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Allison says its Wide Body Dump transmissions going far with Chinese mining trucks OEMs

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Allison Transmission says that several Chinese mining equipment manufacturers have expanded their global presence with the export of trucks equipped with Allison WBD (Wide Body Dump) Series™ transmissions to the Americas, Asia and the Middle East. The WBD Series™ it says provides increased productivity, enhanced manoeuvrability and decreased costs for off-highway mining trucks.

Designed for wide body mining dump (WBMD) trucks operating in more severe duty-cycles and harsher conditions, Allison 4800 WBD transmissions it says provide an extended torque range and a higher gross vehicle weight (GVW) capacity. “They are highly regarded in the mining industry worldwide for their unrivalled performance, quality, durability and reliability.”

Major Chinese mining equipment manufacturers, including SANY, LiuGong, XCMG, PengXiang and Tonly, outfitted their WBMD trucks with Allison 4800 WBD transmissions in the first half of 2023. These trucks were exported in large quantities to Indonesia, Saudi Arabia, Colombia, Brazil, South Africa, the Philippines, Ghana and Eritrea for strip mining and ore transportation.

The Allison 4800 WBD transmission “can perform full-throttle high-torque starts and easy ramp starts, eliminating manual transmission issues such as difficult starts, easy-to-burn clutches, and failures to shift gears on a slope, which could cause the vehicle to skid. In addition, the transmission can automatically and intelligently shift gears in response to changes in road conditions and slope gradient, keeping the engine running efficiently without power interruptions and enhancing the vehicle’s uphill dynamics and safety.” The integral hydraulic retarder in the transmission assists braking without thermal decay, and when used in conjunction with the constant speed downhill function, prevents over-speeding downhill.

WBMD trucks operating in harsh environments need to carry heavy loads, and those equipped with the Allison 4800 WBD transmission are powerful enough to handle frequent starts and stops and to avoid potential failures from working around the clock. Allison’s patented torque converter avoids clutch wear common in manual transmissions and requires only periodic filter and fluid changes to maintain peak performance. Meanwhile, the hydraulic drive of the torque converter reduces mechanical shocks and improves engine and axle life. The Allison 4800 WBD transmission is also equipped with prognostics that provide feedback on the transmission’s health and maintenance needs in advance, and error codes are displayed on shift selectors for easy identification.

For the day-to-day operation of a vehicle, the Allison 4800 WBD transmission “offers the advantages of easy operation, high reliability and low maintenance costs. These benefits allow drivers to better focus on vehicle control in harsh working environments, effectively reducing operational errors and easing the driver’s workload.”

“Allison Transmission is pleased to have maintained a long-term relationship with major mining equipment manufacturers in China. Allison is capable of fulfilling specific requirements from our customers,” said David Wu, Managing Director, China Sales at Allison Transmission. “In line with Allison’s brand promise, we will continue to provide reliable and valuable propulsion solutions that deliver industry-leading productivity and total cost of ownership.”

Epiroc initiates ReNAM project to boost further autonomous mining tech development

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Together with the robotics and AI team at Luleå University of Technology and the technology company Algoryx, Epiroc is initiating the ReNAM project to push the development of autonomous mining even further. The project will utilise simulations and apply state-of-the-art research on Epiroc’s underground mining machines “to enable the next level of autonomy and safety.”

The ReNAM project will develop and validate advanced sensor technology and autonomous control technology for mining vehicles. The project has received funding from the Swedish innovation agency Vinnova and will run from 2023 to the end of 2025.

“Through this partnership, we are contributing to a new generation of machines with improved autonomy capabilities. This is an exciting addition to the on-going development of our automation offering, which helps to further improve safety and productivity for our customers” says Åsa Gabrielsson, VP Research & Development at Epiroc’s Underground division.

As a first step, realistic digital twins of mining machines and surroundings will be modelled in a physics-based simulation environment. Once the sensor- and AI-equipped virtual mining machines have been developed to the point where they can solve tasks safely and reliably in the digitally simulated environment, the next step is to transfer the developed control systems to Epiroc’s mining machine and have it perform the same tasks in a real, physical test mine.

“Through realistic simulations and with safety in mind, where the AI can be trained on the whole system, the machine that is, with its environment and real forces, contacts and behaviours, the outcome will be superior to most projects we see in the world. In order to be successful, collaboration between universities, high-tech, and industrial companies is extremely important,” says Urban Wikman, Business Director at Algoryx.

“We are doing so much more than autonomy, essentially, we are accelerating machines to a new level of technology. The overall quality of Swedish mines, efficiency and safety will be unparalleled,” says George Nikolakopoulos, Chair Professor of Robotics and AI, at Luleå University of Technology.

The goal of the project is to develop and validate two use cases that can lay a foundation for future robotics research and contribute to Epiroc’s future development of commercial products with fully developed machine autonomy.

Scania’s commitment to battery electric vehicles

Scania’s aim is to be the leader in the shift towards a sustainable transport system. Battery electric vehicles will be the main tool to drive this shift and to enable decarbonised transport solutions with better transport economy to customers.

The rapid development of electric solutions for heavy duty vehicles includes the fast advancement of battery technology in respect of energy storage capacity per kg. Charging time, charging cycles and economics per kg are improving rapidly. This means these solutions will become more cost effective, primarily in repetitive and predictable applications. They will gradually overtake Scania’s industry-leading fossil and biofuel powered solutions in most transport applications.

 

“We see that battery electric solutions are the first zero-tailpipe emission technology to reach market broadly. For the customer, a battery electric vehicle requires less service than a conventional one, meaning higher uptime and improved costs per km or hour of operations. We have learnt from the bus segment where transformation started earlier and battery electric options are in high demand. Scania’s timing in that segment was not optimal, however it provided good experiences and we are presently accelerating with the new Scania bus range. It also gave us good base knowledge as we ramp up the electrified truck business,” says Alexander Vlaskamp, Head of Sales and Marketing at Scania.

 

The company has already launched a fully electric truck as well as a plug-in hybrid truck. In a few years’ time, Scania plans to introduce long-distance electric trucks that will be able to carry a total weight of 40 tonnes for 4.5 hours, and fast charge during the drivers’ compulsory 45-minute rest.

 

By 2025, Scania expects that electrified vehicles will account for around 10 percent or our total vehicle sales volumes in Europe and by 2030, 50 percent of our total vehicle sales volumes are expected to be electrified.

Battery electric vs hydrogen

Scania has invested in hydrogen technologies and is currently the only heavy-duty vehicle manufacturer with vehicles in operations with customers. The engineers have gained valuable insights from these early tests and efforts will continue. However, going forward the use of hydrogen for such applications will be limited since three times as much renewable electricity is needed to power a hydrogen truck compared to a battery electric truck. A great deal of energy is namely lost in the production, distribution, and conversion back to electricity.

 

Repair and maintenance also need to be considered. The cost for a hydrogen vehicle will be higher than for a battery electric vehicle as its systems are more complex, such as an extensive air- and cooling system. Furthermore, hydrogen is a volatile gas which requires more maintenance to ensure safety.

 

However, hydrogen is a promising energy carrier; good way of storing energy over long cycles, and will play an important role in decarbonisation if produced in an environmentally friendly way. Scania looks forward to sourcing fossil free steel for its trucks as hydrogen will play a greater role in several industries.

 

Stationary fuel cells are an important component of the electric charging system. This solution is especially promising in areas with abundant renewable energy, and in rural areas off the main electricity grid.

 

“To do what’s best for both our customers total operating economy and our planet, we are not closing the door on any possibilities. It is clear that Scania’s focus in the here-and-now perspective as well as short- term is a combination of renewable fuels and battery electric vehicles. We see that for basically all segments,” Vlaskamp continues.

Committed to more electric products

Scania’s science based climate targets will see the company cut COemissions from its own operations by 50 percent by 2025, as well as reduce emissions from the customers’ vehicles by 20 percent during the same period. To fulfil these far reaching targets, Scania’s focus is on well-to-wheel, which is more stringent than many of the legislative regulations coming up which centre on tank-to-wheel.

 

The company commits to launch at least one new electric product application in the bus and truck segment every year. At the same time, societal investments in a solid infrastructure for battery electric vehicles remains a priority.

 

“Scania’s focus is our customers’ business. Transport operators must be able to continue  performing assignments in a sustainable way at a reasonable cost,” Vlaskamp concludes.

Scania builds battery laboratory

With Scania’s planned rapid introduction of electric vehicles over the coming years, there is a concurrent need to intensify battery testing and tailored deployment. Scania is therefore investing EUR 15.5 million in a new battery laboratory at its research and development facilities in Södertälje, Sweden.

With Scania’s planned rapid introduction of electric vehicles over the coming years, there is a concurrent need to intensify battery testing and tailored deployment. Scania is therefore investing EUR 15.5 million in a new battery laboratory at Construction of the 1,000-square metre laboratory recently commenced and building works will be completed by spring 2021. Following extensive testing and verification of equipment and instruments, the laboratory will be fully operative by autumn 2021.The laboratory will contain three 250-square metre test halls for battery cells, modules and packs. Adjacent to these halls, the laboratory will also have facilities for test sample preparation in order to improve work environment, safety and testing uptime.

 

“With the accelerating pace of development, the laboratory will strengthen our capacity to right-size batteries for every application,” says Claes Erixon, Head of Research and Development at Scania. “We have an ambitious roadmap ahead of us in annually launching new and updated electric products with related battery services. This underscores the need for world-class skills and knowledge in battery usage and lifecycle optimisation.”

 

The laboratory will primarily focus on battery performance and lifespan evaluation in varying climate conditions from -40°C to 70°C. Scania’s engineers will examine and identify the best operational conditions for the battery with regard to, for example, temperature setpoint, state of charge window and charging power profile for tailored utilisation in optimising battery life and customer needs.

 

“Scania will continue to invest in competence both in our own operations as well as through important partnerships. We are going to make sure that the Södertälje and the Stockholm region will remain in the forefront of in the research and development also in an electrified future of heavy transport,” says Erixon.

 

The new battery laboratory will complement a smaller facility with a climatic chamber for battery pack testing that was taken into use earlier this year. With this lab, Scania can test the performance of battery packs on operational electric trucks and buses without removing batteries. Vehicles are parked adjacent to the lab and connected to testing equipment.

Logistics African Magazine [Published by PWL Global Network] team to be distributing at TOC Africa- Morroco

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TOC Africa will be the essential event connecting Africa’s ports and terminals with the wider international container supply chain.

Built upon the expertise of TOC Worldwide’s 40+ years of experience in connecting and informing the leaders, technology experts and policymakers at the centre of today’s highly-complex container supply chain – TOC Africa aims to propel the region’s imminent port revolution.

Bringing together the continent’s key shippers, logistics providers, shipping lines, 3PLs, ports, terminals and more, TOC Africa is your gateway to the continent’s ports and logistics supply chain.

Join us and let’s shape the future of this exciting region – by building a stronger, more sustainable and more efficient industry together.

Cobre and Sandfire kick off joint airborne surveys over Kalahari copper belt projects

Cobre Ltd has kicked off a collaborative airborne gravity gradient (AGG) survey with neighbour Sandfire Resources, covering a large portion of the Kalahari Copper Belt (KCB), including Cobre’s Ngami Copper Project, Kitlanya West and Kitlanya East (KITE) Projects.

Notably, the results are expected to provide valuable information on KCB basin architecture and the location of sub-basins, margins and controlling structures where copper-silver mineralisation may be targeted.

The survey will complement results from the recently completed 5,000-metre diamond drilling, ongoing soil sampling, and aircore and reverse circulation drill programs, providing valuable additional data for area and target prioritisation at Kitlanya West and Ngami Projects.

Furthermore, AGG results may also help in the detection of copper-silver bearing trap sites analogous to Sandfire’s neighbouring T3 and A4 deposits at KITE, providing new targets for drill testing.

Significant insights

Cobre CEO Adam Wooldridge said: “We are pleased to announce that the AGG survey, in collaboration with Sandfire, is finally underway. These results are expected to provide significant insights into our understanding of the regional controls for copper distribution in the KCB.

“They will also provide a new targeting tool to complement our other datasets. The deliverables from this survey are expected to be highly complementary to the results from our ongoing aircore, reverse circulation drilling and soil sampling programs at KITW as well as providing further context for the distribution of copper-silver grades at NCP.

“Additionally, the results over the KITE project will be particularly interesting given its proximity to the T3 deposit and potential for hosting similar styles of deposit.”

Survey background

Gravity data is routinely used for mapping sedimentary basins where it provides a cost-effective method for modelling the basin architecture, often key to understanding the distribution of sedimentary copper deposits.

This is demonstrated in the historical regional ground gravity data over the north-eastern portion of the KCB where correlations are evident between the margins of gravity lows and known copper-silver deposits.

The higher resolution AGG is expected to build on these correlations, identifying further priority sites for copper-silver deposits as well as providing important structural information and potentially identifying trap-site targets where mineralisation may be economically upgraded.

Ivanhoe Updates On Sustainability Initiatives

Ivanhoe Mines, a diversified miner with a 26-year history in the African mining sector, is aiming to enhance the sustainability goals of the group and its flagship Kamoa-Kakula copper complex in the Democratic Republic of Congo (DRC).

The company plans to utilize hydropower potential and abundant sunshine to decarbonize the mining industry, while also exploring various options to increase alternative power solutions. Ivanhoe has obtained approval for environmental and social impact assessment amendments for Kamoa-Kakula’s Phase 3, while it awaits the same for its Platreef project in South Africa. The latter is expecting to receive power from a 5 MVA solar power plant before year-end, and evaluating other power options.

The company has also completed a greenhouse gas alternatives analysis for Kamoa-Kakula and implemented GHG emissions programs to reduce emissions. Additionally, the company has established a biodiversity project nursery and an apiary as sanctuaries for pollinators, promoting natural habitation and plant diversity.

To meet local procurement obligations, Ivanhoe has implemented targeted enterprise and supplier development programs, which have supported seven informal enterprises and 41 formal enterprises. Additionally, eight opportunities have been exclusively earmarked for local community suppliers.

The company is also building the Kamoa Centre of Excellence to create a sustainable and community-focused higher learning environment.

The community development initiatives of Ivanhoe have provided communities with valuable infrastructure, as well as supported local businesses and established value chains in the areas around the mining complexes. These initiatives also include investments in sustainable agriculture and farming, early childhood education, and gender equality.

START WITH CHUTE DESIGN TO REDUCE DUST, SAYS WEBA

Many industrial facilities, mines and power stations rely too much on dust suppression and extraction systems, when the real answer is to improve the flow of material through well designed chutes.

 

This is the considered opinion of Weba Chute Systems technical director Alwin Nienaber, based on decades of experience in this field. His view is that 50% to 80% of the dust problem around conveyors and transfer points can be resolved by applying the right chute system design and positioning equipment correctly.

 

“Many of the dust suppression and dust extraction systems that are applied in these applications are expected to do more than they are capable of,” says Nienaber. “A preferable approach is to get the chute design right first, and then apply these other systems to deal with the residual dust load.”

 

He explains that the advantages of doing this extend well beyond the health and safety benefits. He has seen more than a few situations where the dust created by a poorly designed chute can prevent personnel from moving or working in that area. This often prevents the checking or maintenance of critical equipment during operating hours, requiring more downtime to wait – literally – for the dust to settle.

 

“In examples like this, excessive dust can reduce an operation’s efficiency, so there is an opportunity to improve overall productivity by fixing the dust problem,” he says. “Other equipment in these areas also gets heavily coated with dust, and needs regular cleaning to ensure optimal performance. Cleaning becomes yet another avoidable cost.”

 

To address excessive dust creation, a good chute design is based on understanding the physics of material flow – and avoiding uncontrolled velocity and impact. A lack of control over the way material flows will degrade the material and create higher levels of aeration – which is what leads to dust dispersal.

 

“Our philosophy at Weba Chute Systems is to ensure that material flows more easily and remains consolidated as a homogenous stream,” he explains. “We base our designs on the ‘supertube’ effect, which also allows the controlled transfer of material onto the conveyor belt. Not only does this reduce dust, but it also cuts down on the wear rate of the belt itself.”

Seepex’s new BF range of pumps has been tailored to the needs of the growing battery production industry.

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The gigafactories being built around the world to meet the huge demand for lithium-ion batteries in the automotive, electronics and semiconductor industries require a large number of pumps.

In battery production, chemical resistance and chemically compatible materials are required to avoid contamination of valuable raw materials. During the critical process of formulation, continuity and high repeatability are essential. Contamination-free pumps are also needed for smooth operation. The coating process plays another important role, as the pump has a direct impact on product quality by minimizing variations in coating thickness.

The Seepex BF pump is precisely tailored to these requirements; ensuring safety, cleanliness, high product quality and cost efficiency. The maintenance-friendly design reduces downtime and the total cost of ownership (TCO). The clamp connections for quick installation/removal and the removable rotating unit simplify replacement and maintenance work. With proper maintenance the robust pump has a long product life.

The Seepex BF pump can be installed quickly, has a flow rate of up to 30 m³/h and operates at a pressure of up to 12 bar. It is available in block or bare shaft design and can meet customer-specific drive requirements. A TA-Luft or ATEX certified version is also available.

“Operational safety and maximum cleanliness when using valuable dispersed raw materials were the driving forces behind the development of the BF range,” says Thomas Dufner, Battery Market Manager at Seepex. “It helps reduce total cost of ownership and improve energy efficiency in virtually all battery applications by eliminating contamination and being easy to maintain. Cleaning cycle failures and disposal of contaminated battery compounds are not only wasteful, but also very costly.”

“Chemical resistance and chemically compatible materials are necessary to prevent contamination of expensive raw materials,” added Dufner. “With BF, we assure that the materials are chemically compatible. The stainless steel design and flexible titanium shaft ensure contamination-free product quality. Contamination by oil or grease is impossible. The pumps can be thoroughly cleaned with common solvents and deionized water.”

Battery compounds, from lithium to electrolyte, can be added to the mixing process in precise, drop-by-drop doses. Continuity and high repeatability are critical during the formulation process. In the coating process, the pump has a direct impact on product quality by minimizing variations in coating thickness. The BF range achieves this continuity and high repeatability by using the Seepex progressive cavity pump principle with the advantage of extremely low pulsation. This ensures the highest dosing accuracy, resulting in better coating results and more accurate slurry recipes.

Seepex progressive cavity pumps, with their special design, have no spillage or leakage due to their high degree of sealability. In addition, a wide range of seals is available for different battery compounds.

Seepex, which is part of the Ingersoll Rand Group, produces its battery pumps in Shanghai, China and Bottrop, Germany in order to be able to offer large quantities with short delivery times.

Switzerland’s Maag Group is expanding its presence in China creating additional production capacity and introducing new products specifically for the Chinese market.

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Maag has been stepping up its localization strategy in China since 2022 where it currently employs 103 people. Recently, for example, Maag’s assembly shop in Jiading, a district of Shanghai, has doubled in size.

“With this expansion, Maag is now well positioned for the further expansion of its localization activities in China,” says Ueli Thürig, president of the Maag Group. “‘Made in China for China’ is one of the key strategies our company has been focusing on in recent years; more than 90% of the equipment assembled in our Shanghai plant is intended for the Chinese market.”

Maag already produces GA series extrusion pumps, BAOLI strand pelletizers and ZHULI underwater pelletizers in China. A similarly adapted version of the M-USG underwater strand pelletizing system will now expand the market-specific portfolio as the C-USG. The original German design will form the basis for this new version. While some key components will be supplied from Germany, the majority of parts will come from local production. The first C-USG systems will be delivered to customers at the end of 2023.

The added space will also accommodate a new service center for the Maag/Ettlinger recycling filter to enable MAAG to serve local customers more quickly. MAAG is responding to the increased number of continuous melt filters installed across Asia.

The Maag Group is a business unit of Pumps & Process Solutions, a segment of the Dover Corporation.