May 17, 2020

Q&A: Innovation and productivity in the mining sector

Austmine
Q&A
Australia
interview
Admin
5 min
Q&A: Innovation and productivity in the mining sector
​​Austmine 2015: Transforming Miningis just around the corner, so with its emphasis on innovation and productivity, we decided to catch up w...

​​Austmine 2015: Transforming Mining is just around the corner, so with its emphasis on innovation and productivity, we decided to catch up with SRO Technology's Managing Director, Peter Seligman about innovation, collaboration, productivity and the greatest challenges across the mining value chain right now. Peter is a qualified engineer, who has been at the helm of SRO Technology for 2 years now, the latest role in a career spanning property, infrastructure, mining and investment banking.

As an Australian-owned mining equipment, technology and services (METS) company recognized as the world leaders in innovation and technological advancement, how important is it to keep innovating and collaborating within the industry as a whole to ensure its future?

No single mining equipment, technology and services (METS) business can solve all the challenges faced by the customers in our industry. Real innovation and advancement comes from connecting adjacent technologies in an effective and efficient way.

For example, at SRO Technology, we focus primarily on designing and installing belt scale, metal detector, bin level and density gauge systems for the mining industry. However, we regularly collaborate with a range of partners to ensure that our customers get the right mix of technology and support to solve their problem.

METS in Australia is a highly fragmented industry, made up of many great niche players and a few larger generalists. In order to obtain its strong global reputation, businesses within the Australian METS sector have had to collaborate to both compete on a global stage and access the combination of technology required to solve high-end problems.

To remain competitive and profitable, it is critical that METS businesses continually innovate in a collaborative way. Fundamentally, collaboration (and in many ways innovation) are not optional extras--they must be core to business as usual.

SRO Technology has a field service team of engineers and technicians as part of your wider service offering. Field service management is a huge area of focus for many organizations, with significant opportunities existing to improve customer satisfaction, efficiency and productivity. What are the biggest challenges with having a field service team? How does it allow you to better deliver for your customers?

It all comes down to the customer, followed by the team and then our profitability.

The first and most important challenge is having the right technician with the right expertise available at the right time to solve the problem for the customer. This reliability requires a business focus on recruiting, training and retaining a great team of people, and then having sufficient unutilized capacity to respond to customer needs. This approach demands real confidence in the vision and strategy of the company in order to invest in the team--any lacking clarity of purpose will only undermine the confidence to build and field a strong team.

Ultimately our customers want accurate and reliable output from their measurement instruments. Our field service team frequently fixes problems on site before those problems begin to significantly impact accuracy. They do this by working with what’s available on site to keep the customer operating reliably whilst a longer term solution is resolved. This real-time problem solving is valued by our customers in an environment where the cost of downtime can have a significant impact on net productivity and efficiency. Extending the useful life of critical instruments is also of great value in the current capital-constrained, productivity-focused environment.

Our field service team is on the front line of our customer relationships – their insight and regular feedback allows us to constantly look for ways to improve the customer experience.

The transport of ore around the site and processing plant is obviously a critical part of the overall mining value chain. Where are the biggest risks in this part of the chain? How can miners ensure the most efficient conveyance of resource on site?

I believe that a significant commercial risk in the movement of ore and product through the mining process is not having accurate and reliable measurement information. If you cannot rely on your information, or you are inadvertently relying on inaccurate information, you will make decisions that will drastically impact your efficiency and you may not truly understand the flow and position of material and product across the site.

A great opportunity to improve the efficiency of material movements, and therefore productivity, on site is to improve the accuracy and reliability of measurement instruments. More accurate information will more readily identify inefficiencies in the system and allow process engineers and other members of the mining team to refine the process.

For example, a small error in the belt weighers supporting a crushing and screening process may influence a misinterpretation of the sizing of the screen or the effectiveness of the crusher. A minor error in the bin level system that controls the loading of trains or trucks may under or overload vehicles, requiring either material to be removed or dispatch vehicles to not be fully loaded. A small error in the resolution of a tramp metal detector could allow tramp to pass into a critical process, or cause a false trip that results in unnecessary, costly downtime. The smallest error in a density gauge may influence the wrong specific gravity in a float tank, sinking valuable material, or sending precious product slurry to tailings when it should be retained.

Improving the accuracy and reliability of measurement instruments across the site will increase the resolution of information available to key decision makers and allow them to refine their process to maximize efficiency.

What do you see as the biggest opportunities for the mining industry in Australia in 2015 to improve productivity?

Increasing productivity is all about getting more output from less input. Therefore, more accurate and more comprehensive measurement of product and processes on site will allow for a better understanding of the productivity challenge--and subsequently the success or failure of productivity initiatives.

Firstly, measurement instruments must be properly applied on site to avoid errors inherent in application and deliver more accurate information to decision makers. These instruments are essentially the nerve endings of the mining information system. Regardless of the inherent accuracy in any instrument, if it is not properly applied it will never deliver its optimum accuracy. Technology is increasingly ‘plug-and-play’; however, failure to ensure proper physical application will not deliver accurate results.

Raw data can be interesting, but relevant and useful information derived from that data is far more insightful. Translating raw data into useful information to target critical key points in the production chain and then communicating those insights effectively from the site through to the boardroom will allow a better understanding of productivity at every level in the organization and the steps required to improve it.

Visit AustMine.com.au for more information.

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Jun 30, 2021

Rio Tinto and Alcoa begin construction with ELYSIS tech

Rio Tinto
ELYSIS
Decarbonisation
Alcoa
3 min
ELYSIS
Rio Tinto and Alcoa’s JV project ELYSIS has the potential to transform the aluminium industry, with a significant reduction in its carbon footprint

Eliminating all direct greenhouse gases from aluminium smelting has taken a major step forward with the start of construction on the first commercial-scale prototype cells of ELYSIS’ inert anode technology, at Rio Tinto’s Alma smelter in Saguenay-Lac-Saint-Jean, Quebec.

ELYSIS has the potential to reduce the carbon footprint of aluminium production

ELYSIS is a joint venture company led by Rio Tinto and Alcoa that is developing a new breakthrough technology, known as inert anode, that eliminates all direct greenhouse gases (GHGs) from the traditional smelting process and instead produces oxygen.

The technology has the potential to transform the aluminium industry, with a significant reduction in its carbon footprint.

The inert anode prototype cells will operate on a commercial scale typical for large modern aluminium smelters, using an electrical current of 450 kiloamperes (kA).

The Honourable Francois-Philippe Champagne, Minister of Innovation, Science and Industry joined representatives from ELYSIS, Rio Tinto and Alcoa to mark the start of construction and announce a further CAD $20mn financial contribution from the Government of Canada to support the project.

The federal government's financial support will enable the creation of a unique commercial size inert anode technology showroom for future customers and will help develop the supply chain by involving local and regional equipment manufacturers and suppliers in the project.

ELYSIS is working to complete the technology demonstration by 2024 followed by the commercialization activities.

ELYSIS technology at a glance:

  • The ELYSIS technology addresses the global trend towards producing low carbon footprint products, from mobile phones to cars, planes and building materials.
  • The new process will reduce operating costs ofaluminiumsmelters while increasing production capacity. It could be used in both new and existing aluminium smelters.
  • In Canada alone, the ELYSIS technology has the potential to reduce GHG emissions by 7 million tons, the equivalent of removing 1.8 million cars from the roads.
  • ELYSIS will also sell next-generation anode and cathode materials, which will last more than 30 times longer than traditional components.

Alcoa and Rio Tinto will continue to support the ELYSIS development program alongside the Governments of Canada and Quebec.

ELYSIS is working closely with Alcoa's Technical Center, where the zero-carbon smelting technology was invented, and the Rio Tinto technology design team in France.

Alcoa's Technical Center supports ELYSIS in the manufacture of proprietary materials for the new anodes and cathodes that are essential to the ELYSIS process. The Rio Tinto technology team in France is creating commercial scale designs for the ELYSIS technology.

 

Vincent Christ, CEO, ELYSIS commented: “This is a great day for ELYSIS. It means that we are becoming the first technology company in the world to build commercial-size inert anode cells. While we refine the technology in our R&D Centre, we start the construction of our prototype cells. This shows our confidence in our process and in the know-how of our team. The combination of ELYSIS' zero CO2 technology and Quebec's renewable energy will be great competitive advantage for the future. I would like to thank the government for its support and all the partners for their commitment.”

Samir Cairae, Rio Tinto Aluminium managing director Atlantic Operations and ELYSIS board member added: “Today marks a real step towards the future of the aluminium industry, by progressing this breakthrough technology to cut carbon emissions. Rio Tinto is committed to supporting its ongoing development here in Quebec where we already use clean hydropower to deliver some of the world’s lowest carbon aluminium. Combining this technology with renewable hydropower holds the promise of zero carbon aluminium smelting.”

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