• A recent publication highlights how gearless grinding solutions can enhance efficiency and support decarbonization in the mining sector.
• Research reveals that Gearless Mill Drives (GMDs) are up to 3.6% more energy-efficient than traditional Ring-Geared Mill Drives (RMDs).
• The energy savings linked to GMDs could lead to a reduction of up to 195,000 tons of CO₂ emissions, which is equivalent to removing 89,000 cars from circulation.

On September 25, 2024, ABB issued a comprehensive white paper examining the significant role gearless grinding technologies play in boosting mining productivity while reducing carbon emissions. One of the primary insights, based on extensive testing of ABB’s Gearless Mill Drives (GMDs) already installed, is their high energy efficiency. GMDs have shown to be up to 3.6% more efficient than Ring-Geared Mill Drives (RMDs), helping to reduce energy consumption and lower mining operational expenses. The cumulative efficiency across ABB’s GMD installations translates into a potential reduction of 195,000 tons of CO₂ – equal to taking 89,000 vehicles off the roads. Even with a more conservative 2% increase in efficiency, this would still result in saving 106,000 tons of CO₂, or the equivalent of removing 49,000 cars.

Such efficiency improvements are critical for the future of the mining industry. The rising demand for essential minerals, fueled by digitalization and the energy transition, is paralleled by a decline in ore quality, requiring the mining of more material to yield the same amount of metal. This is further compounded by mounting pressure to minimize mining’s environmental footprint. Tackling these challenges concurrently presents a significant test for the industry.

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The new ABB white paper investigates how these dynamics are shaping the copper industry. Copper is fundamental to the energy transition, and demand for it is projected to double by 2050. Yet today, only about 0.5% of mined ore is turned into copper, down from historical rates of 1%. This means that to maintain current copper production levels, today’s mines need to process twice the amount of ore. However, scaling up output without implementing sustainability measures could result in emissions that outweigh copper’s benefits in clean energy technologies.

“The only way to meet the rising demand for critical minerals like copper, while simultaneously minimizing the environmental impact of mining operations, is by utilizing GMDs,” commented Wilson Monteiro, Global Business Line Manager for Gearless Mill Drives at ABB. “For over 50 years, GMDs have proven their worth across industries, showcasing the potential for more eco-friendly, efficient, and reliable grinding operations compared to alternative solutions. This white paper demonstrates why GMDs are the preferred choice for mines aiming for a more productive and sustainable future.”

The white paper outlines how technology will be crucial in addressing these challenges. GMDs, having fewer mechanical components, have proven to be more energy-efficient, reliable, and easier to maintain. These qualities contribute to a less energy-intensive process with greater uptime, delivering the dual advantages of a reduced carbon footprint and increased operational efficiency.

The full interactive whitepaper can be accessed online here.

ABB’s Process Automation division supports the automation, electrification, and digitalization of industries, addressing critical needs such as energy, water, and material supply, as well as the production and transportation of goods. With around 20,000 employees and leading technological and service expertise, ABB Process Automation enables clients in process, hybrid, and maritime sectors to enhance operational safety and performance, supporting a more sustainable and resource-efficient future.

ABB, a global leader in electrification and automation, is driving the shift towards a more sustainable and resource-efficient future. Through innovative solutions that blend engineering expertise with software, ABB optimizes the manufacturing, transportation, powering, and operation of industrial systems. With a legacy spanning over 140 years, ABB’s workforce of more than 105,000.

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