Pushing the Limits
Handling heavy metal with light footprints
Even with its global leadership, the mining industry in Chile is still pushing itself to higher standards. One way in which this is noticeable is the focus on sustainability within comminution and material handling companies. This has been achieved thanks to huge investments in crucial technologies, with several trends emerging, such as grinding ball recycling, dry-tailings solutions, usage of data-based diagnostics, or longer product life, just to name a few. But sustainability is not the only field in which the sector is raising the bar, with productivity and navigating Chile’s increasing regulatory hardships being other areas of innovation. Moreover, several companies have recently opened new facilities, demonstrating their willingness to go further.
Sustainable innovation in mining's core processes
ME Elecmetal, which introduced its QuickScan technology in 2024, and completed acquisitions in Peru and South Africa to make its offerings more holistic, has also secured a CORFO subsidy to develop a solution for recycling grinding balls and recovering environmental liabilities in the grinding process. “We focus on reducing the mining industry’s carbon footprint by offering solutions that allow companies to repair components rather than purchase new ones when it is more environmentally sustainable,” explained Jose Pablo Dominguez, general manager.
Likewise, Magotteaux also offers in Chile a full range of grinding media, and in 2024, it signed a five-year contract with Codelco for grinding balls that incorporates a 100% supply model from recovered material. Enrique Vargas, country manager in Chile and Peru, noted: “More than 80% of our raw materials come from recycled products. We invest in energy efficiency and renewable energies while applying an active reduction, recovery, and recycling strategy.” Furthermore, the company has also focused on process optimization and impact applications as part of the Sigdo Koppers Group since 2013.
In yet another twist to this technology, Tecnología en Transporte de Materiales (TTM) and ME Elecmetal turn waste into value. Both joined to form the Footprint Alliance, which recovers contaminated mill balls for reuse. TTM, the material handling company, traditionally focused on conveyor components, dust control and maintenance of conveyor belts in open-pit and underground mines, has invested almost US$6 million in a pilot plant for the Footprint Alliance in Nogales. “Our process separates usable mill balls, metal scrap, and clean minerals. Previously, this work was done manually, but our automated plant requires only four people to operate. In October, we secured a CORFO award, receiving CLP$3 billion in subsidies,” described Phillip Hemmerdinger, TTM’s CEO.
Metso was also celebrating the opening of a new facility in a positive 2024 for them in Chile, positioning it to be part of the new large-scale projects anticipated in the coming years. “A major milestone for us was the inauguration of our first large-scale recycling plant for mill linings in Chile. This facility can separate and recycle steel and rubber components, addressing sustainability challenges in mining equipment,” said Eduardo Nilo, CEO of Metso in Chile. He continued: “We are also exploring advanced filtration technologies, such as economic tailings filtration, which allows for water optimization and more sustainable processing methods.”
Cbb Cales also has plans to become greener, with a strong focus on sustainability and safety. As Ulises Poirrier, CEO of the company, declared: “One of our key priorities is reducing our carbon footprint. To that end, we’re planning the installation of two high-efficiency vertical kilns in Chile, equipped with cutting-edge global technology. These kilns will be more energy-efficient and significantly reduce CO2 emissions, contributing to a lower environmental impact. This commitment is fully aligned with our sustainability agenda, which emphasizes responsible growth and respect for the environment and local communities.”
The firm has had a busy 2024, with substantial investments amounting to US$100 million, mostly directed towards operations in the Argentinian market. They are also in the process of increasing their lime production by 30% thanks to two new kilns.
Weir experienced a dip in new projects during 2024 but supplemented this with growth in aftermarket services and digitalized solutions. “Monitoring and diagnostic technology are becoming more important, as seen through the growing number of operations centers that are opening away from the mine site. Whilst these are not revolutionary technologies, Weir’s ability to collect data on our products and enact changes that optimize them will separate us from the rest of the industry,” said Martin Brenner Knoch, regional managing director of Latam for Weir.
Chile's transformative path in material processing
Data usage is an emerging trend in comminution, just as in material handling. For the latter, it is one of many mechanisms to cope with decreasing ore grades and the subsequent larger bulks that machinery has to carry, with the added difficulty that this must be done faster to keep up with productivity levels.
As part of the BEUMER Group, FAM recently experienced its largest order intake in Chile since entering the market in 2000. One of these orders from Codelco will be the largest spreader in the Southern Hemisphere and all of the Americas. Traditionally, systems used to process 900 t/hour, but nowadays, the number is closer to 15,000 t/ hour. To counter the increased environmental impact of this, FAM is focusing on generating renewable energy to sustain operations. “Last month, we reached a significant milestone by not only achieving carbon neutrality but also becoming financially neutral in terms of energy costs. The efficiency of our solar panels in La Negra, Antofagasta, has been exceptional, generating around 60% of installed capacity within 12 hours of sunlight,” highlighted Sergio Zamorano, the company’s CEO.
Also noticing increased capacity demands from clients was STM, which extended conveyor belts from 10,000 to 12,000 t/hour. Despite the environmental steps the industry is taking to offset the increased amount of material mined, problems are still present at a bureaucratic level. Andrés Osorio, general manager of STM, outlined: “The key issue is permitting. It is important to ensure that projects comply with environmental norms and community interests, but processes need to be clearer. Many projects end up in judicial disputes, which delays the process.”
“Collaboration is essential as we strive to reduce environmental impacts, improve safety and optimize resources. By combining our capabilities with those of other innovators, we create comprehensive solutions.”
Jose Pablo Dominguez, General Manager, ME Elecmetal
With this need for increased capacities also comes an increased possibility of accidents and problems, and enhanced tire and wear on equipment. “Decreasing ore grades requires transporting larger bulk faster. This is a serious challenge that can entail enhanced wear of materials; belt misalignment is a common problem, which can produce fires; or the spilling of material and dust, causing pollution,” as Fernando Miller, managing director for Latin America at Flexco, confirmed.
Flexco is currently the fourth largest conveyor supplier in the world, and it is growing rapidly in Chile’s aftermarket due to the aforementioned enhanced stress that belts endure, providing service tools, bespoke solutions, and products that have built-in services for predictive maintenance.
Martin Engineering has also encountered this problem across jurisdictions, having focused on product life. Rodrigo Trevenzolli, regional director for Latin America at the company, elaborated: “This challenge has become increasingly common, as conveyors are required to handle higher tonnage and a broader range of materials. Thus, we are collaborating with our customers to deliver products with longer life spans and simplified maintenance procedures enabling conveyors to withstand heavier loads while maintaining — or even improving — operational speed. Of course, solutions must be customized to each customer’s needs. Some of them will aim for mining larger volumes to compensate for lower grades, while others will focus on mining less material with higher grades.”
Being the main conveyor supplier in Chile, the company has launched two new products into said market, the Cleanscrape and Orion systems, focusing on endurance and workplace safety.
“Efficiency is a very important challenge for customers, so using high chromium alloys in grinding media as well as composite materials in high value-adding products allows for improved mineral recovery with a lower carbon footprint.”
Enrique Vargas, Country Manager Chile, Peru, Magotteaux
Also, looking after safety is Multotec, a company specialized in mineral classification consumables and capital equipment. “One major challenge is that suppliers are the majority of workers in a mine. For every four people working in mining, three are suppliers. This means that transformation must come primarily from us”, comments Mario Saavedra Vergara, general manager.
With such a recurring presence on mine sites, it is only logical for providers to accompany their clients throughout the mining process, providing key insights and services to their partners. "Clients seek strategic partners who add value from the early stages. Our differentiator is our presence with the client on-site, understanding their real operational needs. We provide advice on how to achieve their objectives, whether it is improving maintenance intervals, increasing throughput, or adjusting particle size to fit upstream or downstream processes. It is part of the journey to become true long-term partners to the mining operations we serve," Saavedra Vergara remarked.
Multotec has recently partnered with Zip Technik and Robins to devise new screening equipment, while also working with local manufacturers to decrease the company’s carbon footprint.
Glencore Technology has also toiled towards this end, making their signature Jameson Cell more eco-friendly. “One of our primary sustainability initiatives is the reduction of CO2 emissions and energy consumption. We have developed the Jameson Concentrator, which integrates the Jameson Cell with the IsaMill. By combining both technologies, we can reduce CO2 emissions by up to 140% and lower capital expenditures by up to 160% for both greenfield and brownfield projects. This makes the Jameson Concentrator a very competitive and successful solution today. We expect competitors to eventually follow suit and adopt similar strategies to achieve this level of efficiency,” affirmed Christian Pastén Cortés, regional business development manager at the company, about a critical initiative to enhance the competitiveness of a product that, while well-established in other jurisdictions, is only starting to gain footing in the region.
“Chilean mining operates under extremely demanding conditions, dealing with hard rock and very high ore throughput. Conveyor systems here are larger and faster than in most parts of the world.”
Joerg Von Loebenstein, Owner and Engineering Manager, Tecnipak
TAKRAF has many things to celebrate this year beyond its 300th anniversary. The company responsible for the world’s largest and most powerful conveyor belt, located at Chuquicamata in Chile, has also devised some new breakthrough technology. “While paste tailings exist, Dry Stack Tailings are emerging as the most viable solution, and we’ve successfully integrated DST systems in Brazil. Combining material handling with liquid-solid separation lets us deliver integrated solutions. We’re expanding product lines like filter presses and investing in technology to make waste management economically viable,” emphasized Andrés Costa, CEO at TAKRAF Chile.
Also among the conveyor manufacturers, Tecnipak is designing solutions that are adapted to Chile’s unique challenges. "Our equipment appears oversized compared to what is commonly seen internationally, but it is specifically engineered to perform in Chile’s particularly challenging conditions. Our direct contact with mining operations allows us to adjust our designs with precision and speed,” Martín Villaseca, marketing manager, commented.
“The combination of high tonnage, high speed, and extremely abrasive material is already complex, but now we are also seeing a significant increase in corrosive conditions due to intensified leaching processes, generating corrosion challenges beyond traditional wear resistance. Tecnipak has modified its designs and material selections to meet these dual challenges, abrasion and corrosion”, elaborated Joerg Von Loebenstein, owner and engineering manager at the company.
Chile’s comminution and material handling sector is not content to be a global leader today, but these developments highlight the will to lead the sector in the future too. Be it through sustainability initiatives, the application of new technology, or the opening of state-of-the-art facilities, this underlines this forward momentum, shaping a more sustainable, productive, and resilient future.
Article header image courtesy of Glencore