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mine operators formulate accurate financial forecasts.” “Along this line, mining companies should Lonely also be mindful of associated costs that come with building or purchasing a permanent power plant. When a mine operator goes for the rental option, all spares and ancillaries will be power provided by the temporary power company. “Mine operators will be happy to know that in hiring power plants, they will no longer need to employ new operators or allocate or re-train existing staff members to manage the plant. Temporary power providers will provide the necessary expert services to ensure the faultless operation of the power station.” Temporary power plants can also assist in reducing the energy intensity of mine operations. “Hiring power plants will preclude the chances of generators being under-utilised, because the capacity of rental power generation Access to reliable and cost-effective forms of energy is a equipment can be increased or decreased with respect to the demand of specific mine strategic priority for the global industry. John Chadwick processes.” examines both traditional and solutions Zahid says that as conventional power plants are usually specified to meet the peak demand ining has traditionally relied on operations can make significant adjustments to of a particular site, they are left under-utilised conventional fossil-based fuel sources their capital expenditure. “Electricity,” he says, when the power requirement decreases. “When M— diesel, oil, coal and — “remains to be the life-blood of mine sites a power plant is running at part-load, it to meet its growing energy demand. The anywhere in the world. However, with the consumes fuel less efficiently. This will no industry is expanding into new and often remote present economic situation, mine operators longer be the case with rental power plants on locations as a response to increasing demand cannot afford to devote, rather strap, a large board, thanks to their flexibility and scalability.” from growing emerging markets. This often portion of their scarce capital to a major Zahid says that renting power during the means having to deal with unreliable power expenditure, like a permanent power plant. exploration stage of a mining operation yields supply from the grid and uncertain power prices. Considering this, mine operators can instead myriad advantages. “By hiring temporary power In most instances, grid-connected electricity choose to hire multi-megawatt temporary power plants, mining companies will have the freedom needs to be supplemented with on-site solutions.” to start with a small power plant, and then grow generation, typically large-scale diesel A consistent, dependable and sufficient as operations expand. When the long-term generation, resulting in a dependency on diesel supply of electricity is vital throughout the life- prospect of a project is still uncertain, it may not fuel. The more remote the mine, the more likely cycle of a mine operation. “Temporary power make sense to invest in permanent facilities. off-grid power solutions are required (From EY’s plants,” says Zahid, “can adequately provide for Renting power, therefore, protects companies Mining: the growing role of renewable energy). the electricity needs of a mine site. They can from the unsecure future of mining projects at “Many of the world’s largest mining power camp sites during prefeasibility, the exploration stage. companies are evaluating greater use of feasibility and exploratory stages, and support “Rental power plants are highly suitable for renewable energy plants — a trend set to the establishment of the mine operation after a exploration activities in remote areas, because intensify rapidly — as part of a broader strategy successful exploration. They can provide power they are containerised and modular, so they are to lock in long-term fixed electricity prices and to the machinery and the processing plants, and easily transported and installed. The latest- availability while minimising exposure to also to the temperature-control equipment. generation temporary power plants have state- regulatory changes, market pricing and external Obviously, they can also provide the necessary of-the-art switching and transformation systems fuels.” power for expansion. that give them the ability to connect to any “In a highly volatile market”, says Majid “Multi-megawatt temporary power plants location’s grid, regardless of its age, quality or Zahid, Group President-Energy at Zahid Group, could not be more relevant to the mining condition. This is possible even without a sub- the parent company of Altaaqa Global, a global industry than in these times,” says Zahid, and station, as the same systems allow the power provider of multi-megawatt temporary power adds that renting power is a logical decision for plants to assume the role of a sub-station and solutions, “it is essential for mining companies any miner looking to effectively streamline its connect to available overhead lines or to strike a balance between controlling costs operations. transformers. and capitalising on growth prospects and “For instance, in this economic climate, one “Temporary power plants also have cutting- profitable opportunities. It is, therefore, cannot overstate the importance of precise edge electric power control and protection imperative for them to ensure the efficient allocation of funds and of better management of systems, which allow them to switch operational utilisation of their working capital.” financial resources. A key benefit of renting mode, from grid, to island, to base load or to Zahid is of the view that power generation power is that payment schedules are fixed and standby at a push of a button in mere minutes. and supply represents an area where mining regular over a contracted term. This can help This is particularly useful for companies whose

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exploration activities take place in areas unconnected to the grid. “Caterpillar believes,” Zahid says, “that to be an innovator, a company must be working directly in the service of its customers. As part of the Caterpillar family, we at Altaaqa Global are proud to be well positioned to offer our clients in the mining industry the latest technologies in temporary power generation. “For example, it is now possible for our engineers to monitor the status and performance of our engines from any location through Cat Connect. This gives us temporary power providers relevant insights on the go, so we can better manage our equipment, optimise their performance or perform preventive maintenance, if necessary. “There are also hybrid power solutions, which now allows renewable solar and systems of any size to be delivered to and installed in literally any location on earth. In tandem with our temporary power plants, the solution guarantees a reliable, sufficient and sustainable power supply to any mining operation anywhere in the world. Remote projects that are far from national power grids will tend to pay a premium for generating their own energy; so they need to plan carefully to use it as efficiently as they can. This is the advice of Zest WEG Group CEO Louis Meiring, who emphasises the opportunities presented by modern technology to reduce energy consumption in just about any mining enterprise. “Savings of 3 to 5% of energy consumed on site is a realistic target for most projects, especially if the enabling technologies and equipment can be incorporated into the design at an early stage,” says Meiring. He says the potential savings lie not only in the operating cost of the standalone power generating facility, but in the capital expenditure for construction, as better utilisation efficiencies can reduce the maximum output capacity required from the plant. Alastair Gerrard, Managing Director of Zest Energy, says his company – which specialises in power supply solutions – works closely with EPCM companies or directly with customers to plan and implement optimal solutions. This approach ensures that equipment life cycle costs are well controlled and contribute to overall project efficiency. “In addition to ensuring the right power generation solution for customers, we enhance our value-add through our knowledge of exactly how the generated energy can be best used,” says Gerrard. “WEG’s high efficiency, IE3 rated motors, for instance, can reduce the power consumed in a range of industrial functions such as pumping, conveyor systems and ventilation.” Zest Energy recently installed a turnkey diesel power generation facility for the Balama graphite project in a remote region of . Technology options such as variable speed drives can further enhance efficiencies and reduce the consumptive demands that a standalone power plant will have to meet; regeneration strategies also lower costs by feeding power back into the network. “There is also potential for ‘heat and power’ co-generation as an efficiency strategy,” says Gerrard, “where heat can be drawn off equipment like engines to feed back into plant functions, rather than being dissipated with no benefit.” He sees a trend among many users towards pursuing higher energy efficiencies, as this can improve the cost-per-hour of running their assets and lead to a reduction in emissions by using more efficient technologies. “There is also a growing interest in hybrid solutions that can incorporate renewable energy sources like solar and wind, alongside traditional fossil fuels,” says Gerrard.

Diesel power Conventional diesel power generation continues to have its place for remote mines but is being strongly challenged by renewable resources. One such traditional example is Wärtsilä supplying a power plant extension

JANUARY 2018 | International Mining 27 POWER FOR MINES #3_proof 21/12/2017 11:07 Page 3

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2017-2020, thanks to The switch over is the outcome of a special With this Siguiri project, Wärtsilä will mining investments, arrangement between the company and have over 6,800 MW of installed capacity on the African continent increased food independent power producer (IPP), Genser production and Energy , that will spare some 18 MW of electricity service. power for the national grid while insulating the “This is a significant company's operations from the erratic power proof of confidence for supply. Wärtsilä in West The company's Vice President and Head of Africa,” comments Stakeholder Relations, David Johnson, explained Arnaud Gouet, that the new arrangement will result in the Regional Director, West generation of 20 MW of electricity each in the Africa, Wärtsilä Energy Tarkwa and Damang mines within the first two Solutions. “Wärtsilä is years. Later, the amount of power generated a trusted partner to could be raised depending on the growth profiles AngloGold Ashanti at of the two mines, Johnson explained. to AngloGold Ashanti's gold mine in Siguiri, Siguiri mine where we operate the power The two mines currently consume a total of 55 Guinea. This turnkey project consists of three 20- generation enabling them to focus on their MW, with the Tarkwa operations, one of the cylinder Wärtsilä 32TS engines running on heavy mining operation.” biggest surface mines in West Africa, consuming fuel oil. They will be connected to the existing “We selected Wärtsilä for the new power plant 38 MW and Damang 17 MW. power plant at site, also supplied by Wärtsilä. at our Geita mine in in 2016 and have The production of 20 MW each in the two The extension is expected to be operational again selected Wärtsilä for our Siguiri project as mines, therefore, means that Gold Fields can during the second half of 2018 and the total we have full trust in Wärtsilä's technology and in spare a total of 15 MW of electricity for the power output at site will be 30.4 MW. their understanding of the criticality of power national grid, which can then be redistributed Siguiri, a multiple open-pit oxide gold mine generation in the operation of such a gold mine,” among new and existing customers of the and the largest gold mine in Guinea, is AngloGold says Dale Bates, Project Manager, CAR Projects, national power supplier, the Electricity Company Ashanti's sole operation in the country. AngloGold Ashanti. of Ghana (ECG). AngloGold Ashanti holds an 85% interest in Nearby, Gold Fields Ghana is switching the Beyond shielding the company's operations Siguiri with the balance of 15% being held by the source of energy supply for its mining operations from the erratic power supply, Johnson said it Government of Guinea. After two difficult years, in the Western Region of the country from the would also save cost as the alternative power to the Guinean economy is recovering, with an national grid to privately generated electricity by the grid was comparatively less costly. average projected growth of 5% over the period the end of the third quarter. For the Damang installation, Centrax Gas Your complete source for DRILLING rocki

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Turbines sold five CX501-KB7 generator sets to competition. Genser Energy Ghana. Each incorporates a ACTOM was Siemens 501-KB7 gas turbine. The KB7s will run contracted for the on vapourised propane with fuel supply and mechanical treatment also part of the Genser contract with installation of two Gold Fields. Skoda Doosan (Czech Genser’s expertise in running turbines on Republic) 150 MW propane opens up a large potential market in turbo generator sets, Africa for Centrax where pipeline natural gas is which each comprised not available and liquid fuel is not economically of an integrated high viable. Peter Ward, Centrax’s Sales and Marketing pressure and Manager commented: “this order further intermediate-pressure strengthens Centrax’s position in West Africa and turbine, a low pressure follows on from the sale of a CX501-KB7 to turbine, a Siemens generator, a radial condenser, The turbine generator set for Cobre Panama Cometstar, .” and auxiliaries. showing the Siemens 150 MW generator and the low pressure and high pressure Skoda Doosan ACTOM Turbo Machines demonstrated its Richard Botton, Marthinusen & Coutts’s CEO turbine set ability to provide complete electro-mechanical as well as ACTOM Turbo Machines’ Managing solutions with the installation of 150 MW turbo Director, Chris Bezuidenhout and eventual Site generator sets for First Quantum Minerals’ Cobre Manager John Squire, took several trips to Machines installation crew’s expertise was Panama new large open-pit copper mining Panama to review the scope of work, drawings pivotal to the successful installation of the turbo operation in the Donoso District, Republic of and site conditions to compile the proposal, generator sets. Panama. which resulted in Marthinusen & Coutts’ first The tropical region’s high rainfall and open Securing what was the first international international installation. building also placed extreme strain on the contract to have been won by ACTOM Turbo ACTOM was responsible for the installation of schedule. The turbo generators’ house was Machines can be attributed in part to the the centreline of the turbo generator sets, which largely open, and only equipped with a 40 t longstanding relationship between Marthinusen started with the inspection of the civil works, overhead crane, whereas the larger assemblies & Coutts, also an ACTOM division, and the followed by the systematic assembly of the turbo and components, such as the HP-IP double customer, as well as its established track record generator’s in the form of transportable turbine and the LP turbine components weighed of successes on previous projects for this mining components and sub-assemblies. As the original 125 and 161 t, respectively. company. It is also noteworthy that this contract equipment manufacturer (OEM) only supplied an Weather permitting, ACTOM made use of was secured against tough international Installation Quality Controller, ACTOM Turbo crawler cranes to install these larger This Changes Everything!

EFD’s HydroFloat™ Separator radically improves the traditional

Particles approximately 850 microns sulfide processing circuit through Coarse Particle Flotation. Unlike conventional flotation, the HydroFloat Separator Þ`Àœœ>ÌÊ-ÞÃÌi“ recovers particles as large as 800 microns with as little as 1% mineral surface expression. By rejecting the balance as “coarse” tailings, much of the recirculating load is eliminated, thus greatly increasing mill capacity… with NO loss in mineral recovery! Overflow Coarse Mineral Coarse Particle Flotation using EFD’s HydroFloat Separator can: U ˜VÀi>ÃiʓˆÊÌ ÀœÕ} «ÕÌÊLÞ Recovers virtually all Air particles which exhibit >ÃʓÕV Ê>ÃÊ£x‡Óä¯ greater than 1% hydrophobic surface expression U ,i`ÕViÊi˜iÀ}ÞÊEʓi`ˆ>ÊVœ˜ÃՓ«Ìˆœ˜ Underflow Coarse Tails U *Àœ`ÕViÊ>ÊVœ>ÀÃiÊÌ>ˆˆ˜}ÊÃÌÀi>“

RECOVERY OF VALUES FROM A PORPHORY COPPER TAILINGS STREAM RY COPPER TAILINGS STREAM

Michael J. Mankosa, Jaisen N. Kohmuench,nch, Lance Christodoulou Eriez Flotation Division, 2200 Asbury Road Road, Erie, PA 16506 USA Phone: (814) 835-6000 Email: [email protected] RTICLE [email protected] SPLIT- OARSE PARTICLE FEED CIRCUIT DESIGN FOR PRIMARY SULFIDE RECOVERY HNOLOGY Jaisen Hilsen and Gerald H. Luttrell Mining & Minerals Engineering, 100 Holden Ha H. Luttrell ll, Virginiaginia Tech, BlaBlacksburg, VA 24061 USA cksburg, VA 24061 USA Phone: (540) 230-7112 Email:: [email protected]@vt.edu Eriez FlotationMichael Division J. Mankosa

-GRADE COPPER ORE WITH THE HYDROFLOAT TECHNOLOGYes and THE SIGNIFICANCE OF EXPOSED GRAIN SURFACE and Yan AREA Wang IN C Phone: , Jaisen N. Kohmuench , C.L. Lin ABSTRACT (814) 835 2200 Asbury Road FLOTATION OF LOW , College of Mines and USA Earth Sciences -6000 Jan D. Miller Mining & Minerals Engineering, 100 Holden Ha Email: [email protected], Erie, Rejects only those The efficiency of the froth flotation process has long been known PA 16506 Metallurgical Engineering, Salt Lake City, UT 84112 own to be strongly dependentdepende on particle size. USA [email protected] For sulfide minerals, good recoveries are typically ach nt on particle size. Gerald H. Luttrell Department ofUniversity of Utah Email: ieved in industrialindustrial flotation circuits for pparticles -581-5160 the 10 to 200 micron size range. Particles outside this c articles in Phone: (540) 230 Phone: 801 USA riticall size are typically lost iin the tailings streams ll, Virginia Tech, Blacksburg, VA 24061 USA Jaisen N. KohmuenchPA 16506 rejected by industrial operations due to inherent constraints associated with the physicaln the interactionstailings streams that -7112 , Erie, occur in the pulp and froth phases of conventional flotation equipment.associated withIn response the physical to thes interactions that Email: [email protected] Michael J. Mankosa, 2200 and Asbury Road equipment. In response to thes series of experimental studies were c e limitations, a Mining Engineering John A. Herbst ion Division 6000 Email: [email protected] onducted to determine whether particles Eriez Flotat (814) 835- could be economically recovered using a suite of previously lost as tailings West Virginia University,, 365A MineralMorgantown, Resources WV 26506Building Phone: novel flotationon technologies developed for Phone: ( of ultracoarse and ultrafine particles in the industrial mineral the upgrading 304) 293-7680 Gerald H. Luttrell s industry. F a fluidized-bed flotation system called the or the case of ultracoarse particleparticless, HydroFloat separatorator was Email: [email protected] novel flotation device in both tested. The data obtained using this A new generation of advanced Mining & Minerals Engineering, 100 Holden Hall laboratory and pilot-scale trialss Email: [email protected] lost sulfide values up to 0.7 mm in diameter showed that good recoveries of previously deployed ABSTRACT Virginia Tech, -Blacksburg,7112 VA 24061 USA could be achieveded. A sample photograph of coarse mid during in the industrial minerals industry. One su particles recovered by this technology is shown in Figure 1. coarse middlingdling unique fluidized flotation technologies has particles that have no Phone: (540) 230 Similarly,imilarly, for ultrafine particl intensity flotation system es, a new high successfully treated-bed by flotation system has dramatically increas ABSTRACT 0-200 microns due to- known as the StackCell was tested - novel fluidizedfluidize high-energy contacting of slurry and . This technology, which utilizes high scale equipment indicate that this te ions, a gas, was capable of recovering -shear froth recently been developed and commercially were previously lost as waste vering valuable ultrafine sulfide slimes that be recovered by conventional flotationflotation. machines. ch technology is the HydroFloat separator. This y limited to a particle topsize of 150ally for the purpose due to low capture efficiencies Recent s. Over the last describe the es. The objectives of this article metal concentrator indicate that this mineral unique operating principles of these two advanced are (i) to chnology canstudies also be co used toed float the upper particle size limit that can be -scale unitsu ancillary classification equipment nced flotation technologies and associated containing nducted using laboratory, bench- arator has been developed specifically several for thefull purpose of , (ii) to present experimental test data as little as 5% hydrophobic mineral. Conventional flotation machines are typicall -based test wwork of this approach for upgrading coarse and fine sulfide minerals,te stand data (ii showshowinging the metallurgical benefits metals industry has the potential to offe sulphide ththat is s, and (ii technology canData float collected composite from middlingpilotcoarse sulfide middlings that cannot inherent constraints created by the pulp only and minute froth phases.amounts toTo ofindustrial overcome exposed minerals hydrophobicthese limitations, with mineralseveral a full analysis of the proposed system for upgrading i)i) to provide a generic cost-benefit the use of split scale and pilot containing ues at a grind size tailing streamsms historically rejerejected by sulfide mineral bed flotation system called the HydroFloat Sep values at a grind size concentrators. cted by sulfide mineral involves segregation-feed circuitry.of the feed The into split- more than one size class followed by sepa-scale tests conducted at - coarse particles , X-ray microtomogmicrotomography r many advantagesAs such, thefor recovery, selectivity and capacity through floating ceeding 3 mm diameter. More recently, sulphide using separator For more details download crossover of this technology into the base this technology has been successfully applied ace exposure necess feed concept, which is s as large as 700 microns decade, . In the current study, X flowsheet for sulfides/reagent flotation that in a base indicate that both wp s specifically optimized for that particul installed to recover particles up to and ex gree of hydrophobic surfaceta indicate exposure that necessaryboth particle to this case often sed in industrial concentrators flotation from a lo use of the, acoarse coarser particle grind flotationsize and correspondinglyequipment. The objhigher mill throughput used forcan upgrading be accommodated via the hydrophobic has shown that this novel device is also capable of recovering metalliferous was achieved providedp cludes coarse and fine processing circuits ons features of the split industrial minerals, much coarser than currently u ing the HydroFloat orstechnology. in coarse 850The particle micronsda flotation was from a low grade ar size class. Anrate example upgrading of ofa eachsplit was used to experimentally quantify the de large as ides detailed 3D analysisan of (Figure 1) data showing the metallurgical-feed circuitry benefits incorporating of the This article providest of dsurface area split class recover particles of different sizes us s the extent of surface area exposure -feed circuitry illustrating the increased m is provided in Figure 1 . Fundamentalundamental issues of bubble ectives of this article are (i) to introduce the key-feed mass and surface area of exposed grains are critical, factwhich defineSeparator ons. HydroFloat technology, (ii) to copper ore. Excellent recovery for multiphase particles as operati this processing scheme, and (iii) to . In sufficient surface exposure-ray microtomography of locked sulfide grains. there was fed to the HydroFloat illing capacity that may be attained by th Split- present flotation products using X Sulfide FlotatioFeed provide experimental test necessary for recoverydiscussed of each as size well class as process strategies for improved plant operations. n simulations of the also is approach. attachment are Conventional Rougher Conventional Scave nger Primary Secondary these White Papers at surface expression Classifiers Classifiers Regrind Classifiers Figure 1 – Photograph of coarse middling partic HydroFloat les recovered as froth concentrateconcent discarded tailing stream using the rate from a previously HydroFloatFloat technology. Primary Grinding Column KEYWORDS Circuit Regrind Feed Cleaner Final . Mill Concentrate Coarse Particle Flotation, Fine Part puted tomography icle Flotation, HydroFloat, StackCell X-ray computed tomography ckCell Figure 1 – Flowsheet for a split

– Analysis of locked particles by Figure 1 Circuit Design, Circuit Simulation , -feed sulfide flotation circuit. KEYWORDS , HydroFloatHydroFl Separator Tails 1.604.952.2300 /ExposureExposure KEYWORDS

ed Tomography, Liberation Split-Feed Flotation, Ray Comput , X- Coarse Particle Flotation www.EriezFlotation.com Coarse Particle Flotation POWER FOR MINES #3_proof 21/12/2017 11:17 Page 5

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components. To avoid fouling of the equipment Networks and Power, APA Group. “Together with provides a proven, cost-effective solution for due to the high humidity, ACTOM had to practice Clarke Energy as the EPC and GE’s demonstrated powering the Gruyere mine site power station.” extreme caution when handling and preserving technology providing the components during installation. power, we will be able to, once again, deliver a GE/APR commitment The remoteness of the site required ACTOM to compelling energy solution for our customer APR Energy, a global leader in fast-track power carefully plan and supply certain essential using both our interconnected pipeline and power solutions, and GE renewed their strategic alliance equipment, such as highly specialised laser generation capabilities to the remote gold mine.” to provide mobile turbine technology into the levelling and alignment equipment. Gruyere is a 50/50 joint venture between ASX- fast-track power rental market in January 2017. According to Site Manager Squire, projects like listed Gold Road Resources and global miner The strategic alliance grants APR Energy these require technical crews with in depth Gold Fields Ltd. It is located in the Yamarna exclusivity around the globe as the rental knowledge of rotating equipment, and the ability greenstone belt of Western , 200 km provider of GE mobile gas turbines under 50 MW. to perform with high-precision in remote sites. northeast of Laverton and to the north of APA As part of the agreement, APR Energy will acquire “All challenges were overcome by ensuring that Group’s Eastern Goldfields Pipeline. new Generation 8, GE TM2500+ mobile turbines we had the necessary resources available on site GE’s Jenbacher J624 is the world’s first two- in connection with its initiative to upgrade and and on time, as well as readily having the stage, turbocharged gas engine. GE says it standardise its fleet. In addition, GE and APR appropriate people with the correct skill sets.” “provides the highest levels of engineering Clarke Energy, a GE distributor and service excellence and significant advantages, partner, will provide 11 of GE’s high-efficiency particularly in the areas of Jenbacher J624 gas engines to Australia’s leading operation in hot environments— energy infrastructure business, APA Group, for its such as the Gruyere project new 45-MW Yamarna power station in Western location—and in multiple engine Australia, which is being constructed to supply power plants for independent power to the Gruyere gold project. Clarke Energy power production and The Jenbacher J624 gas engine is based on GE’s will be the EPC contractor for the gas-fired power combined heat and power proven Jenbacher Type 6 platform with over 4,300 station. Gas for power generation will be applications. It offers customers high efficiency units sold and delivers higher output and transported a total of almost 1,500 km using four and improved flexibility and can power up to increased efficiency APA Group interconnected pipelines including its 10,000 Australian households.” latest greenfield, 198-km Yamarna Gas Pipeline, “GE’s high-efficiency, high-performance and Energy will collaborate on leads for customers currently also under construction. dependable gas engine technology is an looking for interim or rental power solutions as a “As an infrastructure owner, our priority is to excellent fit for APA Group’s needs of safety, bridge to more permanent power solutions. provide safe, reliable and efficient energy to our reliability and efficiency and is well-proven with The acquisition of the new mobile turbines customers,” said Sam Pearce, Group Executive an installed gas engine fleet of over 700 MW in further strengthens APR Energy’s position as Australia,” said Greg Columbus, Managing what it says is “the world’s leading provider of Director, Clarke Energy. “We look forward to mobile gas turbine power”, expanding its total providing safe, on-time and on-cost project fleet capacity to more than 2 GW. delivery for APA Group and supporting its needs Jeffrey Immelt, Chairman and CEO of GE, said, at the Gruyere project well into the future.” “We are very pleased to continue our partnership GE’s Jenbacher J624 gas engines will be built with APR Energy. We have been impressed with Tailored Hydropower Solutions in the company’s Jenbach, Austria, facility and their high level of customer service and ability to were expected to ship during late 2017. deliver turnkey power generation projects in Commissioning of both the pipeline and power remote locations all around the world. With this DesignEngineering station is expected to be in late 2018 to align strategic alliance, customers will benefit from ManufactureInstallation with the Gruyere JV’s expectation of first gold APR Energy’s expertise, and can use GE CommissioningTesting scheduled for early 2019. technology as a bridging solution while their “GE’s Jenbacher J624, high-speed gas engines permanent GE power plants are under TrainingSupport provide numerous benefits for customers. In construction.” addition to high power density Gilkes Turgo Turbine, designed to be in hot ambient temperatures operational on silt laden water over long and best-in-class electrical periods with minimum wear, and with efficiency of more than 45%, limited service & maintenance makes it they also include the capability perfect for mining applications and remote locations. to operate successfully with large transient electrical loads associated with mining processing plants. We are again proud to be supplying our channel partner, Clarke Energy, for this project,” said Daniel Angelo Icasiano, Sales www.gilkes.com Director Asia-Pacific, GE’s Inside view of an APR Energy mobile gas power Distributed Power. “GE’s gas engine technology module

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“We are very excited about the mutual benefits renewable energy with our renewed alliance brings, and appreciate the the reliability of diesel- increased collaboration between our two generated power to companies,” said John Campion, Chairman of APR provide uninterrupted Energy. “Our partnership will provide APR Energy power round the clock. access to new leads and opportunities The hybrid program throughout the GE global network, helping to was developed at support our business growth and thereby Aggreko’s state of the art increasing demand for GE equipment. The manufacturing and alliance also provides us with the latest technology centre in generation of TM2500+ units, giving us the Dumbarton, Scotland, newest fleet in the industry, while benefiting and uses the latest diesel customers with the latest advancements in fuel generators, which are efficiency and emissions controls.” considered to be the most efficient in the world. Working with miners to develop clean, cost- They are monitored using Aggreko Remote effective and reliable power sources is not a new concept for Aggreko. It developed an innovative Monitoring (ARM) telemetry to ensure optimum Hybrid power approach to such a problem in partnership with Aggreko has signed a 10-year deal to provide operational and fuel efficiencies. Sibanye Gold at its Beatrix gold mining solar-diesel hybrid power to Nevsun in Eritrea. Aggreko notes solar power is now “more operation in . The infrastructure allowed Aggreko to capture naturally occurring The company will supply 22 MW of diesel and 7.5 affordable than ever, but it can be intermittent methane gas intersected during underground MW of solar-generated power for the mine’s and unreliable. Night falls or clouds come in and mining operations to create a self-sufficient, free copper and zinc operations. power is lost. Seasons change and power source of fuel that would otherwise have been wasted as flare gas Aggreko’s CEO, Chris Weston: “Technology capacity drops, which means that your business never stands still, and neither does Aggreko. Our cannot rely on it as a sole energy source. Diesel produces over 400,000 oz/y of gold. Essakane mobile, modular power enables us to make a power is reliable, so you can have electricity Solar, a local entity created by the project massive difference to the communities and round the clock. But for off-grid customers diesel developers, will operate the solar power plant industries we serve, and our solar-diesel hybrid fuel is often a high proportion of operating costs. that sells the energy to the Essakane mine. offering is an example of an innovation that brings “Our solar-diesel hybrid package combines “Hybrid power systems enable energy cost-effective, reliable, uninterrupted power with seamlessly both sources of energy thanks to a intensive industries, such as mines, to reduce additional fuel flexibility to customers.” state-of-the-art energy management system, fuel consumption, decrease energy costs, protect Aggreko’s solar-diesel hybrid power package minimising operating costs without against fuel price volatility, as well as improve combines cost-effectiveness and green compromising on reliability. This gives you their social and environmental footprint by reliable power, 24/7, cutting greenhouse gas emissions and boosting with cost savings of up local employment,” commented President and  to 20% over diesel only CEO of IAMGOLD Steve Letwin. “This 15 MWp power all packaged into solar project may only be the beginning for our 0/..-,+*-/,)('& a single contract.” Essakane mine, but IAMGOLD is already well on 0$#")!/ , )/+*)-$ )#-)'' )'& A power purchase its way to increase the proportion of renewables -,+*)+('&%$#"%! +' %'( +)%))'%!*'( %,'*%- ('# %))+ ')%(*&* %-++*)%* )% '( )%% ' )% +') ' agreement has been to 15% of its total energy needs within three to !-%--% -& % +'% '*+'% ! %& *'%! '(  signed between five years. Switching power generation to  %%*'(* +* %!** IAMGOLD Essakane, renewables has been on IAMGOLD's agenda for -//."*$+)('& EREN Renewable several years as evidenced by the 5 MW solar -,/" ) $.- -$ ) +,")''' )'& Energy, AREN ENERGY power plant that was installed in 2014 at the -,+*)+('&%$#"% +'%%*'(* +* %!** and Essakane Solar to company’s Rosebel gold mine in Suriname.” +*$-,$ ")-,"$)'& begin the development With the transition to processing harder ore, -,/" ) $.- -$ ) +,")'' )'& -,+*)+('&%$#"%--% +'%*'(* +* %!** %%  of a 15 MWp solar power energy consumption at the Essakane mine has plant for IAMGOLD’s increased from about 14 GWh/month in 2013 to /")-,"$/)'& Essakane mine in 26 GWh/month in 2015. In light of this, IAMGOLD 0$#")!/ , )/+*)-$ /". ")'' )'& -,+*)+('&%$#"%--%('(% '(+%) '(%-'*%%*'(* +* % Burkina Faso. The Essakane decided to partner with EREN !** agreement is for an Renewable Energy (EREN RE), a global renewable -!")"*$'& initial period of up to 15 energy independent power producer (IPP), and 0$#")!/ , )/+*)-$ /". ") )'& years. The mine is AEMP, a South-African based developer and -,+*)+('&%$#"%*'(* +* %!** located about 330 km independent power producer, to push the frontier 0/.#+*$*-/,$)/"-,)' northeast of the of innovation in power solutions to mines. 0$#")!/ , )/+*)-$#-) )' Burkinabe capital city, Together they are constructing solar capacity to -,+*)+('&%$#"%*'(* +* %!** Ouagadougou. Jointly complement the existing 57 MW heavy fuel oil -$)"#$$*-/,' owned by IAMGOLD (HFO) power plant. In the project's first phase, 15 0$#")!/ , )/+*)-$$)' )' (90%) and the MWp of solar capacity would be built and the -,+*)+('&%$#"%*'(* +* %!** %  Government of Burkina hybridisation of IAMGOLD Essakane's HFO power       Faso (10%), IAMGOLD plant will allow savings of approximately 6 Essakane, which owns million litres of fuel and a reduction of 18,500 t/y        and operates the mine, of CO2.

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EREN says it is “the largest solar farm analysed our client’s load curve and specific complements the EPC agreement Wärtsilä signed connected to a thermal-based power plant.” The needs. From there, we conducted fuel simulation in March 2017 for the solar power plant. fixed-tilt 15 MWp solar power plant is comprised and grid stability studies to come up with an Wärtsilä’s task is to optimise the production of of close to 130,000 photovoltaic (PV) panels, optimal size of the PV plant while ensuring stable the PV plant and make sure that the thermal deployed over an area of nearly 22 ha. and non-disruptive power supply. plant delivers effective, efficient and stable “The solar power plant project engages our “Renewable energy for mining companies can power with unsurpassed performance. In parallel, Essakane mine in energy transition, sparks real be competitive and reliable today. The business the thermal plant, which operates on 11 Wärtsilä local sustainable development and is an honour rationale is really simple: maximise the savings 32 engines, retains a sufficient number of for Burkina Faso. It’s worth noting that this hybrid for our customers. EREN RE thrives to lead the engines in stand-by mode to cover potential diesel-solar power plant will be the first of its energy transition of mining companies in Africa, fluctuations in the PV production. kind in this country,” declared Bruno Lemelin, but also globally. The Essakane solar project truly Maximising the PV plant’s production means CEO of IAMGOLD Essakane at the inauguration. highlights our expertise in actually delivering that less heavy fuel oil is needed for the thermal The IPP solution obviates the mining company large scale sustainable and economical energy plant, reducing both fuel costs and from deploying significant upfront capital and solutions that are adapted to the needs of the environmental impacts. adding the power asset to its balance sheet. It is extractive industry.” The local operations of the PV plant in Burkina also a way of handing down the development, Wärtsilä signed its first Asset Management Faso are remotely supported by Wärtsilä financing, permitting, construction and operation Agreement for a PV power plant in April 2017 and Expertise Centres which continuously monitor to an expert, therefore freeing some time to focus will assume full responsibility for the operation the plant parameters and alert for potential on the core business. The power purchase and maintenance of the Essakane solar plant. problem situations that may arise in the day-to- agreement signed between the independent The solar plant shares a control system with a day operation of the facility. power producer and the off-taker sets an thermal power plant. Operative co-ordination to “This agreement is significant to Wärtsilä in electricity price which is applicable over the long- maximise the production of the two plants is key many ways. It is our very first operation and term – renewable power serves as a solid hedge in the new agreement. maintenance agreement for a solar plant, against fuel price volatility. The seven year agreement includes the daily beginning an entirely new chapter in the story of Christophe Fleurence, Vice President Business operation of the solar plant, preventive, Wärtsilä. In co-ordinating production of the two Development – Africa of EREN Renewable Energy: scheduled and corrective maintenance, cleaning power plants, we will be able to combine our “The project started with a site visit two years of the modules and coordination of operations strong background in engine-based power ago where we assessed the best terrain for a with those of a thermal power plant using the production with our solar offering. We look solar project, meaning relatively flat land and the same control system. The new Asset forward to many years of successful cooperation closest possible to the diesel power plant, and Management Agreement seamlessly with EREN RE,” says Serge Begue, Vice

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Solar, the rising energy star Total Mining Solutions has become the partner of choice to mining companies. Today, it supplies fuel, lubricants and associated services to over 200 mining sites in over 40 countries. Its professionals from the mining sector also have expertise in hydrocarbons and its management on mine sites. Total has combined its solar offer with its SunPower offers standard and back up PV Total has combined its solar offering with its mining expertise to develop a sustainable and solutions, fully solar and hybrid solutions mining expertise reliable energy solution. It says that “besides (solar/diesel). Building on this, SunPower has being environmentally sustainable, solar energy excellent experience in deploying and environmental stewardship and social represents several advantages for the mining maintaining off grid systems in all types of responsibility as key corporate priorities in doing industry. Often located in remote areas, mining challenging conditions. business,” said Mark Dawe, Managing Director companies can boost their operational reliability and Country Manager for B2Gold Namibia. “As with this off-grid energy solution. The highly Harness the Namibian sun one of the largest solar installations in Namibia, reliable PV panels can also be used as a back up B2Gold Corp has selected Caterpillar and Cat® the facility at the Otjikoto mine will help us to power supply. dealer Barloworld to supply 7 MW of solar power leverage a plentiful, renewable resource while Through its SunPower division, one of the at the Otjikoto mine in Namibia. The full system, improving the quality of life for nearby world's leading suppliers of solar panels, Total is including Cat PV solar modules and the Cat communities.” also a supplier of the innovative option of a microgrid master controller (MMC), will be used Caterpillar’s solar PV system is powered by hybrid solar-diesel energy solution, combining to reduce reliance on a heavy fuel oil (HFO) advanced thin-film solar modules that are setting sustainability with cost-effectiveness. power plant currently used to power the mining the industry benchmark with improved With the addition of Tenesol, SunPower has facility. performance over conventional silicon solar acquired the expertise to design and tailor-make Barloworld is supplying EPC services for the panels. Fully scalable and pre-engineered for off-grid solutions. With nearly 30 years of project. Installation of the system is underway, quick and easy installation, the system offers experience working in tough geographical areas with the completion of the project expected in reliable and predictable energy in all climates it can meet energy consumption needs. early 2018. “At B2Gold, we embrace and applications with modules that are

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independently tested to pass accelerated life and stress tests beyond industry standards. Caterpillar’s solar PV offering is a key component of the Cat Microgrid technology suite, an innovative lineup of power systems that adds environmentally friendly solar panels, state-of- the-art , and advanced monitoring and control systems to Caterpillar’s traditional line of reliable power generation equipment, including HFO, natural gas and diesel generator sets, switchgear and automatic transfer switches. BESS + solar PV benefits for an off-grid remote brown-field mine (~5 MW demand example) The Cat Microgrid technology suite is designed to reduce fuel expenses, lower utility bills, decrease emissions, and reduce the total cost of ownership while increasing energy efficiency in even the most challenging environments. “A key differentiator in Caterpillar’s offering is the Cat MMC, which keeps loads continuously energised with high-quality power at the lowest cost. It manages the flow of power from every source in the system, including the main grid when connected. The Cat MMC determines optimum recharge times for the energy storage systems while managing power during times when solar energy is not available.” investment IRR of 36% was possible by installing Up to 28% reduction in fuel and CO2 possible when combining diesel with BESS and solar PV The MMC also uses Cat Connect technology for a Battery Energy Storage System (BESS) where real-time collection and communication of on-site the main benefit comes from improved generator performance data that can be monitored and operational efficiency that results in a reduction benefits and capital requirements of the four analysed remotely. “The economic viability of in maintenance costs. Alternatively, by combining scenarios tested. remote mining operations depends on the cost- this with solar PV generation we can additionally “In some cases, mine operators may prefer the efficient generation of power,” said Tom Frake, substitute expensive diesel fuel with cost incremental hybridisation route as it allows more Vice President of the Global Power Solutions competitive solar PV thereby delivering the gradual changes to the operating system and Division for Caterpillar. “Caterpillar’s solar largest reduction in fuel consumption (28%) and strategy. This analysis shows that it makes sense technologies provide a scalable, sustainable LCOE (11%), while maintaining a healthy IRR to consider BESS in the first step without power solution that significantly reduces fuel (16%). Additional power quality benefits provided additional renewable energy capacity as this consumption while delivering the reliable power by a BESS such as reduced stress on the offers the highest IRR. Ideally, the use of a needed to support mining sites.” electrical installations across the mine site and flexible BESS, such as the ABB PowerStore, associated reduction in maintenance cost and would allow the storage capacity to be increased Renewable and storage technologies down-time have not been modelled in this if renewable energy systems are later added. ABB says “for off-grid mining in particular, study.” “In terms of renewable options, wind has also renewable and storage technologies present an Finally, ABB’s analysis shows that the most proven itself to be effective in the mining sector, ideal opportunity not only to improve the mine’s important factor impacting system design is the particularly in those areas with high wind environmental footprint, but also to reduce price of delivered diesel followed by the cost of resource and low solar resource. Due to energy costs while improving power quality. the installed solar PV system. historically lower costs, high scalability and “For off-grid mines operating in remote Two conclusions can be drawn from the relative ease to gain approvals in remote locations, the cost of electricity can reach business case: locations, wind has accounted for 59% of $300/MWh and consume up to 15% of mining n Mining companies have the opportunity to installed renewables in mining to date. Where revenues. Lowering energy costs will not only start transforming their mines today as solar mine lives are shorter than 10 years new increase viability of mining operations today but PV now delivers a lower LCOE than diesel business models allowing for relocatable solar also help future proof them against rising fuel n Deployment of solar PV + BESS is an PV to be installed could be considered. Once you costs. excellent hedging solution against diesel have found the right renewable choice for your “To test the viability of storage plus price increases and/or future carbon costs. location, combining with a BESS can provide renewables for brownfield mining sites, ABB ABB concludes that “powering remote mines additional cost-savings that mining operators can considered four scenarios that were optimised with diesel generators provides a proven and benefit from today.” using HOMER Pro2 microgrid modelling software. reliable energy source, but leaves the mine For more detail, see http://register.e.abb.com/ The benefits compared include: operator vulnerable to diesel price fluctuations, ABBMicrogridBusinessCaseforMining

n Fuel saving (and associated reduction in CO2 fuel supply risk as well as uncertainty around emissions & maintenance costs) future carbon taxes. It also fails to capitalise on Hydro power n Reduced Levelised Cost of Electricity (LCOE) the economic and operating benefits that BESS In 2016, Gilkes Hydro won a contract to supply its with an attractive IRR and solar PV offers today and potential cost Compact Turgo turbine to AngloGold Ashanti n Improved power quality. savings from carbon taxes in the future. The in Mali, where it will generate in the region of “The results showed that the highest figure presents an overview of the economic 150 kW. At the time, the company said “we are

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The ITG-M Series features a unique direct- drive, synchronous, permanent magnetised generator (PMG) that harvests the energy of moving water from gravity-fed pipelines. The unique all-in-one rim design of the generator removes the need for a central shaft and couplings, resulting in a simplified, compact and efficient generating system that improves efficiency, limits noise, and prevents vibration.

Power storage One way to overcome the problems of intermittent power from renewable sources is to store some of the power when it is available. A huge amount of R&D dollars is being poured into battery research. Aggreko has spent £40 million to acquire Younicos, a global market leader in the development and deployment of integrated energy systems, based on battery storage. The 12" Compact Turgo unit to be supplied by expensive diesel fuels and inefficient generators Aggreko stated: “This acquisition strengthens Gilkes Hydro to AngloGold Ashanti in Mali is spend approximately $212 to $281 per MW for our position as global energy markets continue very similar to the one pictured electricity according to data provided by the to evolve and is in line with our strategy to invest very excited about this new opportunity of re- Rocky Mountain Institute. At these rates, mines in technology in order to reduce the cost of entering the mining sector, where we have a long are spending approximately $65 to $100 million energy for our customers.” history worldwide, and to expand our presence in annually on energy for the 30 to 50 MW of Younicos delivers smart energy solutions Africa. electricity they need for operations.” integrating battery storage, which are modular “We believe that there is huge opportunity for “Our Industrial Turbine Generator-M Series is a and scalable. “Its knowledge of batteries our Turgo to be installed on the tailings of mines perfect fit for mining companies,” said Michael combined with proprietary control systems, due to their superior resistance to abrasion.” Prendergast, Managing Partner at ClearPower enables the seamless integration and The Turgo Impulse turbine was developed by North America. “Mines utilise millions of gallons management of all forms of power, including Gilkes to be a simple impulse type machine with of water every day. This water can be thermal, renewable and battery energy a higher specific speed than a Pelton. The design economically converted into an inexpensive and resources; this is becoming critical in an therefore allows a larger jet of water to be sustainable source of clean energy. ClearPower’s increasingly distributed energy market.” directed at an angle onto the runner. in-conduit ITG-M platform provides a robust bolt- Global energy markets are changing: Covering the boundary between a Pelton and on solution that can dramatically cut the cost of decarbonising and becoming more decentralised Francis machine, Turgo turbines have proved power for a fraction of the investment of other and digital. As renewables penetration themselves to deal extremely well with ‘dirty’ renewable sources, while reducing their carbon increases, intermittency becomes a more water without any detriment to performance. footprint.” difficult issue to manage across grid systems. Originally designed and patented by Gilkes, Integration and control of thermal, renewable the first ever Turgo turbine was installed in and battery systems will be increasingly Scotland in 1919. Since then, turbines of Gilkes required to ensure power stability and reliability originated design have been operating in over 80 are maintained. Off grid and microgrid energy countries worldwide and many of the original solutions are ever more integrating renewable units are still in operation. generation, whilst industrial and commercial ClearPower North America has expanded the customers are also taking advantage of market for its patented, Straflo design Industrial opportunities for renewable integration and Turbine Generator (ITG) with the launch of its demand-side management. new ITG-M Series for the mining industry. The “The capabilities brought by Younicos, ITG-M Series allows mining companies to use leveraged through our global footprint and their existing gravity-fed pipelines or outfalls to experience in distributed power generation, are convert water and selective water slurry flows compelling. The Younicos integration and control into a source of sustainable, renewable, low-cost systems, combined with batteries, can be electricity. By harnessing sufficient water flow deployed across our existing business to lower and head, mining companies that install the ITG- the cost of energy, ensure reliability and reduce M Series can produce over 30 MW of economical carbon emissions for our customers around the ClearPower North America’s ITG-M Series is a off-grid power, significantly reducing their world. Younicos has invested heavily in R&D since bolt-on platform that can be installed quickly electricity costs. The ITG-M is capable of with potentially no downtime or disruption to it was founded in 2005. It is based in Germany producing up to 3 MW of electricity per 46 m of operations. It also offers a small footprint that and the USA and has over 200 MW of installed easily becomes part of an existing head. storage systems, with a strong pipeline across infrastructure that removes pressure while not ClearPower says that “mines that currently use affecting flow both developed and emerging markets.” IM

38 International Mining | JANUARY 2018