- ACIM is a leading Australian provider of specialised hydraulic fracturing solutions for the mining industry.
- The company positions itself as the only one of its kind in Australia to offer a complete turnkey hydraulic fracturing solution that encompasses design, manufacturing, and operator training specifically for underground mining operations.
- A newly developed system by ACIM, utilising ABB drives and motors, is set to improve productivity, enhance caveability, and mitigate seismic activity at a copper and gold mining operation in Asia.
- The technology is helping mining corporations to maximise ore recovery, optimise production time, preserve energy resources, and ensure reliability in ore extraction applications.
ACIM is a locally based Australian manufacturer of customised inflatable packers and fracturing systems (commonly referred to as fraccing or preconditioning), which are exported to mine sites worldwide.
Based in Melbourne, Victoria, their systems are designed and built to support efficient ore body preconditioning and the mitigation of in-situ stress in mining environments. This helps mining corporations to maximise ore recovery, optimise production time, preserve energy resources, and ensure reliability in ore extraction applications.
Managing Director Anthony Coleman founded ACIM with his wife, Lisa, driven by a shared vision to create a family-owned company that builds safe and cost-effective products for Australia’s geotechnical, mining, and oil and gas industries.
Their business began by supplying inflatable packers and downhole tools for hydraulic fracturing applications in underground mining and water well development. Anthony has consistently recognised the benefits of hydraulic fracturing in the mining industry. A forerunner in spearheading the adaptation of hydraulic fracturing techniques from the oil and gas industry into mining, Anthony has advocated replacing diesel-powered equipment with cutting-edge, electrically driven systems due to their environmental and operational benefits, as well as quieter operation.
Why hydraulic fracturing?
A hydraulic fracturing system has the power to fracture rock more cost-effectively and consistently than traditional blasting methods. It also provides more precision control through remote Motor Control Centres (MCC), intuitive digital software, and variable speed drives (VSDs) for controlling motor speed.
Implementation in a major mining operation
An influential mining and metals company recently engaged ACIM to design and engineer a hydraulic fracturing system for their underground gold and copper mine located in Asia.
In the first phase of the project, the technology will be trialed to evaluate its effectiveness in fracturing the ore body through high-pressure water injection. This hydraulic process is designed to break the rock and boost ore recovery.
The objective for the mine is to export copper and gold - critical materials essential for decarbonisation and electrification used in everyday products like electric generators, appliance wiring, computers, and smartphones.
Integrating ABB technology
ACIM chose ABB to supply the drives and motors that form the core of this system solution for the underground mine. According to Anthony, the mine operator itself specifically requested the implementation of ABB technology.
"They have existing ABB drives on-site ... and have consistently reported positive experiences."
“They have existing ABB drives on-site integrated with other equipment and have consistently reported positive experiences,” he said.
ACIM ultimately installed a customised ABB motor and drive package as part of a fully turnkey hydraulic fracturing system. The system is comprised of an MCC, a control room housing ACIM’s proprietary fully digital control system (designed for easy operator training), and a trailer-mounted Fracturing Pump Unit.
(L-R): Anthony Coleman, Managing Director at ACIM, together with Arvind Sharma, Business Development Manager for Drives at ABB Australia standing in front of an ACIM fracturing trailer. 
ACIM’s hydraulic fracturing pump trailer. 
ACIM’s Mobile Motor Control Centre (MCC) trailer that provides control over motors, pumps, compressors, mixers, and other heavy-duty equipment used during hydraulic fracturing operations in mining. 
(L-R): Arvind Sharma with Anthony Coleman, standing in front of the ACIM headquarters in Clayton, Vitoria (just outside of Melbourne). 
An ACIM developed charge pump and packer inflation solution controlled by ABB Variable Speed Drives. 
An ABB ACS880 low harmonic variable speed drive, which controls a primary pump application. 
An ACIM MCC trailer featuring the main switchboard.
Motor performance
An M3BP 500-kilowatt IP66 process performance motor is a mining spec motor that will be used to inflate packers before creating the fracture and is specifically designed for harsh environments.
This range of ABB motors has been engineered with the specific demands of the mining sector in mind to support efficiency, reliability, and environmental protection. The motors maximise productivity, improve performance and operational efficiency, and enhance safety thanks to their robust design, Class H insulation, and IP66 ingress protection. They are suitable for any type of variable speed drive supply without the need for filters.
Three 22-kilowatt M3BP motors will also be used to operate the water charge pumps, while a 15-kilowatt M3BP motor will operate the packer inflation pump which inflates the packer to seal the borehole. As a fully integrated system, it’s optimised to deliver improved production outcomes.
About the drive technology
One ACS880 630-kilowatt ultra-low harmonic (ULH) variable speed drive will control the motor that powers the primary water pump application.
The electrical stress caused by harmonics and high starting currents pollute electrical networks with dirty power that can make connected equipment behave erratically. In severe cases, they can cause damage to sensitive electronic equipment, interfere with communication equipment, and give false readings on measurement devices. ABB’s ULH drives ensure that the total harmonic distortion (THDi) is less than 3%.
Variable speed motor control allows the hydraulic fracturing system to advance from a fixed speed application for more flexible and efficient performance.
“Running a motor at variable speed is more energy efficient than running it at full speed because power is only consumed when required,” said Arvind Sharma, Business Development Manager for Drives Products at ABB Australia.
“It’s also optimising the demands of the process with less wear and tear, lower pump cavitation and hydraulic stress through the pipes, simply by its ability to reduce motor speed via the drive and simultaneously start the pump gradually.
This avoids a hard start on the motor which can cause bearing failure leading to misalignment and ultimately a shorter lifespan of the equipment.”
Four ABB ACS580 plug-in ready, general-purpose drives are also featured in the ACIM system. Three will control the charge pumps to change pumping speed when needed, and one will control the packer inflation system, to adjust the output water of the pump.
When it comes to safety, ACIM’s system makes no concessions. The ABB ACS880 drive is certified for arc flash resistance and type-tested for hazardous environments, offering safety compliance of the highest standard.
The system is also PLC-controlled which allows for the adjustment of the injection rates. If the system happens to go above the designated set points like injection pressure, oil pressure, experience low water flow, or - if the motor signals functional warnings, for example, the integrated PLC safety interlock automatically triggers a system override to cease operations and maintain safety on site until the system is safe to become operational again.
“This solution accommodates the precise requirements of underground mining environments with its portability and heavy-duty design. Furthermore, we’re proud to be an Australian business supporting the upskilling and re-skilling of the engineering workforce, and designing and manufacturing exceptional technological solutions that are exported all over the world,” said Anthony.
Arvind said, “It was great to work with ACIM on this very niche technology for hydraulic fracturing. ABB equipment is already prominent throughout the mining and oil and gas industries and this partnership with ACIM will collectively further strengthen our distinctive offering globally.”
What’s next for ACIM?
“We’re excited to commence working with several large mining companies on new overseas projects, where they’re looking to implement ACIM’s hydraulic fracturing systems in more underground mines to keep tunnels safe for workers.
It’s captivating to see how technology developed 30 years ago has gained renewed popularity, thanks to the industry’s growing understanding of hydraulic fracturing as an exceedingly beneficial solution across diverse mining applications.”
