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Mining

Haul Track’s robust data lets managers set fuel efficiency targets. (Image source: Rokbak)

In the high-pressure world of mining, quarrying, and construction, fuel efficiency is a make-or-break factor for both profitability and environmental impact.

Garry Moore, a veteran customer support manager at Rokbak, a Scottish manufacturer of articulated dump trucks (ADTs), has spent nearly 20 years refining strategies to optimise heavy equipment performance.

Here, Moore unveils seven expert tips for harnessing Rokbak’s Haul Track telematics system to slash fuel expenses, curb carbon emissions, and boost site productivity.

Here are seven ways to achieve it

1. Keep engines in top shape for fuel savings

A neglected engine burns more fuel and pumps out excess emissions. Haul Track’s real-time diagnostics alert managers to issues like blocked filters or suboptimal fuel systems, enabling quick fixes. By acting on these email notifications, operators ensure ADTs run lean, saving fuel and reducing environmental harm.

2. Spot and fix delays with idling insights

Trucks idling in queues waste fuel and stall progress. Using Haul Track’s GPS and idle-time tracking, managers can identify bottlenecks where ADTs wait for loaders. Moore suggests rebalancing fleet setups—adjusting loader or hauler sizes—to keep operations moving, cutting fuel use and CO2 output while ramping up efficiency.

3. Maximise loads with precision weighing

Half-empty trucks force extra trips, inflating fuel costs and equipment wear. Rokbak’s On-Board Weigh, synced with Haul Track, provides live load data, empowering operators to fill trucks to capacity every time. This approach boosts output, conserves fuel, and keeps production targets on track.

4. Redesign sites for shorter, smarter routes

Inefficient haul roads and traffic snarls sap fuel economy. Haul Track’s movement tracking, combined with fuel and idle reports, works across all equipment brands to highlight trouble spots. By streamlining routes and easing congestion, managers can trim fuel bills, lower emissions, and extend machine life.

5. Coach operators for smoother driving

Aggressive driving habits, like rapid acceleration or sudden stops, can inflate fuel consumption. Haul Track’s fuel usage comparisons reveal when specific trucks burn more than peers on similar tasks. Moore advocates using these insights for constructive training, helping drivers adopt smoother techniques to save fuel.

6. Protect tyres, save fuel

Underinflated tyres increase drag, forcing engines to work harder and wear out faster. Haul Track’s real-time tyre pressure monitoring catches issues early, allowing quick corrections. Proper inflation optimises fuel use, prolongs tyre durability, and enhances site safety.

7. Drive progress with clear performance goals

Haul Track’s robust data lets managers set fuel efficiency targets and monitor results over time. By analyzing trends and sharing feedback, teams stay motivated to improve. This data-driven approach fosters smarter decisions and a culture of continuous progress.

Moore’s strategies show that Haul Track is more than a data tool. It is a  game-changer for cost-conscious, eco-aware operations. With these seven tactics, site leaders and operators can transform insights into action, driving down costs and emissions while keeping their sites running at peak performance.

Fake parts could undermine OEM equipment. (Image source: Metso)

Using genuine parts for crushers and screens is crucial for ensuring operational efficiency and long-term sustainability. Original Equipment Manufacturers (OEMs) like Metso provide high-quality, reliable equipment designed to keep customers’ projects profitable

However, using counterfeit, non-genuine, or fake parts presents significant risks to operations, undermining the very principles that OEMs stand for.

Francois Marais, sales and marketing director at local Metso distributor pilot crushtec, said, “OEMs like Metso spend decades developing and supporting technologies that provide customers with reliable and high performance solutions for crushing and screening. However, this work is quickly undone when non-OEM parts are installed in our equipment, supposedly to save a few rand in maintenance costs.”

Marais goes on to explain that Metso’s equipment’s performance and reliability stem from its proven design and precision engineering. The various components and wear parts that need replacing over time are an integral part of this. Non-genuine parts, however, do not benefit from this technical heritage, leading to compromised performance and reliability.

Merja Tyyni, vice-president of aftermarket distribution management at Metso, added, “Our customer relationships focus on the whole process of delivering value to their operations. We pay attention to the end-product value, where we can supply not only the appropriate capital equipment, but also the follow-up trouble-shooting, repairs and overall technical advice.”

Karima Dargaud, head of aftermarket for Europe, Middle East, Africa, and Central Asia at Metso, emphasises the in-depth knowledge OEMs have of their equipment, which enables them to help customers achieve optimal, predictable results.

“Our OEM spares are an essential aspect of the support we provide, so that customers can reliably meet their production targets and avoid costly penalties. Customers build their reputations on this consistent performance, by producing the right results safely, on time and within budget. Using non-OEM spares only puts this reputation at risk, as machines then become unreliable,” remarked Dargaud. 

Marais also underscores the critical safety concerns associated with using non-genuine parts. Crushing equipment, in particular, involves extreme forces and speeds, and Metso’s wear parts are designed with specialised materials and hardening techniques to ensure both safety and performance.

“Fake parts will compromise worker safety, as there are normally a number of people in close proximity to this equipment who could be affected by a failure. A business that buys and fits pirate parts runs the risk of sending a negative message to its operators – that saving money is more important than the safety of crews on site,” concluded Marasis. 

The UAE is strengthening its footprint in Africa’s mining industry

The UAE is strengthening its footprint in Africa’s mining industry, with a series of strategic investments aimed at boosting production, infrastructure, and energy security across key markets.

Just this February, investment fund Ambrosia Investment Holding acquired a 50% stake in Canadian company Allied Gold’s mining projects in Ethiopia and Mali.

The deal includes a US$375mn capital injection to accelerate project development, increasing gold output in Ethiopia by 290,000 ounces per year by mid-2026 and in Mali by 400,000 ounces per year by 2028.

As part of its commitment to sustainability, Ambrosia also plans to introduce solar photovoltaic and battery storage systems at the Sadiola mine in Mali, ensuring energy security by July 2026.

Here are some other UAE investments in Africa:

AD Ports begins operations in Luanda

AD Ports Group launched operations at Angola’s Luanda Port in January 2025 as part of a US$250mn investment plan.

The port, which handles 76% of Angola’s cargo, plays a key role in facilitating trade between Angola, Zambia, and the Democratic Republic of Congo.

AD Ports has secured a 20-year concession to operate the terminal and is considering increasing its total investment to US$380mn to support growing demand, as Angola’s container volumes are projected to rise by 3.3% annually over the next decade.

IHC boosts production at Zambia’s Mopani Mine

International Holding Company (IHC) increased ore production at Zambia’s Mopani Mine from 2.2 million tons to 2.8 million tons in January 2025.

The expansion followed a US$1.1bn investment made in March 2024.

As a result, copper grades improved from 1.68% to 2.21%, while employment at the mine grew from 10,765 to 12,684 workers.

Emiral accelerates projects in Ghana and Mauritania

Emiral Mining is fast-tracking its iron ore project in Mauritania, with a pre-feasibility study expected in the first quarter of 2025.

The company has invested US$40mn in exploration since February 2020.

Meanwhile, in Ghana, Emiral is strengthening its presence through its majority stake in Asante Gold Corporation, the operator of the Bibiani and Chirano gold mines.

A US$522mn expansion program is currently underway to enhance production at both sites.

Future prospects for UAE-Africa partnerships

Public and private sector entities from the UAE are actively exploring new investment opportunities in Africa’s mining industry.

International Resources Holding signed an agreement with South Africa’s Public Investment Corporation in late 2024 to fund projects in mining, green energy, and logistics.

In mid-2024, DP World announced a US$3bn five-year plan to improve Africa’s logistics infrastructure and facilitate mineral exports.

Additionally, in Kenya, the UAE Ministry of Investment and Abu Dhabi’s sovereign wealth fund ADQ signed agreements in 2024 to invest in the country’s mining sector as part of broader efforts to strengthen trade and economic cooperation.

The upcoming African Mining Week, set for October 1-3 in Cape Town, could also provide a platform for UAE and African stakeholders to explore new partnerships and drive forward industry collaboration. Held under the theme From Extraction to Beneficiation: Unlocking Africa’s Mineral Wealth, the event will bring together key players in the mining sector to advance projects and solidify Africa’s position as a global leader in mineral production.

Also read:  Oman resumes copper exports after 30 years

Volvo Penta’s BESS subsystem offers fast-charging, transportable energy storage for construction and mining, bridging grid gaps with reliable solutions. (Image source: Volvo Penta)

Volvo Penta has introduced a compact, energy-dense BESS subsystem, offering fast-charging, transportable power solutions for construction and mining sectors

Tightening emissions regulations, along with increasing electric demands that surpass grid capacity, have driven a surge in energy storage needs within the construction and mining sectors. To address these challenges, Volvo Penta has introduced its energy-dense and compact Battery Energy Storage System (BESS) subsystem, designed to offer transportable and fast-charging benefits. This solution provides system integrators and BESS manufacturers with a reliable option for deploying energy storage in microgrid scenarios such as quarries, urban restoration sites, and other demanding environments.

Powering future operations 

The construction and mining industries face several energy-related challenges. Some sites have access to grid capacity and electricity but require fast charging or peak shaving solutions to optimise power usage. Others must develop energy strategies to generate or deliver power due to grid limitations, particularly when projects are not sized accordingly from the outset. Additionally, businesses and worksites in transition phases may find themselves neither fully off-grid nor completely secure in their energy capacity for ongoing projects. Volvo Penta’s BESS subsystem presents an effective solution to these challenges, supporting the growing power demands of heavy-duty industries that exceed grid capabilities or face restricted grid connectivity. These energy storage systems can seamlessly integrate with renewables or other power generation assets, ensuring a stable and reliable power supply crucial for large-scale or remote operations transitioning to electrification.

Volvo Penta’s BESS subsystem is particularly well-suited for battery-electric vehicle (BEV) charging, offering a favorable C-rate to facilitate fast charging and grid stability in high-demand applications. Given the frequent capacity and frequency challenges associated with electrification, this subsystem provides a crucial solution to maintain consistent energy availability.

Beyond BEV charging, the BESS subsystem also supports microgrid deployment and peak shaving strategies. Its transportable design enables flexible power solutions for zero-emission construction zones and remote mining sites. These energy storage units can power equipment directly on-site and be relocated for recharging without disrupting operations. Furthermore, they enhance stationary equipment functionality by supporting the energy needs of electric excavators, wheel loaders, and crushers, ensuring continuous uptime in rugged work environments.

At the core of Volvo Penta’s BESS subsystem is an energy-dense battery pack with a high-performance C-rating, allowing for efficient fast charging and discharging. Adapted from the proven battery technology used in both on- and off-highway Volvo Group applications, the subsystem is built to withstand tough environmental conditions, with a high IP rating against corrosion and dust. The system also features a DC/DC converter for auxiliary power, a telematics gateway for real-time monitoring, and a thermal management system that optimises performance in various operating conditions. CAN and DC interfaces, derived from Volvo Group’s expertise, ensure secure and reliable data transfer, while a robust Battery Management System (BMS) enhances overall performance, maximizes battery life, and safeguards cybersecurity.

Each Volvo Penta BESS subsystem provides the essential DC energy supply, while original equipment manufacturers (OEMs) manage the AC setup, container integration, and system configuration. This collaborative approach allows for tailored energy solutions that meet the unique needs of each customer.

Volvo Penta has conducted extensive testing and prototyping with customers and is now ready to bring its production-ready BESS subsystem solutions to the industry. At bauma 2025, the company will showcase how these advanced energy storage solutions can support the transition to electrification in construction and mining. Attendees can visit Volvo Penta’s stand (A4.412) to meet with experts and explore opportunities for integrating BESS technology into their operations.

A concept machine of a large dump truck equipped with a hydrogen combustion engine. (Image source: Komatsu)

Komatsu Ltd., led by president and CEO Hiroyuki Ogawa, has developed a concept version of its HD785 large dump truck, which boasts a maximum payload of approximately 92 metric tonnes, now equipped with a hydrogen combustion engine

The company has begun proof-of-concept testing at its Ibaraki Plant in Hitachinaka City, Ibaraki Prefecture. This initiative marks the world’s first instance of integrating a hydrogen combustion engine into a large dump truck.

Through these trials, Komatsu seeks to deepen its understanding of hydrogen engine applications, paving the way for the advancement of hydrogen-powered construction and mining machinery.

Innovating with hydrogen technology

As part of its commitment to achieving carbon neutrality, Komatsu continues to explore and develop alternative power sources.

In its pursuit of hydrogen engine technology, the company has leveraged the expertise of KEYOU GmbH, a German startup specialising in hydrogen engine solutions for heavy-duty trucks.

The concept machine integrates a hydrogen combustion engine and hydrogen tank system co-developed by Komatsu and KEYOU. To optimise hydrogen storage, the tank is mounted on a platform beside the operator’s cab.

Additionally, newly installed cameras and monitors both inside and outside the cab enhance visibility for the operator.

The proof-of-concept tests will assess key factors such as driving performance, operational duration, fuel efficiency, and safety measures associated with high-pressure hydrogen gas.

Advantages of hydrogen combustion engines

Compared to battery and hydrogen fuel cell alternatives, hydrogen combustion engines present a cost-effective solution for construction and mining equipment.

This is largely due to the ability to retain powertrain components from conventional diesel-powered machines, reducing the need for extensive modifications.

Moreover, with nearly zero CO emissions, some mining operators have shown interest in adopting hydrogen engines as part of their carbon neutrality efforts.

Challenges remain, particularly in hydrogen supply infrastructure and safety management. Komatsu plans to collaborate with industry groups and key stakeholders to address these issues and support the wider adoption of hydrogen technology.

Commitment to carbon neutrality

Under its mid-term management plan, Komatsu aims to cut CO emissions by 50% in both product use and production operations by 2030 (relative to 2010 levels), with the ultimate goal of achieving carbon neutrality by 2050.

The company has already introduced hydraulic excavators, tethered electric hydraulic excavators, and battery-powered excavators across various sizes.

Additionally, Komatsu is actively developing eco-friendly technologies, including carbon-neutral fuel solutions, battery-powered equipment power supply systems, hydrogen fuel cell-powered excavator trials, and a power-agnostic truck concept.

Komatsu remains dedicated to meeting diverse environmental demands through in-house research, open innovation, and strategic partnerships, reinforcing its commitment to a sustainable future.

Also read: Liebherr strengthens Middle East presence with strategic investments

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