Mining+Industry+Energy+Efficiency+Workshop

Energy efficiency for the mining industryGo-to-market workshop materials

Liz Darling, Energy Efficiency ISI, August 2012

ABB Confidential - - Internal Use Only

ABB Confidential - - Internal Use Only| Slide 2© ABB Group04/08/2023 | Slide 2

Outline

Mining market overview

Challenges / trends

Top global companies / producing countries

Mining process

Energy efficiency

Energy demand

Energy efficiency opportunities

ABB EE products / solutions

Go-to-market strategy

Key messages

Target market / audience

Obstacles to sales

Sales strategy concept

Marketing materials


Mining industry 2011 results

The last ten years have seen some of the greatest ups and downs in the mining industry due to the global economy

2011 showed record profits for the Top 40 mining companies of $133B but market capitalization fell 25%

European debt crisis lingered and the market questioned the long-term growth of developing countries

Net profits increased but net profit margins remained steady reflecting a change in cost base. Costs increased 25% on previous year

The industry invested a record $98B in capital projects and plan for $140B in investment for 2012 in an effort to increase supply

Structural change seen in mining: higher average commodity prices with higher production costs and lower ore grades - - therefore, increasing gross margins not guaranteed

Source: PWC “Mine 2012: The growing disconnect”


Mining industry 2011 results

The mining industry is considered an indicator of the global economy and as a result, mining stocks have been volatile. Mining stocks are more volatile than the general market but uncertainties of the global economic has added uncertainty

2011 financial results for Top 40

Revenues increased 26% to over $700 billion

Net profit was up 21% to $133 billion

Total assets remained about $1 trillion and grew a 13 percent

Miners must balance pressure to expand supply requiring development of new projects, and investors demanding capital discipline to increase shareholder returns

Mining companies also required to develop resources sustainably



Top 4 mining companiesBased on market capitalization


Top 4 companies constitute 38% of Top 40 capitalization (down from 44% in 2009)

Primary gold companies represent the single largest commodity group at 21% (up from 16% 2010) include Barrick Gold, Newmont, Randgold and Kinross)

Iron important to emerging markets: Less diversity: more iron ore mining for the largest diversified mining companies: BHPB, Rio Tinto, Vale, AngloAmerican and Xstrata. Iron ore now 42% of revenue percentage (from 20% in 2007)


Top 40 mining companies (based on capitalization)

Company Country

Anglo American* UK

AngloGold Ashanti S. Africa

Antofagasta plc UK

Barrick Gold Canada

BHP Billiton Australia/UK

China Coal Energy Co China/HK

China Shenhua Energy China/HK

Coal India Limited India

Compania de Minas Buenaventura SA

Peru

Vale SA Brazil

Eurasian Natural Resources

UK

First Quantum Minerals Canada

Fortescue Metals GP Australia

Freeport McMcRan USA

Company Country

Glencore International UK

Gold Fields Limited S Africa

Goldcorp Canada

Grupo Mexico S.A. de CV Mexico

Impala Platinum S Africa

Industrias Penoles Mexico

Ivanhoe Mines Limited Canada

Jiangxi Copper Co. China/HK

Kinross Gold Corp Canada

MMC Norilsk Nickel Russia

National Mineral Development

India

Newcrest Mining Australia

Newmont Mining Corporation

USA

Peabody Energy Corporation

USA

Source: PriceWaterhouseCooper “Mine 2012: The growing disconnect.” Country refers to primary listing site.

Company Country

Polyus Gold UK/Russia

Potash Corporation of Saskatchewan Inc.

Canada

Randgold Resources Limited

UK

Rio Tinto plc & Limited* UK/Australia

Silver Wheaton Corporation

Canada

Tech Resources Limited Canada

The Mosaic Company USA

Uralkali JSC Russia

Xstrata plc UK

Yamana Gold Inc. Canada

Yanzhou Coal Mining Company Limited

China/HK

Zijin Mining Group Company Limited

China/HK

*Group Accounts


Mining industry environment

PWC submits that though “demand” has been the headline story over the last five years, the main story for the next will be “supply.” Issues facing supply include

Structural changes to cost bases caused by decreasing grades and increasing input costs

Changes in fiscal structures (government) and resource nationalism

Disruption to production

Remoteness of mining locations and increasing capital expenditure required to bring supply to market

The industry has struggled to bring new mines online on time and in budget. Remote locations lack infrastructure to support mining activities and miners

Capital investment and time required to bring projects online is immense, especially for iron ore and coal



Mining industry environment

Mines are remote – hard to get to locations

Large capital investment required for mining equipment, personnel, infrastructure.

Mining sites are like their own cities requiring power, remote facilities, water treatment, transportation (rail, etc.) to ports or utility sites

Often in countries that are not political stable

Persistent pressure from government and communities demanding share of mining return - environment and taxing concerns



Shifting social, economic and political trends affecting mining sector

Cost inflation is higher (cost of doing business) – cost of equipment, electricity to labor demands. Taxes & royalties to hauling truck tires

Fiscal governmental policy changing – increased unpredictability, associated costs, volume

Commodity price volatility greater than ever driven my market uncertainty

More community activism over sustainability and the environment

Infrastructure strain – rail, ports, housing, schools expected to account for 82% of project spend

Corporate cash holdings increased resulting in shareholder expectations

Economic crisis / destructive weather

Source: Deloitte “Tracking the trends 2012”

In the last year, mining royalties have increased in Australia, Chile, Peru, S. Africa, Ghana, Tanzania & Burkina Faso. Export duties introduced in India, Kazakhstan & Russia


The mining environment

Ernst & Young’s global mining and metals division recently published a report stating the top business risks in mining for 2012

1. Resource nationalism

2. Skills shortage

3. Infrastructure access

4. Maintaining a social license to operate

5. Capital project execution

6. Price and currency volatility

7. Capital allocation

8. Cost management

9. Interruptions to supply

10. Fraud and corruption


Revenues by commodityIron ore, coal and copper are 57% of Top 40 revenue

Source: PWC “Mine 2012: The growing disconnect,” PWC Analysis

Top 40 posted revenues of $700B for 2011. Iron ore increased the most. Aluminium revenues the only to decrease.


Emerging versus traditional marketsTop 40

Source: PWC “Mine 2012: The growing disconnect,” PWC analysis

Top 19 of the Top 40 have primary operations in emerging markets (up from 18 in 2010).

Traditional markets are those with bulk of operations in Australia, Canada, S. Africa or USA.


Top iron ore producing countries

Source: U.S. Geological Survey, Mining Commodity Survey, January 2012

Country Mine Production* Reserves*

2010 2011e Crude Ore

China 1070 1200 23,000

Australia 433 480 35,000

Brazil 370 390 29,000

India 230 240 7,000

Russia 101 100 25,000

Ukraine 78 80 6,000

South Africa 59 55 1,000

USA 50 54 6,900

Canada 37 37 6,300

Iran 28 30 2,500

Sweden 25 25 3,500

Kazakhstan 24 24 3,000

Venezuela 14 16 4,000

Mauritania 11 11 1,100

Other countries 48 50 12,000

China production estimate based on crude ore, rather than usable ore which is reported for other countries

*Million tons


Top coal producing countries

Coal Statistics 2011 - coal provides 29.6% of global primary energy needs and generates 42% of the world's electricity

PR China 3162Mt

USA 932Mt

India 538Mt

Australia 353Mt

South Africa 255Mt

Russia 248Mt

Indonesia 173Mt

Kazakhstan 105Mt

Poland 77Mt

Colombia 74Mt

Germany 169Mt

Indonesia 163Mt

Russia 76Mt

Turkey 69Mt

Australia 67Mt

USA 65Mt

Greece 56Mt

Poland 56Mt

Czech Republic 44Mt

Serbia 37Mt

Top Hard Coal Producers (2010e) Top Brown Coal Producers (2010e)

Source: World Coal Association 2010 estimate


Top copper producing countries

Country Mine Production* Reserves*

2010 2011e Crude Ore

Chile 5420 5420 190,000

Peru 1250 1220 90,000

China 1190 1190 30,000

USA 1110 1120 35,000

Australia 870 1120 86,000

Zambia 690 715 20,000

Russia 703 710 30,000

Indonesia 872 625 28,000

Canada 525 550 7,000

Congo (Kinshasa) 343 440 20,000

Poland 425 425 26,000

Mexico 260 365 38,000

Kazakhstan 380 360 7,000

Other countries 1900 2000 80,000

Source: U.S. Geological Survey, Mining Commodity Survey, January 2012

*Million tons


Top gold producing countries

Chinese 2011 production grew 11.4% from 2010

Total gold output at 2789 tonnes, a 5.7% increase from 2010 production of 2638 tonnes

Source: London based metals research company CRU states

Country 2011 Production (tonnes)

2010 Production (tonnes)

China 380 341

Australia 272 260

USA 243 236

South Africa 221 209

Russia 205 197

Peru 156 163

Ghana 102 92

Canada 101 91

Indonesia 97 128

Mexico 82 72


Mining process


Mining and minerals processingMining

Ore Concentration(beneficiation, blending, concentration, agglomerating)

Ore Preparation(Screening, classification, pelletizing

Minerals Processing(Leaching, electro winning)

Coal Processing

Underground

Open pit


Mining development

Mining development steps

Exploration or prospecting – discovery of ore body

Development – create access to ore body, power, accommodations, processing plants, equipment obtained. Mine the mineral

Reclamation – Once ore cannot be produced profitability, process to make land used by mine suitable for future use


Mining methods and processing

Mining methods – two basic types

Open pit (cast) – surface mining

Underground or sub-surface mining

Processing of ore materials consists of

Gravity-dependent methods of separation such as panning, hydraulicking or sluice boxes

Crushing or pulverizing such as for iron ore – valuable mineral extracted aster crushing by mechanical and chemical techniques

Leaching is a less common method that may be used for target minerals that are soluble, eg., potash, potassium chloride, sodium chloride, sodium sulfate and uranium oxide which dissolve in water. No digging in process.


Mining methodsExtraction of solid mineral resources from Earth’s crust

Objective is to extract ore of a predetermined grade or higher, leave behind as much lower grade ore and barren rock

Open pit (cast) – surface mining

Dragline removing mountain top or in pit

Dozer along contour

Auger mining

Strip mining – (example: over bridge with bucket wheel excavator to remove overburden then extract coal)

Overburden is removed, blasting may be required to break up the rocks or excavating with digging / scraping machinery


Mining methodsExtraction of solid mineral resources from Earth’s crust

Sub-surface or underground mining in slopes or rooms, materials left to support the ceiling is called a pillar and may be recovered and used later

Shaft mine (hoist)

Slope mine

Drift mine

Long walling (coal)

Less disruption to surface (unless cave in due to vacant materials)

More expensive

Mine drainage water can require significant costs


Mining methods

Heavy equipments such as draglines, shovers, bucketwheel excavators, trucks, large drills, cranes, conveyors, etc. used to remove materials. Sometimes minerals have to be broken up via blasting. Materials are sometimes processed or crushed before transporting via truck or conveyor.


Mining steps

Mining wastes

Large quantity of rock and water wastes generated by extraction operations

Another waste is “overburden” generated by surface mines


Mining machineryHeavy machinery is needed in large scale mining for

Exploration and development to remove and stockpile overburden

Breaking and removing rocks of various hardness (blasting)

Processing the ore

Reclamation efforts after the mine is closed

Example equipment

Draglines

Shovels

Bulldozers

Front-end loaders

Bucket wheel excavators

Drills

Cranes

Conveyors

Hoists

Blasting equipment

Trucks (diesel or electric)

© ABB Group April 8, 2023 | Slide 25

Stockyard andstorage blendingsystem


Ore beneficiation (Milling and leaching)

Following the initial mining step, often content of valuable mineral in mining ore is too low to allow for efficient processing. Therefore the ore must be “beneficiated.”

Goal is to ship highest quality

A “concentrator” is the factory to beneficiate the ore“

Comminution” is the function of crushing or grinding the ore to physically liberate the target mineral. Concentration is separation of mineral values

Milling consists of several steps. Concentrator normally located next to mine to minimize shipping costs.

Milling steps for beneficiation start with

Screening

Primary crushing

Secondary crushing


Ore beneficiation or concentration

Typically stage 2 beneficiation includes

Grinding – usually two stages (water added at SAG / ball mill)

Separation

Flotation (often primary and secondary steps)

Thickener, tailings pond and waste water treatment plant

Electrolytic filtration

Drying

Concentrate shipping

All plants have unique layouts and sequence of steps


Ore beneficiation or concentrationGrinding

After materials go through primary and secondary crushing, grinding is the next operation

Particles reduced in size by a combination of impact, chipping and abrasion

Grinding primarily done in rotating steel cylinders known as tumbling mills

The difference between crushing and grinding is that in addition to ore particles, also loose grinding media present (steel rods, balls, hard rocks (pebbles), etc.) for grinding

Very high recirculating loads – or, each tonne of product is ground multiple times

Grinding can be done dry but is usually done wet (in slurry) which allows for transport of materials in a slurry, dust suppression and heat dissipation

Speed of drum is calibrated to where falling media pieces must not fall on the drum liner, but on the ore particles (centrifugal acceleration equal to gravitational acceleration)

Dry grinding prevails where materials will react with water (cement, iron ores)

Grinding is a major use of energy. A high percentage of grinding energy converted to heat.



Grinding media and liners are consumables

Grinding media

Balls forged from steel

Cast balls, cylinders (cylpebs), truncated cones

Steel rods (63 to 115 mm in diameter, up to 6 meters in length)

Grinding balls

Ball mills range from 25-100 mm in diameter

SAG mills from 100 – 150 mm

Tower, verti and stirred mills are 15-30 mm

Grinding liners are custom made from high chromium white cast irons. Wear resistant but brittle (crack). Multiple segments for a complete set.


Tube mill

Grate overflow ball mill


Tumbling mills have horizontal cylindrical shell with changeable inner liners. The cylinder rotates on trunnions are either end. Incoming materials continuously fed through one trunnion while the ground materials leave via the other trunnion or ports around the shell. Course fraction is returned to the mill – this is called “re-circulating load” and can be up to 3 times

Rod – used for fine crusher or course grinder

Ball – usually final step. Give finder finished product

Hardinge mill – balls segregated by size (matched to particles ground)

Tube mills (high length to diameter ratio)

Fully autogenous (AG) – large diameter and low L/D ration (~0.5:1). Use tumbling w/o media. Ore grinds itself. Abrasion used.

Semi-autogenous (SAG) – ore self-grinding is enhanced by addition of some balls (large)

Central discharge rod mill

Hardinge mill

AG mill

Copper /gold SAG mill


Ore beneficiation Milling

Concentration

PrimaryCrushing

SecondaryCrushing

Grinding

SAG / Ball Mill

Conditioning

Tailings Pond

To Water Treatment Plant

Separation

Flotation

Water

Dewatering

Thickener

Dryers

Filters

ElectrolyteFiltration

Concentrate to Smelter / Market


Ore beneficiation Leaching

Some ores can be extracted via a technique called leaching (example: bauxite (source of aluminum). The process includes

Primary crushing

Secondary crushing

Agglomeration curing

Leaching by acid or alkaline solution to leach solution

Solvent extraction

Electro winning

Electro refining

Leachate regeneration

Product to market


Ore beneficiationLeaching

Primary Crushing

SecondaryCrushing

Water

Leaching

Leached Solution

Pump Station

SolventExtraction

Electro winning

Product to Market

Agglomeration/ Curing


Ore preparation

Ore preparation / dressing(Screening, classification, pelletizing)

Screening

Classification

Pelletizing

To market


Coal mining and processing

Coal is a soft rock found in large seams either just below the surface or at deeper sites

Underground coal mine – coal extracted through tunnels and shafts. Coal is broken into a size that is easily moved and stored

Long wall mining is a technique where about 200m of the coal face is mined at one time via a Anderton shearer that claws coal from the face and loads it into a conveyor

After mining, processing is not as extensive as other mineral processing. Coal separated from rock using specific gravity and size and sometimes ground

Coal breaker

Coal washing

Bradford coal breaker


Coal mining and processing

Coal processing

Substation

Stock pilesProcessing

(breaker, washing, drying)

To market

Underground or open pit mining


Minerals processing for further refinement(Smelting and refining)

Pyro-metallurgy (smelting, refining, roasting): The next step is usually smelting which liberates metals form the concentrate - - which means it happens above the melting point of the concentrate.

For oxide concentrates like iron ore, a carbon is added and the product is molten metal and slag. Sulfide oxides are also smelted, but an oxidant (air) is blown in to liberate copper, zinc lead and similar metals

The molten metal is impure and at least another smelting process follows for further refining.

Metals is then cast into billets, blooms, slabs, or other shapes.

Hydrometallurgical operation: Example: digestion of phosphate in producing phosphoric acid

Electrometallurgical operation: Electrolytic refining (copper & zinc)


Energy efficiency


Mining and energy efficiency

The mining industry is a large consumer of energy

South Africa’s Department of Minerals and Energy (DME) estimates the mining industry uses 6% of all energy consumed in South Africa

Vale, mining giant in Brazil, is the single largest energy consumer accounting for around 4% of all energy used

In the U.S., it is calculated that the mining industry uses 3% of industry energy.

Energy cost is estimated to represent more than 15% of the total cost of production (USA) - yet – still minimal focus on energy efficiency

Source: *Cleantech magazine – Fuel Cell Special, Sept/Oct 2010. **“Energy Use and Loss Analysis, U.S. Manufacturing and Mining April 2004

Mining industry uses 3% of industry energy in the U.S. making it # 6 in primary energy use, fuel and electricity use and onsite losses**



Increasingly stringent government environmental policies

The industry is working to address sustainability issues such as carbon emissions, finite availability of resources, water quality

Mines working on low emissions technology either directly or through funding research

Advanced management techniques and technologies are increasing productivity to permit exploration, extraction and processing to occur with minimal environmental impact

Mines considering power generation for their own mine distribution and use of renewables

Source: Cleantech magazine – Fuel Cell Special, Sept/Oct 2010

According to the U.S. EPA, 400 mines operate 8,300 diesel powered vehicles creating greenhouse gas emissions and exposure to particulate matter.



Though energy is estimated at about 15% of cost of production (USA number, Cleantech magazine – Fuel Cell Special, Sept/Oct 2010), little attention spent on EE

Increase on EE due to global recession and decline in commodity prices or in regions where there is a shortage of energy (example: Mines in northern Chile have reduced power use to avoid introduction of rationing).

Regulatory pressure is a stronger driver to mining companies to take action

Governments, especially in countries with large mining sectors, are imposing standards for EE

Australia’s miners obliged to comply with the Equipment Energy Efficiency (E3) program for EE.

S Africa, The DME set a target in 2007 for mining industry to reduce energy demand by 15% by 2015. 32 S African mining and industrial companies have signed up on a voluntary basis

Source: Cleantech magazine – Fuel Cell Special, Sept/Oct 2010



Energy efficiency offers the opportunity to

Reduce cost of production – energy efficiency is a low-cost opportunity to enhance profits

Reduce carbon emissions thereby supporting environmental concerns

Improve productivity and availability as a byproduct of actions

Maintain competitive position


Mining and energy efficiencyAll mining activities require energy

Exploration

ExtractionBlasting

Drilling Dewatering

Ventilation

Digging

Finished Product

Extraction

Materials Handling ElectricDiesel

Preparation, Beneficiation & ProcessingGrindingCrushing Separation

Mining is a massive industry involving a diverse range of energy intensive processes

Mining operations are often remote and require infrastructure such as building, water processing, rail, electrical (substations or on site generation) to be considered


Energy used in the U.S. Mining Industry

Coal10%

Diesel34%

Electricity32%

Natural Gas22%

Gasoline2%

Mining and energy efficiencyMining industry energy sources

Type of energy used at a mine site will depend on the mine type (surface or underground) and processes used

The exhibit shows energy used in mining industry for coal, metals (iron, lead, gold, zinc, copper) and minerals (phosphate, stone, sand, etc.) (U.S. example)

Each mined product has a different recovery ratio which can significantly impact energy required per ton of product

Source: U.S. DOE Industrial Technologies Program “Mining Industry Energy Bandwidth Study, 2007

Electricity major energy source for underground mining for hoists and ventilation

Majority energy source for surface mining is diesel for hauling

“Fuels” such as diesel used for service trucks and hauling equipment, electricity for fans, drills, crushers, conveyors, etc.


Mining and energy efficiencyEnergy use by mining industry equipment

4%

Digging 6%

Dewatering 2%

Ventilation 10%

Crushing 4%

Grinding 40%

Separations 4%

Ancillary Operations 6% Drilling 5%

Blasting 2%

Materials handling electric equip 4%

Materials handling – Diesel Equip 17%


Majority of electricity used in milling process


Mining and energy efficiencyEnergy loss profile - motors represent 29% of onsite losses

Losses occur in equipment and distribution systems that are converting energy into work or supplying energy to process operations

42% of the energy that enters the plant is lost prior to use in processes

62% of energy lost in energy conversion systems

Source: U.S. DOE, “Energy Use and Loss Analysis” April 2004

Generic energy footprint and flow of energy losses


Mining and energy efficiencyMining industry motor system loss profile


Almost 50% of the energy input for motor driven systems is lost through subcomponent inefficiency

Materials processing systems can have inefficiencies as high as 90%

Pump systems inefficiencies are considerable at 40%

Highest motor system losses occur during energy conversion

Fuel mix for motor systems is 82% electricity and 18% fuel

Losses ~40%


Grinding and diesel equipment for materials handling offer the greatest savings potential of 37%

Savings achieved by implementing best practices and new advances in R&D


The study reports energy savings independent of each other. Improving savings in one area could increase savings in another. Study based on average energy use for a process, energy use by above average EE mines,

Incentives to innovate upstream becomes greater as processing plant becomes more tuned. Quality of feed becomes more important to meet productivity, emissions and quality targets


Example mining industry energy saving opportunity

U.S. mining industry (excluding O&G) consumes ~ 1,246 Trillion Btu/year (TBtu/yr)

DOE bandwidth analysis estimates that investments in state-of-the-art equipment and best practices could reduce energy use by over 50%

Potential to save a total of 667 TBtu/yr – 258 TBtu/yr by implementing best practices

Additional 409 TBtu/yr from R&D to improve mining technologies

CO2 emission reduction achievable from total practical energy savings estimated at 40.6 million tonnes


~20%

~50%

Study based on 8 commodities mined by the U.S.

• Coal• Potash. soda ash & borate

• Iron• Copper• Lead & zinc• Gold & silver• Phosphate rock

• LimestoneThese commodities used to define average Btu/ton for coal, metals & industrial minerals.


Mining energy efficiency opportunities

Mining operations are typically remote and some processes are highly energy intensive. Rock crushing, drilling and grinding require considerable mechanical forces and subsequently large amounts of energy. Energy use increases as ore grade declines

It is estimated that approximately 90% of the electricity for mining is used by motor driven systems such as fans, compressed air and pumps (Xenergy, 1998). A large portion of this is to drive fans for mine ventilation (Xenergy, 1997)

Energy efficiency measure can also lead to non-energy benefits such as better equipment reliability, longer equipment life, reduction in maintenance costs and downtime and improved work environments (mine ventilation, lighting, etc.)

Source: “Energy Use, Loss and Opportunities Analysis: U.S. Manufacuturing and Mining

Estimated that 90% of electricity used for motor driven systems


Mining energy efficiency opportunitiesExploration and extraction

Non-invasive technologies such as remotely-operated sensors and ground-based technologies to minimize exploratory digging and drilling*

After prospected materials found, advanced communications technologies can guide sophisticated equipment to improve accuracy of mining thereby optimizing equipment and time use and allowing for remote control

Advanced techniques for characterizing mineral content at exploration site* (reduce waste transport)

Efficiency of separation or liberation at the mine face reduces waste

Source: Multiple. *Energy Efficiency Guide for Colorado Businesses. **”Energy & Sustainable Development in Mining and Minerals Industries Jan 2001). ABB Energy Consultancy studies.

Roughly one third of mining energy demand is in excavation (removal one half, haulage one fourth, and the rest for drilling, blasting and ventilation)**

There is a bias towards energy efficiency improvements in processing versus mining portion. Improved blasting techniques have energy efficiency effects downstream


Mining energy efficiency opportunitiesExtraction

Reduce handling of materials. Every movement of materials adds costs - reduce waste transported to processing facilities, investigate stockpile management

Consider alternative materials handling solutions such as conveyor systems versus truck haulage where feasible – may use less energy

Large number of motors and pumps are used in excavation process (drilling, excavation and ventilation)*

Correctly size motors and pumps

Select premium-efficiency units

Employee variable speed drives in applications with highly varying load requirements and gearless drive systems (gearless mill drives; AC for shovels, drag lines, bucket wheel excavators, conveyors, hoists, etc.)

Source: Multiple. *Energy Efficiency Guide for Colorado Businesses. Colorado Governor's Energy Office. ABB Energy Consultancy studies



Mine ventilation and cooling

Systems approach to mine ventilation that takes into account parameters from the point power enters the motor to required function. Ventilation system automation to constantly analyze requirements with smart sensors to determine air quality and adjusts flow (power supply, flow control devices, ducks, sensors / meters, high-efficiency motors and fans, variable speed drives). Additional benefit of improved power factor and reduce penalties.

For cooling, consider moving air via insulated pipes and pumps to fan/coil heat exchanges located in the mine itself versus moving cool air from the surface to the underground mine via fans and ducts. The closed loop used to pipe chilled water takes advantage of gravity to move water into and out of the mine.*

Source:. *Energy Efficiency Guide for Colorado Businesses. Colorado Governor's Energy Office. “Increasing Energy Efficiency of Mine Ventilation Systems.” multiple authors, Lawrence Berkeley National Laboratory, ABB Energy Consultancy studies



Refueling underground versus bringing trucks up top

Use drives with regenerative capability when braking or downhill operation (hoisting, conveyors)

Use spinning battery reserve on hoists – reduce diesel operation required when reducing peak load of system*

“Mining Registry” – Australia government registry of opportunities implemented


Mining energy efficiency opportunitiesMaterials handling

Large numbers of motors are used for moving and handling ore and other materials. Energy can be saved through

Proper sizing and maintenance of motor systems

Use of premium-efficiency motors

Variable speed drives for applications with varying load requirements

Alternative materials handling systems including electric solutions versus diesel trucks / front-end loaders (conveyors, electric trucks)

Automated controls for optimizing materials handling – adjustable conveyor speeds to ensure consistent optimum hauling loads (VSDs required)

Remote control of automated hauling cycles employing sensors to identify fill, quality, etc. Optimization of start up process for conveyors

Source: Multiple. *Energy Efficiency Guide for Colorado Businesses. Colorado Governor's Energy Office. ABB Energy Consultancy studies

For coal – transportation accounts for 50 to 80 percent of the cost; therefore, transportation energy savings considered more important than mining


Mining energy efficiency opportunitiesMaterials handling

Consider gearless drives for appropriate applications (long-haul conveyors)

Stockpile management – reconfiguration of stockpile patterns / storage arrangement can reduce energy use. Consider loading areas and minimize re-piling

Use drives with regenerative capability when braking or downhill operation (hoisting, conveyors)

Optimize all loads. Reduce unloaded or wasteful fixed loads. Always fill to optimum capacity

Adjust conveyor speeds to optimize loading and unloading (w/ or w/o VSDs)Δ

Evaluate equipment used to load and unload – perhaps mobile conveyor more cost effective to front-end loaderΔ

Idle equipment when not in use

Improve road conditions – consider road traffic designSource: Multiple. *Energy Efficiency Guide for Colorado Businesses. Colorado Governor's Energy Office. ABB Energy Consultancy studies


Mining energy efficiency opportunitiesPreparation, beneficiation and processing

Large numbers of motors, pumps and blowers are used for moving, crushing, handling, fans and dewatering ore and other materials. Energy can be saved through*

Proper sizing and maintenance of motor systems

Use of premium-efficiency motors

Variable speed drives for applications with varying load requirements

Improved techniques for characterizing ore

Preparation and processing proximity to mining (reduced materials transport energy use)

Consider gearless drive (ring-motor) for grinding with VSD where ore is various hardness – allowing mill to slow when soft ore encountered**

Preparation and beneficiation & processing (smelting, refining and coal preparation) – smelting and refining not discussed

Source: Multiple. *Energy Efficiency Guide for Colorado Businesses. Colorado Governor's Energy Office, ABB Energy Consultancy studies

Rock crushing and grinding require large mechanical forces and therefore large amounts of energy

“Mining Registry” – Australia government registry of opportunities implemented**


Mining energy efficiency opportunitiesPreparation, beneficiation and processing

Remove “scats” (non-spherical ball fragments) that take energy but don’t have enough energy to grind*

Centrifuge – lowest energy use centrifuges

Flotation –Consider most efficient motors, control systems, VSDs to vary air compressor speed, efficient mechanical impellers.** Only deliver air required to meet demand. Switch off when not in use. Prevent sump pumps running dryΔ

Leaching requires large volumes of electricity in the electro-winning process (electro-plating). Coal may be used to produce the steam to produce electricity. Opportunities for efficiency may include boiler optimization, improved air compressor flow control, regular maintenance for steam traps, variable speed drives for stack gas, air leak reduction programs, insulation for steam distribution, etc.Δ

Source: Multiple. *Mining Registry (Australia Review), **Energy Efficiency Guide for Colorado Businesses. Colorado Governor's Energy Office, ABB Energy Consultancy studies

Preparation and beneficiation & processing (smelting, refining and coal preparation) – smelting and refining not discussed


Mining energy efficiency opportunitiesEnergy for water use

Most mines both consume and produce water. Energy is used to pump the water

Water used in mining for drilling, transportation ( materials slurried near mine and transported through pipeline suspended in water (size reduction facilities)), and processing (grinding, washing, separated via screening or other gravity separation). Water is also used to suppress dust when crushing and on hauling roads, etc.

Often water produced during exploration or operation and must be removed to prevent flooding and may need to be treated before discharge

Significant energy can be used to remove water due not only to amount but it must be lifted to the surface

Sometimes water must be imported or transferred as surplus mine water to treatment or discharge locations

Source: “Industrial Water Management: A Systems Approach,” CH2M HILL for Center of Waste Reduction Technologies, American Institute of Chemical Engineering, ABB Energy Consultancy

Water used for• Mining• Minerals conveyance•

ProcessingOptimized pump efficiency to reduce energy use

Coal Mining: Water might be used for cooling the cutting surfaces of mining machinery (coal mining) and to inhibit friction-induced ignition of coal fines or gas



Pumping one of the biggest uses of electric motors

Right size motors / pumps for water sources

Replace motors with more efficient solutions

Use VSDs to adjust pressure / flow to meet requirements (turn off when not needed)

Other pump optimization measures (buy based on life cycle costs, maintenance programs, intelligent pump systems for multipumps)

Turn off water pumping equipment when idleΔ

Physically position machinery required for less distance pumpingΔ

Consider reducing water to just meet requirements when possible: boiler water for steam generation, heat generation, flotation, to transport ore (coal) where possibleΔ


Any reduction in water use reduces energy use



Evaluate dewatering process to reduce energy needed Δ

Recover water when possible (condensate from air heater)Δ

Optimize steam use at air heatersΔ

Reduce water leakage (maintenance strategy) Δ



Mining energy efficiency opportunitiesIn general

Invest in system to provide information on energy use so behaviors can be modified for efficiency, cost negotiated

Holistic approach: Energy management software for monitoring energy use throughout the plant and visualize reporting in real time

Install meters to provide energy use information – identify what will be measured

Integrate systems into other systems (EM with MES Manufacturing Execution Systems)

Remotely monitor across multiple location to compare use, efficiencies

Reduce lighting costs with new lighting technologies, control systems including timers, sensors to turn off lights when not in use.

Energy efficiency byproduct - better designed processes, buildings, etc.

Source: Mining Registry (Austrialia Review), Mining IQ, ABB Energy Consultancy studies



Optimized HVAC systems – timers, variable speed drives, efficient fans, high efficiency motors

Best practice training – change behaviors – educate team to look for energy efficiencies.

Procedural changes: example is to turn off light in pit once sufficient natural light.

Consider total life cycle cost of energy use versus just initial costs

Invest in more efficiency technologies

Compressed air reduction (compressed air used for air drill)

Off-peak pressure reduction

Optimal compressor scheduling, controlsΔ, generating pressureΔ

Leak repair strategies – systematic ID and repairΔ

Variable speed drives vs mechanical solutions where applicable




Preventative maintenance practices – also improving availability along with saving energy

Example: truck tire pressure management, steam trap maintenance / leak repairsΔ, conveyor roller maintenance to reduce frictionΔ

Mine site electricity generation - reduce energy associated with use for transmission or transport (of fuels)

Tune generic systems

Steam generators

Onsite power systems

Fired heaters

Boilers – steam leaks repaired, steam distribution insulationΔ




Robotics as automation solutions to improve efficiency, improve productivity and increase safety

Power quality – power factor correction to ensure operating within intended performance – reduce reactive power use and charges

Second power line to UG mine decreased overall resistance through transmission lines and therefore losses were lower and power plant load reduced

Consider using any heat generated by a process to be used for other requirements

Consider peak electricity costs – reduce loads during periods of high costΔ

Institute an overall motor repair / replacement policy to ensure efficiencies (rewind vs high efficiency)Δ




Implement an energy program with management and employees responsible for meeting energy goals

Develop a clear energy policy with KPIs and an identified leader and team

Clearly communicate energy policy

Adapt techniques used in successful safety improvement programs to raise awareness and importance of energy efficiency

Develop a process for bringing forward opportunities for energy savings


Mining energy efficiency opportunitiesSummary

Invest in most efficient technology – consider total life cycle costs (VSDs, high-efficiency motors, etc.)

Consider new blasting methods the reduce impact on mineral seam and reduce contamination - waste

Improve process controls, introduce equipment automation

Improve hauling efficiencies – consider alternative materials transport throughout mine, optimized stockpile management processes, location of process circuits

Optimization of auxiliary systems: HVAC, water, lighting

Mine automation – intelligent software

Pit design and overburden management

Behavioral changes

Source: Multiple. ABB Energy Consultancy studies


ABB energy efficiency solutions

See Value Proposition slide presentation for details

ABB Confidential - - Internal Use Only| Slide 69© ABB Group April 8, 2023 | Slide 69

ABB’s approach to energy efficiencyDoing more while lowering costs and emissions

By reducing energy losses, ABB technologies mitigate demand for new power generation, make better use of natural resources, and

help make industries more efficient and competitive.


Technologies

Energy efficiency solutions

ABB has technologies for the entire energy value chain to squeeze the most value from each unit of energy used

ABB contributes to energy efficiency improvements in two ways:Specialist Equipment, systems & solutions

ABB the company

ABB Confidential - - Internal Use Only| Slide 70

Manageable, measurable improvement programs

Understanding how and where you use energy, decision support

Increasing motor energy efficiency while reducing maintenance wear and downtime

ABB Energy Solutions services

Energy efficiency solutions aligned with mining productivity and profitability objectives


cpmPlus Energy Manager for industry

Variable speed drives and premium-efficiency motors systems for underground and open pit mining, ventilation, materials transport, materials crushing and grinding and auxiliary systems ( fans, water pumps, compressors, etc.)


Improving efficiency and reducing costs associated with underground air handling

Underground mine ventilation



Underground materials transport systems that increases capacity, improves air quality, and reduces energy requirements

Electric truck electrical systems

Enhanced energy efficiency for underground materials handling systems while boosting capacity and productivity

Hoists with regenerative braking and energy storage systems to use energy efficiently and reduce peak impact on network. Services to upgrade to AC drive system




Gearless mill drives Ring-geared mill drivesDrives for high-pressure grinding rolls

Lower energy requirements for materials preparation

Improving productivity and energy efficiency of conveyor systems

AC drives and premium-efficiency motors, Active Front End to recover braking energy

Integrated electrification and automation

Optimized conveyor load / Inverse Start Route systems

Gearless drive alternative




Optimized electrification of plant / mine integrated with automated processes

Integrated process control and automation, drive and electrical systems. Substation automation integration

Increasing availability and efficiency of mining assets such as shovels and drag lines

AC drives for energy efficiency, excellent power quality and better control of current and torque


Improve reactive power compensation and power factor correction

Site assessment services and solutions such as active filters, capacitors for power factor

Solutions that are aligned with your mining processes and energy efficiency objectives


Low loss “green” distribution transformers

Measurement products, emergency power supply / UPS, gas insulated switchgear, substations

Lower total cost of ownership and improve efficiency of transformers (large load or low load losses)

Energy efficiency enablers

Services Shovel and dragline retrofit servicesLifecycle servicesEngineering servicesFull Service



Related solutions for mining operations

Mines are often remotely located and require infrastructure for power generation and materials transport such as rail. Water is also a limited resource required for multiple mining operations as well as removal or transference

ABB offers energy efficiency expertise and products associated with power generation, transportation, water usage and building automation energy efficiencies.

Efficient management of water resources used for mining processes or requiring removal or transference

Site assessment services including pump system optimization

Power generation assessment services and energy efficient products

On-site power generation



Related solutions for mining operations Rail infrastructure and

rolling stock efficienciesTurbochargers to boost performance of diesel engines to regenerative braking systems and efficient grid to railway power efficiency solutions

i-Bus® KNX automation systems for monitoring and control of lighting, HVAC, etc.*

Energy efficient buildings and facilities

High-power electrical port connections (turn off ship diesel engines) and coal terminal and general stockpile management

Energy efficient port / ship power management that reduces air and noise pollution. Coal terminal electrification / automation optimization

*Not available in the Americas


Go-to-market strategy

Target offerings

Key messages

Target market / audience

Obstacles to sales


Marketing materials

What

Who

How


1. Services ABB Energy Solutions to accelerate energy savings -

including performance-based contracting

2. Software

cmpPlus Energy Manager

3. ABB product / solutions

Target offerings

What

Who

How

ABB will lead with the following energy efficiency offerings


Key messages

There is a global need for energy efficiency

Global energy use predicted to increase by 96% by 2035 compared to 2008 levels

The IEA estimates that energy efficiency measures can deliver half of the cuts in emission that are needed over the next 25 years

In a 2011 global survey by the Economist Intelligence Unit, almost 90% of manufacturers said that improvements in their energy efficiency will be critical for business success in the next two decades

The mining industry faces a number of challenges from higher costs of doing business, fiscal governmental policy becoming increasingly unpredictable, the advent of carbon emission penalties, commodity price volatility, and the struggle to bring new mines online on time and within budget, to increased requirement for infrastructure capital expenditures due to remote location of mines

What

Who

How


Key messages

Energy efficiency is one way to help combat some of the challenges

Energy efficiency

Decreases operational costs

Reduces greenhouse gas emissions

Improves productivity

Makes the mine site more sustainable

And - results in improved competitiveness

“Improving energy efficiency worldwide is the fastest, the most sustainable and the cheapest way to reduce greenhouse gas emissions and enhance energy security.” (Final statement of G-8 summit, Germany, June 2007)

What

Who

How


Key messages

ABB has been in the energy business for over 120 years and pioneered many innovations such as HVDC, variable speed drives and gearless mill drives

ABB has the experience and tools for helping customers implement energy efficiency solutions along with the success stories

What

Who

How


Target market

Target market

Mining installations

Top mining countries

Key countries with BU Minerals and GAM / SAM coverage

#1 brown fields, #2 green fields

Primary target

As high up as possible – CEO, CFO, CTO, Energy Officer

Mine manager

Mine superintendent or process superintendent

Environmental officer

Business improvement officer

What

Who

How


Source: Australian Government: Department of Energy and Tourism. “Driving EE in the Mining Sector: The Business Case and Beyond”

Target market: decision makers at mine site

What

Who

How


Common obstacles to promoting and bringing energy efficiency awareness in mining companies

There are many obstacles to implementing energy efficiency in the mining industry due to historically low energy market prices, focus on rapid expansion of production driven by market demand, and fear that energy efficiency projects are expensive and impact productivity - - or that they are often small scale and discretionary in nature

No “one size fits all” solution to the energy challenge

Each mine site requires a different approach

What

Who

How


Common obstacles to promoting and bringing energy efficiency awareness in mining companies

Management is not always up to date on business implications of energy use including

Strong trend toward increasing electricity and diesel fuel prices - which continue to fluctuate. Increased production opportunity in energy efficiency projects along with the substantial impact on operating costs

Potential energy supply issues at many site

Compliance requirements

May not have good information on energy efficiency projects – need cost and benefits analysis including financial or operational risks identified. Need to link broader benefits – projects must achieve important business priorities

EE projects can be identified through assessments but need skilled support in particular technologies for implementation

Robust financial analysis required along with the right expertise to complete projects

Source: Patrick Crittenden presenting at Mining IO’s Energy Efficiency in Mining 2011 Australia

What

Who

How


Gaining mining management support

Know the business – align energy efficiency business case with core business objectives

Link benefits of energy efficiency projects to production benefits, cost containment and maintaining safe working conditions

Understand customer interests so you can promote energy efficiency as helping to achieve their goals

Understand who makes decisions and target communications on how project supports their role, interest or understanding of the issues

Talk to site financial officer to find out current investment policies. Make sure the financial officer is aware of energy issues and costs and potential price increases in the future

Enlist the business improvement managers by discussion potential energy efficiency projects and relating to productivity and other business improvement priorities

What

Who

How

Source: Patrick Crittenden presenting at Mining IO’s Energy Efficiency in Mining 2011 Australia


Enlist BU Minerals team to expand “share of wallet” with mining customers and make introductions for EE solutions offered not only in PAMI but other divisions – take a “systems” approach

Leverage ABB Energy Solutions HUBS

Work with the ABB Energy Solutions (PASV) team to identify opportunities for conducting EE assessments that will pull through other ABB solutions

Work with EE Champions in key countries to pull together team to focus on Mining Industry

Employ GAMs, SAMs, BU Minerals to identify targets and introduce team to key accounts


What

Who

How



Team up with DM motor/drive assessment team BU Minerals focused on mining assets (shovels,

conveyors, grinding solutions) – many other motor / drive auxiliary systems to consider

Capability to assess auxiliary systems available in more countries

BU Minerals team locations BU Minerals organization GAMs

Cluster leader – John Olsen Anglo American – Per Wanland Rio Tinto – Alain Zagouri Vale – Roberto Held BHP Billiton – Regina Roos

What

Who

How


Training materials

Mining industry process

Mining industry market / trends

Mining industry energy efficiency opportunities

ABB energy efficiency solutions

Key messages / target audiences / sales strategy concept

Marketing materials

Marketing materials

What

Who

How


Marketing / sales support materials

Presentations

Mining Energy Efficiency Value Proposition

ABB Overview (Complete)

ABB Overview (Summary)

Energy Efficiency Trends

ABB Sustainability Story

ABB Success Stories

Flyer – Summary of Mining Value Proposition (2-pager)

Group EE Overview Brochure

EE Trends Reference Document

Web portal to hold content

Marketing materials

What

Who

How


Print-on-demand pieces ABB Energy Solutions for the Mining Industry

(consultancy) cpmPlus Energy Manager Conveyor Systems (Materials Handling PAMI) Underground Mine Ventilation (in development PAMI) Underground Hoists (in development PAMI) Underground Mine in General (in development PAMI) Boiler Fingerprint LV Soft Starters LV Contactors Baldor Cooling Tower Motor & Drive Assessments

Marketing materials

What

Who

How


Marketing materials

Print-on-demand pieces

Full Service

Instrumentation / Measurement Products

Power Generation Energy Efficiency Assessments

Success stories

Peňa Colorado Iron Ore Variable Speed Drives

Dragline Retrofit

Mine Hoist Grid Reliability

Vigier Cement Conveyer

Brochures

Sustainability in Mining

Efficiency in Mining Motor Driven Systems

What

Who

How


Key messages

Elevator pitch

Clip art images

Roll up and poster templates

All items available as InDesign file for local translation or a high resolution, print ready PDF

Materials for local workshops

Informational presentation (processes, market, etc.)

Flash stick with files

Target account list + BU ABB contact information (provided by country EE champion)

Marketing materials

What

Who

How


Level 1 overview roll up banners


Level 2 informational banners

Level 3 informational poster


Marketing materialsPortal links

External portal on energy efficiency

www.abb.com/energyefficiency

Inside ABB portal

http://inside.abb.com/cawp/db0003db004341/ccbbd25c30a117b3c12578ed0056a851.aspx?

Mining portal

http://inside.abb.com/cawp/db0003db004341/f1644a689e2bb820c1257a6400460cca.aspx

Auto portal

http://inside.abb.com/cawp/db0003db004341/21b3396087dc487ec1257905002db1cf.aspx

Iron and Steel portal

http://inside.abb.com/cawp/db0003db004341/94ff432377791fc6c12579bb0035bd30.aspx

Trends report

http://www.abb.com/cawp/gad02465/b9225505ced8f7d7c1257853004a7a00.aspx?

What

Who

How




Appendix


Mining ranks 6th in primary energy use, fuel and electricity use and onside losses in the U.S.


Mining

Direct use of purchased energy. Top six industrial consumers in the U.S.

Mining energy use impact varies by country. Comparison numbers are hard to acquire. South Africa mining is estimated to use 25% of the electricity


Generic energy footprint



Flow of energy losses



Results of DOE mining study

Best practice energy use based on various reports of top-performing mining equipment

Theoretical minimum energy – minimum energy needed to complete a process in the absence of energy losses to heat, etc.

Practical Minimum – Considered closest approach to the theoretical limit allowed by implementing best practices and technologies developed by ongoing R&D. This is a moving target since science and technology continue to improve energy efficiency

Factors in electricity generation losses in analysis – employed the “tacit” energy consumption values, i.e., energy used onsite plus the energy lost in generating and distributing the energy instead of onsite consumption. One Btu of electricity onsite requires a total energy use of 3.17 Btu. Conversely, saving 1 Btu translates to saving 3.17 Btu



Mining industry energy savings opportunities


Go-to-market materialsSuccess stories (1 of 2)

Industrial Energy Efficiency assessments

Ore processing plant / electro-winning process

Iron ore mine

Coal mine

Performance guarantee

Conceptual design analysis

Modernization of coal mine fan station

Mine ventilation automation system

Modernization of copper mine

Variable speed drives for grinding mill

Variable speed drives for iron ore pellet cooling fan

Hoist upgrade

Go-to-market materialsSuccess stories (2 of 2)

Dragline retrofit

Conveyor regenerative power

Shovel upgrade

Optimized bucket wheel excavator

Variable speed drives for high pressure grinding rolls (HPGR)

Belts Conveyor automation, motors, variable speed drives

Integrated electrification and automation of coal plant

cpmPlus Energy Manager

i-Bus® KNX building automation system

Optimized boiler operation

© ABB Group April 8, 2023 | Slide 107© ABB Group April 8, 2023 | Slide 107

Global Business Unit MineralsRepresented around the world

Business Unit Minerals headquarters


Business Unit MineralsOrganization chart

Brazil

Renato Finoti

North America

Gabriel Azeroual

Chile

Gerardo Mendoza

Mexico

Fernando Cantu

Peru

Adolfo Samaniego

Switzerland

Marcelo Schumacker a.i.

Baltic States

Leho Kuusk

Germany

Peter Mühlbach

Greece

Yannis Happas

Norway

Roger Nilsen

Poland

Jacek Dziezak

Spain

José L. Caballero

Sweden

Andreas Malmport

Australia

Andy Kostiono

China

Stephen-JiHao Zhu

India

Amogh Nawathe

Indonesia

tba

Oman

Sanjay Jog

Saudi Arabia

George Kuruvilla

Thailand

Kitti Kangwalklai

Vietnam

JianPeng Fu

Egypt

Nour Nassar

South Africa

Max Luedtke

Electrical, Control & Instrumentation

SystemsAndre Inserra

Material Handling & Grinding

Marcelo Schumacker

Service

Marici Santos

Head of global Business Unit Minerals

Giuseppe Di Marco

CFO

Satish Kolala

Technology

Clive Colbert

Marketing Communications

Marion Hug

Assistant

Carla C. Castillo

Management Team

OperationalExcellence

Markus Ahrens

Kazakhstan

Anuar Sakharkhanov

Supply Chain

Domenico Chieffo

Underground Mining

Remy M. Lanoue

Argentina

Pablo Perez Esmoris

Serbia

tba

Local Business Units

Malaysia

Mohan-Raj Paranjothy

Main Technology Centers

Status: January 01, 2012


BU Minerals Service Product group global service team

Global PG Service

Marici dos Santos

Materialhandlingservices

Eduardo Botelho

Grindingsolutionsservices

Jari Koponen

PG MH&G(Material handling and grinding)

Cement plantsservices

Minerals plantsservices

PG ECIS

(Electrical, control & instrumentation systems)

Undergroundmining

services

PG UGM

(Underground mining)


BarbaraObrist

Hans-Helmuth

Jung

BengtHedlund


PAMI conveyor team


c

ABB‘s industrial plants solutionsPortfolio

Overheadtransmission lines

Process control Cabling InstallationMV motors

HV-substation

KnowledgeManager

Grounding /Lightning protection

Supervisionof installationLV motors

Transformers Instrumentation Lighting CommissioningMulti-drives

Engineering, Supply, Construction, Management, Service

Optimizationpackages

Containerized e-room

MV/LVswitchgear

Variable speed drives

Training ofpersonnel

Emergencypower

Power factor correction

Applicationsoftware Communication

Life cyclesupport

DC power RectifiersVentilation

air-conditionOperationsassistanceMCCs

PowerDistribution Drives Automation Infrastructure Services

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