MechChem Africa January-February 2025

⎪ Minerals processing and materials handling ⎪

Gearless mill drives and CO 2 emissions

Martin van Zyl of ABB argues the case for switching to Gearless mill drives (GMDs) to simultaneously maximise productivity while still achieving efficiency and sustainability objectives.

processing plants. ABB’s latest white paper investigates how such issues are impacting the copper industry. Copper is vital for the energy transition and demand is predicted to double by 2050. Yet today, roughly only 0.5% of ore can be converted to copper, down from historical levels of 1%. To main tain the same levels of copper production, modern mines must process double the quantity of ore. However, increasing mining outputs without supporting sustainability initiatives could contribute more emissions than copper can negate. One way to help produce more critical minerals such as copper while also mini mising the environmental impact of mining operations is through the use of GMDs. GMDs have proven their value across industries for more than 50 years and have

demonstrated the potential to deliver a more environmentally friendly, efficient, and reliable grinding operation than would be possible with alternative technologies. GMDs are the system of choice for

mines looking to a more efficient and productive future. As GMDs have fewer mechanical parts, they have been found to be more energy efficient, more reliable and easier to maintain. These char acteristics mean it is less energy intensive while having more uptime, de

A chieving energy efficiency sav ings is highly important to the future of the mining industry. Humanity’s demand for critical minerals is growing thanks to the twin drivers of increasing digitalisation and the energy transition. Meanwhile, ore quality is declining, requiring more ore to be mined to produce the same amount of metal. This challenge is further compounded by grow ing pressure to reduce the environmental impact of mining. Addressing all challenges simultaneously is a challenge of enormous proportions. ABB has released an in-depth white paper detailing the vital role that gearless grinding technologies can play in driving productivity in mining while simultaneously reducing their carbon footprint. One of the key findings in the report, based upon exten sive testing of ABB’s current installed base of gearless mill drives (GMDs), is the high level of efficiency they provide. GMDs can be up to 3.6% more en ergy efficient than ring-geared mill drives (RMDs), reducing energy consumption and operational costs of the mine. This level of efficiency across ABB’s GMD installed base equates to 195 kt of CO 2 , the equivalent of 89 000 cars taken off the road. Even a conservative 2% of increased efficiency equates to 106 kt of CO 2 saved, or 49 000 cars taken off the road. Grinding operations at mines around the world are undergoing a transforma tion. Multiple marketplace pressures are driving mining owners to deploy technol ogy solutions that minimise energy use and maximise productivity while achieving sustainability objectives. Going gearless can meet mining business objectives by exceeding standard availabil ity targets in grinding operations. ABB’s GMD is the most powerful mill drive system on the market to power semi-autogenous (SAG), ball, and autogenous (AG) mills. This workhorse for grinding operations combines a robust, service-friendly, and fit-for-purpose design to provide highest throughput, reliability, and availability for

The full interactive White Paper can be accessed by scanning the QR code.

livering the twin benefits of a reduced car bon footprint and increased productivity. https://new.abb.com

An ABB GMD control room at a mining site.

Gearless Mill Drives (GMDs), GMDs can be up to 3.6% more energy efficient than Ring-Geared Mill Drives (RMDs), reducing energy consumption and operational costs.

January-February 2025 • MechChem Africa ¦ 9