Future of Manufacturing

004- Le dispatch, salle de contrôle de la mine de Tiébaghi AUS MN

Nickel Producer enhances quality of ore calcination through kilns

Société Le Nickel (SLN), part of the Eramet Group, is the world’s largest producer of ferronickel. Pictured is one of the five furnaces managed by Rockwell Automation’s FactoryTalk Analytics Pavilion® software. Image copyright: Société Le Nickel (SLN), part of the Eramet Group. Characterised by the ability to resist corrosion at high temperatures and its usefulness as an alloying element, nickel plays a critical role in a host of industry sectors ranging from aerospace and chemical to electrical and automotive. Société Le Nickel (SLN), part of the Eramet Group, is the world’s largest producer of ferronickel. The 140-year-old company also produces manganese, lithium, and titanium which are critical for the manufacturing of batteries, paint pigments, and wind turbines among other products. Processing ores is a complex activity requiring the stable control of the rotary furnaces’ temperature profile and automating operations across different operating ranges. Feed ore introduced into the rotary kiln undergoes calcination as it travels through the length of the furnace. If the calcined product is not at a high enough temperature, product quality is compromised. Heat is distributed across the furnace with air being supplied for combustion to occur. If there’s too much air supplied, more fuel needs to be burned to maintain the same product temperature, thus decreasing energy efficiency. Excess oxygen must be minimised to a safe level to reduce operating costs and greenhouse gases. Legacy system lags SLN was using an expert system, an existing fuzzy logic controller, designed to automate the operation of the furnace. However, the company faced several challenges with the legacy system, particularly with varying ore content and variable heating values leading to temperature spikes and frequent electrical trips. Trips were being caused by high product temperature, which compromises both the quality of the product, and the integrity of the […]

Oil and gas dominates future major resources projects driving economy

Australia’s oil and gas industry has emerged as the dominant driver of nation-building new resources projects, creating new jobs and attracting billions of dollars of spending in Australia. The Australian Government’s Resources and Energy Major Projects (REMP) 2023 report said 12 oil and gas projects accounted for $36 billion of investment (46.5 per cent) of the $77.4 billion pipeline. Lithium and iron ore each represented $7.2 billion (9.3 per cent) worth of committed projects, gold accounted for $6.6 billion (8.5 per cent) and coal was behind $4.6 billion (5.9 per cent) of ventures. Australian Energy Producers Chief Executive Samantha McCulloch said the results showed how critical the oil and gas industry was to the national economy. “Australia’s oil and gas continues to power the national economy, creating jobs and delivering billions of dollars of investment, much of it into regional communities,” she said. “The pipeline of new gas projects highlights the importance of policy settings and regulatory certainty to unlock investment in new supply. “With Australia facing energy shortfalls on both coasts, new gas supply is urgently needed to avoid blackouts and put downward pressure on prices while securing future economic benefits.” According to the report, only one new oil and gas project reached a final investment decision in the 12 months to November 2023. Ms McCulloch added: “The pipeline of mining and critical minerals projects will also rely on natural gas supply, with AEMO forecasting resource projects will add a further 23 TJ/day to gas demand in Western Australia by 2026.” The report also found growing interest in hydrogen projects but with only three out of 76 planned projects reaching the committed phase in 2023, representing a capital expenditure of $234 million. Ms McCulloch said: “Natural gas combined with carbon capture, utilisation and storage (CCUS) is today the most […]

Hydraulink trendsetter doubles commitment with Bayside Brisbane franchise

Martin Smith, left, with the Hydraulink team including partner Andrew Schuler (fifth from left) and Hydraulink Bayside’s Andrew Richardson, (sixth from left). One of the pioneers of the Hydraulink hose and fittings organisation in Queensland has backed the success formula of the of the expanding national network by taking up a neighbouring franchise, in the Bayside district of Brisbane. Martin Smith – who has more than tripled the size of his existing distributorship in Brisbane North over the past nine years – has joined with his business partner Andrew Schuler to extend the range of Hydraulink services available to Bayside businesses seeking the same world standards of safety, compliance, cost-efficiency, and operational uptime. “Brisbane North already has major resources in Brisbane, with a strong engineering home base, established contractors, and a fleet of six vehicles giving 24/7 service. This will be further expanded with more vehicles and resources to back the local knowledge of Hydraulink Bayside’s Andrew Richardson, who is widely respected in the area,” he said. Hydraulink hose and fitting services are used by machinery ranging from forklifts and trucks, through to major civil engineering, primary industry, construction, logistics, manufacturing, warehouse, materials handling, and heavy machinery including tractors, graders, scrapers, bulldozers, diggers, and cranes, including wheeled and tracked equipment. The Hydraulink network – trading under the corporate signature “Best Under Pressure” – now includes 150 service points throughout Australia priding themselves on high ongoing standards of training and product, extensive machinery knowledge, and being able to deliver uniformly high standards of work across single businesses and machines, through to multiple sites and machinery fleets. Queensland Experience Martin Smith has long Queensland experience with the Hydraulink network and the opportunities for its can-do franchise operators, who are selected for their knowledge, enthusiasm for customer service – and willingness to continuously […]

DECO Australia powered by renewable energy

DECO Australia, family-owned Australian manufacturer of timber-look aluminium building products, has proudly announced the successful completion of the company’s solar panel installation project at its manufacturing facility in Minto, Southwest Sydney. The addition of over 950 solar panels further solidifies DECO ‘s commitment to environmental stewardship and sustainability. The newly installed solar panels will bring DECO’s total solar energy capability to over 500 kilowatts and will provide enough energy to power approximately 60 per cent of the company’s operations. That’s equivalent to powering approximately 100 average-size homes per year or planting over 10,000 trees. “DECO has always been committed to improving our carbon footprint and we are thrilled to further invest in our renewable energy program through the installation of these additional solar panels.” said Richard Hamber, General Manager of DECO Australia. The additional 400 kilowatts generated by the new solar panels will specifically contribute to powering two of DECO’s largest production lines, resulting in a substantial reduction in the company’s overall carbon emissions. This initiative aligns with DECO’s dedication to providing cleaner, greener building materials, addressing the growing demand from specifiers, builders, and end-users for sustainable products. “Reducing environmental impact is a strategic focus for DECO and we understand that it aligns with our customers priorities too. Manufacturing lower carbon products is not merely a preference; it has become a necessity for those specifiers, builders and homeowners who are making conscious decisions to source greener building materials and products for their projects.” said Hamber. This latest sustainability initiative from DECO represents a significant investment for the company and showcases their commitment to a cleaner industry. With ever changing building codes, like the introduction of the NSW Government’s ‘BASIX Material Index’ in October this year, DECO remains committed to reducing the embodied carbon of their building materials and supporting the industry’s […]

Graphene Manufacturing Group commissions modular graphene production plant

Graphene Manufacturing Group Limited has commissioned its cutting-edge natural gas to graphene production plant in manufacturing facility at Richlands. The facility is based on the GMG plasma technology with which the Company’s existing production plant has been making graphene for over five years, however this new plant is built in a modular fashion which can allow more production units to be installed as the sales of Company’s products grows. GMG expects to be able to install at least an additional 20 graphene production units in the Richlands manufacturing facility with most of the supporting infrastructure for these additional production units already installed as part of this initial project. Details of the new modular Graphene Production Plant: Technology is based on GMG’s self developed plasma technology which splits natural gas into graphene and hydrogen gas. The production plant’s automation allows for repeatable graphene quality, higher plant reliability and lower operator time. The graphene production technology has been developed internally by GMG staff and continuously optimised over the past five years to be able to make the different graphene required for GMG’s end products – including THERMAL-XR(R) and G(R) LUBRICANT and Graphene Aluminium Ion Battery. The Company expects that Graphene production from both its existing plant and this newly started up plant will be adequate for production. The expected final cost of the facility is approximately AU $2.9 million – which also includes the infrastructure for other future modular production units. More production units will be installed as required for the Company’s sales. The modular plant can be built in various locations around the world, for example in North America where natural gas cost is low and abundantly available, significantly reducing the cost of the graphene. At scale the GMG graphene production process will produce large amounts of hydrogen. GMG’s Managing Director […]

The path to a successful career in manufacturing and making a positive impact

Australian Research Council (ARC) Laureate Professor Veena Sahajwalla is an internationally recognised materials scientist, engineer and inventor revolutionising recycling science. As a leading expert in the field of recycling science, and founding Director of the Centre for Sustainable Materials Research & Technology at UNSW. Veena is producing a new generation of green materials, products and resources made entirely, or primarily, from waste. Veena also heads the ARC Industrial Transformation Research Hub for ‘green manufacturing’ – a leading national research centre that works in collaboration with industry to ensure new science is translated into real world environmental and economic benefits. Veena has been extensively recognised for the innovation and significance of her work, including via election to be a Fellow of the esteemed Australian Academy of Science. At the Women in Manufacturing Summit 2023, Veena examined how to use sustainability and circular economy strategies to improve environmental, social, and financial bottom lines in manufacturing. CAN YOU BRIEFLY INTRODUCE YOURSELF? I grew up Mumbai, which is such a fabulous city with so much going on. As a child, it was about understanding, first and foremost, how people actually made a living. It always impressed me that people would do this by fixing shoes, clothes and all kinds of electronic stuff that we had at home. To me, the creation of all these products out of things that were supposedly broken was really fascinating. I see my work not just as science and engineering, but as wider social reform. I have lived with my family in Australia for almost 30 years. WHAT ARE YOU DOING NOW? I’m the Director of the UNSW Sustainable Materials Research and Technology (SMaRT) Centre where we are known for pioneering the high temperature transformation of waste in the production of a new generation of ‘green materials’. Our best […]

Hunter class frigate program passes Preliminary Design Review milestone

BAE Systems’ Hunter Class Frigate Program has successfully completed its Preliminary Design Review (PDR). The review, which started in July, is a technical assessment that ensures the design is operationally effective and underpins the more detailed work that will now be undertaken. More than 1,800 people are now working on the Hunter program, which is transforming Australia’s shipbuilding industry by helping build a world-class, continuous naval shipbuilding capability. A celebratory event to mark the completion of the PDR was held at the Company’s Osborne shipyard to mark the milestone. BAE Systems Australia’s Managing Director Maritime, Craig Lockhart, said: “The Hunter Class Frigate Program has come a long way from initial head contract signing, to the acceptance of the shipyard, start of prototyping work, and commencement of the first Schedule Protection Block. The completion of the preliminary design review is another significant step forward for the program which is developing Australia’s sovereign industrial capability and is growing the nation’s engineering workforce.” Companies from across Australia are working with BAE Systems to support the manufacture of the first batch of three Hunter class frigates. It is anticipated the program will create and sustain more than 5,000 jobs at BAE Systems and the wider Australian defence supply chain, including up to 1,000 apprentice and graduate roles. “Through this national endeavour, we are committed to maximising opportunities for Australian industry. More than 80 contracts have been placed with Australian businesses to support the program,” said Craig Lockhart.

Kemppi Australia opens new Welding Innovation and Training Hub

Kemppi has recently opened of its Welding Innovation and Training Hub in Australia. The Hub will allow Kemppi to train welders in Australia and New Zealand on Kemppi equipment so that they can improve productivity and performance in the workshop and on the work site. Kemppi dealers and service agents will also benefit from the Hub’s opening as it will facilitate product knowledge transfer and allow them to train-up on new welding machines away from normal working day distractions. The opening of the Welding Innovation and Training Hub occurred on site, at Kemppi Australia’s head office in Sydney, where the new Hub has been constructed within Kemppi’s facility. Some 65 people attended the event including dealers, service agents, overseas visitors and local officials. The purpose-built and fully-equipped Welding Innovation and Training Hub, consists of three dedicated areas comprising of two welding bays for demonstrations and training, a presentation area for classroom training and learning, and a compact showcase. According to Kemppi Australia’s Managing Director, Mr Paul McVicar, the Welding Innovation and Training Hub will provide welders with training on Kemppi equipment, new features and technology so that they can get the most out of their machines. “Our welding equipment is leading-edge and has developed significantly over the years. Today, depending on the welding machine, it may include features such as Weld Assist, Double-Pulse, MicroTack and Optima AC. These features help the welder create quality welds quickly to enhance their productivity. “Some of the equipment can also be paired with Kemppi welding software such as WISE processes and MAX welding processes. These digital solutions further enhance the capability of the machine and can improve the welder’s performance. “The new Hub will let us bring welders up to speed on these features and the software so that they can get the most […]

Australia’s first ever AI Month launches

Australia’s inaugural Artificial Intelligence (AI) Month launches today, calling on Australians to help shape and plan for the AI future they want to see. Held from November 15 to December 15, AI Month is an initiative from the National AI Centre (NAIC), which sits within Australia’s national science agency, CSIRO. The initiative will bring together leading AI organisations, entrepreneurs and researchers to showcase the country’s domestic expertise and provide a forum to discuss Australian perspectives on AI. National AI Centre Director Stela Solar said that AI Month was central to the NAIC’s mission to pave the way for a responsible and inclusive AI future for Australia. “The rapid advancements in AI this year have emphasised the need for Australia to seize the AI opportunity and accelerate its global competitiveness,” Ms Solar said. “This month we are encouraging everyone to join in the important conversations to make the AI opportunity real. Together we can shape a responsible and inclusive AI future for Australia.” More than 50 free and ticketed AI-related events hosted by over 40 organisations will take place across the country. These workshops, panel discussions, hackathons and conferences will highlight AI use cases, opportunities, best practices, and the strength of Australia’s AI industry. “AI Month is a moment to learn new things, sharpen your skills, and step into new opportunities the future.” Ms Solar said. Australia’s AI Month was officially launched by the Minister for Industry and Science, the Hon Ed Husic, at the opening of Friend or Foe – The Rise of Artificial Intelligence, a new exhibition by Australian technologist and artist Luke Millanta at Queston this morning. Get involved in Australia’s AI Month by joining or submitting an event (please email naic@csiro.au).

Amokabel doubles production capacity for special cable in Sydney

Investment will enable Australian engineers in the defence, mining, rail, telecoms, power grids and supermarket industries to benefit from short lead times and flexible order quantities. Amokabel has doubled production capacity at its cable factory in Sydney. The upgrade has boosted the manufacturer’s ability to deliver specialist cable for the defence, mining, rail, telecoms and frozen food industries. In turn Australian engineers will benefit from short lead times and greater flexibility in terms of minimum order size. Specialised cables are essential to meeting specific performance criteria in many industries. Engineers often need special arrangements when it comes to the conducting and communication cores that carry power and signals inside the cable, as well as insulation and protection layers, and other elements such as identification features. These non-standard details mean that cables must be specially manufactured. As a specialist producer in Australia, Amokabel can deliver orders of as little as 500 metres in just 1- 2 weeks. This enables customers to control cashflow improve flexibility by enabling them to keep small stocks of cable. That compares with large cable producers in Asia , which typically have a minimum order quantity (MOQ) of 5,000 metres or more and several months lead time. “Time is money in industry – so when an engineer can source the product they need within weeks and in small batches, they can deliver their projects faster and more cost-effectively,” says Steve Rutland, Managing Director for Amokabel in Australia. “By investing in additional capacity at our plant in Sydney, we’re establishing a strong manufacturing base and showing engineers that we’re committed to the local Australian market .” Amokabel acquired its production facility in Sydney from Euro-Tech Cable in December 2022. Building the business as a supplier of niche specialist cables will enable it to grow its special cable business […]

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Future of Manufacturing