experience from developing underground battery rigs, this new model is designed to improve environmental standards in mining and large quarry sites. Along with its low emissions, it offers the same range of smart features, and delivers high safety, reliability, and performance in a quieter working environment.

“We have seen a demand in the mining business for greener solutions—and with SmartROC D65 BE we meet those demands,” commented Mattias Hjerpe, global product manager, Epiroc Surface Division.

The leading service provider, Capital Limited, has been a close partner during the testing phase. Following the exhibition, the SmartROC D65 BE demonstrator will proceed directly to Capital Limited for field trials. Capital Limited highlights that the SmartROC D65 BE will be a key asset in their journey towards reducing emissions and decarbonisation.

“We are excited to be partnering with Epiroc to field test this innovative electric drill rig technology that will help drive our industry towards more sustainable operations. To be at the forefront of the transformation towards emissions-free surface drilling supports our company’s overarching commitment to decarbonisation, as well as providing value for our customers,”stated Peter Stokes, CEO, Capital Limited.

The SmartROC D65 BE is powered by a battery that drives the tramming motors and is connected via an electric cable to supply power for drilling.

The SmartROC D65 BE is crucial to Epiroc’s sustainability goals for 2030. Epiroc’s battery-electric solutions are generating strong market interest, offering benefits such as emissions-free operations, reduced noise pollution and vibration, and increased productivity. This rig is vital to Epiroc’s ambitious 2030 sustainability goals, which include halving CO2 emissions in operations and from sold products compared to 2019 levels. In 2021, these goals were validated by the Science-Based Targets initiative as aligned with keeping global warming to a maximum of 1.5°C, in line with the latest climate science and the Paris Climate Agreement. Epiroc is committed to offering its full range of underground equipment in an emission-free version by 2025, and for surface equipment by 2030.