Canadian Mining Journal | November 2024

Page 1


UNDERGROUND MINING

> Technology, Equipment, and Workforce

> Unprecedented visibility for caving operations

VENTILATION

> Ventilation monitoring to reduce GHG emissions

15 Mine ventilation monitoring and controls to reduce greenhouse gas emissions.

30 An energy-saving ventilation option for underground mining. UNDERGROUND MINING: TECHNOLOGY, EQUIPMENT, AND WORKFORCE

18 A case study: Waterproofing high-temperature water flows in mining operations.

21 Driving peak performance in modern mining with high-torque, low voltage motors.

26 Bridging the gap: Training considerations for transitioning from open pit to underground mining.

28 Mechanization offers opportunity: Innovative solutions for construction and demolition.

32 Technology-enabled monitoring in the mining industry.

35 Unprecedented visibility for caving operations: New technology is optimizing productivity and reducing risk.

41 Revolutionary crushing technology guarantees lower cost per tonne on processing operational expenses.

REBREANDING MINING

39 What have you done today that did not involve a mineral?

ENERGY TRANSITION/DECARBONIZATION

43 No copper, no net-zero: The role of nature’s greenest metal in the energy transition.

DEPARTMENTS

4 EDITORIAL | An impressive MINExpo 2024.

4 LETTER TO THE EDITOR

6 FAST NEWS | Updates from across the mining ecosystem.

10 MIN(E)D YOUR BUSINESS | Reshaping the future: The 2025 risks and opportunities in mining and metals.

12 LAW | Mining meets sustainability: Challenges in renewable energy integration.

45 ON THE MOVE | Tracking executive, management, and board changes in Canada’s mining sector.

www.canadianminingjournal.com

An impressive MINExpo 2024

MINExpo 2024 was a total success. It was my first MINExpo experience, and it was astonishing. Waiting in line under a scorching Nevada sun to complete registration at the “outdoor” registration kiosks on the first morning was not a pleasant experience for someone from Ottawa, Canada. However, as soon as I entered the north exhibit hall, I felt like a kid in a candy store! Luckily, I had a full schedule that allowed me to visit as many manufacturers and suppliers as possible and have so many useful discussions with experts from the industry. It was exhausting but rewarding, as evident by the daily average readings of my pedometer.

On page 10 of this issue, Theo Yameogo from EY discusses the 2025 risks and opportunities in mining and metals. The issue features several articles that shed light on the recent technology, equipment, and workforce training in underground mining and ventilation (see pages 15 to 38 and page 41). Additionally, Donna Beneteau and Bruce Downing continue the discussion on rebranding mining on page 39, and more.

Our next issue (December 2024-January 2025 combined issue) will include several round up articles, featuring the most recent technologies and products exhibited by manufacturers and suppliers during MINExpo 2024, in addition to CEO interviews. We will also look at what is happening around the world as mining grows more interconnected in our shared quest for net-zero, and we will have a feature report on mining in B.C. and Yukon. Editorial contributions can be sent to the Editor in Chief no later than November 18.

• LETTER TO THE EDITOR

Regarding the article “Minister’s statement on the 10-year anniversary of the Mount Polley dam breach,” published in the September edition of the Canadian Mining Journal , pages 8 to 9.

The article made no mention of the cleanup and rehabilitation, and that fish are returning to Hazeltine Creek and that Imperial Metals has spent over $70 million on this remediation. This article and ensuing comments are great for sound bites but failed to mention that the spill did not kill fish or cause any human casualties. Neither the website: www.mountpolley.com, which discusses the remediation, nor the published peer-reviewed paper (entitled: Water quality impacts and river system recovery following the 2014 Mount Polley mine tailings dam spill, British Columbia, Canada) were mentioned. What about the recent and natural landside on the Chilicotin River (July 2024) or the Bute Inlet/Elliot Lake landslides or any future ones in November 2021? These two natural landsides were catastrophic to the environment. No rules and regulations would have prevented these landslides or any future ones from happening. An article should be balanced and not just for promotion of various sound bites with ensuing third party comments.

— Bruce Downing, M.Sc., P.Geo., FGC, FEC (hon.)

NOVEMBER 2024

Vol. 145 – No . 8

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Updates from across the mining ecosystem

• MILESTONE |

Canada’s first diamond mine, Ekati, reaches historic 100-million carats

Canada’s first diamond mine – Ekati near Lac des Gras, NWT – has reached a historic milestone of producing 100 million carats since production began in 1998. The mine is 100%-owned and operated by Burgundy Diamond Mines of Australia.

”As Ekati currently celebrates 26 years of production, this impressive achievement is a reminder of the quality of this long-life asset and everyone’s efforts, hard work, and dedication over the past two and a half decades,” said the company in a release.

Ekati ranks in the top 10 producers worldwide producing high-quality, ethically sourced diamonds. It also offers job creation, resource generation, and community investment.

Burgundy purchased Ekati mine in July 2023 and remains committed to continuing this legacy by working collaboratively with northern communities, government, and impact benefit agreement partners, and working to expand mine life potential opportunities identified for future growth. The future is looking bright with opportunities at Ekati, namely the Misery underground extension, Sable underground, Point Lake open pit, Fox high-value stockpiles, Fox underground, and other undeveloped resources on the property.

“Ekati still has 140 million carats remaining in indicated mineral resources, one of the largest unmined diamond endowments in the world, which provides Burgundy shareholders with an indication of Ekati’s remaining mine life potential,” said Burgundy CEO Kim Truter.

• ANNIVERSARY | 80 years of innovation and growth celebrated at Martin Engineering

The world leader in bulk handling solutions, Martin Engineering, is marking 80 years of product innovation, engineering expertise and global growth.

During a month of celebrations in September 2024, the firm invited customers, local communities, and employees’ families to its flagship Center for Innovation in Neponset, Illinois, and see for themselves the extent of Martin’s investment in engineering research and technological advancement over eight decades.

Martin Engineering holds dozens of patents for engineering designs that have revolutionized workplace safety and production efficiency in foundation sectors like mining and quarrying, cement and steel production, as well as resource recovery and recycling.

Primarily focused on conveyor belt performance and bulk flow technologies, Martin products are proven to eliminate blockages, prevent spillages and reduce dust emissions – a commitment that’s reflected in the company slogan “Problem Solved - Guaranteed”.

Visitors to the Center for Innovation were impressed by what they saw according to Martin Engineeringmarketing manager Seth Mercer.

“People commented that the research facility was much bigger than it looked from the outside and more impressive than they anticipated, and they were amazed by the scale of the operation and breadth of our product range. Even those who were familiar with Martin were both surprised and impressed with how much the company has grown in recent years,” he said.

• MILL RESTART | Maritime to restart Pine Cove mill

Maritime Resources has begun refurbishment work at its Pine Cove mill in the Baie Verte mining district of Newfoundland. The company thinks it will take a few months before the 1,300-t/d plant, which has been on care and maintenance since the first quarter of 2023, is restarted.

Sourcing of reagents and consumables and recruitment of key personnel is underway. Dwight Goudie has been named mill manager. He is a resident of the Baie Verte mining district and has over 40 years of combined mill maintenance, plant construction and mineral processing experience, from the Tumbler Ridge region, and in more recent years operating process plants for FireFly Metals (previously Rambler Metals and Mining).

Maritime has identified approximately 85,000 to 115,000 tonnes of stockpiled and tailings material grading approximately 1.1 g/t gold for approximately 3,000 to 4,000 oz. of contained gold.

The Pine Cove pit tailings impoundment area is also being prepared. The first tailings storage facility supporting former operations at Pine Cove, TSF1, contains inert tailings and is located adjacent to the site office complex. Maritime is currently working with Shoreline Aggregates to schedule the beginning of reclamation work of this area in the fourth quarter of 2024.

A feasibility study has been prepared for the Hammerdown gold mine. In June 2022 the project had an open pit measured and indicated resource of 2.8 million tonnes grading 3.61 g/t gold, containing 330,000 oz. of gold. The inferred resource was 302,000 tonnes at 1.31 g/t gold, containing 13,000 oz. of gold. A much smaller underground resource has also been outlined.

• MINE RESTART | Northstar to mine high-grade #2 zone at former Cam copper mine

Northstar Gold is making plans to mine the high-grade #2 zone at the Cam copper mine 20 km southeast of Kirkland Lake, Ont. The historic mine sits on part of the Miller copper-gold property, 100% owned by the company.

Northstar has signed a memorandum of understanding (MOU) with  Novamera, which will secure the needed financing subject to the definition continued pg 8

The parcel containing the 100 millionth carat produced at the Ekati diamond mine.
The Pine Cove mill will be pouring gold again next year.

Smoother

Improved Maintenance

Getting

Improved Mobility

Versatile,

FAST NEWS

and permitting of an economic deposit. Novamera will use its Surgical Mining technique.

Surgical Mining is Novamera’s proprietary mining process that combines its mapping, positioning and steering technologies with conventional drilling equipment to exploit narrow, high-grade copper deposits.

This innovative solution is said to be a more cost-effective, rapid path to production that radically reduces environmental and social impact. Given the low upfront capital costs and minimal development costs, Surgical Mining offers junior mining companies the opportunity to exploit small, narrow, high-grade mineralized zones, generating sustainable cash flow to fund strategic plans and reduce their reliance on the capital markets. In addition, permitting time and expense are generally significantly reduced owing to the small environmental footprint and operational scale.

The Cam copper project is divided into four stages as spelled out in the MOU. First is the conceptual Surgical Mining economic desktop evaluation and 3D block model development, which is nearing completion. The second stage includes guidance tool calibration activities, mine permitting, and an environmental impact assessment. Surgical Mining using rotary drill methods will begin in stage 3. The fourth and final stage will expand the technique into other areas of the Cam copper project.

Historic drilling at the #2 zone returned 10.5% copper over 0.2 metre, 19.9% over 0.9 metre, 23.1% copper over 1.4 metre, and 12.4% copper over 1 metre.

BATTERIES | FPX completes pilot refinery tests by making battery-grade nickel sulphate

FPX Nickel successfully completed pilotscale hydrometallurgy test work at its nickel refinery by producing battery-grade nickel sulphate (NiSO4). The company is intent on building North America’s largest such refinery with the capacity to produce 32,000 tonnes of nickel in sulphate.

“The results of our hydrometallurgy refinery pilot plant test work confirm the technical advantages of awaruite nickel mineralization to produce battery-grade nickel sulphate, further demonstrating the opportunity to develop a more streamlined nickel supply chain entirely in Canada,” commented Andrew Osterloh, FPX Nickel’s SVP projects and operations.

“Baptiste would represent an almost 50% increase to Canada’s current annual nickel production, all without adding to or displacing any of Canada’s nickel smelting or complex refinery capacity, thereby pioneering a uniquely low-cost, low-carbon link between mining and EV battery production, “ he said.

The pilot-scale tests used awaruite concentrate (60% nickel) as feed. The feed would be supplied by the Baptiste nickel-iron concentrator in central B.C.  The concentrate would undergo an atmospheric leach followed by precipitation of cobalt, nickel sulphate, and nickel scavenging in the presence of ammonium sulphate. A copper concentrate would also be produced from the leach circuit.

The pilot plant had overall leach extractions of 99.3% for nickel and 97.9% for cobalt.

Awaruite in a core sample from the Baptiste nickel deposit.

Reshaping the future: The 2025 risks and opportunities in mining and metals

As the world continues to request key minerals and metals for the transition to low-carbon economies, the landscape of risks and opportunities for the metals and mining sector is constantly evolving. The latest findings from EY’s “Top 10 Risks and Opportunities in Mining and Metals Report for 2025” reveal a significant ranking shift in the sector’s priorities. For the first time in three years, capital has overtaken environmental, social, and governance (ESG) considerations as the paramount risk facing the sector. This change underscores the urgent need to balance growth with capital discipline amidst the burgeoning demand for minerals crucial to the energy transition.

The sector is at a pivotal juncture, with companies striving to elevate environmental stewardship and focusing intently on managing waste, water, and ensuring nature-positive outcomes. This shift towards a more targeted approach to ESG reflects the industry’s commitment to not just meeting, but exceeding, environmental standards. Moreover, the backdrop of increased geopolitical uncertainty weaves through the rankings, emphasizing the need for the sector to embrace transformation through innovation, collaboration, and agility.

Interestingly, the latest survey indicates a departure from

the top 10 risks of governance, cyber, digital, and workforce concerns. This evolution suggests that for many in the industry, the challenges and opportunities presented by cyber and digital advancements have become a standard part of operations. However, the diminished focus on governance and workforce issues raises critical questions, especially as companies venture into new projects in regions with potentially less stringent regulatory frameworks and as the industry grapples with attracting and retaining the talent essential for its future.

In the survey, our clients have pinpointed capital as the foremost risk for 2025, ascending from the second spot last year and the eighth in 2023. Environmental stewardship was re-rated to the second biggest risk. Following closely is geopolitics, marking a notable shift as it ranked seventh in 2024 but was second in 2023. A detailed exploration of these concerns, as highlighted by leading global metals and mining firms, unveils insightful perspectives.

Capital balance: Aligning investments with growth strategy

The scrutiny from investors regarding the deployment of investments has intensified, with a pronounced emphasis on capital discipline and returns. In response, companies are

seeking growth and value enhancement through mergers and acquisitions, business models, divestitures of non-core or lowgrowth assets, and exploring diverse financing options. The current macroeconomic challenges underscore the importance of partnerships, joint ventures, or integrations to mitigate risks associated with large-scale projects. There is a growing recognition that meeting the investment demands for the energy transition may require a fundamental shift in financing strategies to prioritize long-term value creation.

Nature-positive legacy: Mining’s path to environmental stewardship

The focus on the environmental aspect of ESG is more pronounced than ever, with mining companies making strides in creating a positive environmental legacy. Initiatives aimed at waste and water management are gaining momentum, alongside a significant increase in nature-positive projects. With nearly half of the survey respondents (46%) expressing confidence in meeting their nature-positive commitments, it is clear that the industry is taking decisive steps towards reversing nature loss by 2030. The collaboration with Indigenous communities, who play a crucial role in sustainable land management, is also highlighted as a key factor in achieving these environmental goals.

The geopolitical game: Sector’s strategy amidst resource nationalism

The rise of resource nationalism, impacting tax regulations

BROKK PEDESTAL BOOM

and ownership rights, underscores the complex interplay between the sector and geopolitical dynamics. The concentration of strategic minerals and metals supply adds another layer of complexity, emphasizing the need for transparent supply chains. Companies are encouraged to explore joint ventures with local entities and licensing as strategies to mitigate investment risks in certain geographies. Additionally, the trend towards national self-sufficiency in strategic sectors highlights the importance of balancing immediate revenue goals with long-term benefits.

In conclusion, the metals and mining sector is navigating a landscape marked by significant shifts in risk priorities and opportunities. The industry’s focus on capital, environmental stewardship, and geopolitics reflects a broader trend towards sustainable growth, responsible resource management, and strategic adaptation to geopolitical challenges. As companies chart their course through these evolving dynamics, the emphasis on innovation, collaboration, and agility will be crucial in reshaping the future of the sector with confidence. The journey ahead promises to be one of transformation, with the potential to redefine the industry’s role in building a more sustainable and prosperous world.

Theo Yameogo is the Americas mining & metals leader at EY, based in Toronto (www.ey.com/en_ca/mining-metals).

Mining meets sustainability: Challenges in renewable energy integration

While being a critically important part of Canada’s economy, the mining industry is also one of its most energy-intensive sectors and remains heavily reliant on fossil fuels, which emit large amounts of greenhouse gases (GHG). Since it is not economically feasible to provide hydroelectricity or connect to the national grid without significant government subsidies, companies that operate in remote areas have historically had to rely on the use of diesel generators. With the global population steadily increasing, low-income nations pursuing development and a growing demand for transition metals, the demand for critical raw materials is expected to rise significantly and could lead to higher GHG emissions across all phases of mining in Canada.

Many industry leaders recognize that prioritizing the reduction of GHG emissions can align environmental responsibility with tangible business benefits. By lowering emissions, mining operations can both enhance their reputation and meet increasingly strict regulatory requirements. This approach can also differentiate a company from its competitors and attract investors and partners who prioritize supporting sustainable industries, leading to better funding opportunities and potentially improved stock performance. Additionally, energy-efficient technologies that reduce emissions often result in lower operational costs, increasing overall profitability.

Finally, projects that incorporate renewable energy may be more likely to receive the support of adjacent local communities, including Indigenous communities that prioritize protecting the environment. In light of Canada’s commitments to decarbonization and net-zero emission targets, the time is ripe for the industry to evolve in ways that minimize the adverse

impacts of mining activities on the environment.

Below is a discussion of endeavors undertaken by several Canadian mining companies to integrate renewable energy sources such as wind turbines and solar plants, as well significant strides made towards electrification. We also address some of the practical and regulatory challenges associated with their integration and highlight how companies can take advantage of recently introduced government funding in their transition to renewables.

Integration of renewable energy in mining operations

Wind energy is increasingly being utilized to reduce reliance on fossil fuels, with several off-grid mines integrating wind turbines into their energy mix. One notable initiative is the Raglan mine project undertaken by Glencore in partnership with Tugliq Energy. This award-winning project incorporates various energy storage technologies, with two turbines that meet approximately 10% of the mine’s electricity demand and reduce emissions by 12,000 tonnes. Another project worth noting is the Diavik diamond mine, operated by Rio Tinto in Canada’s Northwest Territories, with a wind farm that generates around 17 GWh annually, meeting about 10% of the mine’s power needs and reducing GHG emissions by up to 6%. Both projects demonstrate the successful integration of wind power, showcasing its potential to supplement energy needs and reduce diesel consumption and emissions.

Photovoltaic (PV) solar panels have also found promising applications in electrifying off-grid Canadian mine sites, usually as a way to augment other power sources. A noteworthy example is the PV system at Snowline Gold’s Forks exploration camp in the Yukon. Its off-grid system provides clean, on-site energy production to the exploration camp while reducing carbon emissions by 90% and saving an estimated 12,527 litres of fuel annually. The solar array and associated equipment are leased from the First Nations-owned Nacho Nyak Dun Development and is installed and maintained by the Yukon renewable energy company Solvest. Another project to note is the new array of PV solar panels added to Glencore’s Raglan mine site in the summer of 2021. The project’s solar installation comprises 108 photovoltaic panels, with the renewable energy produced being added to that of the site’s wind turbines.

Reducing emissions through electrification has also proven to be a viable approach, with some forward-thinking enterprises investing in fully electric or hybrid vehicles and others focusing more broadly on electric equipment. The New

Afton underground block cave gold-copper mine, operated by New Gold, was among the industry’s earliest adopters of battery electric vehicles (BEVs), which have contributed to the mine’s sustainability and productivity goals. This project far exceeded its 2023 targets for reducing energy consumption and GHG emissions, with battery BEV haul trucks being the largest contributor. Another industry leader in electrification is the Borden gold mine in Ontario, operated by Newmont, which is Canada’s first all-electric underground mine and fully relies on battery-powered drilling and hauling equipment.

While wind and solar offer sustainable options for mining, a widely recognized issue is the variability in power generation due to weather conditions and nighttime, which make them less reliable compared to continuous energy sources. Excess energy can be stored in batteries, but these have limited capacity and remain prohibitively expensive. In the context of electrification, one of the primary challenges for remote projects is having the right power infrastructure, without which the investment needed for charging stations, trolley lines, electricity storage or co-generation can be significant. As a result, these alternative power sources are currently often best suited for a hybrid approach alongside more continuous methods.

Regulatory considerations

Companies looking to incorporate wind or solar into their offgrid projects should also be mindful of the regulatory approval process for the installation of wind turbines and solar farms. In addition, any logistical challenges, projects undertaking the

construction of renewable energy infrastructure will be subject to various environmental laws and regulations, including, depending on their capacity, a likely environmental impact assessment (EIA) under the Impact Assessment Act, as well as the corresponding applicable provincial legislation.

An EIA is a thorough process required to evaluate the potential effects of a project before construction begins, including those on the environment. The assessment involves the analysis of various factors, such as the potential impact on local wildlife, and also examines potential disruptions to ecosystems, including effects on vegetation, water bodies, and soil. Additionally, the EIA assesses the noise pollution and visual impact on the landscape, as well as potential effects on nearby communities. Public consultation is a key part of any IA process, providing opportunities for local communities, Indigenous groups, environmental organizations, and other stakeholders to give input on the proposed project.

Federal and provincial regulatory agencies respectively review the assessment to ensure compliance with federal and provincial environmental laws, such as the federal Species at Risk Act and the Fisheries Act. If the assessment identifies significant environmental impacts, the project may need to implement mitigation measures, such as modifying the project design or conducting ongoing monitoring programs to minimize harm to ecosystems. On the other hand, it should be noted that if renewable power sources are part of the initial mine design, this could advance the EIA process for the overall project by showcasing the project’s low-carbon and renewable

LAW/RENEWABLE ENERGY

energy potential. In some situations, the renewable energy project may be considered together with the larger mine design in undergoing environmental assessment or the two may be considered separately.

In addition, companies looking to incorporate renewable energy into an existing mining project can typically expect that amendments to existing permits or new permits will be required. For example, a mining operation in Ontario planning to build a wind farm to power its operations would need to apply for a Renewable Energy Approval (REA) under the Ontario Environmental Protection Act. Similar to the federal EIA, this process evaluates potential impacts on the environment, wildlife, and local communities. In addition, since it is expected that renewable energy components of a project will have an impact on the environment, including for example on the wetlands or on certain species, it should be noted that compensation of some sort to the provincial authorities may be required under applicable provincial legislation. For example, certain provinces require that compensation for damage to wetlands or bodies of water, calculated based on a set formula, be paid before the environmental authorization for the activity causing the damage is issued.

As is the case with the EIA process, obtaining permits for the incorporation of renewable energy into the mine plans for a project pre-development may be a more straightforward approach, as the relevant provincial authorities will typically assess the impact of the project as a whole in most jurisdictions. However, since these components are often novel to the regulator, projects could face an expanded timeline due to the additional consultation required in connection with such applications.

Incorporating renewable energy not only impacts operational permits but also those related to closure and reclamation. Companies must demonstrate how renewable energy systems will be decommissioned or repurposed after mining operations cease. For instance, if a mining site uses solar panels, the closure plan must address how these will be removed, recycled, or left in place for future use.

Government funding initiatives

One of the primary challenges to transitioning to renewable energy is the significant upfront investment required. Fortunately, Canadian funding and regulatory schemes are increasingly supporting the integration of clean technology in the mining industry.

The Strategic Innovation Fund (SIF), which is overseen by the Ministry of Innovation, Science, and Economic Development and has a total budget of $1.5 billion, presents a significant opportunity for mining companies looking to incorporate renewable energy. By covering up to 50% of project costs, the SIF provides financial support for innovative projects, including those that implement clean technologies, automation, and advanced processing techniques. To tap into this funding, companies must undergo a detailed application process that includes consultations with SIF representatives and a robust project proposal.

In January 2024, the Government of Canada announced that

it had passed various Clean Economy Investment Tax Credits (ITCs), including the Clean Technology ITC. The Clean Technology ITC will provide support to qualifying taxpayers who are investing capital in specified clean technologies in Canada at a rate of up to 30% of eligible capital costs. Eligible clean technologies include clean electricity generation equipment such as wind turbines and solar panels, stationary electrical energy storage and non-road zero-emission vehicles. Companies interested in utilizing the ITCs must ensure their investments meet the eligibility criteria set out by the Canada Revenue Agency (CRA).

Some other potential sources of government funding include the Net Zero Accelerator, the Mining Innovation Commercialization Accelerator, the Sustainable Technology Development Fund, the Clean Growth Fund, and the Critical Mineral Infrastructure Fund, all managed by Natural Resources Canada (NRCan). In addition to the various federal initiatives, many provinces have their own funding programs aimed at promoting clean technology and renewable energy, including for example British Columbia’s CleanBC Facilities Electrification Fund.

For many sources of funding, collaboration is a key element, as partnerships with research institutions and local communities can enhance the strength of applications. Collaborating with Indigenous communities can open doors to funding through various initiatives aimed at supporting sustainable development, as some programs specifically target projects that benefit Indigenous communities and promote environmental stewardship. In addition, universities and research institutions often have grants available for projects focused on clean technology and sustainability, and collaborating with academic partners can provide additional funding opportunities for mining companies looking to innovate.

Summary

The incorporation of renewable energy into mining projects represents a new frontier, offering substantial opportunities along with various challenges, including logistical hurdles, regulatory complexities and the need for considerable upfront capital investments. Pioneers in the industry are taking on these challenges with the understanding that environmental responsibility can become aligned with significant business advantages.

Companies wanting to navigate these opportunities effectively should engage with their legal, financial and other strategic advisors early in the process when considering renewable energy solutions. This proactive approach will help ensure that the integration process is streamlined and that potential funding opportunities are identified and secured, facilitating a smoother transition to more sustainable mining practices.

McMillan LLP authors: Cory Kent is an office management partner in the Vancouver office, and a partner in the capital markets and securities team. Andjela Sabet is a counsel in the capital markets and securities team in Vancouver. Martin Thiboutot is a counsel, environment, in Montreal office. Jia Hwang is an articling student in the Vancouver office.

The importance of underground ventilation

Mine ventilation monitoring and controls to reduce greenhouse gas emissions

Underground mining is a critical industry that provides essential minerals and resources for various sectors including the new green economy. However, it also poses significant environmental and health challenges, particularly in terms of greenhouse gas (GHG) emissions and air quality for the underground miners.

Ventilation in underground mines serves multiple purposes. It ensures a supply of fresh air to miners, dilutes and removes hazardous gases, and controls the temperature and humidity levels within the mine. Without proper ventilation, miners are exposed to dangerous levels of toxic gases such as carbon monoxide (CO), nitrogen oxides (NOx), dust, and diesel particulate matter (DPM), which can lead to severe health issues and even fatalities.

Moreover, without directing the air to the correct location, the ventilation circuit will result in increased GHG emissions. Mines often rely on diesel-powered equipment, which emits significant amounts of CO and NO2 pollutants. Effective ventilation systems help to disperse these emissions, reducing their concentration and impact on human health.

Traditional ventilation systems in mines are often based on fixed schedules and manual adjustments via drop board manual regulators, which are inefficient and fail to respond to realtime changes in the mine environment. This is where advanced monitoring and control systems come into play. By continuously monitoring air quality and adjusting ventilation parameters in real-time, these systems can optimize air flow, reduce energy consumption, and minimize GHG emissions by as much as 50%.

The Vigilante AQS Air Quality Station by Maestro Digital Mine is a state-of-the-art solution designed to provide real-time monitoring of air quality in underground mines. It measures various parameters, including airflow rate, CO, NOx, dust, temperature, and humidity, providing comprehensive data on the mine’s atmospheric conditions.

One of the key features of the Vigilante AQS is its ability to integrate with existing mine ventilation systems. This integration allows for automated adjustments based on real-time data, ensuring optimal air quality and energy efficiency. For instance, if the system detects high levels of CO or low levels of

The Vigilante AQS provides real-time air quality monitoring, ensuring that underground ventilation systems optimize miner safety while reducing greenhouse gas emissions.

airflow, it can increase ventilation to dilute these contaminants, thereby protecting miners’ health while minimizing the mine’s overall GHG emissions. By directing ventilation to areas where it is most needed, mines can ensure that air quality is maintained without over-ventilating areas with fewer people and equipment.

Complementing the Vigilante AQS, MaestroFlex regulators are designed to control the flow of air within the mine’s ventilation network. These regulators can be adjusted remotely, allowing for precise control over ventilation rates in different zones of the mine. This flexibility is crucial for responding to dynamic changes in the mine environment, such as varying levels of gas emissions, changes in temperature, or modification of mobile equipment.

By using MaestroFlex regulators in conjunction with the Vigilante AQS, mines can achieve a highly responsive and efficient ventilation system without the necessity of expensive PLC or DCS panels. This combination not only enhances the safety and comfort of miners but also contributes to significant reductions in energy consumption and GHG emissions while reducing project capital expenses.

Duetto Analytics, an on-premises software platform, provides advanced diagnostics to ensure the reliability and safety of the ventilation industrial internet of things (IIoT) devices by

providing real-time monitoring and fault detection. This allows for the early identification of potential issues, preventing minor problems from escalating into major failures.

One of the significant benefits of advanced diagnostics is enabling predictive maintenance. By analyzing data from IIoT devices, this software can predict when equipment is likely to fail and schedule maintenance before a breakdown occurs. This not only reduces downtime but also extends the lifespan of the devices.

Ventilation on demand (VOD) systems rely heavily on sensors to monitor air quality and the sensors require frequent maintenance to maintain accuracy to enable the system’s effectiveness. Duetto Analytics solves the “Achilles heel” of VOD systems by tracking and recording sensor calibrations both for regulatory and system reliability.

Lowering GHG, boosting efficiency

One of the primary environmental benefits of advanced ventilation monitoring and control systems is the reduction of GHG emissions. By optimizing ventilation rates and ensuring that air quality is maintained at safe levels, these systems can significantly reduce the amount of energy required for ventilation. This, in turn, leads to lower CO2 emissions from the mine’s power sources. This is particularly important in the context of

KCA PILOT PLANT AGGLOMERATING SYSTEM

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global efforts to combat climate change and reduce industrial GHG emissions.

Beyond environmental benefits, advanced ventilation systems also offer significant operational advantages. Real-time monitoring and control allow for improving the overall productivity of mining operations by assuring the miners return to the face quicker and safer.

CREDIT: MAESTRO

Furthermore, the ability to remotely adjust ventilation parameters reduces the need for manual interventions, freeing up personnel to focus on other critical tasks. This not only enhances operational efficiency but also improves safety by reducing the exposure of workers to hazardous conditions.

Case studies and real-world applications

With installations in over 40 countries, mines around the world have successfully implemented Maestro Digital Mine’s Vigilante AQS and MaestroFlex regulators, demonstrating the practical benefits of these technologies. For instance, several mines in Canada reported a significant reduction in energy consumption and GHG emissions after integrating these systems into their ventilation network. The real-time data provided by the Vigilante AQS allowed the mine to make informed decisions about ventilation adjustments, leading to improved air quality and reduced environmental impact.

Similarly, a mining operation in Australia achieved enhanced operational efficiency and worker safety by using MaestroFlex regulators to control air flow in response to real-time conditions. The ability to remotely adjust ventilation rates allowed the mine to quickly respond to changes in gas concentrations and temperature, ensuring a safe and comfortable working environment for miners.

Conclusion

The importance of underground mine ventilation monitoring and controls cannot be overstated. Effective ventilation systems are essential for maintaining safe working conditions, protecting miners’ health, and reducing the energy intensity of mining operations. Maestro Digital Mine’s Vigilante AQS air quality stations and MaestroFlex automated regulators represent cutting-edge solutions that enable mines to achieve these goals through real-time monitoring and control.

By integrating these advanced technologies into their ventilation systems, mines can significantly reduce GHG emissions, enhance operational efficiency, and ensure a safer working environment for their personnel. As the mining industry continues to evolve, the adoption of innovative ventilation solutions will play a crucial role in promoting sustainability and reducing the environmental footprint of mining activities.

The MaestroFlex regulator allows precise control of mine ventilation, dynamically responding to changing air quality conditions to enhance efficiency and reduce energy consumption.
Duetto Analytics ensures reliability and safety by providing advanced diagnostics and predictive maintenance for ventilation systems, helping to minimize downtime and emissions. CREDIT: MAESTRO

A CASE STUDY

Waterproofing high-temperature water flows in mining operations

In this study, the mine was in the process of tunnel excavation. Initially, the mining advanced under dry conditions. However, as the excavation cycle continued, water ingress started to appear. With further development, the volume of water inflows increased, and the internal temperature of the tunnel began to rise, reaching around 35°C. This combination of water ingress and elevated temperature levels started to adverse-

ly affect the well-being and performance of the mining staff. By the time the mine reached its final development phase, the water inflow had intensified to a degree that it was hindering blasting activities.

Traditional methods, which involved controlling the water flow using cement injections, proved ineffective. The persistent water flow, coupled with a significant pressure of 1200 kPa, resulted in the cement being washed away before it could solidify and set within the ground.

Given this challenging situation, the decision was made to turn to a polymeric resin as a potential solution to divert and manage the water inflows and allow continued tunnel development.

In usual scenarios, fast-setting resins with a setting time of 1.25 minutes are the go-to choice. However, because of the excessive water pressure experienced in this mine, a twophase plan was proposed to achieve effective waterproofing.

Phase 1: Superficial waterproofing

The first phase entailed the use of an ultra-fast setting resin

Tunnel Inundation.

with a curing time of 30 seconds. This resin was injected into drillings that were two-metre deep, mainly focusing on the tunnel’s face. The primary objective of this stage was to establish superficial waterproofing, approximately one metre deep, to manage and curtail the water inflows and set the stage for a subsequent, deeper resin injection.

The resin’s innate characteristics played a vital role during this phase. Not containing water in its composition, it does not dissolve when in contact with water. More importantly, when the resin interacts with water, it expands, increasing up to five times its original volume. This is particularly advantageous in situations with high water flow, as the rapid expansion allows the resin to seal cracks swiftly and effectively.

Phase 2: Deeper waterproofing

After achieving initial control over the water flow, the next phase commenced. This involved a more profound application of the resin, focused primarily on the tunnel’s periphery. The main aim was to redirect water away from the central tunnel areas, thus facilitating drier conditions for further development. This approach was also instrumental in helping with ground consolidation during blasting operations.

Transforming ideas into solutions

shaft sinking raiseboring mine development construction services contract mining technical services project support engineering design

Injection in the face of the tunnel.
Injection points for deep injection on the tunnel’s periphery.

UNDERGROUND MINING

A planned drilling pattern for injection of the resin was instituted for this phase. Each injection point was two metres apart and extended six metres in depth.

A 1.25-minute setting resin was employed. This resin, once injected, moved into the ground’s fissures, expanded, set, and then carried on its migration to effectively seal the ground across the injected length. The application of the resin showcases the perfect blend of these two aspects of migration and expansion. The resin’s strength is contingent upon its expansion degree, with a compressive strength that varies between 8 MPa and 40 MPa. The robustness of the resin ensures ground consolidation, and concurrently, achieves waterproofing — a pivotal factor in ensuring mine safety and effectiveness.

During the preliminary injection phase, especially in the vicinity of the primary leakage point, there was a notable rise in ground water pressure when obstructing the water flow. Without the right measures, this surge in pressure could have led to ground fractures. But, with the strategic positioning of resin injection along the tunnel’s face, not only was waterproofing accomplished, but it also served as a buffer against potential fractures from increased water pressure. This strategy effectively stopped the emergence of new leaks within the tunnel while sealing the primary ones. With the successful primarily waterproofing, the water influx was significantly reduced, paving the way for the subsequent waterproofing

phase. This phase was characterized by a more in-depth application of the resin, enabling the mine to push forward on a ground that was both dry and consolidated.

Given the mine’s dynamic situation where water influx intensified with every advance, this deeper treatment was critical. It prevented a regression to potentially dangerous situations like flooding and elevated temperatures that could adversely affect the crew’s productivity and safety.

Thanks to the groundwork laid in the initial phase, the second phase of injection proceeded without any hindrance from water pressure flushing the resin. The resin seamlessly migrated into the ground. Occasionally, certain pressure spikes were noticed, signifying the resin’s saturation and the filling of the cracks. Whenever this was observed, the injection process was halted before moving to the subsequent holes.

A noteworthy feature of the resin was its rapid setting time, coupled with its expansive nature upon interacting with water. This meant that the amount of resin required was substantially reduced, translating to a solution that was both cost-effective and logistically efficient.

Conclusion

Upon completion of the injection process, the mine progressed its initial five metres on completely dry ground, leaving a waterproofed barrier of one metre. In this case, after drilling holes to check for water presence, two more six-metre advances with resin injection were made past the water-bearing area. Resin injection allowed for safe advancement without the risk of gallery flooding, enabling personnel to work at acceptable temperatures. At the same time, consolidating the periphery ensured no over-excavation, facilitating overall progress.

Anthony Ferrenbach is the general manager at Weber Mining Mexico.

Six-metre-deep injection on the tunnel’s periphery.

Driving peak performance in modern mining with high-torque, low voltage motors

How high torque electric motors are designed to endure the rigors of harsh mining environments while bringing new levels of sustainability to the mining industry

ECP5000 severe duty motors from ABB provide high-horsepower, high-torque solutions in a low-voltage package. CREDIT: ABB

In the pursuit of efficiency and productivity, modern mining hinges on equipment reliability across all stages — from exploration to processing and transport. High torque motors are pivotal in this ecosystem, powering essential machinery like crushers, mills, and conveyors. Their role is indispensable in ensuring operational continuity and economic success.

Mining environments pose unique challenges for electric motors, exposing them to dust, moisture, vibration, and extreme temperatures. Dust leads to component wear and overheating, while moisture can cause electrical shorts and corrosion. Vibration induces misalignment and bearing damage, risking motor failure and operational downtime, which negatively impacts schedules, budgets, and above all, profitability.

Designers of motors for mining machinery must also account for various use conditions, including improper speed control by operators as well as the slow operation needed during routine belt inspections. Instances of overspeeding and sudden stops cause significant wear and mechanical strain. Ensuring

smooth, robust, and simple operation is key to mitigating these risks and enhancing motor reliability.

Selecting the appropriate motor for a specific mining application is a crucial decision. Factors like motor size, power rating, efficiency, and operating environment must be meticulously considered. Oversizing a motor can lead to inefficiency and unnecessary energy consumption. Undersizing a motor can result in overloading, overheating, and premature motor failure. Hitting the “sweet spot” of motor sizing often requires motor manufacturers to find creative ways to increase power density in smaller spaces.

Powering productivity

In the demanding world of industrial mining and bulk material handling, severe-duty and process performance motors are the unsung heroes. Paired with variable frequency drives (VFDs), these motors provide the high torque that is essential for belts or conveyors in the high-vibration, dusty, and dirty environments typical of outdoor settings.

Precise motor sizing is critical for performance, ensuring

they can withstand stress from emergency stops and resist severe impacts of shock loading — whether from rock dumping or temperature-induced jamming. Durable windings in these motors combat vibration and supply necessary torque to prevent costly downtime.

Operators often push these motors to their limits, leading to potential overspeeding or overloading, which necessitates extremely robust construction. Load-sharing capabilities (within the VFDs) between lead and follower motors can help maintain operational harmony and protect the costliest component of conveyor systems: the conveyor belts.

For maintenance, motors must operate at ultra-low speeds, or “creep”, to facilitate periodic belt inspections. This need for resilience, precision, and adaptability make high-torque severe-duty motors indispensable for continuous operations in challenging environments.

Variable frequency drives (VFDs)

and corrosion-resistant components contribute to a motor’s ability to withstand harsh environments.

Mining operations demand reliable, 24/7 equipment, making durability and extended life critical. Although VFDs have become popular in low voltage applications, it is estimated that only 10% to 15% of large motors use VFDs because of the high costs and complexity. VFDs enable soft starts for large motors, reducing thermal stress and insulation damage, thus extending motor life.

Unlike traditional mechanical drive systems with multiple components like variable-speed fluid couplings, VFD-based motor-drive systems have fewer moving parts, resulting in less need for maintenance and fewer potential failure points. They also offer precise speed and torque control, adapting efficiently to varying loads, and with proper maintenance, often outlast traditional systems.

Motor selection matters

Choosing a reliable motor manufacturer with a strong track record offers significant advantages. Established manufacturers possess the expertise to design motors that can withstand the rigors of mining environments. Their understanding of the specific challenges faced by mining operations can translate into motors and drives with features like the following: Robust design: Utilization of high-quality materials and robust construction techniques ensures durability and extended operational life. Features like sealed bearings, enhanced cooling, high ingress protection, low vibration,

Tailored solutions: Mining applications are diverse, with varying needs for motor size, power rating, and specific operating conditions. Reputable manufacturers often offer both standard configurations and customized options, ensuring a perfect fit for each application.

Expert support: A reliable motor manufacturer provides comprehensive global support beyond the initial purchase. This can include readily available spare parts, on-site service expertise, and technical support to address any operational challenges.

End-to-end solution: Choosing a partner that has expertise in providing a solution from concept to commission ensures that the entire system is optimized for efficiency and reliability in mining operations.

Wide portfolio: A single manufacturer’s ability to provide solutions across the spectrum of motor and drive needs can simplify sourcing and future service requirements.

Long-term thinking

Reliability offers long-term benefits beyond just technical specifications. Minimized downtime is a critical factor for maximizing productivity throughout a motor’s lifecycle. Rugged motors designed for harsh environments, coupled with preventative maintenance practices, can significantly reduce downtime associated with motor failures. Predictive mainte-

ECR580 crusher duty motors from ABB are designed specifically for hightorque, high-vibration applications.

nance programs, utilizing vibration analysis, and temperature monitoring, among other analytics, can further minimize the risk of unexpected failures, allowing for proactive maintenance scheduling.

High-efficiency motors contribute to mining operations by consuming less energy to deliver the same output. This translates to lower energy costs and a reduced environmental footprint. Modern motors often incorporate features like optimized stator and rotor designs and advanced bearings to minimize friction losses, leading to improved efficiency.

While the upfront cost of a high-quality, well-suited motor may be slightly higher than a standard motor, the long-term benefits outweigh the initial investment. Reduced downtime, improved efficiency, and lower maintenance costs contribute to a lower total cost of ownership over the lifespan of the motor. Investing in reliable motors can yield significant financial returns over the course of a mine’s operation.

Real-life applications

The Mining Association of Canada reports that Canada’s mineral exports increased to $153 billion in 2022, making up 21% of Canada’s total merchandise exports. The bulk of Canada’s exports, 57% in 2022, were to the United States. The United Kingdom (9.2% in 2022) and the European Union (7.8%) were

Historically, ABB tackled the challenges of hard rock mining, which demands robust machinery. Advancements in conveying mined materials from underground to above-ground hoppers have been substantial, with motors ranging from 400 to 600 hp featuring NEMA D flange designs and zero-alignment gearboxes. These innovations have introduced a new era of reliability and efficiency, with machines capable of running for up to 20 years when properly maintained.

Today, the challenge is efficient material conveyance. From 300-hp motors to the widespread use of IE4-rated, severe-duty motors, mining continues to scale up. The industry has shifted towards high-horsepower low voltage solutions — a significant change from the days when anything over 300 hp required 4 kV. Now, 460 V systems can handle over 1,000 hp, even in diverse electrical environments like those in South America.

As global mining rebounds, driven by the rising demand for lithium and other essential minerals for modern technology like EV batteries, manufacturers are poised to meet these evolving needs. Mining equipment manufacturers have undergone a rush of mergers and acquisitions exemplifying the consolidation trend in an industry always in motion. While coal may be fading, mining’s inherent momentum remains strong, underscoring a dynamic and ever-adapting sector.

also significant export destinations. The mining industry in Canada is not just increasing in size, it is also becoming increasingly global.

This is because mining, as an industry, has always sought to push the boundaries of what is possible. After a slump in the last decade, the industry is returning to prevalence, and long-standing suppliers like ABB are finding a landscape that is both familiar and transformed. Previously dominant in medium voltage (MV) dual-drive systems, ABB has now expanded its focus to low-voltage, high-torque, high-horsepower overland conveyors, highlighted by projects like Inverta in Chile.

Improved operational efficiency

The reliable and efficient operation of motors is crucial for mining success. By selecting high torque motors designed for harsh conditions, prioritizing energy efficiency, and partnering with trusted manufacturers, mining companies, regardless of size, can reduce downtime and costs.

With pressing environmental concerns front of mind, it has been, and continues to be, vital for the motor industry to proactively research, develop, and adopt low-carbon technologies to push beyond basic compliance and lead the way toward greater sustainability. It is now up to the ambitious leaders in the mining industry to select those partners whose products and practices embody that vision.

As mining embraces a future-focused approach, featured prominently across all three of the show floors at the recent MINExpo2024, electric motor and drive use will evolve to prioritize sustainability through lifecycle assessments while simultaneously leveraging smart technologies like predictive maintenance, to optimize performance, minimize environmental impact, and ultimately drive long-term productivity gains.

Robert Boyce is the U.S. division manager for IEC low voltage motors at ABB. For more information, visit new.abb.com/motors-generators/iec-low-voltage-motors.

ABB ACS880 Drives are designed for demanding industrial applications.

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Bridging the gap: Training considerations for transitioning from open pit to underground mining

A student during training at Cambrian College’s mining engineering program.

As some mines evolve from open pit to underground operations, a fundamental transformation occurs in the skills and knowledge required from the workforce. This transition brings new challenges necessitating specialized training to ensure worker safety, operational efficiency, and overall productivity. With distinct underground environments and advanced technologies like automation and remote systems, a comprehensive approach to workforce development is critical. Training that emphasizes both technical expertise and safety is essential to manage these changes effectively and sustain mining operations. While much of the discussion around transitioning from open pit to underground mining tends to focus on the technical aspects, such as equipment and operational procedures, the equally important human resource shift often receives less attention. Addressing both the technical and human elements is key to a sustainable shift in mining practices.

Training considerations in this context must address the distinct challenges of underground environments, such as confined spaces, reduced visibility, and heightened risks of rock falls or equipment failure. Workers accustomed to the open pit setting need to learn how to navigate the unique hazards posed by underground mining, including the need for enhanced ventilation, ground control, and emergency evacuation procedures. Additionally, specialized equipment used underground, such as low-profile vehicles and drilling machinery, requires targeted training on operation and maintenance. Emphasis should also be placed on adopting new technologies, like autonomous systems and remote monitoring, which are increasingly integrated into underground mines. Training programs must therefore not only focus on technical skills but also on fostering a culture of safety, continuous learning, and adaptation to emerging technologies. Furthermore, leadership and communication training have become crucial in the underground context, where coordination and timely decision-making are vital to maintaining a safe and productive work environment. In sum, a comprehensive training strategy is pivotal for a smooth transition, ensuring that the workforce is well-equipped to meet the operational and safety demands of underground mining.

A smooth transition from open pit to underground mining

relies not only on comprehensive training programs but also on a strategic decision about when to make the shift. While training equips workers to handle the unique challenges of underground operations, determining the right time for the transition involves a deeper evaluation. Two common approaches guide this decision: maximizing the open pit mine’s potential before transitioning or conducting a cost analysis to determine when underground mining becomes more financially viable. Both approaches must consider workforce readiness and operational demands.

In underground mines, several job functions are unique because of the specific challenges of working below the surface. Ground support technicians are crucial for stabilizing rock formations using bolts and mesh. Ventilation engineers design systems to ensure proper airflow, maintain breathable air, and manage hazardous gases. Underground tradespeople like electricians and mechanics handle the maintenance of equipment and infrastructure installations in confined spaces. Underground drill operators drill vertical shafts for ventilation and ore transport, while underground surveyors map and measure tunnels to ensure accurate excavation and safe mine planning, critical for navigating underground environments. To make a shift to the underground easier for workers into these specialized roles, comprehensive reskilling programs are essential, equipping open pit workers with the technical skills needed for underground environments while minimizing workforce disruptions.

Upskilling and reskilling open-pit mining staff to work in underground mines is crucial for sustaining local economies, as the potential for job losses during this transition poses a significant risk to communities dependent on mining. Without adequate training programs, many workers could face unemployment, leading to economic decline in regions where mining serves as a primary source of income. This not only affects individual livelihoods but also puts pressure on local businesses and services that rely on the spending power of mining employees. By investing in comprehensive training, companies can retain their workforce, reduce layoffs, and ensure continued economic stability. Furthermore, skilled workers who are adaptable to underground operations become valuable assets, helping to future-proof the workforce and promote long-term growth in mining regions. This proactive approach not only benefits the company but can also preserve the social fabric of the community, fostering resilience in the face of industry shifts. In service of this goal, colleges and training centres play a crucial role in offering the necessary training to fill this skills gap and support a successful workforce transition.

Canada’s college system is wellequipped to support the upskilling of workers transitioning from open pit to underground mining through its diverse corporate training offerings. Corporate training offers industry access to resources and programming typically used to train post-secondary students. Whether through short-term, targeted courses or longer-term, multi-course programs, colleges can support the training needs of the mining sector. In addition to specialized education in key underground technical areas like ground control, surveying, and ventilation engineering, colleges can provide cutting-edge courses in topics ranging from data analytics and artificial intelligence (AI) as well as electric and autonomous vehicle maintenance. With the rise of digital technologies and the shift towards electrification in underground mines, these programs equip workers with vital skills for analyzing operational data and maintaining systems. This ensures that the workforce is not only technically proficient in traditional underground roles but also adept at handling

modern, technology-driven mining operations. By addressing both technical services and new technological competencies, corporate training centres help create a highly skilled, adaptable workforce capable of meeting the demands of modern underground mining.

Successfully transitioning a mine from open pit to underground operations hinges on the ability to upskill and reskill the existing workforce. By investing in targeted training programs, min-

ing companies can ensure that workers are well-prepared for the demands of underground environments. This not only prevents job losses but also supports local economies, enhances safety, and fosters long-term stability in mining communities. A well-trained workforce is the cornerstone of a safe, efficient, and sustainable transition.

Steve Gravel is the manager of the Centre for Smart Mining at Cambrian College.

Mechanization offers opportunity

Innovative solutions for construction and demolition

The construction and demolition industries continue to see steady change. Contractors, labourers and project managers are pushing for safer and more productive solutions to transform modern jobsites while facing an ever-growing backlog of projects fueled by the US$1.2 trillion Infrastructure Investment and Jobs Act. At the same time, “The Great Resignation” and Baby Boomer mass retirements contribute to labour shortages across the board.

With all these factors at play, relying on manual labour is simply unsustainable in terms of worker recruitment and retention, safety, productivity, and overall cost-effectiveness. As a result, successful contractors work to think outside the box and supplement experienced crew members with technologically advanced equipment like robotic demolition machines to increase efficiency and reduce the physical strain on labourers. Additional mechanization options help contractors take advantage of current opportunities while accommodating industry trends.

Productivity boost

Handheld pneumatic breakers and other highly physical methods have been commonplace on jobsites for decades. However, increased jobsite mechaniza-

tion has allowed contractors to revolutionize productivity. A demolition robot paired with a hydraulic breaker, for example, improves productivity with an impressive hitting power, on par with excavators three times their size, and offer industry-leading power to weight ratios. These compact machines access some of the most confined and restrictive jobsites — including those with dust, vibration, and noise restrictions as well as low floor loads. At 79 cm wide and weighing 560 kb, the most compact units are small enough to fit through standard doorways and light enough to be transported on passenger elevators, making them ideal for confined spaces and interior demolition projects. Larger models are available with higher power ratios for more challenging applications.

By employing these heavy-hitting machines, contractors can greatly increase efficiency in applications previously limited to large crews with handheld equipment. For example, one contractor was able to cut their demolition crew by a third during the nearly 92,903-m2, multi-level tear out. The two 990-kg demolition robots could access floors where even skid steers were deemed too heavy. With each robot

Robotic demolition machines increase efficiency and reduce the physical strain on labourers.
CREDIT: BROKK
Demolition robots have an industryleading power-to-weight ratio on par with excavators three times their size.
CREDIT: BROKK
Remote-controlled demolition equipment addresses some of the most pressing safety concerns with an operating distance of up to 300 m.

only requiring a single operator, the contractor was able to better utilize remaining employees across simultaneous jobsites while increasing productivity and lowering overall labour costs.

Safety benefits

For many in construction and demolition, increased safety is one of the biggest benefits of mechanization. Remote-controlled demolition equipment addresses some of the most pressing safety concerns these industries face.

With an operating distance of up to 300 m, remote-controlled units physically distance employees from harmful silica dust, as well as the strong vibrations of handheld equipment such as breakers, rivet busters and chipping guns. Long-term use of these common demolition tools is linked to a number of chronic injuries, including carpel tunnel syndrome, nerve damage, and hand-arm vibration syndrome.

Additionally, remote-controlled demolition machines help prevent one of the most common causes of serious work-related injury and death in construction — falls. A remote-controlled unit allows operators to remain a safe distance from ledges and other fall hazards. This provides peace of mind for workers and project managers, but also increases productivity by minimizing the need for erecting fall protections.

For contractors using remote-controlled machines, these safety benefits can quickly add up to significant savings on workman’s comp and insurance premiums. Remote operation paired with smaller crew size can significantly lower worker liability costs by limiting personnel in confined spaces or hazardous operations. One concrete cutting contractor who made the switch to demolition robots has seen a decrease in annual workers’ compensation claims by about 50%. The company has also seen a 25% decrease, or about US$40,000 to US$50,000 savings, in injury costs per year. Another concrete cutting operation reduced its experience modification rate (EMR) by adding demolition robots to their equipment fleet. Insurance companies calculate EMR based on a company’s safety record. Higher EMRs result in higher insurance premiums.

Recruitment and retention

Implementing innovative technology also offers some power-

ful recruitment and retention tools. When it comes to safety, for example, the workforce is well-aware that quality of life and length of career can be significantly affected by injuries and silica dust exposure. Currently, the median age of a construction worker is 42.3 years. Contractors who invest in mechanization reduce the amount of dangerous and hard manual labour workers must perform, which is a powerful benefit to young and experienced workers alike. A young employee may consequently see construction as a long-term profession while an experienced worker may see it as more realistic to remain in the industry for the duration of their career.

Innovative technology also attracts younger workers. For one concrete cutting company, including advanced robotic technology in their fleet helped reduce the median age of their 300-strong workforce to just 25 years old and cut turnover 10%. The machines also allowed the contractor to do more work with fewer people, increasing productivity 17% over three years.

The mechanization advantage

Opportunities abound for contractors, especially those who find creative ways to recruit, retain and best use the skills of

their workers. Technological advances, such as robotic demolition, can help change the way contractors work and make it possible to thrive in today’s environment while preparing for the future. Mechanization allows companies to quickly adapt to changes in labour, process, or regulation, keeping them ahead of the curve — and the competition.

Jeff Keeling is the vice president of sales & marketing for Brokk Inc.

Above: Contractors who invest in mechanization reduce the amount of dangerous and hard manual labour workers must perform, which is a powerful benefit to young and experienced workers alike. CREDIT: BROKK
Left: Mechanization allows companies to quickly adapt to changes in labour, process, or regulation, keeping them ahead of the curve and the competition.
CREDIT: BROKK
Technological advances, such as robotic demolition, can help change the way contractors work and make it possible to thrive in today’s environment while preparing for the future.

RIGID PLASTIC DUCTS: An energy-saving

ventilation option for underground mining

Ventilation serves three essential purposes in underground mines: (i) to provide fresh air for workers to breathe, (ii) to remove noxious contaminants and hazardous gases (which arise from diesel exhaust, blasting, and the rock itself), and (iii) to regulate temperature and humidity.

An underground mine ventilation system is comprised of fans, ducting, coupling, and curtains to get sufficient fresh air to the working face of the mine. As mines advance deeper, stronger airflow is required. Ventilation accounts for a large portion of energy use in underground mines and ranks second in terms of financial cost for these mines globally, behind ground support.

Energy conservation is a major concern, and there is an opportunity for energy-saving ventilation options. The Canadian Mining Journal spoke with Don Turgeon, director of sales at Rocvent, to discuss the future of underground mine ventilation.

Polyvinyl chloride (PVC) ducts

The most popular material used for underground mine ducts is a durable fabric coated with polyvinyl chloride (PVC). It is estimated that 60% of ducting used in underground mines is made of this PVC fabric material, and that PVC fabric is the only product used consistently around the

world for underground mine ventilation.

PVC is popular because it is lightweight and flexible. It can be folded and tucked away for storage, and it is easier to bring underground and install. It also has beneficial tensile and tear strength characteristics, which are important for use near heavy equipment and debris.

Future ventilation requirements

With the industry push toward carbon-neutral and net-zero mining, mines are looking for ways to cut carbon emissions and save energy. As mines switch from diesel-powered to battery-operated machinery, the following question arises: Will underground mines require less ventilation in the future?

Although there will be less diesel exhaust, batteries generate lots of heat. Ventilation will still be required to help regulate the temperature deep underground, especially because mines get hotter as they go deeper. There is also increased demand for the critical minerals used to create those batteries, resulting in many new underground development projects that will need ventilation solutions.

When it comes to energy conservation, reducing ventilation underground is not an option. Luckily, rigid plastic ducting is emerging as an efficient and energy-saving ventilation option and represents an opportunity for ventilation manufacturers like Rocvent.

The move toward rigid plastic ducts

According to Rocvent’s website, the company is a “major manufacturer of all types of mine and tunnel ventilation, tubing,

Miners inspecting an underground ventilation system in an underground mine.
Manufacturing of PVC ducts at Rocvent.

and ducting”. Rocvent is based in Chelmsford, Ontario, within Greater Sudbury, the heart of the mining industry in Northern Ontario. The company was founded in 1989 and has historically focused on PVC-coated woven fabric ducting.

Recently, Rocvent expanded its product offerings to include steel ducting and rigid plastic ducting. Don Turgeon said the company has cornered 75% of the mining ventilation market in Northern Ontario and is expanding business into the U.S., Mexico, and Chile via distribution. Its customers are usually technical services (engineering) and mine planners at both new mines and those that are advancing farther underground. Rocvent conducts ventilation surveys on site and employs engineers that can recommend mine-specific solutions. The company’s goal is to become a “one-stop shop” for all underground mining ventilation needs.

Rocvent has taken a leading role in product development to help mines reduce ventilation costs and improve the amount of fresh air at the face. A large part of this is its rigid plastic ducts, including rigid elbows and lateral pieces, made of fire-resistant high-density polyethylene (HDPE).

Benefits of rigid plastic ducting

Flexible PVC fabric ducts create a fluttering effect when air is blown through them. This creates a loss known as “friction loss.” Rigid plastic ducts, as their name implies, do not produce this fluttering effect. They have less friction loss, are less porous, and can push fresh air at longer lengths than PVC fabric ducts. This results in higher-efficiency airflow, which in turn requires less energy from fans, generating energy savings. Rigid plastic ducts work with both positive and negative pressures.

Challenges of rigid plastic ducting

Unlike PVC fabric ducts, rigid ducts are difficult to bring underground, since they are not flexible or foldable and take up a lot of space. When a mining project concludes, rigid plastic ducts cannot easily be brought back up to the surface and cannot be recycled. For these reasons, rigid plastic ducting often ends up sitting in a yard underground.

The inflexibility of rigid plastic also makes its transportation difficult and costly. One pallet can fit about 304.8 metres of flexible ducting, but only 24.3 metres of rigid ducting. For shipping, a truck can fit more than 9,100 metres of PVC fabric ducting, but only about 61 metres of rigid plastic ducting. Thus, there are large expenses and a substantial carbon footprint associated with shipping rigid ducts. Turgeon said this is especially relevant for Rocvent, who makes all its ducts in Northern Ontario (Sudbury and North Bay) and ships them out to mines across Canada and internationally. Mine planners often prefer

flexible ducting because of these costs, but mining engineers prefer rigid ducting for its higher efficiency.

Rigid HDPE ducting is also seven times more expensive to produce than its PVC fabric counterpart, but according to engineering calculations, the savings on energy costs over the course of a mining project are often worth the higher initial investment.

Another challenge is getting operations teams to buy in to rigid ducting. Although executives and managers may want to use rigid ducting because of carbon rebates and energy savings, miners do not always like working with rigid ducts, as they are not the easiest option for installation underground. Furthermore, miners are not as invested in the energy consumption or long-term planning of a mine, so they may not fully appreciate the benefits of rigid ducts. It can take time and effort to resolve disagreement between management and operations and to create buy-in among miners. “If the miners do not buy in, it is not going to work,” said Turgeon. Rocvent assists in this process by training operations teams on the proper installation of its products.

Choosing a ducting material

Turgeon noted that Rocvent has not seen any existing mines switch their ducting from PVC fabric to rigid HDPE, but in the last five or six years, new mines tend to favour rigid ducting. Many products from competing ventilation manufacturers are interchangeable, so mines that are advancing or have damaged ducts do have the option to change from one ducting material to another, or to have rigid ducts branching off into flexible ducts. Rocvent is creating fittings between rigid plastic ducts and PVC fabric ducts to make it easier for mines to adapt. However, there are other factors to consider when selecting a ducting material.

Different materials are used based on the volume of air being delivered to the working face. Certain parts of the mine may require a different material. For instance, flexible ducts can be used for headings, whereas rigid ducts can be used in the main ramp underground and areas where there are longer runs. The various types of ducting are built to withstand different climatic conditions and can be used around the world, but they may face country-specific regulations.

Despite the potential challenges, underground mines appear to be moving toward rigid ducting for efficient airflow, energy conservation, and carbon rebates. Is it worth using rigid plastic ducts for underground mine ventilation? Each mine will need to weigh the pros and cons — and costs and savings — for themselves.

Kesiah Stoker is a Canadian multiskilled freelance writer.

Rigid plastic ducts on a pallet (left) versus PVC ducts on a pallet (right) ready for shipping.
Standard steel galvanized duct.
Rigid plastic HDPE ducts at Rocvent. CREDIT:

Technology-enabled monitoring in the mining industry

The

safety, operational, and business benefits

The mining industry continues to digitalize and leverage technology within day-to-day business operations. Mine operators and owners are adopting and deploying purpose-built, industry-specific technologies and applications designed to boost productivity and efficiency, navigate industry challenges like labour shortages and increased regulation, and improve safety for workers and surrounding communities.

Now more than ever, the need for mining companies to accelerate their embrace of technology is critical, given the range of industry challenges at hand which include the following:

Increasing demand: The insatiable thirst among consumers for smartphones, electric vehicles, solar panels, and just about anything that requires a battery is driving demand for the minerals extracted by mining activity. Industry analysts believe there will be a need for hundreds of new mines. Existing and new mines must operate with maximum productivity and speed to meet demand.

Labour concerns: Securing skilled and experienced labour that can replace an aging mining workforce is a rampant challenge across the industry. The migration of talent to other industries means mining companies need to turn to technology and pursue opportunities to automate and remotely operate some of the activities that were once done manually and on-site.

Safety a pervasive issue: Mining is an inherently dangerous industry. Despite advances in workplace training and the introduction of many new safety initiatives, fatal workplace injuries rose 41% in 2023, according to the U.S. Department of Labour Statistics. Improving safety is of paramount concern to mining operators

Environmental impact: Even under normal conditions, mining is harmful to the environment, causing sinkholes, erosion, and chemical emissions. Failures and accidents can be catastrophic. Operators are under increased scrutiny and pressure to minimize their ecological impact, including reducing greenhouse gas (GHG) emissions and protecting surrounding lands where mining activity is taking place.

To address these and other challenges and remain competitive, while capitalizing on growth opportunities, mining companies are turning to a range of technologies to improve operations and safety. Mine site monitoring is a key area where mine owners and operators can deploy next-generation technologies to enhance operational efficiency, lower costs, and dramatically reduce risk.

The critical and growing need for monitoring

The hazardous nature of mining sites, where huge machines are continuously digging and excavating hazardous materials,

Real-time monitoring devices set up.

and where harmful chemicals are frequently used in mining processes, makes the ongoing monitoring of a mine site crucial for the safety of workers on-site and the surrounding community. A pit wall collapse or leach pad leakage can have serious health, safety, and environmental consequences. The more that can be monitored and tracked in real-time, the greater the opportunity to identify and address minor issues before they become major ones that imperil business operations and lives. There is no shortage of conditions and factors to monitor at any given mine site.

Stability: As digging happens and materials are extracted and moved from one location to the next, miners need to note the emergence of any displacements, or lateral or horizontal deformations, and flag any changes as settlement and movement of earth occurs.

Water: Water management is always a major concern in mining operations. The largest Superfund site presently in the U.S. was created when dewatering pumps were switched off as the Berkely mine pit was being abandoned in 1982. Rainfall and groundwater combined with high concentrations of remaining metals like arsenic, cadmium, zinc, and sulfuric acid to create a toxic lake that contaminated the groundwater and threatened the water supply of nearby towns. Monitoring of water flow, water levels, and pressure can help operators guard against flooding during dewatering processes.

Effective and proactive monitoring can help mine owners and operators become aware of a problem before it spins out of control.

Given the breadth of variables that should be monitored at a typical mine site, operators need to adopt a modernized, tech-enabled approach to monitoring. Unfortunately, even as digitalization has taken hold, too many mining operators are relying on outdated, manual, error-prone approaches to monitoring.

The varying forms of mine site monitoring

Superfund sites are polluted locations in the U.S. requiring a long-term response to clean up contaminations. These sites include landfills, mines, manufacturing facilities, or processing plants where toxic waste has either been improperly managed or dumped.

Tailings: Leftover materials and contaminated water leeched out of minerals need to be monitored in tailing facilities to ensure that contaminants do not escape and threaten the water supply of a nearby community. The failure of a tailing site and earth dams contained within can effectively wipe out an entire mine site.

Rail: Larger mine sites with rail systems need to understand the condition of tracks to ensure materials can be moved seamlessly without threats of derailment or delays resulting from failures.

Chemicals: Workers need to be constantly aware of the presence and levels of dangerous chemicals stored on-site, like cyanide.

Weather: Operators need to have constant situational awareness of the environment around the mine site, including changing weather conditions or anomalies that range from minor vibrations to major earthquakes. With everything happening at any given time at a mine site, failures can happen quickly. Even the smallest unexpected negative event can create a domino effect leading to a crisis.

In many cases today, monitoring is still being done by human beings who periodically visit mine locations to manually take readings and collect data from various devices. This outdated approach has many drawbacks. In addition to being incredibly time-consuming and inefficient, manual monitoring prevents mine operators at headquarters from having access to realtime data and insights into the conditions at the mine. Information is only available as often as the mine is physically visited by inspectors. Manual monitoring in this fashion is also extremely costly, as dozens of employees traveling to multiple mine sites, often in far-flung, difficult-to-reach locations is a hefty expense. Finally, when employees are spending their time traveling to sites and doing what is essentially an administrative task, they are not engaged in more meaningful work that could directly contribute to increasing mining outputs and growing revenue.

Mining companies seeking to automate and improve monitoring have taken different approaches. Some have deployed cabling systems where engineers dig trenches and place nodes capable of collecting data at various points along the way. These systems require a lot of maintenance and seem constantly needing repair, as cables are frequently damaged during surrounding mining operations. In reality, trench and cable systems are only moderately more efficient than manual monitoring, as humans are still needed to collect data from the nodes.

Others have turned to mesh radio network systems, which feature multiple gateways and repeaters capable of relaying messages and data in a closed environment. Mesh networks are notoriously complex to install and maintain, requiring an elevated level of technical expertise many mining companies may not possess. Because nodes and repeaters must be close to one another to effectively transmit data, systems often need to have multiple pieces of equipment which increases the likelihood of failure and poses difficulty in troubleshooting.

Real-time monitoring powered by LoRa wireless monitoring systems

The newest and most tech-enabled systems available today for mine site monitoring are those powered by LoRa technologies, or low-range radio. With long-range connectivity and low-

power communications running on long-lasting batteries, LoRa is ideal for mine sites. LoRa systems are extremely easy to configure, require little maintenance once installed, and can transmit data between sensors and loggers across much longer distances than mesh networks. Sensors are resilient to harsh conditions and can be set up to monitor anything across the mining site. LoRa software systems can be installed without the involvement of expensive electricians or engineers and can integrate with existing sensors, precluding the need to rip out legacy equipment.

At an open pit gold mine in Nevada, operators were concerned about water seepage caused by runoff from a nearby mountain. They sought an efficient and cost-effective way to continuously monitor for leaks, changing water levels, and the conditions of dewatering and pumping stations. By deploying a LoRa-powered wireless system, with water level measuring piezometers connected to vibrating loggers, the operators were able to get regular, reliable data on water flows and levels, safeguarding and enhancing operations at a fraction of the cost that would be needed for manual monitoring.

At a major oil sands mining site in Canada, a large energy company had been manually collecting readings from more than 2,000 piezometers to measure pore presses and moisture levels around a tailings dam. Because of the volume, readings could only be taken about once a week, and less often during the freezing cold winters common to northern Alberta. By installing a LoRa-powered monitoring system, the Canadian company was able to increase the frequency of monitoring by 40 times and spend more time analyzing and using data to

optimize performance and less time collecting it.

Beyond access to real-time data and situational awareness, LoRa-powered monitoring systems deliver several additional ancillary benefits, including from a labour and human resources perspective. Instead of going out and collecting readings, valuable employees can have more time to engage in substantive planning and business activities. By reducing travel to mine sites and leveraging a system that uses less material and equipment, LoRa monitoring systems can also enable mining companies to improve their environmental footprint.

Adopting a tech-enabled and modernized approach to monitoring has implications for business continuity and productivity as well. Anytime mining activity is forced to stop because of a problem that could have been identified ahead of time, expensive equipment is sitting idle, workers are unproductive, and money is being lost. Data captured from monitoring delivers insights that can inform analytics-driven business decisions.

From exploration to prospecting to production, real-time monitoring must be enacted across all phases of the mine life cycle. Technology advancements, like wireless monitoring systems, now offer mine owners and operators new opportunities for greater visibility and real-time access to data that can optimize operations and enhance safety as mining demand accelerates.

Kelsey Kidd is North American sales director for Worldsensing, a provider of IoT solutions for monitoring critical infrastructure.

Open pit mine site relying on tech-enabled monitoring.
CREDIT: STOCK PHOTO. WORLDSENSING HAS EDITORIAL RIGHTS TO THE STOCK IMAGE.

Unprecedented visibility for caving operations

New technology is optimizing productivity and reducing risk

Cave-based mining is increasing worldwide as a way of extending the life of open pit mines where near-surface ore has been depleted. It allows mining companies to reach large, lower-grade deposits deep underground (typically porphyry-style deposits), achieving high production rates at a fraction of the operating cost and environmental impact of conventional surface mining methods. Block caving, specifically, is a process that involves undermining an ore body and then allowing it to collapse under its own weight. The broken ore then falls into funnels (draw bells) built underneath the caving zone, where it is then extracted.

For all its advantages, the block-caving technique also comes with a set of unique challenges. Once a block cave is initially developed (through drilling in underground tunnels), it propagates upwards in a largely uncontrolled process, and it is not possible to directly observe the void as it evolves over time. Cave miners also encounter stalling of progressive caving and draw bell blockages, alongside challenges in reliably predicting ore body cave-ability, understanding cave propagation, managing ore flow effectively and predictably.

Geological uncertainty drives inefficiency, delays investment, and slows time to market

At a time where a looming multi-trillion-dollar supply gap in critical metals is putting the mining industry in the spotlight, there is immense pressure on mining companies to deliver outputs quickly — with less cost, risk, and environmental impact than ever before. Caving can deliver against these objectives, but the geological uncertainty involved in the process directly impedes that growth and slows time to market.

Operators constantly evaluate and monitor cave propagation, and mitigate geotechnical hazards during the deposit investigation, mine design and planning, and operational stages of the caving process. Current monitoring methods offer point measurements only, leaving operators to interpolate what may be happening between discrete points inside the cave. They have not been able to confidently or accurately

delineate the ever-changing parameters of the cave edges, the growing air gap created, and the muck pile forming at the cave bottom. Until now.

Canadian-made mining tech uses natural energy from space

The new technology uses naturally occurring energy from supernova explosions, in the form of subatomic particles called muons, to image deep beneath the Earth’s surface. A subsurface intelligence platform — called “REVEAL” — comprises proprietary data generation; data integration and

Block caving involves undermining an ore body and then allowing it to collapse under its own weight. The broken ore falls into funnels (drawbells) built underneath the caving zone, where it is then extracted.
CREDIT: IDEON
Muon detectors are positioned beneath the active block cave, at or near the extraction level, imaging upwards to cover millions of cubic metres of earth.

multi-physics; data science and artificial intelligence (AI); modelling and analysis

REVEAL for caving solution allows mining companies to remotely and fully

rounding the cave.

By measuring muon activity through detectors positioned in the extraction layer (deep beneath the surface), the average density in the overburden can be determined within a wide field of view above each detector. Each detector produces a radiographic (X-Ray-like) image of the rock mass above it, and combining these images enables three-dimensional tomographic reconstructions of subsurface density (CATscan-like). Subsurface voids like caves stand out clearly because of their density contrast with the surrounding rock. Ongoing imaging of evolving block caves yields a dynamic, high-resolution 4D model that shows how a cave and the surrounding rock evolve over time.

The innovative foundational technology — muon tomography — is the only straight-line subsurface imaging technology available today, delivering the highest available resolution along with precise anomaly location information. It uses a passive and free energy source (from space), offers the ability to image in noisy or conductive environments (where other techniques do not), provides insights from depths that other techniques cannot, and captures data continuously — improving imaging results over the course of a survey. This unique data source, combined with advanced processing algorithms and multi-data-set analysis, gives block caving companies a comprehensive set of subsurface intelligence that they have never had access to before. It is a game-

Muon tomography

for cave

mapping at New Gold’s New Afton mine,

Located about 15 km west of the city of Kamloops in central B.C., the New Afton mine is a gold and copper mine situated within the Iron Mask batholith complex. The silica-saturated, alkalic porphyry-style deposit is being mined with the block caving method. In fact, New Afton mine is currently the only operating block cave mine in Canada and has a mine life that extends beyond 2030. The current operation occupies the site of

For the first time, caving operators can map and monitor the full extent of the cave remotely and in high resolution.

the historic Afton open pit mine, which operated from 1977 until 1997, and includes an inactive open pit and other historic facilities.

Porphyry-style mineral deposits  result when large amounts of hot water that carry small amounts of metals pass through permeable rocks and deposit the metals.

Ideon worked with New Gold to install the world’s first muon tomography-based block cave monitoring solution in the operating B3 zone at New Afton mine, with a goal of demonstrating the power of muon tomography to delineate the full 3D extent of the target cave, map heterogenous density variations in cave zones, and measure any observed temporal changes in both rock flow and cave extents.

Outcomes opened a window of insight into cave characteristics previously unavailable

The technology provided New Gold with high-resolution visibility of a volume of earth measuring 830 million m3 using no drillholes. The unconstrained analysis, later validated and constrained with New Gold-provided data, provided high-resolution geological and geotechnical insights throughout the sur-

vey area, resolved directly with measurement data, and mapped the full cave back to 10 to 25 m or less spatial resolution at a depth of approximately 800 m, using no additional drilling.

The full expanse and boundaries of New Afton’s active block cave was accurately delineated, and a pillar of denser material separating two caving phases in a neighbouring cave was mapped. This was achieved remotely and without any instrumentation inside the cave itself. Deploying instrumentation in existing workings enabled broadscale monitoring with minimal operational disruption and no surface environmental impact.

“Blind” imaging program was designed to map and monitor cave structures, completely remotely

Commissioned in March 2024, the “REVEAL” for caving solution used nine imaging locations in New Afton mine, leveraging various formats of muon detectors to suit each location. Detectors were situated at approximately 600 to 800 m deep

and gathered data over five months (to date of publication). Data intake and analysis were conducted remotely via the New Afton mine network, unlocking near-real-time subsurface density imaging with continuously improving resolution. Imaging updates were provided on a monthly cadence to reflect typical cave reporting timelines.

This was a blind, unconstrained data analysis — except that LIDAR constrains the top of the model and the known extraction level was incorporated as a bound on the bottom. Even in the constrained model, the prior cave shape is not used as a constraining factor in the analysis. The reconstructed muon trajectories from all detectors were incorporated into the “REVEAL” platform. A robust 3D density model of the target area was generated using muon data alone, yielding a mesh-based representation of the best-fit current cave shape, that satisfies the observed

New Gold’s New Afton mine in Kamloops, B.C. is currently the only operating block cave mine in Canada.
The new technology provided New Gold with high-resolution visibility of a volume of earth measuring 830 million m3 using no drillholes, mapping the full cave back to 10 to 25 m or less spatial resolution. Muon detector positions are identified with orange circles.
The muon tomography imaging program at New Afton mine successfully demonstrated the viability of applying muon tomography to accurately delineate and map the caved rock and key features.
CREDIT: IDEON

UNDERGROUND MINING: TECHNOLOGY

muon data and a full 3D distribution of subsurface density across the cave zone.

The New Gold team is excited about muon tomography and the value it can add to its block-caving operations. A follow-on commercial deployment is being advanced for a new cave at depths down to 1.2 km as part of New Gold’s production plan for the development of Cave C, New Afton.

“ We have now seen first-hand what this breakthrough technology can bring to block caving sites like New Afton. The technology integrates well into industry standards for cave monitoring, as it can lead to improved resolution of the cave shape, resulting in a better 3D understanding of operational performance and safety,” Corey Kamp, director, mining and rock mechanics, New Gold Inc.

Leveraging technology to increase visibility, improve productivity, and reduce risk

By mapping and monitoring cave behaviour over time, this technology can help companies assess and track multiple scenarios for mapping propagation of the cave back of the mine, allowing for detailed production schedules to be generated

based on targeted production rate and ore flow. This data can also be used to identify potential geotechnical hazards and inform “what-if” scenario planning by the operator. By leveraging existing mine infrastructure rather than drilling and cementing dozens of holes for beacon instrumentation, Ideon can help mining companies save time and money to efficiently recover lower-grade ore.

The new technology is effectively de-risking critical metal exploration and mining processes by quantifying and reducing geological uncertainty. With few ways to unambiguously know what lies beneath the Earth’s surface, most mining companies rely heavily on point data and interpolation to develop models to guide their work. This technology is reducing uncertainty in an environment that has traditionally been very uncertain. As a result, block caving miners are equipped to make better informed decisions, saving costs, improving productivity, while minimizing risk, and environmental impact.

Gary Agnew is CEO & co-founder of Ideon Technologies. He has led Ideon through the transition from R&D to successful commercialization and engagements with the world’s top five mining companies, leveraging 25 years’ experience in mining technology, equipment, and services sector.

What have you done today that did not involve a mineral?

Marketing: Mining a mineral message (Part 1)

Mike Commito and Steve Gravel concluded their article with the invitation: “If you have your own idea about what mining could be rebranded as, submit your thoughts to CMJ” (published in the Canadian Mining Journal’s August 2022 issue, pages 12 to 14). Instead of advocating for a complete rebrand, we support expanding the messaging by posing the question: “What have you done today that did not involve a mineral?” This simple yet powerful question complements the well-known phrase: “If it is not grown, it is mined.” Together, these statements highlight the essential role of mining in our daily lives. While the original phrase effectively conveys the importance of mining, introducing this new question adds a personal and thought-provoking dimension, encouraging deeper engagement. By expanding the messaging in this way, we strengthen our marketing strategy, helping people recognize how minerals impact every aspect of life. After all, that is what education is about: Engaging with ideas to foster a deeper connection and lasting understanding.

Tell a person — They forget.

Show a person — They remember.

Engage/involve a person — They Learn.

Hearing either phrase alone may not convey the message, but together, they make the point clearer: “If it is not grown, it is mined. What have you done that did not involve a mineral today?” The first half makes a statement about mining’s role, and the second poses a question that encourages the audience to reflect. Rather than telling why mining is important to an audience that may not initially agree, this combined statement invites them to consider their personal connection to minerals. Using this new phrase as part of a branding strategy can effectively communicate the significance of the mining industry. Both parts are short, memorable, and catchy — key character-

istics of good branding. They should stick in people’s minds and are easily recalled, promoting the industry while fostering a deeper understanding and appreciation of minerals. The combined sentences are versatile, fitting various contexts — such as articles, social media, presentations, or educational campaigns — while maintaining a consistent message. In an industry where public perceptions can be negative because of the environmental impacts, whether real or perceived, these phrases help to shift the perspective towards the essential and beneficial roles of minerals.

Each person has unique priorities, and rather than trying to create statements that make mining appealing to everyone, our statement allows people to tailor the message to themselves by connecting what they value to mining. The initial statement conveys the vast importance of mining, and the follow-up question encourages individuals to link something seemingly unrelated back to mining. Mining is so vast that we have yet to find something not connected to it. For example, if someone loves to read and hears, “If it is not grown, it is mined. What have you done today that did not involve a mineral?” they may connect this to their love of books and realize that the printing press is made from mined materials. In this way, mining could become significant to them because it directly

REBRANDING MINING

supports something they care about.

Bruce Downing, a geologist, has based his educational outreach on the opening phrase “What have you done today that did not involve a mineral?” Bruce’s experience with elementary school classroom visits has proven successful, as evidenced by a past student now working in the mining industry who credits Bruce’s outreach with influencing his career path. It is unfortunate that discussions about mining often focus on its negative impacts while positive contributions are seldom highlighted. We are trying to convey what mining brings to our lives, not what it takes from the Earth.

Even if we cannot shift public perception that mining is evil or inherently harmful, perhaps we can at least demonstrate that it is a necessary evil. It is a component of modern society, an industry that strives for sustainability and innovation. At the core of the complex relationship of environmental science, mining, and exploration, lies “geochemistry.” This vital field studies the chemical composition and processes of minerals, water, and the Earth’s crust. The facets of geochemistry are rarely discussed outside academic circles. By bringing geochemistry to light, we can help highlight mining’s crucial role in environmental stewardship.

Downing introduced this phrase to Donna Beneteau via email after exploring the Canadian Historical Mines HUB (https://www.cim.org/the-hub/). They subsequently met up in Vancouver during the CIM (Canadian Institute of Mining, Metallurgy, and Petroleum) annual Convention in May 2024. This collaboration began with a shared commitment to expanding the conversation beyond our usual circles and exchanging ideas. Downing has helped Beneteau to further her appreciation of how everyone in the industry can contribute to education.

Downing’s message has reinforced for Beneteau that we all have a role in sharing our knowledge about minerals with our respective networks. For instance, Beneteau’s son compared Minecraft (the video game) to the mining industry in an article because he wanted to show her that the public has fun mining virtually with this best-selling game of all time (Mining engineering hit a Roadblock, published in the November 2022 issue of this publication, pages 39-40). Beneteau created a YouTube video “The Hidden Geology in Quilting, From Rocks to Stitches,” demonstrating the importance of geology in quilting. Instagram

Blogger Cate Larsen (@groovygeologist) of GeoLifestyle explains “Minerals’ Role in Fireworks” in one of her many posts on where geology meets daily life, and Rohitesh Dhawan, president and CEO of ICMM, captured attention by beginning his speech with “Please raise your hand if you went to the toilet this morning.”

Dhawan emphasizes the importance of sparking curiosity about how the world works, rather than simply listing minerals in toothpaste. For those looking to improve their communication skills, “Geologize” provides practical online training in geo-communication. From the experiences of Downing and Beneteau, it is clear that we improve with practice. And please try to add momentum to the conversation to change the definition of mining in dictionaries as per the article “Crafting a New Definition of Mining” (published in this publication in the October 2023 issue, pages 37-38).

Embrace what you are comfortable with, be authentic, and speak truthfully. Bruce Downing’s passion for geochemistry and Donna Beneteau’s focus on rocks complement each other, with Bruce suggesting and emphasizing that rocks are funda-

mentally made up of minerals. They hope their enthusiasm makes a meaningful impact. Sometimes years later, we may discover the influence of our efforts. With incremental progress, bright individuals might eventually be eager to pursue roles in the industry. By embracing fresh ideas, our industry can learn from past mistakes and continue to advance in sustaining our resources and planet.

Connections within the industry can expand our knowledge. Bruce Downing is a geoscientist consultant living in Langley, B.C. Donna Beneteau is an associate professor in geological engineering at the University of Saskatchewan.

Revolutionary crushing technology guarantees 20% lower cost per tonne on processing operational expenses

PowerMaster, a leading innovator in mining technology, announced its groundbreaking “Revolution” crushing technology. This state-of-the-art gyroscopic grinder is engineered to not only crush materials with unprecedented efficiency but also to remediate mine sites and reprocess valuable tailings. The introduction of “Revolution” sets a new benchmark in sustainable mining practices.

This innovative technology is a versatile solution, capable of handling a wide range of materials — from large chunks of ore to finely dispersed tailings. By cutting processing costs by up to 50%, this eco-friendly innovation significantly reduces the

environmental impact of mining operations. It achieves this by reclaiming valuable minerals, reducing emissions, and minimizing waste.

“The mining industry faces growing challenges with economic fluctuations and increasing environmental regulations,” said Haiku York, president of PowerMaster. “With millions of dollars spent daily on processing materials and tailing storage, effective waste management is crucial. Our “Revolution” technology addresses these challenges so efficiently that it guarantees mining companies a 20% lower cost per tonne compared to a traditional crushing technology, and

PowerMaster Revolution unit.
PowerMaster Revolution demo site.

TECHNOLOGY: CRUSHING

at the same time, it offers reduced environmental impact,” added York.

The “Revolution” technology stands out in its ability to perform across all stages of crushing — primary, secondary, and tertiary — maximizing resource recovery from various materials. It is also highly customizable, allowing operators to program it for different material types and adjust the output size as needed. Furthermore, by eliminating excess moisture from the material, the technology processes rock and tailings into dry material, thereby lowering the cost or processing and the risk of groundwater contamination.

“There is no other technology like it,” said Lila York, director of special projects at PowerMaster. “Our machine costs half as much as other machines, has one-tenth the maintenance cost, and virtually no downtime. The “Revolution” is the safest machine on the market today. Once people realize how much it reduces both waste and cost, we will be hard pressed to keep up with demand,” Lila added.

With the launch of the “Revolution” technology, PowerMaster

is poised to transform the mining industry, offering a solution that not only enhances operational efficiency but also contributes to a more sustainable future.

PowerMaster Revolution Forthood site. CREDIT POWERMASTER

No copper, no net-zero

The role of nature’s greenest metal in the energy transition

Achieving net-zero by 2050 essentially means completely phasing out fossil fuels in under 30 years. We cannot do that without copper. In this article, we discuss the challenges facing our relationship with this ancient metal.

Humanity’s history with copper goes back almost 10,000 years. Neolithic peoples first used native copper in tools, weapons, and decorative items, and smelting of copper kicked off the Bronze Age about 5,000 years ago. The Romans mainly sourced it from Cyprus, calling it “aes cyprium” (metal of Cyprus). This subsequently became “cuprum,” the origin of the English word “copper.”

In Roman times, copper was predominately used in the empire’s coins and to make brass for specialised uses like ornaments and some aspects of plumbing and architecture. Today however, more than two thirds (70%) of modern copper production are earmarked for electrical applications. Copper is involved at every stage of the electricity system: generating it, transferring it, and using it.

Why copper?

On the journey to net-zero, electricity is our main tool, and the backbone of our electrical system is copper.

Copper is the second most conductive known metal after silver, and more conductive than gold, but the scarcity and price of these two precious metals make them unsuitable for the millions of tonnes required for a global energy network. Copper’s physical properties, such as its ductility and resistance to corrosion make it ideal for countless components like cables, connectors, and coils. Finally, it is the 25th most abundant element in Earth’s crust, and it can be recycled without any significant loss of quality.

Copper’s unique properties solidify its position as the essen-

tial material for electrification, the energy transfer system that underpins humanity’s path to net-zero.

More power, faster

As electrical infrastructure develops and standards of living improve around the world, we will naturally need more megawatts of power to meet demand. But a side effect of the green energy transition is that each megawatt of electricity end use will be more copper intensive than fossil fuel alternatives.

The main reason is that renewable electricity generation is much more dispersed than conventional thermal generation from fossil fuels, making it more material intensive. For example, each wind turbine of 1 to 5 MW has its own generator, while a coal fired thermal power plant has one generator of typically 400 MW. A more dispersed generation also means that the grid for transferring electricity from where it is made to where it is needed must expand.

In addition, generating electricity from sustainable sources is often weather-dependent. While coal can burn nearly 24/7, wind power needs a consistent breeze, and solar power only works during the daytime. To compensate for natural low-output periods, we will need extra production capability and storage to keep up with demand, meaning more copper for more renewable energy systems. This is another reason why we need a stronger grid: the better all sites of generation and consumption are interconnected, the easier it becomes to tap the electricity from where it is available at that moment.

Generation is one thing, but net-zero means decarbonizing energy at the other end of the chain too: the end user. Carbonfree end-use energy on the roads, for instance, means more electric vehicles, but each requires 2-3 times more copper than an internal combustion engine powered vehicle.

Clean electricity will be the largest consumer of copper by 2040, but copper is also used for some of the non-electrical systems that aid the transition to net-zero. For example, as an excellent thermal conductor, copper is often used in heating and cooling systems, such as those found in heat pumps, which

CWIEME Berlin is one of the premier events in the world of electrical engineering, and it is an essential destination for both experts and enthusiasts. This yearly occasion, situated in the heart of Europe, presents an unparalleled opportunity for networking, knowledge acquisition and the exploration of cutting-edge industry developments.

By Bruno De Wachter and
Copper wire reels at a factory.
CREDIT: PARILOV/ADOBE STOCK

Large native copper nugget (157 g) from Keweenaw, Michigan, U.S.

CREDIT: BJÖRN WYLEZICH/ADOBE STOCK

are playing a major role in reducing fossil fuel use for heating. Finally, the quest for energy efficiency itself is copper-intensive. According to Joule’s law, energy lost as heat in an electrical wire is proportional to resistance and resistance is inversely proportional to wire diameter — so the thicker a copper cable is, the less energy is wasted as heat and therefore the more efficient the system is. This includes the windings of transformers and electric motors. Essentially, the more copper we use in each application, the more energy we save.

Is there enough?

The International Energy Agency has published two scenarios for future copper demand. The Stated Policies Scenario (STEPS) is based on what governments have already pledged to do, and the more aggressive Sustainable Development Scenario (SDS) is based on reaching net-zero by 2050. Both scenarios see annual copper demand increasing to 40 million tonnes by mid-century (from around 26 million tonnes nowadays), either in 2050 for STEPS or 2040 for SDS.

Considering these lofty figures, it is natural to wonder whether Earth has enough copper to meet our requirements. The short answer is yes. Enough resources exist to support the energy transition and meet society’s needs. The question is whether we can extract that copper quickly enough to align with STEPS or SDS.

Primary copper production currently sits at 22 million tonnes annually. Together with 4 million tonnes of recycled copper, this meets current demand of 26 million tonnes. Demand has grown by about 3.3% per year for over a century, doubling about every 30 years. In the past, the drivers for copper demand were population growth, electrification deployment, and electricity usage. Today, it is the green energy transition and improving global standards of living. At present, we have about 41 years’ worth of copper reserves — copper in the ground at operational mines — and up to 250 years’ worth of predicted, but currently unexploited resources.

Surprisingly, the number of years’ worth of copper reserves has been roughly the same for decades. Just like with oil, the scarcer it becomes, the more effort goes into finding more.

It may be possible to reduce our reliance on copper by developing alternatives such as aluminium. Aluminium is about three times lighter than copper, so might be advantageous for use in electricity overhead lines, for example. On the other hand, in space and weight constrained applications, the increased volume of aluminium and surrounding structure required to provide the same functionality as copper makes it unsuitable.

Another area of research is graphene, which is also three times lighter than copper but more than twice as conductive and made from carbon, which is ten times more abundant. It is promising, but the uses of graphene in the electrical industry is a field currently dominated by research, and it will likely be decades before

graphene becomes a mainstream alternative to copper. If growth continues at historical rates and copper production increases in line, as it has done for over 100 years, there is nothing to be concerned about. Meanwhile, changes in the way we produce copper are being introduced.

Low impact production

It is essential that we maximize copper recycling to keep secondary copper in circulation. Electrical copper’s properties, such as purity, favour recycling and doing so is much less impactful than mining. However, current recycling of pre- and post-consumer scrap (10 million tonnes) provides just a third of today’s demand and a fifth of 2040’s SDS. Furthermore, post-consumer scrap only becomes available after the lifespan of the equipment has passed, around 30 years for a transformer, for instance.

Green copper

For now, at least, mining existing resources for primary copper is essential. In fact, without mining, there can be no netzero. While zero-impact mining is impossible, mining must be responsible — a careful balance of economic, environmental, political, and social challenges.

In some cases, that balance is hard to strike, as evidenced by the closure of one of the world’s largest open pit copper mines in late 2023. In response to nationwide protests ranging from environmental concerns to corruption suspicions, Panama’s top court ruled that Canadian miner First Quantum Minerals’ contract at Cobre Panama was unconstitutional and forced it to shut down operations at the mine. The site in Donoso employed 7,000 people, accounted for around 5% of Panama’s gross domestic product and 1% of global copper output.

International collaboration and sharing of ideas and expertise at events like CWIEME Berlin help the industry collaborate and do its part to maximize the benefits of copper use and reduce the environmental impact of copper production.

For example, 0.2% of global carbon emissions come from the production cycle of copper, from mining to refining and production. While this is much less than the emissions copper helps prevent, the members of the International Copper Association have committed to the ambition of reaching netzero for Scope 1 and 2 emissions by 2050. Or consider “The Copper Mark,” an industry-wide standard to encourage the responsible production, sourcing, and recycling of copper and other critical metals. Based on 32 indicators, the certification is designed to cover social and environmental themes, from social engagement and prevention of child labour to responsible use of water and management of resources.

Humans have been using copper to make life better for thousands of years and, with the right approach, we can continue using it for thousands more — perhaps its greatest era is still to come.

Bruno De Wachter and Fernando Nuño are representatives of the International Copper Association and members of the advisory board of International Electrical Engineering trade show, CWIEME Berlin.

A slightly modified version of this article has been published elsewhere earlier this year and is republished based on a request from the authors and their representatives.

ON THE MOVE

Executive, Management and Board Changes in Canada’s Mining Sector

TOP MOVES IN THIS ISSUE

Dave Ross, PGeo, the new VP exploration at Radisson Mining Resources. He has over 25 years of experience, particularly in the hunt for gold. Formerly with Calibre Mining and Marathon Gold, he oversaw the resource growth program at the Valentine gold project in Newfoundland. He was also employed by Teranga Gold and for 15 years, by Roscoe Postle Associates. Ross holds a BSc in geology from Carleton University, and MSc in mineral exploration from Queen’s University.

David Minchin joined Eastport Ventures as non-executive chair, bringing over 20 years’ experience in exploration/ mining geology and corporate finance to the role. Previously, as director of geology for African Minerals Exploration & Development Funds, he was responsible for allocating and monitoring $450 million investment into exploration projects at various developmental stages and in various commodities across Africa. Minchin has a successful track record of launching exploration and development companies in both the private and public sectors.

MANAGEMENT MOVES

» The new CEO and chair of Americas Gold and Silver is Paul Andre Huet.

» Big Red Mining named Jim Atkinson as CEO and president.

» The new CFO at Corcel Exploration is Kyle Nazareth of Branson Corporate Services.

Sami Takaluoma was appointed president and CEO of Metso Corp. after 27 years with the company. Born in 1973, he is the holder of an MSc in engineering degree. He joined Metso’s leadership team in 2017, and became the head of the services business in 2021.

Takaluoma took up his new role on Nov. 1, replacing Pekko Vauramo, who will remain with the company until the end of the year to ensure a smooth transition of responsibilities.

» Caprock Mining named Kyle Nazareth of Branson Corporate Services to the post of CFO.

» Fokus Mining named Philippe MacKay as CEO, effective Nov. 4.

» Freeman Gold named CFO Bassam Noubarak to succeed William Randall, who resigned his role of

» Global Copper named Scott Davis as CFO.

» Gold Candle named Dean Crick its new VP exploration.

» Gold79 Mines named Quentin Mai as president.

» The new CFO at GR Silver is Robert Payment following the retirement of Blaine Bailey

» Heliostar Metals appointed Hernan Dorado as VP sustainability and special projects.

» Heliostar Metals named Mike Gingles as VP corporate development.

» Jubilee Gold named Sonia Agustina as CFO.

» Magna Mining added Philip Ng as manager of

Dave Minchin
Sami Takaluomo
Dave Ross

MANAGEMENT MOVES

» Nations Royalty named Josh Kierce as CFO.

» Nevada King Gold appointed John Sclodnick as president.

» Northern Graphite announced the departure of CFO Guillaume Jacq

» Oracle Commodity Holding appointed Alex Bayer its chief legal officer. He will hold the same role at Flying Nickel Mining and Silver Elephant Mining.

» Puma Exploration named Martin Nicoletti its new CFO.

» Robex Resources named the development team for the Kiniero gold project: chief development officer Dimitrios Felekis; construction manager Daniel Kotzee; commercial manager Hesbon Okwayo; and earthworks manager Guillaume Hubert

» Gregg Orr is the new CFO of Santacruz Silver Mining.

» Suzette N. Ramcharan has joint Spanish Mountain Gold as its VP invest relations and corporate development officer.

» Teck Resources named Lyndon Arnall as EVP, chief legal and sustainability officer.

» Wesdome Gold Mines appointed Guy Belleau as COO.

» West Oak Corp., which is changing its name to Silicon Metals, has named Andrew Brown its CFO.

» Westgold Resources named Aaron Rankine its new COO and acting COO Jacob Mesiha was promoted to GM project and operational readiness.

» Atex Resources added Rick McCreary to its board.

» Julian Ovens joined the board of Canada Nickel Company

» Core Nickel named Paul Reid and Marc Pais as directors, and Shane Shircliff and Karen Lloyd have resigned.

» Equinox Gold said Fraz Siddiqui resigned from the board.

» First Nordic Metals strengthened its board with the addition of Jeffrey Couch

» Founders Metals named Christ Taylor a director.

» G Mining Ventures named Naguib Sawiris as a director.

» Global Copper added Nathan Chutas to its board.

» Gold79 Mines named Brodie Sutherland to the board.

» Group Eleven Resources welcomed Gatlin Smeijers to the board, replacing Ken Klassen

» ICMM selected Tom Palmer, president and CEO of Newmont, as its new chair. He succeeds Ivan Arriagada

» The International Copper Association chose Shehzad Barmal, EVP and COO of Teck Resources, as its chair for the next two years.

» Intrepid Metals appointed Matthew Lennox-King as a director.

» The newest board member at Kapa Gold is Josephine Pantazidou.

» Magnum Goldcorp added Dave Smith to its board.

» Mandalay Resources named John Jentz an independent director.

» Manuel Peiffer joined the board of Cartier Resources.

» Nuclear Fuels asked Brahm Silfogel to join the board.

» Omai Gold appointed Drew Anwyll to the board.

» Palisades Goldcorp accepted the resignation of William (Bill) Hayden from the board.

» Pure Energy announced the resignation of Mary Little from the board.

» Laurie Lefcourt is now on the board of Sayona Mining

» T2 Metals appointed Martin Hoff to the board.

» Tintina Mines added Cesar Garrido to the board as Ricardo Landeta stepped down.

» Tres-Ore Resources named Martin Doyle a director.

» Volt Carbon Technologies said Rob Martin resigned his seat on the board.

» Wesdome Gold Mines named Philip C. Yee as an independent director.

» Western Copper and Gold welcomed Raymond Threlkeld as chair, replacing interim chair Bill Williams

» Westmount Minerals announced the departer of director Kenneth Cawkell.

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