NMA Hosts MINExpo INTERNATIONAL in Las Vegas

Suppliers gear up for the mining industry’s largest trade show

By Steve Fiscor, Editor-in-Chief

MINExpo INTERNATIONAL takes place September 24-26, 2024, at the Las Vegas Convention Center (LVCC) in Las Vegas, Nevada, USA. Those that have never attended a MINExpo trade show will likely be awestruck. For those that have attended previous versions of the world’s largest mining trade show, the format has changed, but they can still expect to see more than 2,000 equipment and technology suppliers in three halls.

This edition of MINExpo begins on a Tuesday and runs all day for three days. In the past, the show started on a Monday and ended with a half day on Wednesday. The National Mining Association, which produces the event, has also taken a different approach with the technical program for this edition. Instead of concurrent sessions with professionals discussing various aspects of mining and mineral processing, the program for this edition has four guest speakers, Mike Rowe, Danica Patrick, Kevin O’Leary and Jon Dorenbos. They will share their unique perspectives, experiences and secrets for success. These sessions are ticketed and require advanced registration.

In the three years since the last MINExpo, which was held in 2021 as society was emerging from COVID-19, the LVCC has made some major changes with its venue. The biggest change is the new West Hall. It sits to the west of the North Hall, which connects to the Central Hall. The Central Hall is notorious for housing some of the largest earthmoving equipment on Earth during MINExpo.

Registration will be in the West Hall and ongoing construction activities will likely impact direct access to the North and Central Halls. The entrance area near the Central Hall where delegates entered in the past will be under construction, and the cafeteria that sat between the Central Hall and the North Hall will be demolished. Attendees should expect to encounter some barriers and plywood during the visit and past prime parking spaces may no longer exist.

Therefore, having a MINExpo plan in place before hitting the ground in Las Vegas could save a few thousand steps and lead to a more efficient trade show experience. With that in mind, the editors at Coal Age reached out to many suppliers to find out what attendees could expect to see at the end of September. What follows is a collection of what they learned.

Brookville Locomotives Move Men and Materials

Brookville Equipment Corp. (Central Hall, Booth 6154) is a leading manufacturer of rail-mounted diesel and battery-powered mining equipment, including locomotives, personnel carriers, and utility units. Featuring planetary final drive gear reducers at each wheel end to divide driveline torque, shock loading for reduced stress and longer service life, and liquid-cooled internal wet disc brakes to extend brake life and provide maximum braking capacity for long, continuous grades, Brookville’s units are designed for dependability. Optional equipment features include explosion proofing and patented on-board rerailing systems to enhance safety in all work environments.

Brookville can also assist mining companies with above ground material movement. Brookville’s industrial switcher locomotives come in both diesel-electric and diesel-hydraulic designs. This equipment is ideal for shuttling rail cars within the confines of a facility, or across short line and regional railroads.

The Cat Experience

Caterpillar (Central Hall, 6333) said its MINExpo 2024 experience will immerse visitors into the mine site of the future; featuring industry leading technologies, groundbreaking advancements in the energy transition and first-of-a-kind customized solutions designed to increase customers’ efficiency, safety and profitability. The company said its exhibit will reinforce its position as the global industry leader in mining technology.

“Caterpillar’s legacy is to deliver an exceptional experience at every job site through customer focused solutions and services,” said Denise Johnson, group president for Caterpillar Resource Industries. “As our exhibit shows, together with our customers, we are mining better, smarter and safer.  And this is just the beginning of our closer-than-ever before collaborations with customers.”

The towering 410-ton Cat 798 AC mining truck will be a focal point for the exhibit. It has the highest standard payload in its class. The 798 AC is configured for autonomous haulage with Cat MineStar Command for hauling. “We believe systems, such as Command for hauling, are essential to optimize mine site performance, both with our current product line and as we introduce new offerings like our battery electric solutions,” said Marc Cameron, senior vice president, Caterpillar Resource Industries.

From fleet management to fully autonomous machine operation, Cat said its MineStar technology has transformed the mining industry. Caterpillar provides building block technology packages that are scalable to meet the mining operation’s needs as it moves along the technology integration journey. Visitors will be able to experience interactive engagement with MineStar fleet management solutions at the exhibit’s conversation stations. A third station allows attendees to explore precision mining solutions dedicated to site optimization.

Visitors will also see the optional technologies available for the Cat 995 wheel loader, which include payload overload prevention, operator assist, and operator coaching.

Cat said it will launch two new technology offerings for the MineStar ecosystem at the show, a Collision Awareness System (CAS) and Terrain Payload Management. Delivering the next layer of safety, CAS is a site-wide solution that uses the latest in technology advancements to enhance situational awareness by warning operators of potential machine interactions before they have a chance to happen. CAS will be highlighted on the 995 and 798. A new office application for Terrain Payload Management expands the payload tracking technology for Cat electric rope shovels and draglines.

Virtual reality experiences will allow attendees to “get into the cab” of the Cat 7495 electric rope shovel and a 6060 hydraulic mining shovel. Showcasing the capabilities of Cat Command technology, two remote operating stations will give visitors the chance to operate a dozer or rotary blasthole drill located hundreds of miles away from the Cat exhibit. A third station will offer simulations of Cat Command for underground, demonstrating the technology’s versatility and ease of use.

The in-booth Caterpillar service bay and nearby displays will highlight options available to mining customers for maintaining the machinery and meeting production targets. Track pad displays for rope and hydraulic shovels and dozers will show the latest offerings designed to maximize undercarriage life.

The Cat 24 motor grader will also be displayed. It represents the range of haul road maintenance machines that includes the 14, 16 and 18 models. The C24’s High-Performance Circle provides a 16,000-hour service life and eliminates frequent inspection, wear strip replacement and circle shoe adjustments. It will be displayed with Caterpillar’s 28-ft moldboard option — 16% longer than the standard blade — to enhance safety at larger mines by reducing the amount of time spent in the middle lane to clear the wind row.

The largest of the Cat drill rig offering, the exhibited MD6310 rotary drill shares a common platform, parts, components and technologies across the product line. Ideal for high-production drilling on 39.4- and 49.2-ft bench heights, it is capable of drilling up to 12.25-in hole diameters and offers up to 30˚ angle hole drilling for cast blasting. With building-block technologies through semi-autonomous operation, the MD6310 was one key contributing factor to global mining services provider, Thiess, surpassing 1 million meters autonomously drilled milestone using Cat drills.

Conn-Weld Specializes in Custom Fabrication

Conn-Weld Industries (West Hall, 10401) is a leading manufacturing and engineering firm based in southern West Virginia with a global reach. Taking pride in manufacturing screening equipment from raw material to finished product, Conn-Weld specializes in custom fabrication in separation technology and process solutions. Conn-Weld’s vibrating screens, sieves, screen media, and parts are designed to meet each unique application. Specialties include onsite support, measuring to direct fit, maintenance seminars, and more. Their vertically integrated approach to manufacturing ensures that miners receive the best product, from the highest quality materials, all backed by service they can rely on. Since 1975, Conn-Weld remains committed to gaining the trust of their customers by delivering the kind of service and support that makes them stand above the rest.

Eriez to Unveil New Equipment

Eriez (West Hall, 11851), a global leader in separation technologies, will introduce new feeding and metal detection equipment. The new metal detector uses optimized detection algorithms to reliably detect damaging iron and manganese steel. This equipment provides superior protection for crushers, screens, and conveyor belts. The new high-capacity electromagnetic vibratory feeder offers nearly 70% greater capacity than the previous model, significantly enhancing material handling efficiency. The Eriez line of suspended electromagnets provides tramp metal collection from conveyed materials.

Flanders Offers an Agnostic Options for Drills and Trucks

Flanders (West Hall, 11273) stands at the forefront of the electrification industry as the true agnostic world leader, catering to the largest and most complex applications. Since 1947, its expertise was developed by designing, and manufacturing electric rotating machines, and repairing, servicing, and distributing them.

Leveraging its electrification heritage, Flanders proudly provides state-of-the-art AI-powered predictive maintenance platforms, tailored controls, seamless systems integration, and cutting-edge automation solutions such as ARDVARC Autonomous Drills, Truck Hybridization, electric repowering retrofits for drills and excavators, as well as DC-to-AC conversions for draglines.

Flanders will also present an adaptive hybrid retrofit system that offers mine operators the capability to meet corporate decarbonization goals while continuing to use their existing fleets of mechanical and diesel trucks across a variety of OEM designs, platforms and sizes.

Flanders said it understands the mining business, and its solutions focus on optimizing costs. The ultimate mission revolves around maximizing machine uptime and minimizing the total cost of ownership for miners. The company said it achieves this by incorporating paramount elements such as safety, quality, reliability, and productivity enhancements through its agnostic approach in designing processes, parts and subsystem commonalities. An unwavering commitment to meeting the needs of its valued clients drives them to continuously innovate and deliver exceptional solutions that elevate their operations to unprecedented levels of efficiency and success by exceeding their expectations.

IWT Combines Gas Monitoring and Communications

Innovative Wireless Technologies (IWT, West Hall, 13281) is the industry leader in underground wireless networks. Its systems are comprised of integrated components working together to build an overall network that is not only reliable, but increases safety, efficiency and productivity. New products on display include the Guardian Proximity System, featuring game-changing detection technology, and the all new WGM+, which provides both wireless gas sensing and communications in one device. IWT’s communications, tracking, data, sensors, tailings management, and wireless gas monitoring systems can help mines improve safety and productivity.

Komatsu to Showcase Innovative Solutions

The theme for Komatsu stand (Central Hall, 7132) is a sustainable future together. The company said its focus reflects a commitment to collaborating with customers to unlock the full potential of today’s solutions and technologies and help them prioritize safety, reliability, cost-effectiveness and environmental impact. For underground coal, this year’s show will also emphasize leveraging the latest advanced equipment and technology to work toward greater production and cost efficiencies.

Attendees will also see how Komatsu is leading the way for remote management and automation for underground longwall and room-and-pillar mining to drive greater efficiency, improved safety and workforce retention. The current state and future vision for automation will be shared.

Beyond room-and-pillar machinery, like the 12HM26 continuous miner, Komatsu will unveil how data and technology can effectively enhance safety, productivity and performance. Remote operations, cutting optimization, and lidar and proximity detection will be featured.

Visitors to the Komatsu stand can also explore the next-generation J7500 ranging arm for longwall shearers. The company said it has been redesigned for higher performance and reliability compared to the previous model. Show attendees can also learn more about the Joy-engineered powered roof support solutions for seamless integration, and advanced automation that enhances safety, enables real-time decision-making and empowers pieces of longwall equipment to work together more easily.

They will also learn about Komatsu’s robust mining service and support. Factory-certified service personnel and global service centers are dedicated to helping coal operators keep their equipment productive at the lowest cost per ton with value-added service offerings, reliable parts and machine rebuild services.

Polydeck Will Display Screens

Since 1978, Polydeck (West Hall, 12457) has distinguished itself as a leading provider of modular synthetic screening media and comprehensive screening solutions. Serving the aggregate, mining, energy and industrial sectors, Polydeck’s mission is to lead the industry with groundbreaking, innovative screening solutions and products while upholding the highest standards of quality, safety, and environmental stewardship. With the fastest lead times in the industry, decades of application experience, and risk-free performance guarantees, discover why thousands of sites depend on Polydeck for their screening needs.

Richwood Solves Dust Containment Issues

The Richwood exhibit (Central Hall, 4007) will feature an engineered approach to solving dust containment issues at conveyor transfers. Containing dust and fines has become more important than ever. When it comes to solving problems with dust and material containment, Richwood achieves success with engineered passive dust containment systems. Application-specific solutions optimize efficiency through sealed and protected load zones without the need for vacuums, filters or other additional equipment. The reduced wear and tear on equipment and controlled dust and spillage create a safer and more productive work environment. Worry free load zones are designed and built by Richwood every day.

Tema Isenmann to Display Wear Protection

Tema Isenmann (Central Hall, 5201) is a leading manufacturer of American-made polyurethane screening products and systems. For more than 35 years, the company has been providing solutions for the North American mining and aggregate industries. Tema Isenmann’s WS 2.10 magnetic systems are patented wear protection products that can be applied to any steel that sustains wear. This high-quality, wear-resistant protection system is one of the most innovative products developed for mining and aggregate plants. The use of high intensity rare earth magnets allows for ease of installation and removal when worn reducing maintenance downtime and costs.

Tema Isenmann said all its systems provide screening and wear solutions with products engineered with simplicity in mind to deliver higher wear life, improved efficiency and reduced labour resulting in lower costs per ton processed. The company is also the official distributer of the Multotec Manufacturing range of screen panels including polyurethane, rubber, wedge wire and saddle top rail systems that complement its own range of products.

Weir to Showcase New Equipment and Technology

Weir (Central Hall, 8833) said it will debut its newest ground engaging tool (GET) system — the ESCO NEXSYS GET and lip system for rope shovel dippers. Weir believes the NEXSYS GET and lip system will deliver  exceptional performance with significantly less maintenance and downtime. The new system extends service life due, in part, to its revolutionary leading-edge inserts, improved adapter protection, new rear wear cap and advanced tooth profile. The NEXSYS optimized nose position and geometry extends adapter life, providing better penetration and loading. The new tooth system requires fewer point changes, while the single, sealed lock reduces impacted fines for easier removal with an off-the-shelf hand tool.

Notably, mines have relied on ESCO products for industry-leading lip and GET systems for nearly 100 years, and rope shovel dippers have been a mainstay for that entire period. Weir’s experience when it comes to designing, manufacturing and optimizing its ESCO mining-class dippers ensures it delivers value and performance to its customers all over the world. The ESCO Production Master dipper improves performance and reduces maintenance load and can be engineered to suit any machine and customer application.

Weir’s precision engineering and manufacturing increases shovel availability, while its reliable, longer-lasting components reduce unplanned downtime and maintenance costs and improve safety.

Weir custom engineers each ESCO Production Master dipper to meet the mine’s specific requirements. Scale model testing is used to maximise productivity and digging efficiency. Weir consults with mine personnel to address capacity, lip, GET, rope connection and wear package options to improve reliability and productivity.

Weir’s Motion Metrics will showcase AI and computer vision technology that delivers accurate real-time particle size analysis throughout the mining process, from extraction to processing. These systems integrate seamlessly with shovels, loaders, conveyor belts and haul trucks, ensuring uninterrupted productivity. It helps mines minimise equipment downtime and enhances performance by precisely detecting missing GET, monitoring material volumes, analysing particle sizes and addressing oversized elements.

Weir’s latest tooth wear monitoring innovation and advanced Payload Monitoring (PLM) system developed for ShovelMetrics Gen 3 will be displayed in the Weir booth. Continuous monitoring of bucket teeth, lip shrouds, and the addition of wing shrouds releasing later this year – coupled with active tooth wear tracking – assists maintenance crews in anticipating change-outs. With PLM for ShovelMetrics Gen 3, operators can now accurately measure the weight of material bucket by bucket, overcoming challenges like overloading and underloading and maximizing the efficiency of loading and hauling cycles

Weir will also launch its new Enduron Elite screen, which is a double-deck banana screen, available in a range of sizes, the largest of which has a deck measuring 4.3- x 9.7-m and weighing nearly 50 metric tons (mt).

The Enduron Elite screens are driven by Weir’s new ETX exciters. It’s developed three new models — the ETX150, ETX200 and ETX250 — that are able to drive these large, high-capacity screens with just two exciters. There isn’t another machine on the market that can do that. This delivers advantages in terms of efficiency, lowering energy consumption, as well as simplifying the maintenance requirements.