Mining Magazine December 2014 by Webmaster Aspermont Media

The mining industryâ&#x20AC;&#x2122;s leading magazine

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1909

Flotation Tailings Where is flotation heading next? From reagents to management new cell designs and coarse

Following a series of highflotation, MM tracks the trends profile dam failures, MM examines what mines should be doing to ensure best practice

Bulk handling Software Underground Explosives Growing congestion on US railroads Learn about the current market is side-lining coal and fuelling concern for business-management software drilling & blasting among power producers and miners. and how it can be used to gain a Learn about the current state of the MM reports on the situation contract drilling market and what the key drivers are for R&D and sales at top rig manufacturers

From ultra-high intensity blasting to competitive advantage reducing NOx emissions, MM looks at the latest techniques and technology developments globally

Mining ISSN 0308-6631 CovIMM1412.indd 1

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REDUCE EMISSIONS INCREASE PROFITABILITY Tier 4 engine technology not only reduces ventilation requirements in your mine but also improves mobile fleet fuel economy without sacrificing performance. Itâ&#x20AC;&#x2122;s your key to reducing emissions while increasing profitability. Using the latest ultra-low emissions diesel engine technology, and by working with selected manufacturers, we can help you make the switch to cleaner engine technology quickly and smoothly. We have more than 80 LHDs and underground trucks already equipped with Tier 4 engines in operation today. Visit mining.sandvik.com to learn how you can improve your underground mine environment.

CONTENTS

Waiting to explode

new report from Stratum International has suggested that the mining industry is facing what it calls a ‘ticking time bomb’, due to its failure to implement strategies to attract and retain younger professionals. The population of mining professionals is ageing, and there doesn’t appear to be a sufficient number of younger workers replacing them. While the report notes that to a certain extent this trend reflects overall demographic trends, which are influenced by factors such as increased life expectancy and lower fertility rates in developed countries, there seems to be an especially great impact on the mining industry. For example, projections have indicated that 40% of Canada’s mining workforce (at all levels) is aged 50 or over. Coupled with the fact that mining professionals tend to retire earlier than people in other industries, the consequence of this could be a dangerous leadership vacuum in the near future. Stratum is not the first organisation to identify this problem. Earlier this year, a report issued by the Society for Mining, Metallurgy and Exploration (SME) found that the US mining industry will need to find 78,000 new workers by 2019 to take the place of those who are retiring, in addition to projections of the industry growing by approximately 50,000 jobs, for a total of 128,000 new positions by 2019. Stratum’s research was based on a survey of 912 mining professionals globally. 91% of those who responded were male, “There is a career which Stratum stated reflects the ongoing gender imbalance in the industry; over half the respondents (56%) were aged 50 or over, while development only 3% were under the age of 30. programme but it According to the report, only 1% of those surveyed think the sector simply does not is well prepared for these demographic changes. However, in a fairly damning assessment of the situation, 79% of overall respondents (and function. It is just a 85% of those under 30) think the industry is completely or somewhat box-ticking exercise” unprepared. In addition, 82% of respondents think succession strategies are important to the long-term future of their organisations. This rises to 95% among HR professionals, yet only 28% of organisations actually have strategies in place. This could be partly due to the current economic environment. Short-term survival is the top priority for many companies right now, particularly juniors and mid-tiers, so long-term leadership needs are considered less important. As one respondent, a mining executive, commented: “We recognise the importance [of these activities] but [they are] only relevant if the company continues to thrive. And that is the focus right now.” Other respondents highlighted that their organisations technically have formal strategies in place, but they are not applied or prioritised. One respondent explained: “Periodic attempts have been made to create these programmes, but they tend to get flushed every time the CEO calls for a [management consultancy] reorganisation.” Another remarked: “There is a career development programme but it simply does not function. It is just a box-ticking exercise.” So what can be done? Stratum suggested a long-term succession strategy that balances the grooming of an external talent pool with the identification and development of internal high-potential managers. It also advised that organisations that are not struggling with short-term survival should start right now. Such strategies have an important symbolic role for staff and are positive for engagement. The report found that people in their 20s crave development, particularly coaching and clear pathways into leadership roles, while those at the mid-point of their careers are also looking for support, coaching and direction to take them to the next level. Organisations that start preparing as a matter of urgency could gain a significant competitive advantage – even one succession or leadership strategy could differentiate your organisation from the majority. So what are you waiting for? Read Stratum’s full report, ‘The Demographic Time Bomb In Mining’, at: http://bit.ly/10y9Mxe

AILBHE GOODBODY, ASSISTANT EDITOR ailbhe.goodbody@miningmagazine.com Twitter: @MM_AsstEdAilbhe

News Features Column: Futurecasting

Special report: VCI survey

Tailings management

Explosives & blasting

Dust control

Snapshot

Simulators

Underground drilling

Buyers’ guide

Flashback & contacts

Classified advertising

Next month Software – mine design & planning Mapping, surveying & UAVs Raiseboring & shaftsinking Crushing & screening In-situ mining & processing Mining Magazine awards supplement

COVER

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NEWS

Rockmore goes ‘tubeless’ Rockmore International has launched its new ‘tubeless’ T-series down-the-hole (DTH) hammers, with the first model in this class – the ROK 600T. Rockmore said that the T series represents a “breakthrough for DTH drilling technology for mining, construction and water-well applications”. The hammers utilise drill bits with standard shank connections that no longer require plastic parts, commonly known as ‘blow tubes’ or ‘foot valves’. Although tubeless DTH hammers have been offered before, drilling performance was often compromised when designed to operate with an industry standard bit shank. Blow-tube/foot-valve failures during drilling can be catastrophic as the hammer ceases to function immediately. Rockmore hopes to eliminate this issue by removing the plastic bit components. The ROK 600T is a 6in-class model rated for drilling 155178mm (6.1-7in) diameter holes for blast-hole applications. It is also suitable for water-well drilling and exhibits good in-hole flushing to evacuate rock chips in deep applications.

Ventyx and Wipro join forces Ventyx (part of ABB) is partnering with Wipro, a leading global information-technology consultancy to deliver industrial software and services to utility, mining, chemical, oil and gas companies globally. Jens Birgersson, head of ABB’s Network Management business unit, said: “Wipro’s global reach and IT expertise will be a force multiplier in bringing the benefits of Ventyx to customers faster and more powerfully. The partnership also allows us to scale faster and reach companies, in markets we haven’t historically served.” For breaking news as it happens, follow our editorial team on Twitter at @MM_Ed_Carly and @MM_AsstEdAilbhe

New models from Atlas Copco Atlas Copco has upgraded its 42t-capacity MT42 underground Minetruck. The model, which was originally launched in 2009, now has a redesigned box with an innovative tailgate solution and a new engine to fulfil stringent emission regulations. The new box is made of high-strength steel. It has the same physical envelope size as the previous model, but with a reduced dump height. The tailgate folds down automatically behind the box before dumping without affecting ground clearance or visibility for the rear-view camera. The gate is hydraulically operated and the gate’s position is shown to the

The MT42 now has a better engine and payload area operator on a display in the cabin. The new Cummins QSX15 diesel engine meets both EPA Tier 4 final and EU Stage IV regulations and, compared with Tier 3 emission levels, offers a 90% reduction for both particulate matter and NOx. The new MT42 will be ready for

deliveries in 2015, Atlas Copco said. Atlas has also added a new mobile spraying unit, the MEYCO Versa, to its portfolio for shotcreting mid-size tunnels. This is the first Atlas Copco-branded product to be launched since the company acquired MEYCO in 2013. The Versa, named for its versatility, is an all-in-one solution for concrete spraying designed for one operator. It has a new carrier platform with 4x4 crab steering, and is powered by a Tier 4 diesel engine. In addition, it has a new boom, an optional 75kW on-board compressor, a 20m3/h low-pulsation concrete pump and a high-precision dosing system.

Cummins launches its mightiest genset Cummins Power Generation has introduced the QSK95 Series, a new line of high-performance diesel generator sets. The QSK95 Series are the most powerful in Cummins range and offer up to 3.5MW at 60Hz and 3.75MVA at 50Hz of power. Cummins said they are engineered with a high kilowatt per square foot ratio, resulting in a smaller footprint that achieves a

The QSK95 Series gensets are Cummins’ most powerful 20% improvement in power density. Over the course of 8,000 hours of operation, the QSK95

can achieve fuel savings of more than US$400,000. The QSK95 Series are designed for mining, oil and gas, or any project where harsh conditions and challenging environments prevail. They come with various power ratings, and Cummins said that long service intervals and 25,000 hours to major overhaul make them particularly suitable for prime power applications.

ARANZ Geo acquires QG

Geological software provider ARANZ Geo has acquired Australian consultancy QG. QG provides specialist resource-evaluation expertise and education for mining companies. The company, which is headquartered in Perth and has offices in Brisbane and Vancouver, delivers projects across the globe. Shaun Maloney, the CEO of ARANZ Geo said: “QG builds our knowledge, experience and product offering across the

geosciences space and sits alongside our well known Leapfrog 3-D geological modelling software. QG will continue in its current form under the company’s new managing director, Scott Dunham.” Dunham added: “QG and ARANZ Geo have had a good working relationship for some years now. We look forward to continuing to prosper and grow globally with the support of ARANZ Geo.”

CITIC selects SONARtrac for Sino iron CiDRA and KROHNE Australia have won a contract to supply the SONARtrac slurry-flow measurement solution to CITIC Pacific Mining’s Sino iron project in Western Australia. Michael Murphy, managing

director, Asia Pacific at CiDRA, stated: “CiDRA and KROHNE have been collaborating in Australia for over six years and are looking forward to a continued relationship and mutual success in this key industry and market.”

Octagon introduces rugged computers Octagon Systems has released the TRAX series of rugged computing platforms for mobile applications in harsh environments. The first release, the TRAX-5, is powered by the latest Intel Quad-core CPU with high-performance graphics. Octagon said the TRAX-5 lets users consolidate multiple functions on a single, simplified platform. It added that the unit’s versatility, reliability and processing power make it ideal for use on vehicles and equipment that run multiple applications in extreme environments.

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NEWS

In Brief Rockwell buys ESC Rockwell Automation purchased ESC Services, a global provider of lockout-tagout services and solutions for hazardous energy control, in November. ESC uses QR codes to obtain asset information and streamline compliance procedures.

Cave Tracker progress Development of CRCMining’s Cave Tracker system is in its final stages. Prototype systems are installed at two major mines, including Rio Tinto’s Argyle Diamond mine in Western Australia, to refine the system before commercial production.

Downer acquires Tenix Downer EDI has bought Tenix Holdings Australia for A$300 million (US$264 million). Tenix offers engineering, construction, fabrication, project-management and maintenance to mining and mineral-processing companies throughout Australia, New Zealand and the Pacific.

PB at Carmichael Parsons Brinckerhoff is the project-management consultant for Adani Mining’s 60Mt/y Carmichael integrated coal mine, port and rail project in Queensland, Australia. The company will provide assurance services for EPC contracts.

Dredge for Barrick Barrick Gold Corp recently purchased a DSC Wolverine dredge for its Pueblo Viejo mine in the Dominican Republic. The company has been cleaning up the area since acquiring the mine in 2005 and the dredge will help maintain sediment ponds that prevent contamination of the local water system.

Riegl shows new items Riegl Laser Measurement Systems unveiled its RiCOPTER high-performance unmanned aerial vehicle (UAV) in October, equipped with VUX-1 surveygrade LiDAR sensor. Riegl is also launching the VQ-880-G, a turnkey LiDAR solution for topo-bathymetric surveying.

Bentley and Cyest launch MineCycle Bentley Systems has launched a new mine-planning and scheduling package, MineCycle, which was developed under a syndicated model with South Africa’s Cyest Technology and with input from miners including Anglo American Platinum, AngloGold Ashanti, Lonmin, Royal Bafokeng Platinum, Hatch, GHD and PDC. Cyest specialises in mine business modelling software and is part of Cyest Corp, a technology investment firm. Robert Mankowski, simulation product-management vice-president at Bentley, said in a statement that an ability for users to quickly assess operational planning and engineering alternatives was one of the ‘musts’ that

Anglo Platinum was involved in developing MineCycle sponsors identified for the product. He said MineCycle Designer gives mine owner-operators “a single dynamic environment for design, evaluation and scheduling”, and rapid feedback on the evaluation and scheduling impacts of design decisions. Mankowski said that MineCycle has three modules: Designer, Survey, and Material Handling.

Modular FMS installations Modular Mining Systems’ DISPATCH fleet-management system (FMS) is being implemented by EXCON at the 3Mt/y Toconao lithium mine in Chile. With a fall in lithium prices, the mine had to adjust its costs and focus on optimising productivity. Since implementation began earlier this year, the operation has maintained production targets with 7% fewer trucks in operation. It is planned that Toconao will focus on real-time equipment monitoring and cost control by utilising a number of optional modules also purchased, such as the DISPATCH Speed Management and Fuelling modules. The add-ons extend the capabilities of the FMS in key areas. Modular’s MasterLink wireless mesh network will provide communication between the equipment units in the field and the mine’s central control room. Full

Modular’s DISPATCH interface implementation is expected to conclude later this year. A multinational iron-ore producer has also chosen to implement Modular’s technologies at two of its mines near Belo Horizonte, Brazil, replacing its existing FMS. DISPATCH will optimise haulage operations on more than 100 trucks, 16 shovels, and numerous drills, loaders, dozers and auxiliary units across the two sites. The systems are expected to be in operation in early 2015.

Joy Global teams up with IBM Joy Global has selected IBM big-data and analytics technology, including advanced predictive analytics software and optimisation solutions, to enhance its Global Smart Services. Joy Global Smart Services delivers real-time analytics to mining customers that predict machine failures and recommend preventative actions. Joy said that

the cloud-based, mobile-enabled, IBM solution will allow it to take Smart Services from the individual customer level to the worldwide fleet level, identify anomalies in machine performance, and continuously improve its mining products. This promises better machine availability, utilisation and productivity, as well as lower operating costs.

MineCycle Designer features a native open database architecture, which gives the flexibility to share design data across an enterprise and integrate it with other operational systems to support ad-hoc reporting and analysis. MineCycle Survey covers underground and surface mine-survey applications. It accelerates the conversion of raw survey measurements into actionable intelligence. MineCycle Material Handling builds on Bentley OpenPlant and OpenRoads and offers a purpose-built bulk-material handling conceptual design application that lets EPCs and consultants accelerate the preliminary design of facilities.

Immersive scoops NIOSH tender Following a public tender for continuous-miner simulators, Immersive Technologies is to supply equipment to the Office of Mine Safety and Health Research (OMSHR) division of the National Institute for Occupational Safety and Health (NIOSH), a US federal agency that conducts research and makes recommendations to prevent worker injury and illness. NIOSH intends to use the IM360 simulation platform and Joy 14CM15 lightweight remote conversion kit to determine what information continuous-miner operators need to do their job, when they need it, and how it is best presented. Richard Beesley, underground soft rock – business unit manager at Immersive Technologies, said: “By using the patent-pending RealMove technology, NIOSH is able to monitor not only the continuousminer operator’s performance at their jobs, but exactly where they are standing when they do so.”

Immersive Technologies’ continuous-miner simulator

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NEWS

Weir buys Trio, installs Enduron cone crusher Nkomati mine site

Aveng adds to its Sandvik fleet

Sandvik Mining is supplying five D25KS drills to contractor Aveng Moolmans for use at the Nkomati mine site in Mpumalanga, South Africa. The new units will bring the total number of Sandvik drills in the contractor’s African fleet to 40. The agreement also includes a service contract, with Sandvik providing on-site training and spare parts. Sandvik stated that Aveng Moolmans selected the company as its equipment provider based on a 15-year relationship. Additionally, the ease of operation, minimal downtime and ability to transport rigs to other sites attracted Aveng Moolmans to the Sandvik products.

Metso to deliver crusher to Zambia

Metso is delivering an MP2500 cone crusher to First Quantum Minerals’ Sentinel mine in Zambia. The order, worth more than €10 million (US$12.4 million), will see the crusher operational in early 2015. The MP2500 was selected for Sentinel because it can process large volumes of rock as a single machine. It is designed for use in secondary and tertiary crushing and links easily with other Metso products to create a simplified flow sheet for high-production sites. Full-time Metso field-service engineers will be stationed on-site for one year after commissioning and critical spare parts stocked at Metso’s local distribution centre. Metso also introduced the 40t Nordberg C130 jaw crusher in October, which has a 21% larger cavity volume than previous models in the same size class. The larger volume means that more rock or ore can be crushed together, increasing efficiency. The increased volume combined with the extra-large feed opening ensures high-capacity primary crushing in demanding quarrying and mining applications.

The Weir Group has signed a US$220 million deal to acquire Trio Engineered Products, a Chinese-American manufacturer of crushing and separation equipment for the mining and aggregates markets. Weir provides pumping equipment to the mining mill circuit, which separates rock from ore, and stated that the acquisition of Trio will build on its recent successful entry into the adjacent comminution segment. Trio is based in Shanghai, China, where it has two manufacturing plants, and it also has facilities in the US. In 2013, 31% of its revenues were generated in North America, primarily in the aggregates sector, and 25% were in China, mainly serving the domestic mining industry. The balance was broadly spread across Australia, South America, Africa and Europe. In 2014, Trio is expected to generate revenues of US$120 million. Trio is being acquired from

The month in numbers

New supplier of Rajant Corp’s Kinetic Mesh product line. 3D-P became a partner in November.

The capacity in tonnes of five Duratray suspended dump bodies fitted in July on Komatsu HM400-3 ADTs at Anglo Coal’s New Vaal colliery, South Africa.

275

million US dollars – the value of mining/energy contracts won by Aecon in October for the K+S Legacy potash project, Canada.

6,096

Length in millimetres of Terex’s new MHS8203 horizontal screen – its largest model to date, launched in October.

Top: Trio equipment in use Above: Enduron SP cone crusher in South Africa majority owner Navis Capital and the company’s management team. Its three founders have agreed to remain with the company following acquisition. • Weir Minerals Africa has commissioned the world’s first Enduron SP cone crusher at a gold waste-rock aggregate plant in

South Africa. The company stated that early results indicate that the new technology has significant potential for smaller miners and aggregate producers. JD Singleton, process manager at Weir Minerals Africa, commented: “We installed the crusher on a turnkey basis and the customer has been impressed with the increased throughput, compared with other crushers in the plant, and the fact that a more consistent size range is being achieved. “Based on this performance, we believe the Enduron SP cone crusher is going to prove extremely appealing to a lot of operations in the mining and aggregate markets. Having proved its proficiency in this local operation, we intend to roll this technology out to all the territories we serve through our 20 service centres scattered around Africa. These crushers are ideal for the African context, particularly in terms of preparing feeds for high-pressure grinding rolls (HPGRs) or milling circuits, and to support aggregate specifications.” The Enduron line of comminution equipment includes jaw and impact crushers, as well as screens and feeders.

World’s largest flotation cell

Outotec has added the TankCell e630 to its portfolio. With a diameter of 11m and a lip height of approximately 7m, the high capacity of the e630 makes it particularly suitable for rougher and scavenger duties in gold and base-metal applications. Outotec said the new cell outperforms smaller models in terms of energy efficiency while enabling increase in production capacity. Compared with an

equivalent plant built using the smaller Outotec TankCell e300, total capital cost can be reduced by as much as 10-20%. Typical installed power for the e630 is 500kW and specific power consumption is lower than that of smaller TankCells. Outotec recommends using a variable-frequency drive to enable optimisation of both metallurgy and power consumption in these high-capacity production units.

SD Mines scoops ventilation funding The South Dakota School of Mines & Technology in the US has been awarded a US$1.25 million contract to design advanced ventilation systems for block-cave mines. The five-year project from the National Institute for Occupational Safety and Health (NIOSH) seeks to develop a practical mine-ventilation

design procedure that a block-caving mine could use to predict gas emission rates and airflows in underground working areas. It will also allow for the simulation of the caving process in an underground metal/non-metal mine and for the validation of the numerical models through field measurements.

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futurecasting

The Living Mine In their third article for MM, George Hemingway and Jeff Loehr explore how advanced technologies could converge to create an entirely new way of mining A swarm of micro-bots working as a group to mine underground

trategic Futurecasting allows companies to explore possible futures based on observable trends today, and to use these scenarios to guide their strategy and investments. In our first two articles we introduced the concept of Futurecasting and our first operating scenario of the future; The Rock Factory. The Rock Factory, a big-data enabled vision of equipment working as a system to create a factory-like continuous operation is a recognisable, although technologically advanced, type of large-scale mine. It met a lot of the original criteria we laid out for future mining operations of being scalable, reduced, adaptable, consistent, safe and more sustainable than mining today. But it is still a mine. This prompted new questions. What might a mine look like if we reduced the footprint even further? How might we mine a very complex, very low-grade orebody efficiently and with little human involvement?

“The Living Mine enables the mining of orebodies that were previously ‘un-mineable’, either because of Living Mine location or The Our second scenario, The Living Mine, is geology” one answer to those questions. This

George Hemingway and Jeff Loehr

mine operates in such an organic way that it resembles a living organism. The Living Mine is ‘alive’ in that it is: • Intelligent and organised: Within the mine, microscopic machines operate together with ‘swarm logic’ enabled by artificial intelligence. Just like insects working together to attack larger prey, these tiny machines organise to attack a complex orebody and reach minerals, no matter how small. • Adaptable and responsive: With little transparency into the mine from the surface, machines must adjust themselves in real-time to ground conditions and find minerals. Mine design here is more about creating a responsive technological system than designing a definitive mine plan. • Organic and reproducing: Much of the mine is actually alive, relying on biologic mining technologies such as modified bacteria that can digest, leach or convert minerals or modify host conditions to free them up. • A self-regulating ecosystem: The mine works as an interconnected

technological ecosystem with sustainable closed-loop systems for energy and water, underground processing and the reuse of materials.

Better mining anywhere The Living Mine can exist almost anywhere. There are no large trucks moving earth, and no need for large-scale surface operations, or even to fully visualise the orebody or internal mine workings. The Living Mine enables the mining of orebodies that were previously ‘un-mineable’, either because of location or geology. Mine operators cannot actually see what is going on underground or in the mine. Instead, sensor-enabled nanorobots and bacteria miners start with an estimate of where there may be target minerals and work on a probabilistic basis. Swarming under the surface, they seek out valuable ores and congregate when they discover it, no matter how minute the mineralisation. Unlike The Rock Factory mine, which seeks to eliminate variability with precise information, The Living Mine adapts to unexpected variations and re-aligns itself to underground realities. Big data still matters here, but much of the operational analytics are done in real-time within the mine itself. There is also an efficiency benefit to The Living Mine, as much of the mineral processing takes place in-situ, reducing surface processing plants and the alignment of large machines. The technological ecosystem’s closed energy, materials and water loop also makes for a less costly and more sustainable footprint.

Glimmers of possibility As with the Rock Factory, much of this technology is being developed and

applied, in one form or another, today. Unlike our previous scenario, however, more work needs to be done to create the technological ecosystem for The Living Mine. In addition to the higher-order technologies mentioned in the Rock Factory, concepts that enable The Living Mine include: • Nano-robotics: Technology under development includes nano- and, in some cases, atomic-scale machines and structures that can manipulate other molecules in specific ways. Today, these nano-robots can travel the bloodstream to deliver medicines; tomorrow this same thinking will lead to microscopic robots tunnelling for ore. • Artificial intelligence and learning: Several steps beyond simply solving complex problems, robots are now able to work in groups, learning from and adapting to their environment. In the future, this intelligence will allow the robots to explore, adapt and mine all at the same time. • Advanced materials: Advancements in this area include construction materials that can make equipment lighter and stronger, self-powered and contained sensors, and lubricants and coatings that can dramatically reduce friction and maintenance needs, even at microscopic levels. • Bio-mining and genomics: Beyond bioleaching, which could itself change mining, new types of organism have been developed that can process and concentrate materials or interact with their environment to precondition rock. This represents a potential disruption to traditional mining as it could replace the need to mine through biologically engineered solutions.

Caveat miner Both scenarios are different views on how technologies today may evolve and combine to change the operations of the future. They provide a starting point for thinking. Rather than seeking out which future is ‘right’, mining companies should explore what can be learned from these concepts and how they can use these technologies today and in the near future. Operations, however, are just one aspect of mining. Future technologies are enabling entirely new ways of working. Next month, we will explore our vision for the future of work and the mining organisation; The Symbiotic Structure.

The Stratalis Group is a full-service strategy and innovation consultancy focused on helping companies in the resource industry to discover, develop and deliver new pathways to growth, increased profitability and ROI. See: www.stratalisgroup.com

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special report

Delivering mining innovation In the first of a three-part series of articles, VCI presents key findings on innovation delivery from its Mining Innovation: State of Play 2014 survey Fig. 1: innovation delivery approaches

CI’s annual State of Play survey aims to give an objective appraisal of the strengths and weaknesses of innovation in mining. This includes providing a picture of how the industry’s global innovation system works, what could improve it and how companies could improve their effectiveness within it. This year, the survey comprised over 230 respondents at over 100 companies (70% senior executives and above) including chief executives, technology officers and strategists from the top 20 mining companies and mining service companies globally. This month, we present our findings on innovation delivery: how do companies develop and deliver innovation effectively?

“The mining industry is changing, but are Innovation delivery for such a large, geographically behaviours Fittingly and culturally diverse industry, and respondents displayed a range of operations structural innovation approaches. Analysis of the responses from mining positioned executives has provided a clear picture strongly of which approaches or combination of tend to be the most enough or approaches successful, and which do not. reacting There are two types of companies that fast enough have an active and well-resourced innovation programme: to navigate • Mining or service companies whose this downturn?”

Survey results: “how could you best improve innovation in your company?”

•

innovation focus is long term and needs high capital expenditure (e.g. large asset transformations or major capital equipment development); and Service companies whose innovation focus is short term with lower capital investments (e.g. fast product cycles or incremental improvements).

Generally, the companies that felt they had a successful innovation programme were biased towards section A or C shown in Figure 1. However, the best companies will have a combination of both top-down and bottom-up delivery. Mining companies that said they had a relatively unsuccessful innovation programme tended to fall into category B or D. Survey results indicated that the only way to build successful long-term operating-platform change is through a strong top-down approach, guided by a clear vision and systemic roadmap of development projects. Short-term focused innovation, for instance on prod-

ucts or data, is usually better performed by those doing these tasks on a day-to-day basis, or by specific teams working with a ‘fast fail ethos’; that is, bottom up. However, their creativity and ideas will be wasted if not supported by clear structures, processes and well communicated incentives to encourage their efforts.

Innovation philosophy Most large mining companies use top-down delivery and many smaller mining companies tend to use bottom-up delivery. There is good reason for this. Smaller mining companies often do not have the financial or managerial capacity to dedicate to long-term innovation programmes and so default to an unstructured, ad-hoc approach. The best and most successful innovation happens when individuals are incentivised to innovate within a well designed, well supported and led system tied into a company-wide vision. Creative innovation needs structure and process, but this doesn’t have to be expensive. A critical step in enabling innovation is the articulation of a long-term vision, grounded in strategic logic to guide change. The success of this approach is evident in Rio Tinto’s Mine of the Future programme, which has achieved an operating-model paradigm shift within bulk commodities, and AngloGold Ashanti’s deep-mining innovation consortium in precious metals. Both illustrate that clear progress is possible with manageable risk when built on a clearly defined set of challenges within a systemic roadmap. Companies that implement technology and innovations with a whole-of-company view of the ‘to-be’ state overwhelmingly rated their innovation programmes as more successful. It is also the best way to

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facilitate step-change development, using roadmaps and managing innovation challenges as a portfolio. Mining companies commonly state that they are a fast or conservative follower, reasoning that it is an effective approach to reduce innovation and technology risk. In many cases, this will be an unproductive choice. Technology and innovation strategy is not conducive to a blanket fast-follower approach given the complexity of changing technology within an operating system. Understanding where to lead technology development and where to follow is critical to efficiently managing technology. In some areas, the pace of industry development will be too slow. This may be because a company’s needs are very specific, or there is a general lack of industry investment. In these areas it can make sense to lead. In other areas, you may be confident that the industry will develop the technology in your required timeframe. A ‘one size fits all’ approach will lead to suboptimal outcomes.

choose only a few. Miners frequently demonstrate a preference for in-house or closed innovation, matched with a relatively transactional approach to partnerships. Service companies show a preference for in-house R&D, but are increasingly pushing for a more integrated design approach with mining companies. There is space for a more nuanced approach. Currently, in the mining industry it seems that innovation is being stifled to some extent by large companies marginalising smaller service companies. This is justified by miners on the basis that small companies lack the required scale to roll out products throughout larger mining companies, which are in turn more likely to use off-the-shelf technology. Generally,

mining companies with a supportive culture for innovation are more likely to use a broader range of development methods rather than buying off the shelf from suppliers. Approaches that look outside the industry, such as open innovation and closed consortia, are considered less popular within mining than more inward-looking options. The survey data suggests that open innovation is viewed with uncertainty by many large companies, despite increasing use by leading companies in parallel industries such as Statoil and General Electric. Possible reasons for this are: a perceived lack of value, culture, intellectual property and a lack of understanding of how, where and when to use open innovation. However, targeted open-innovation strategies have already proven successful in the mining space, for example, in supplier forums used to share areas of development, in open-innovation intermediaries or technology scanning for specific requirements. Open innovation is about building a system where ideas flow openly from customers, employees and suppliers. This allows ideas to be captured and developed collaboratively, leading to sustained innovation. The benefits are compelling. Open innovation:

Survey results: innovation success by implementation structure

Survey results: who drives innovation programmes with the most success?

Leadership and culture A principle of innovation theory is that the most consistent and successful innovation programmes are driven by proactive and visible leadership. This is underlined by the companies that rated their innovation programmes as highly successful also rating their CEO as the primary driving force for innovation. Visible leadership and clear processes support an innovative culture, but if the emphasis is on hierarchy and micro management, then the outcome may be unproductive, so the right balance is important. Survey results showed that leadership and culture were rated as the best risk-management tools by self-described innovation leaders.

Technology development The mining industry has a range of innovation methodology and partnership options available to it, but tends to

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Vision-led transformation: ‘how to’ Step-change transformation can’t come from incremental ad-hoc improvements to the current system. If step change is the intent, then a vision-led approach is the best method: 1. Define the overarching vision for step change by taking both a top-down and bottom-up approach: a. Top down: define risks and opportunities that address key strategic challenges and external forces affecting the business; b. Bottom up: identify issues in the current system and operations to identify target areas for

innovation, ensuring that operations and the business are included. 2. Articulate the development roadmap to achieve the vision. Outline major challenges and translate into targeted projects to manage and progress the transformation. 3. Use a range of innovation methods: select the method best suited to the specific challenge. This will maximise the development’s chance of success from both technical and change-management perspectives.

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Fig. 2: technology development approaches

• draws the outside in, using access “The success of a new product or service is measured by whether it improves performance in the mining value chain”

Survey results: reasons for innovation implementation failure

• • •

to the external world and other industries to solve challenges; enhances brand position, engages with the new technically aware workforce and external community; shifts culture and acts as a demonstration of openness to innovation within the business; and clarifies key challenges; it is a ‘no regrets’ first step, and others can often see challenges that you don’t.

Even if a full, top-down guided open-innovation programme is a distant goal, the first steps towards openness are not a big a jump. Companies can: • communicate challenges to suppliers: hold forums inviting suppliers to innovate on specific challenges; • run innovation workshops with a group of suppliers on a specific challenge; or • run a test case: open competitions focused on key challenges stimulate a broader open innovation process. The majority of respondents to the VCI survey described the nature of many relationships between miners and

suppliers as “overly transactional”, leading to less than optimal outcomes for both. This may be partly due to a lack of experience in setting up mutually beneficial, value-based partnerships. The most efficient way to overcome this is to structure identified strategic partnerships as though they are a joint venture; set shared goals, visions, incentives and even work practices in common areas.

Implementing change The success of a new product or service in the industry is measured by whether it improves performance in the mining value chain. Often the failure of a new innovation isn’t a result of poor technology – change management and human factors are a large determinant of success. Not including operations in design, the lack of a high-level systems view when addressing root cause or poor communication can derail the implementation of even the best innovations. Figure 2 outlines a range of possible innovation methods. The question is: which method to use for which challenge? The more difficult the problem, the greater the breadth of external ideas (and

therefore participants) needed to solve it. The flip side, however, is that this requires a specific process to manage the participants and drive it through to a result. Although challenging, when well executed this yields great results. For problems that are less complex but more time-critical, selecting and incentivising the right partners can yield faster, more limited results with greater intellectual-property protection. Figure 2 shows only a few examples. However, the chart demonstrates the range of innovation methods to be selected by matching the strengths and weaknesses of the method to the requirements of the challenge.

Recommendations Based on the survey findings, VCI has four key recommendations for innovation delivery: • Establish innovation and technology development roadmaps to drive investment decisions. Have an ongoing budget, clear timeframes and technology focus areas. A long-term asset (greenfield or new brownfield expansion) needs step-change planning. This will also support risk-management strategy. • Understand and use the breadth of innovation methodologies available (including scanning and venture capital). Be deliberate in choosing the method required for a given challenge and concentrate on bringing the outside in. Include suppliers in the innovation process. Manage differing innovation approaches to technology challenges at a programme level to ensure integration. • Leadership is important for both top-down and bottom-up innovation. Put in place top-down design parameters while cultivating a bottom-up innovation culture; the top-down system enables large step change and the bottom-up will help change management. Provide a structure for unplanned innovation; it needs a specific strategy and design. Protect and incentivise change, punish inactivity not mistakes. • Establish a clear change-management methodology for technology implementation that provides specialist input, clear processes, communication and structure. Involve the change-management team throughout the technology-development process to ensure consideration of strategic fit and operational interruptions.

VCI is a global management-consulting company that has helped executives shape the resources industry over the past decade. See: www.govci.com Subsequent articles, which will be available at www.miningmagazine.com, will focus on the industry innovation ecosystem and innovation strategy

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time for a review A series of recent high-profile tailings dam failures in established mining markets have drawn negative attention from the world press and the general public. MM examines the implications and asks six leading engineers and consultants what mines should be doing to ensure best practice

“The physical costs associated with largescale failures such as these average US$30100m”

here are few topics more controversial or more likely to focus the beady eye of the world’s media on the mining industry than the failure of a tailings storage facility (TSF). While the blame for such events is often foisted upon the engineers and consultants who designed and built the facility, the reason for failure can more often than not be traced back to poor operational practices or lack of readiness for a naturally occurring climatic or geological event. While it is down to the engineers and consultants employed to assess design and provide the best possible facility for the given conditions on site, it is ultimately the responsibility of the mine owner to ensure that the right experts are selected for the job, that their involvement comes at the correct times throughout the life of mine, and that best practices, regulations and government guidelines are adhered to during construction, operation and, eventually, closure. TSF failures have been reported by international media this year at the Mount Polley mine in Canada; Cananea in Mexico; Dan River Ash Pond in the US; and at Itabirito, Brazil. In terms of financial liability, the physical costs associated with large-scale failures such as these average US$30-

100 million, while environmental liabilities (clean-up costs) run into hundreds of millions; and that is before considering value losses for shareholders, the implications of business interruption and damages to local communities. More worryingly, events such as these damage the integrity of the mining industry, a sector that, despite huge advances, still carries the unfortunate reputation of causing gross damage to the environment. The general public’s perception of the sector and that of national and international governing bodies is key to its sustainability, and that is why MM has gone back to basics with this article, examining the fundamental principles behind good TSF design, construction and operation with six of the world’s leading consultants and engineers.

WhAt iS A tSF? Mines typically process vast quantities of ore, only a tiny fraction of which is the actual commodity. Most of the material that passes through the processing plant therefore needs to be stored or disposed of in an economical and sustainable way rather than released into the environment where it could potentially have a negative impact on the local surroundings.

The main purpose of a TSF is to do just that: provide a safe, environmentally sound, and cost-effective way of storing the residues issued from ore processing, not only throughout the active life of a mine, but also during the closure and rehabilitation phases. Extracting minerals nowadays is principally achieved through hydrometallurgical processes where material is crushed and ground, and the desired mineral is extracted using physical separation or chemical leaching methods. These processes are conducted at a relatively high liquid-to-solid ratio, so that the residual tailings to be stored are usually at a liquid-to-solid ratio from 1:1 to 3:1. This waste material or ‘slurry’ (a mix of finely ground particles and water) typically comprises more than 99% of the ore and other solids that pass through the process plant. Storage usually involves constructing a large dam or dams that straddle lows in the topography, but can also involve deposition into a previously mined-out open pit. The tailings can also be thickened or filtered to remove most of the water before discharge into the TSF or stacked in piles. Volumes generated over the life of a new mine can vary from tens of millions of tonnes to over a 1,000Mt.

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TSFs can be designed to permanently retain the solids in the slurry after they settle and release the process water for reuse, or to discharge them under permit conditions and water quality standards with treatment as necessary. As such, they are also often used for site water management, including process water supply, containment for site-contaminated water and as a holding basin for flood control before treatment and release to the environment, or for recycling. Potential uses, along with the production volume at the mineral processing facility, will influence the size of a TSF.

the right Site The key feature of a TSF is a confining embankment or dam that can be constructed in stages and raised as extra storage capacity is needed. These are usually built from local fill materials (sand, gravel, clay, waste rock) and possibly imported or manufactured materials where required. In some instances, the coarser particles are separated from the tailings using cyclones and these ‘sands’ are then used to construct the retaining dams. A TSF will also generally feature: • A tailings distribution system (pumps, pipelines, conveyors, trucks);

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• A spillway for flood control; • A water management system

• • •

(process water return pipeline), seepage controls (collection ditches, interception wells and water treatment system); Instrumentation to monitor seepage and stability; An overall operations, maintenance and surveillance plan; and A closure plan.

However, design elements will differ depending on individual circumstances. Due to their potential impact on a project’s development and cost, TSF site selection assessments should be initiated as early as possible – usually at the conceptual design stage. These studies should also be carried out in consultation with any relevant authorities to prevent unnecessary delays in permitting. It is often the case that detailed information covering the environmental conditions is not available at this stage of a project, and it is therefore important to ensure that the impact of long-lead items such as environmental permitting are considered early on. Romain Girard, associate senior geotechnical engineer at Golder Associates, explains: “The first site selection process would consider three

to 10 possible locations at scoping level. This would then be reduced to one to three possible sites at prefeasibility study [PFS] level. This would allow for the preferred site to be developed further before the final feasibility study.” A good site selection study should thoroughly evaluate a variety of aspects and should include social, environmental, engineering and economic considerations. It would include such items as: 1. Environmental, social and permitting considerations, which would include an Environmental and Social Impact Assessment (ESIA). This would also evaluate the management of hazardous materials, if present, and take into account decommissioning and closure considerations. Operators

Main image: probably the best setting and topography is provided by a valley, where the TSF can be built across the low end, as at the Los Pelambres mine Photo: Bechtel

Below: spigoted tailings deposition and ongoing dam raising Photo: Golder Associates

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Tailings dams. SLR recently designed an unlined TSF using Canadian shield bedrock which has low permeability, and seepage collection trenches to protect groundwater Photo: SLR Consulting

“There are significant benefits of utilising a whole life-cycle approach from the outset,” says Irwin Wislesky, technical director of tailings and mine waste at SLR Consulting (Canada), “with appropriate emphasis given to the closure phase as this is the longest part of the life cycle.”

must be aware of variations in local legislation and regulation in the areas in which they are planning to mine. 2. There are also key site requirements that should be taken into account, including an analysis of the topography and geology of the site, as well as the hydrological and hydrogeological setting. A thorough knowledge of previous and current land ownership and use is essential. 3. A storage capacity assessment and plans for efficient and safe disposal methods. An outline of the physical size of the facility (footprint and maximum height) should be put together alongside broader financial plans for capital expenditure, operating expenditure and closure costing. Similarly, plans for tailings transportation and water management should be outlined, and an assessment of the availability of construction

materials should be made. 4. A risk assessment on screening-level dam safety should also take place in parallel with the siting study to identify the main risks and liabilities associated with a particular site. This allows for adequate mitigation measures to be developed during all stages of the design, and subsequently during construction and operation. Site selection planning should take place at the same time as planning for the mineral processing facility, and it should take into consideration the plant’s long-term tailings storage needs. It is often beneficial to locate the TSF at a lower topographic grade than the mineral processing facility to take advantage of gravity flow of tailings slurry. Condemnation drilling should also occur to ensure there is no ore under the selected TSF site.

Working with the environment Every TSF is unique and the design will largely depend on two factors: local conditions and tailings characteristics, both of which are directly influenced by the commodity being mined and how it is processed. For example, the style of operation will dictate the method and rate used to raise the TSF embankments. The local setting and topography can greatly affect the type of containment required (flat topography may result in a larger footprint and more significant dam volume due to a larger perimeter length), as well as the deposition and tailings management strategy employed. Major factors that influence design include: climate, geology, potential seismicity, topography and proximity to areas of human habitation, forest reserves, freshwater or marine ecosystems and downstream infrastructure. The use of 3-D modelling software

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“Site selection planning should take place at the same time as planning for the mineral processing facility”

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allows designers to select locations for development which minimise embankment fill requirements and disturbance to the local catchment area. Girard gives an example: “We [Golder] recently designed a dam in northern Europe utilising thickened tailings deposition which allowed us to reduce the size of the embankments by increasing the beach slope angle of the tailings mass. This provided significant cost-savings for the company where storage space was at a premium.” Stuart Schmidt, manager of technology at engineering firm Bechtel, says: “Probably the best setting and topography is provided by a valley, where the TSF dam can be built across the low end.” In these situations it is particularly important to minimise impacts to the natural hydrology regime; inappropriate siting of the facility can lead to significant risks, such as disruption of the natural catchment drainage regime and contamination of local water supplies through excessive run-off or seepage from the TSF. Climate can also affect the construct ion and design of a TSF, particularly the dam. “It is very difficult to build an earth dam in wet environments, and thus a rockfill dam may prove a better alternative. Very cold climates can impact the delivery of tailings to the TSF,” adds Schmidt. Very dry areas require maximum water recycling, while very wet areas may require additional water management measures. In these circumstances, it is worth considering thickening and filtering to reduce water losses within the facility and provide additional seismic stability. Wislesky described an example of uranium TSF in Namibia where SLR established an approach to both thickening the tailings and depositing them in smaller paddocks created inside the larger TSF, thereby almost halving the water losses. Jamie Spiers, senior consultant at SRK Consulting in the UK, outlines a recent project that SRK worked on in West Africa which considered a valley fill impoundment TSF. “Due to the extreme run-off calculated for the site, it was necessary to design a river diversion to allow dam construction to commence and ensure that run-off inflow into the facility was minimised. This prevents clean water contact with contaminated tailings material,” he explains. “Ideally, the TSF would have been placed in a smaller catchment area, but there was limited availability of land. A trade-off had to be undertaken between the installation of a water-retaining

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embankment which would require liners to prevent excessive seepage through the embankment, and costly perimeter drainage canals to minimise inflow into the facility. The latter was selected as the risks associated with seepage management in the main dam were minimised.” TSFs used for site water management may require extra considerations. “We recently undertook a conceptual design for a gold mine in Saudi Arabia where a key driver was reuse of process water,” says Richard Elmer, head of mining at Knight Piésold. “Our design focused on tailings dewatering options to maximise water savings with the added benefits of minimising the TSF footprint and improving stability. With very low in-country energy costs, the higher capital expenditure associated with filtering the tailings was offset.” For another recent Knight Piésold project in Norway, there were very different drivers. “The principal concern of the client was to provide a TSF design that maximised progressive restoration in an area of steep topography to provide areas of new flat ground that could be reused for construction or agriculture,” explains Elmer. “This was achieved by careful phasing of the TSF construction.” As tailings facilities are usually quite large, they require vast quantities of fill material to provide a containment barrier, so the availability of construction materials can be a limiting factor. At the Antamina site in Peru, where rock was easily available, Bechtel used a rockfill dam with concrete facing as the starting dam for the TSF, while at the Yarwun Alumina Refinery site in Queensland, Australia, where cohesive soil was easily available, earth dams were used. Local clay or till is often utilised as a low-permeability barrier where available, but artificial liner materials may need to be included in the design if natural materials are not available. A flexible approach is often necessary in these situations; SLR recently designed an unlined TSF using Canadian shield bedrock which has low permeability, and seepage collection trenches to protect groundwater. The waste rock generated by the pit was used to create the containing embankment. “It’s natural to home in on engineering issues like health and safety and stability at the design stage,” comments Nick Watson, technical director and head of geotechnics at Wardell Armstrong International. “But a good risk assessment should also look more widely at environmental and social factors, and potential effects on local communities and political fallout.”

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Many of the TSFs that Wardell Armstrong has worked on have been in arid climates in less-developed countries where the availability of suitable construction materials was limited by long lead times. “This often means using less rockfill and more fine-grained material for construction,” explains Watson. “The availability of plant and machinery may also be restricted. The design and width of a clay seal at a site in West Africa, for example, had to be modified when we discovered that the

Tailings deposition into a TSF Photo: SRK

only available machines were refurbished ones originally used for building motorways in France in the 1950s!”

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Liner installation: artificial materials may need to be used if natural alternatives are not available Photo: SRK

Growing with the mine

To store or stack?

A TSF is an active structure, usually built in a staged manner, which is continuously raised or expanded during the life of a mine to meet the needs of the mineral processing facility. Facilities commonly have a starter dam, which is followed by a series of raises or lifts to accommodate increasing amounts of tailings. Girard says: “Any design should be cost-effective for the prevalent conditions at the mine, but new orebodies [and extensions] are frequently found, the processing plant expanded and throughput changed. Therefore, these parameters should be taken into consideration at the start of a project in order to design a facility that is flexible. Sometimes economic conditions dictate that a mine is put under care and maintenance, and this also needs to be considered during the design.” Expansions are often required due to changing commodity prices too; a price rise lowers the grade of mineable ore and, in turn, increases reserves. Should production increase beyond the scope of the original design, then a further design will be required to accommodate the additional tailings or an additional site sought for a new facility. “The choice of method for raising the

While traditional slurry TSFs are widely used, cost-effective and well understood, it’s always good to explore other approaches for managing tailings. “At the beginning of a project, all mines should be looking at alternative storage methods, both on the dewatering spectrum (from thickened tailings to dry stacking) and for backfill, or other options such as tailings and waste rock co-disposal,” states Girard. The choice of tailings storage method is rarely controlled by a single factor. Some mines do consider methods such as dry stacking or backfill, but these options are not always possible or practical regardless of the costs to build, operate or close the facilities. “Regulatory drivers may contribute to the choice of final tailings solution, but we are not currently seeing directives from governments for a particular type of tailings disposal system,” adds Elmer. For underground mines, using tailings to backfill mined-out voids has been common practice for many years. The tailings undergo further processing with the reduction of water content and addition of binding material such as cement before being pumped underground. This provides two key

TSF will be dependent on various factors, including availability of land downstream, consolidation properties of the existing tailings and the design of the existing impoundment,” says Elmer. “Raising an existing facility is usually preferred to finding a new site to minimise environmental and social impacts and to ease the permitting process. Provided the design is thorough, including detailed assessment of the existing facility, expanding a TSF shouldn’t necessarily be avoided.” The cost of expanding the capacity of a TSF can range from almost nothing, where the current operational system accounts for regular raising of the facility with available materials, to quite a significant amount if new facilities have to be designed and built. Errors at the design stage can be extremely costly to remediate during the operational phase.

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advantages: minimising surface disposal while providing support for underground openings. Some mining methods are dependent on backfill, but will usually only require 20-50% of the total waste tonnage generated by the operation, so while a tailings facility is always needed, the size can vary. SRK is currently conducting studies at sites in Australia, Central Africa and Chile to investigate the viability of thickened tails and paste technologies. The advantages of thickened tails include water conservation, efficient run-off management, minimised dam construction costs, enhanced stability and minimised infiltration of supernatant fluids and oxygen which could lead to acid generation. “The increased processing costs incurred by thickening tailings can often be offset by reduced capital costs for embankment construction and water treatment facilities,” explains Spiers. Dry stacking techniques are being increasingly applied to minimise the footprint of TSFs and hence the environmental liability of an operation. By dewatering the slurry and recycling water back to the process plant, less water is lost in storage and mines can better meet their abstraction and discharge

limits. But every method has its pros and cons, and while dry stacking can save a considerable volume of water, it would typically have a much larger carbon footprint than hydraulic tailings disposal. Schmidt says: “We have looked at dry stacked filtered tailings to reduce water makeup by up to two thirds and the concomitant supply costs of that water. The real challenge is applying the tailings filters required at a very large scale to the process – this is first-of-akind technology. The overall cost advantage of dry or backfill system versus wet will depend on several factors, including the proportion of tailings as a function of the ore stream, project location, project-specific terrain, and facility locations and layout.” The two main challenges with dewatering are the difficulty of drying out some material, and the extra cost that might make the project less viable.

Monitoring, audits and inspections TSF dam monitoring equipment and procedures are similar to those used for water storage dams. Routine monitoring through the dam and its foundation, including regularly scheduled visual inspections, is important to validate

design assumptions and ensure dam safety. Monitoring systems vary from site to site, and considerable technological progress has been made in this area in the past ten years. Current technology includes the installation of seepage and dam movement devices that can transmit data via the internet, thus allowing for remote management from a centralised location. These are generally coupled with a predefined alarm system that can also be linked to safety devices such as shut-off valves or the start-up of emergency pumps. A common pitfall is to instigate a monitoring programme, but not have appropriate trigger levels or action plans should specified levels be reached. This is something that should be addressed from the outset. Usually monitoring comprises a range of instrumentation, including piezometers to measure groundwater level, inclinometers to measure any movement in the impoundment walls, and survey points to measure any vertical movement/settlement. The tailings management system is typically integrated with the overall water management system at a mine site, and monitoring strategies to ensure a good understanding of the site water balance are essential.

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“After project construction is complete, a critical element for continued success is that the mine operator maintains professional engineering oversight and inspect ion of the TSF”

Monitoring programmes are developed based on key risks, objectives and routine controls, and a risk assessment carried out at the design stage will enable monitoring to be targeted at the areas of highest risk. If stability is affected by embankment settlement, for example, it will make sense to place settlement monitoring stations along the crest. The site operating manual typically specifies where and how often the monitoring should be done, and what action should be taken on the results. Ideally, all TSFs should have standpipe piezometers installed around the embankment to allow monthly water levels to be measured. Should the position of the phreatic surface within a particular embankment rise above an acceptable level, this may pose a stability risk to the outer embankment structure and remedial measures should be taken immediately. Groundwater monitoring bores should be installed around the dump perimeter to ensure seepage from the TSF does not adversely affect local groundwater supplies. Water samples should be tested regularly to ensure that pH levels, sulphides and selected metal concentrations fall within internationally recognised safe limits. Visual inspections of the structure should be carried out on a daily basis

during the operational phase to ensure that all drainage structures and embank ments remain intact and function correctly. Event-driven monitoring may be required on a more frequent basis in regions with a high level of seismic activity or rainfall, and emergency action plans (EAPs) should be developed and regularly updated.

Avoiding common pitfalls Ultimately, the successful design, construction and operation of a TSF is linked to the mine owners’ commitment to environmental stewardship, safety and sustainability. Every consultant and engineer interviewed for this article agreed that most pitfalls associated with operating a TSF are due to poor water management. This includes: •M anagement of process water stored in the TSF; • R un-off from upstream areas; • S eepage through the dam or foundation; and • P ore water from eventual tailings consolidation. Issues can be avoided by using appropriate fill materials for embankment design, through strict quality control and assurance during construction, and ongoing review of the tailings deposition strategy throughout the operational phase.

Make the most of modelling Modelling tools for TSF design, mining process flow and potential contaminant groundwater dispersion have significantly improved over the past few decades, and modelling tools that can be used for design of municipal water storage facilities can now also be used for tailings dams. These tools provide consultants and engineers with the ability to understand, predict and design much faster and more efficiently, and allow them to assess alternative designs more cost-effectively and thoroughly. Numerous modelling software packages are available on the market, as well as packages developed in-house by companies. These range from advanced numerical modelling tools for stability and seepage analysis, to tailings deposition modelling tools. For example, Golder Associates has developed the Goldtail deposition modelling tools and, originally, Goldsim water balance software which allow operators and designers to develop an understanding of the behaviour of the tailings mass, and the inflows and outflows of water into the TSF; factors that are critical for the safe operation of the facility. Some predictive modelling tools are also being used on TSF design, and allow designers and operators to predict potential behaviour of the TSF under certain conditions. This in turn allows assessors to identify potential weaknesses in a design, and to develop remedial measures if required. Knight Piésold has progressed from using basic CAD packages to tools specifically designed for mine tailings applications, including Muck3D and Rift TD. “These tools are particularly useful in early stages of TSF design where different options can be quickly assessed and modifications made without having to rebuild complex CAD models,” explains Elmer. “They allow for rapid assessment of fill volumes for tailings and impoundment dams as well as giving figures for rate of rise. The principal advantage is that many iterations of TSF configuration can be looked at to optimise the solution.” Stability assessment is another area where today’s modelling packages are of particular use. Complex geometries and groundwater conditions can be modelled in detail to closely represent reality and predict the behaviour of slopes. However, modelling tools cannot be used in isolation and are no substitute for the application of sound engineering principles. With recent developments in 3-D digital terrain models, rapid assessment of tailings deposition scenarios can now be made in both rugged valley and paddock-style TSF structures. This software also assists with visualisation of design scenarios, essential for reporting to project team members, clients and investors.

After project construction is complete, a critical element for continued success is that the mine operator maintains professional engineering oversight and inspection of the TSF, particularly when expansions are designed and undertaken; the second most common concern among interviewees was the level of involvement from a competent geotechnical engineer/consultant throughout the life of the project. Mine personnel in charge of the facility are sometimes more focused on production than tailings disposal, and TSFs must be built and operated in exact accordance with the design if they are to function in line with the designer’s intent. Appropriate allowances for changing operations and for extreme conditions are essential. “Engaging the designer in the ongoing inspection and monitoring of the TSF is good practice, as well as having independent third-party review,” says Elmer. It is also important to remember that TSFs are active structures and that sound design must be coupled with sound construction and operation to keep them safe during the entire life of mine and beyond. “The design must be tailored to the capacity of the mining company, its operators and contractors to build and operate the structure safely,” cautions Girard. Wislesky believes that most common pitfalls can be avoided, or at least reduced by good site selection, design and financial robustness. “These, in conjunction with a dedicated mine policy, clearly demonstrate the need for knowledgeable tailings facility operators who understand their limitations and when it is necessary to call the consultant,” he explains. Meanwhile, Watson says change is probably the biggest issue. “While the mining engineer concentrates on operational matters over the 20- to 30-year life of the mine, people come and go, production changes, regulations change and things are gradually done differently. “The original design intentions can be forgotten or are no longer valid. That’s why regular audits are so important to make sure the containment practices are still safe, or to change them if necessary with the agreement of the regulatory body,” he says. “One specific pitfall is not being able to find as-built construction drawings in the event of a failure, which is why they need to be held securely. Some mines keep all their records in a secure data room for future reference, which clearly helps with carrying out reviews.”

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TAILINGS MANAGEMENT Best practice in practice With heightened coverage of TSF failure events this year comes additional pressure on both service providers operating within the global mining sphere to deliver safe and sustainable facilities, and mine operators to ensure they are doing all they can to adhere to best practice. “There has always been pressure on tailings consultants to deliver safe and sustainable TSF designs that meet with client expectations,” says Spiers. “The occurrence of large-scale TSF failures has generally declined over the past 50 years as the result of a shift towards specialist design teams being responsible for dam engineering, and the involvement of experienced practitioners in the review of existing facilities at operational mines.” The principal effect of recent failures that Knight Piésold has seen is an increase in requests from mines to provide more regular inspections to check that their operations comply with the design intent. “A TSF is never going to be ‘sustainable’ in that it is a facility for storage of a waste product, but designers can apply sustainability principles to post-closure design to minimise long-term negative

impacts,” states Elmer. “A disused TSF need not become a liability if properly closed, and can even become an asset if the land becomes usable where previously it was not.” Any high-profile tailings dam failure places pressure on the industry as a whole, but it also means accrued pressure on the regulators involved in the permitting process and, as a result, can lead to more stringent criteria for TSFs. “In Golder’s experience, most of the technical challenges TSF designers are faced with can be overcome, although in some instances this can lead to significant cost increases for the disposal of tailings by the mining companies,” explains Girard. “In such cases, the cost implications of regulations can be inhibitive and have been known to stall or halt projects altogether.” He reiterates that there is a need for the involvement of competent people throughout the whole process – designers, operators and regulators. Most consultants are on board with sustainable TSF development, but may be influenced by pressures from some mining companies to limit their involvement with the project. Although mining companies are often concerned about sustainable development, other

pressures such as mineral production and budget restraints can lead to shortfalls in the attention paid to a TSF. “The consulting business should pick up, as failures tend to focus people on these high-risk man-made structures. In fact, we expect that third-party involvement and government-mandated reporting will be coming in the near future as a result of recent TSF failures,” adds Wislesky. As poor water management has been linked to many of this year’s high-profile failures, there’s likely to be even more pressure in the future for mines to dewater their tailings. “There will also be increasing emphasis on recycling waste for a more sustainable approach. This isn’t always possible, of course, especially with fine-grained material, but we’ve recently seen some positive examples such as waste material in Namibia reworked to make bricks,” says Watson. In short, some lessons are learnt the hard way, but hopefully the learnings taken away from this year’s events will eventually strengthen the use of best practice from both mining companies’ and service providers’ perspectives, and the mining industry will emerge a better one because of it.

“We expect that thirdparty involvement and governmentmandated reporting will be coming in the near future as a result of recent TSF failures”

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TAILINGS MANAGEMENT

Metal-laden waters: a headache or a gold mine? A modelling programme by Blue Planet Strategies has revealed the opportunity for mines to significantly offset wastewater treatment costs through residual metal recovery

L “Applying DEMET to a represent ative leaching operation drain-down case showed that by using it, a net ~US$90 million lifecycle treatment cost might be reduced to ≤US$5 million”

arge volumes of acidic, metalladen waters generated during mining operations contain high levels of dissolved and biologically persistent toxicity hazards. More and more such waters are reused during operations but they still present a legacy problem at the end of mine life. Costly treatment before discharge/ reuse is often needed. Traditional precipitation treatments use lime to neutralise and remove the dissolved metal toxins as insoluble solids. Target streams high in sulphate (a common situation) create large amounts of insoluble gypsum across a wide span of pH and ‘blind’ selective precipitation approaches. This generates large volumes of mixed sludge often requiring expensive disposal as harmful material, creating both materials management and financial challenges as well as up-front mixing and dosing complications. Recent trends towards residual recovery/reuse have seen emerging efforts using controlled chemical dosing treatments to selectively precipitate and separate common major metal contaminants. Biologically-based systems often target metal-sulphide products and encounter control response challenges, while direct chemical addition utilises expensive chemicals, such as caustic, to achieve the desired neutralisation. Better treatment options would boost profits and cut costs.

Flow diagram showing the advantages of DEMET neutralisation and its possible by-products

Solutions Blue Planet Strategies’ patented Dynamic Electrolytic Metal Effluent Treatment (DEMET) technology offers a simple and low-cost treatment option. The solution, previously introduced in Mining Magazine’s October 2013 issue, was developed for practical direct metal electrowinning from dilute sources and generation of a product concentrated in the target metal. Operational tailoring enables various DEMET processing modes and emphasis on other target reactions of interest. For acidic wastewater, drain-down raffinate, and acid rock drainage (ARD) treatment, DEMET can electrolytically manipulate target stream chemistry in several ways to neutralise acid streams at a lower treatment cost than lime. It can also selectively remove or recover common major mining water contaminants. Other benefits it offers are that: • I t does not need added/consumed chemicals; • I t can significantly reduce mixed sludge generation; and • I t can create potentially saleable treatment by-products to generate new revenues that will further offset treatment costs. DEMET generates a neutralising agent (hydroxide) on site from electricity and abundant ambient water (with no added reagents). The power of a strong

neutraliser like caustic is provided without the high chemical feedstock cost or target-stream contamination with excess metal cations (such as sodium for caustic, or calcium for lime). As a result, problematic gypsum formation of lime treatment is avoided, greatly reducing sludge generation and enabling the ability to selectively remove metals as insoluble hydroxides. Furthermore, valuable sulphuric acid can be generated as a by-product of the treatment process. DEMET’s electrolytic nature allows simple process adjustment and feedback-driven control for low-cost process tailoring and optimisation. Common major leachate metal constituents readily recovered in various target forms to yield potential net profits upon product sale include: aluminium, iron and magnesium. Others are possible but require the consideration of site-specific parameters. As a separated electrochemical cell, DEMET prevents bulk mixing of the respective solutions bathing the cell cathodes and anodes. This allows the products of the target electrochemistry to be kept apart so that the process may be regarded and treated as two separate but coupled steps: reduction at the cathode; and oxidation at the anode. As a result, two input streams are treated and two product streams generated. Advanced DEMET features improve processing rates, energy consumption, and processing efficiencies to yield smaller, cheaper equipment with lower operating costs and higher specific processing rates. DEMET elements can also enhance resistance to cell shorting and fouling, improve target product recovery practicality, and expand the range of practical utility for the process by providing cutting-edge ability to limit and adjust inherent factors constraining conventional electrochemical cells practicality and process tailoring. Tailoring of operation parameters allows the desired dominant reduction reaction to be chosen so that treatments can focus on adjusting target metal oxidation states or hydrogen evolution.

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TAILINGS MANAGEMENT

The former can remove and recover metal directly by electrowinning, while the latter consumes protons (acid) and raises the treated stream pH by shifting the water dissociation equilibrium. Elevated pH (> pH 12) can be generated – enough to precipitate many metals encountered in the target waters in a manner analogous to conventional precipitation treatments. Process control can allow selective precipitation and removal of most of a target metal as potentially useful products. Concurrent water splitting at the anode generates protons (acid), which accumulate with sulphate in the anolyte to generate the target sulphuric acid as a by-product.

In practice Applying DEMET to a representative leaching operation drain-down case showed that by using it, a net ~US$90 million lifecycle treatment cost might be reduced to ≤US$5 million. Representative batch-mode results highlighting early-stage DEMET neutralisation for a strongly acidic stream containing very high metal levels is shown in the graph (above). Initially, ferric iron (Fe+3) reduction to ferrous (Fe+2) was pursued to raise the iron precipitation pH level from pH ~3 to allow other desired constituents to be targeted. This is noted by the loss of orange colouration during treatment. Little apparent neutralisation occurs (red line) in favour of iron reduction, and once completed (around 65 minutes), hydrogen evolution is targeted and yields rapid neutralisation of the target waste stream without blinding precipitate formation and at an equivalent lime neutraliser cost of US$125/t. DEMET process control then allowed the selection of target metal salt precipitate and removal with substantial yields and purities to allow potentially saleable products to be generated. Steady concurrent sulphuric acid (by-product) generation to nearly 3% acid concentration (black line) is seen in the anolyte at 75% net generation efficiency. Up to 6% acid has been demonstrated and conventional post-processing to industrial grade may be pursued. It should be noted that high metal levels strongly buffer the target stream as they consume hydroxide to form complexes and eventually neutral metal hydroxides which precipitate and thereby create neutralisation plateaus, starting at pH ~3 for high aluminium recovery levels.

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Graph showing DEMET neutralisation (lower-cost, no gypsum formation)

Conclusion A net cost reduction approaching 100% (complete cost offsetting) was seen for modelling of DEMET enhanced treatment of a representative leach pad drain-down scenario. DEMET offers a potential low-cost and ‘reagentless’ alternative to acid wastewater neutralisation while presenting opportunities to generate considerable new revenues by selling by-products. The advanced approach can enable cost-effective recovery of major contaminants such as aluminium, iron,

and magnesium while also co-generating sulphuric acid as a by-product. The innovative capability is projected to notably reduce polish costs by recovering major contaminant metals before the polish stage as well as lessen final mixed sludge generation by lightening the polish treatment load and avoiding gypsum creation. Applying this versatile process/ technology can yield treatments for a range of waste and process waters that are greener, cheaper and new sources of revenue.

For more information, see www.bps09.com

“Valuable sulphuric acid can be generated as a by-product of the DEMET treatment process”

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Explosives & blasting

Having a blast Ailbhe Goodbody looks at blasting technologies in surface mining, and the latest developments in ultra-high-intensity blasting and the elimination of NOx fumes

“Blasting is a dynamic process that constantly needs to be refined based on the ground conditions”

An MPU loading a blast pattern on a coal mine in Queensland, Australia Photo: Action Drill & Blast

he approach to blasting at a mine site is determined by the mine owner’s requirements. Typically, for waste areas in a pit the objective will be to remove the waste as efficiently as possible for the cheapest cost per tonne. Orebodies will have more constraints imposed to ensure a specified level of fragmentation is achieved without compromising dilution of the ore. The factors that determine which blast pattern designs are used can be complicated. When designing blast patterns, some of the significant factors to consider include: • The fragmentation requirements for loading, hauling and crushing; • The drilling and loading equipment available; • The energy delivered by the explosives; • The type of rock being blasted and its physical properties and strength; • Geological features and anomalies which may exist in the rock mass; • The bench heights;

• Wet or reactive ground considera• •

tions; Proximity to sensitive receivers such as infrastructure, heritage sites and fibrous areas; and Access to and topography of the work area to ensure that a safe environment is provided for drilling and blasting operations.

Action Drill & Blast says that drill patterns, spacing and depths are determined by considering all the constraints present while striving to exceed the physical and commercial objectives of the blast. The blastability of the rock is dependent on the pre-existing structure in the rock mass, its density and, to a lesser extent, its strength. The higher the blastability index, the more difficult the rock is to fragment by blasting. Tony Rorke, director, blasting technology at BME, explains: “It is important to know what the rock is that is being blasted, but more importantly it is necessary to know how many cracks nature has put into the rock before blasting.” Different combinations of bulk explosives can be used for various reasons. For example, wet ground conditions require a water-resistant product to successfully initiate, and if water is present in the blasthole then the bulk explosive will need to have the ability to displace water when loaded from the bottom of the hole upwards. Variable-density products allow the energy density of the product to be optimised to provide better fragmentation with a higher velocity of detonation (VOD), and a higher ammonium nitrate (AN) content provides a cheaper product that produces increased gas volumes with increased heave characteristics. Rorke says: “For example, brittle rocks may need an explosives product with a high VOD, compared with more friable rock that would respond better to an explosives product with a low VOD.” Explosives companies spend a large proportion of their research budgets formulating explosives that provide the right combination of energy and reaction rate (VOD) for different rock types.

Better blasting Better blasting improves downstream mining processes in a number of ways. It results in increased dig rates and increased crusher throughput, along with reduced ground-engaging tool (GET) and maintenance costs. In addition, it accelerates schedules and reduces overall mining-project durations. An Action Drill & Blast spokesperson explains that the results of good blasting have a compounding effect on downstream processes, which increases the profitability of a project. Blasting systems can use different types of detonators, which are generally mechanically or electrically initiated. Electronic detonators can provide huge benefits in applying novel and effective approaches to sequencing a blast. Examples include the protection of coal in surface overburden blasts. Rorke suggests: “The most important issue to bear in mind is that more explosive energy per unit of rock being blasted remains the most effective way of improving downstream productivity and thus saving money.” For example, BME explosives can be initiated with any of the appropriate commercial initiation systems that are available on the market. Rorke notes: “The important criterion is that the booster used has sufficient energy to initiate our explosives, as is necessary for all commercial explosives.” However, BME also supplies AXXIS electronic detonators, which it says provide big benefits in initiating the explosives charges in the designed sequence. Rorke says: “AXXIS electronic detonators are accurate and provide flexibility that enables explosives engineers to design complex initiation sequences that afford wall control, dilution control, vibration control and required heave. These electronic detonators are also useful in providing control in environmentally sensitive blasts where vibration and air blast need to be contained.” To improve cast blasting by approximately 30% at Yancoal’s Middlemount coal mine in Queensland, Australia, Action Drill & Blast conducted several blasts trialling electronic detonators and adjusting other variables to determine the most successful outcome. Action

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Explosives & blasting

Tony Rorke, director, blasting technology at BME, with the AXXIS electronic detonator equipment

Drill & Blast says that by using electronic detonators with multiple primers within the hole, adjusting timing between holes beyond traditional practices and modifying bulk product formulations, it was able to achieve its client’s improvement target. Blasting and fragmentation can be predicted somewhat by experienced personnel, but blasting is a dynamic process that constantly needs to be refined based on the ground conditions on hand. Prediction of blast fragmentation is a difficult science because the rock is so complex and cannot be easily defined; geological characteristics can change significantly over very small distances. The Action Drill & Blast spokesperson notes that just because a blast worked well on one side of a pit, this does not ensure that the same parameters will work in a different location. The

company endeavours to obtain all the information available, from visual inspections, previous blast results and drill quality assurance data, and refine

Blasting without NOx hazards CRCMining is developing cutting-edge blasting solutions to eliminate the serious hazard of post-blast nitrogen oxide (NOx) fumes from blasting of coal overburden. The industry-driven centre for global mining research and innovation based in Queensland, Australia, states that this will significantly reduce risk of workplace, health, safety and environmental issues. Post-blast NOx fumes from coal overburden blasting seems to be an industry-wide problem; it occurs in a variety of geological conditions and with the use of a variety of bulk AN-based explosive products. Nitrogen oxide and nitrogen dioxide are toxic gases that can cause serious health risks to personnel exposed, and can also adversely affect the environment in various ways. Increased scrutiny of post-blast fume generation and risk control has had a direct impact on the mining industry’s licence to operate. However, CRCMining states that research and development into mining explosives since the introduction of AN and emulsions has been at a standstill for more than 60 years. In partnership with the School of Mechanical and Mining Engineering at the University of Queensland, CRCMining is developing solutions that could potentially eliminate the NOx hazard. CRCMining states that its way to replace AN is a step-change which could offer different possibilities to mining companies, particularly with regards to procurement and security of supply. The current project aims to develop an explosive formulation that will match the rock-breakage requirements of soft and saturated ground conditions, and also substitutes the use of AN as the main oxidising agent, which will completely eliminate the potential of NOx fumes. Dr Italo Onederra, project leader, explains: “This is a very exciting project as it focuses on the

CRCMining’s project aims to develop an explosive formulation that substitutes the use of AN as the main oxidising agent, eliminating the potential of NOx fumes elimination of the NOx hazard by applying scientific principles rather than procedural methods, which are prone to variability. Preliminary detonation test results recently published at an international conference are very encouraging. If the explosive delivers the expected outcomes, there is no doubt that Australia will be at the forefront of mining explosives’ innovation.” Other future benefits may include the elimination of the potential risk of AN discharge into groundwater systems. There could also be improvements in overall community safety associated with manufacturing and transportation processes. The development process will incorporate the use of sustainable and renewable fuel sources into the testing programme. The Australian Coal Association Research Program (ACARP) is currently funding the first stage of development of this project, led by Dr Onederra and Miguel Araos. CRCMining is seeking potential mining partners to launch the next stage of the project and secure trial sites.

the blast design to suit. It can then use blast-modelling programs to simulate and analyse various different designs to determine the optimum design for the job on hand. At this stage, most explosives companies and mines globally use simple equations that can predict blast fragmentation results reasonably, but not accurately. Rorke explains: “Much research and money is being committed to complex numerical models that can predict fragmentation and heave accurately, but the problem is dependent on defining the rock accurately, which is not an easy task.”

The future of blasting Improving safety is always a big trend in blasting. Reducing the exposure of personnel to the risks of blasting operations will encourage technological innovations and product development. In addition, developing a product which can have its density and explosive energy properties changed almost instantly during the loading process would allow deep blastholes to be loaded in a way that allows the areas requiring higher explosive energy to be targeted without subjecting the weaker areas to the same explosive energies. The development of mobile processing unit (MPU) trucks with GPS guidance and remote operation could also be options. Rorke adds: “Electronic initiation systems coupled with effective blast-design software are the biggest technological developments that mines are mostly converting to.” Due to decreasing commodity prices and reduced profit margins, the future of blasting in mining will be focused on delivering the most cost-effective solutions.

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Explosives & blasting

Ultra-high-intensity blasting A new blasting technique has been developed by a team of researchers at Orica, which has already demonstrated its potential to significantly enhance mill throughput while saving costs at mine sites. The new ultra-high-intensity blasting (UHIB) process applies chemical energy to assist the comminution process in ways previously thought to be impossible. With more effective blasting, ore is reduced into smaller particles, or fragments, before the costly and energy-intensive load, haul, crushing and milling stages. By focusing on fragmentation through effective blasting, the milling operation stands to benefit from increased throughput, reduced production costs, a potential reduction in capital costs, lower greenhouse-gas emissions per tonne and improved social licence to operate. The financial savings alone can be tens of millions of dollars annually.

technique as a new paradigm in mining, because it has the potential to increase mine production and profitability while reducing energy consumption and greenhouse-gas emissions. Ian Smith, CEO and managing director of Orica, says: “This research demonstrates Orica’s commitment to the development of resourceful solutions to improve mine productivity. The use of electricity to mill ore is

usually the largest consumer of energy on a mine site and ore comminution constitutes a significant percentage of electricity consumed worldwide.

A closer look at UHIB Researchers and blast engineers at Orica have long recognised that improving rock fragmentation during blasting can deliver substantial gains in the productivity of excavators and the

“Improving rock fragmentation during blasting can deliver substantial gains”

The 2014 CEEC Medal The Coalition for Eco-Efficient Comminution (CEEC) awarded its 2014 CEEC Medal to Dr Geoff Brent and the Orica research team that developed the UHIB technique. The CEEC is a high-level think tank that aims to identify and promote more efficient comminution practices. Brent and his Orica colleagues, Dr Peter Dare-Bryan, Stuart Hawke and Michael Rothery, describe the UHIB

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Trials have shown that UHIB blasts can control flyrock and vibration better than conventional blasting methods

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Explosives & blasting

downstream crushing and grinding processes. Many industry ‘mine to mill’ studies have identified that such gains could be achieved through increased blast energy, or powder factors. In essence, blasting can be considered the first step in comminution. Over a number of years, Orica has worked closely with industry partners including the Australian Mineral Science Research Institute (AMSRI). Modelling by the University of Queensland showed that theoretically, if explosive energy was increased beyond common accepted practice by four or more times, then a step change in mill productivity and power reduction was possible. The limiting factor, however, has been that conventional blasting techniques have not been able to control the rock movement created from significantly higher energies, thus the industry has been limited by safety and environmental issues such as flyrock, unacceptable vibration, airblast and wall damage. UHIB safely utilises blast energies or powder factors several times higher than normal in a novel design. The design involves blasting the rock in two layers within a single blast event, initiated with state-of-the-art electronic blasting systems. Brent states that with UHIB, an upper layer is blasted first using conventional powder factors and the broken rock is allowed to fall to rest before the lower layer is then initiated with ultra-high powder factors. He explains: “In effect, the broken rock from the upper layer provides an effective buffer or blanket to contain the energy in the lower layer. This buffer avoids flyrock while allowing us to use powder factors in the lower layer that are up to five times higher than those used in conventional blasting, delivering much more intense fragmentation of the ore. “Meanwhile, independent studies have found that increasing these powder factors in the range of 2-5kg per cubic metre of rock can produce much finer rock fragmentation and increase mill throughput by 20-40%.” Brent adds that blast modelling and field trials have also shown that control of surface ejection and vibration levels were better with the UHIB method. He comments: “These results are quite remarkable, given the large increases in explosive energy, and reveal that highwall damage as well as vibration and potential damage to key mine infrastructure can be safely controlled when using this method.”

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Field trials Over the past four years, Orica has been trialling UHIB at copper mines in Latin America. Brent declares: “The trials have shown that blasthole patterns as tight as 4m x 4m, with hole diameters of 250-300mm, can be drilled, loaded and fired successfully, and no explosive or initiator malfunctions have been observed. “They have also shown that UHIB blasts can control flyrock and vibration better than conventional blasting methods. The early results from the field trials indicated that rock fragmentation from UHIB was finer.” For example, a fragmentation vision system installed at a mine’s semi-autogenous grinding (SAG) mill feed recorded a seven percentage-point increase in the size fraction under 25mm entering the mill from the UHIB trial section. Another series of full-scale production blasts at a mine in Central America showed increases of 10-15 percentage points in the size fraction under 50mm.

Downstream benefits Brent states that the implications of UHIB for mine productivity and the environment are significant. He explains: “There’s a worldwide trend to decreasing ore grades, so UHIB is particularly useful in complex and lower-grade orebodies because it may elevate them to become practical and economically viable to extract. “The environmental benefits stem from the fact that emissions in open-cut mines from diesel and electricity are typically 100 times greater than the emissions from explosives.

“Independent modelling has revealed that our new UHIB method has the potential to reduce overall energy consumption and cut CO2 emissions caused by grinding by up to 30%. This highlights the potential that UHIB offers for an exciting new era in blasting. “By using far more explosive energy safely and with control, this new technology can enhance mine productivity and reduce overall energy consumption and greenhouse-gas emissions, improving the sustainability of mining well into the future.”

The future of UHIB UHIB is being introduced progressively at a number of mine sites around the globe. The new technology is widely applicable across mining sectors, including gold as well as base metals such as copper, lead, zinc and certain types of iron ore. Steve Boyce, chief mining engineer at Orica who heads up the Mining Applications team that developed the technique, says: “We believe the adoption of the UHIB technique will increase as energy costs rise and the cost of building new mineral-processing plants increases. “It is most applicable in regions where energy is expensive and at mines where the strength of the ore has been underestimated and milling capacity is constrained. “The method is easily applied, but uses highly advanced technology that brings about a step change for the mining industry, particularly at this stage in the metal price cycle when we need to do more with less.”

Over the past four years, Orica has been trialling UHIB at copper mines in Latin America

“The method is easily applied, but uses highly advanced technology that brings about a step change for the mining industry”

December 2014 13/11/2014 16:47

dust control

Coal dust under control Lee Buchsbaum looks at the techniques and products that major US miners are using to control coal dust at their operations, both surface and underground Dusty conditions at a coal mine

“Controversy over coal dust has become a bailiwick for those opposed to developing ports in both Washington state and Oregon”

ut-of-control fugitive coal dust, and the fear of it, are becoming major headaches for coal producers, shippers and handlers. Underground, coal dust remains a major cause of black lung, a disease once thought headed for extinction, but now once again on the rise in the US. While miners have focused on growing their overseas markets by expanding existing export terminals or opening new ones, their attempts have been stymied by a chorus of environmentalists who tout the fouling of rivers and water systems with fugitive coal dust as reasons to move in the other direction. In September, the coal port at Seward, Alaska, lost a major lawsuit over its failure to control certain emissions. Down the coast, controversy over coal dust has become a bailiwick for those opposed to developing ports in both Washington state and Oregon. That’s bad news for coal producers

such as Cloud Peak Energy (CPE), the only ‘pure-play’ Powder River Basin (PRB) surface miner. By many accounts the largest PRB coal exporter in the country and one of the leading exporters of thermal coal to Asia, CPE’s three large surface mines produced almost 75Mt last year in Wyoming and Montana. Focused on increasing the company’s export levels, controlling dust from haul truck to railcar to seaborne vessel has become a major focus. While dust spilling from train cars or during loading is a concern for all producers, inside the mines themselves government regulators are continuing to crack down on coal-dust exposure for underground miners as well. More stringent laws came into effect earlier this year aimed at reducing respirable dust and the resulting diseases for miners. New tools are also coming online to help producers to stay compliant and

ahead of public concerns. As producers sort through a thick cloud of controversy, data and rules, it’s clear that for the industry to thrive, controlling coal dust has never been more important.

dust control underground Beginning at the source, the US Dept of Labor Mine Safety and Health Administration (MSHA) regulators collected 4,255 dust samples from 515 coal mines between August 1 and September 30, based on the new Lowering Miners’ Exposure to Respirable Coal Mine Dust Rule. From that universe of data, only 20 of the samples (about 0.5%) exceeded the compliance levels now being used to determine if a violation is warranted. Of the 3,201 samples submitted by mine operators, another 42 (1.3%) exceeded compliance levels, though these did not warrant a violation. The rules, effective as of August 1, substantially increase operators’

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sampling responsibilities for respirable coal-mine dust and require an operator to take immediate corrective action when a sample shows excessive concentrations. The final rule authorises MSHA to cite an operator based on a single MSHA sample showing excessive dust, rather than on an average of samples. Approximately 99% of the 7,456 valid respirable dust samples collected during the first two months under the rule met compliance levels, according to MSHA. Prolonged exposure to respirable coal dust causes lung diseases, such as coal workers’ pneumoconiosis, emphysema and progressive massive fibrosis. These diseases, collectively referred to as black lung, can lead to permanent disability and death. While major equipment suppliers such as Joy Global and Caterpillar continue to develop technologies to reduce hanging coal dust, new equipment designed by researchers at Southern Illinois University (SIU), Carbondale, has recently been deployed that may knock a significant amount out of the air. Using a radically redesigned water spray system, “we are able to reduce dust concentration for mining operators anywhere from 40% to 60%,” explains SIU mining Professor Paul Chugh. Without chemicals or an increase in water use, the equipment’s advanced nozzles “have more or less perfected the technology that is currently in the marketplace,” Chugh says. He and his team boast that the new spray system will help keep mines in compliance with the aforementioned MSHA regulations. The new technology utilises precise placement of waterspray nozzles, designed to create an ‘umbrella’ effect to seal dust clouds in with spray, causing the particles to fall out of the air and reduce dust by up to 65%, claims Chugh. Following testing at several underground mines in the rapidly developing southern Illinois coalfields, the spray technology, owned by the recently formed Minerals Development Technology (MDT), has been applied to a fleet of continuous miners already in operation at Murray Energy’s American Coal. MDT, partially owned by Chugh, is also working with Wallace Diesel and Mining Equipment in Raleigh, Illinois, to manufacture spray blocks which house varying nozzle arrays that the team mounts on each machine in strategic locations.

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Though water-spraying techniques have been used for decades to control dust in mines, their application was more haphazard than the system Chugh’s team has designed. The overall theory is that wetting the coal dust produced while mining makes it heavier and takes it out of the air. But given the amount of generated coal dust and water being used, often the two elements actually fail to come into contact, or the water fails to adhere to the dust particle. Chugh’s team started their development work based on the idea of creating a smarter way to bend that technique into something more efficient. “The critical thing we’ve done is to create multiple umbrellas at key locations so that the dust cannot escape,” Chugh says. “We are reallocating water volumes to where the dust is being created. And creating multiple check points and doors where we can trap the dust.” During the engineering, and before implementation in each mine, Chugh and his team closely examine how the dust moves in a given setting. They also look at other variables, such as the specific characteristics of the coal seam, ceiling height and air circulation volume. Each variable affects the placement of the spray blocks retrofitted on each continuous miner. Eventually, the outfitted machine may ultimately end up with more nozzles than it came with from the factory, but the volume of water used is practically the same, Chugh says, and no chemicals are used in the process. “We are within a few gallons per minute of the original set-up,” explains Chugh, adding that the system uses water droplets of about 25µm in size. “We try not to use one more gallon of water than is necessary to do the job. Our system is just much more efficient,” he concludes. Now in use at American Coal, the first commercial application of the technology in high mining areas, ranging from 1.5m to 3m in height, presents unique challenges that will be a good test for the technology. “It is a fairly thick coal seam, and the ‘wettability’ of this coal is not as high as others because of its chemical structure, so that will be a challenge for us. It’s a very turbulent environment, so it’s critical to know where to put the sprays,” says Chugh. Although the system is designed for continuous miners, Chugh’s team is already working on engineering similar

dust-control approaches for the mine’s longwall installations. Given that southern Illinois is now host to several of the most productive longwall mines in the nation – if not the world – the call for this technology locally is only going to grow. Research on such an application is being conducted at the SIU’s newly opened Longwall Dust Control Facility. The lab uses state-of-the-art equipment aimed at finding ways to control dust aerosols better in certain types of coal mines. The facility opened in March under Chugh’s direction.

Dust on the surface Though still only a fraction of CPE’s overall production, the company’s export segment is the one that gets all the headlines. With an established overseas customer base and a solid position at Vancouver’s West Shore Terminal – the largest coal port on the North American west coast – CPE ships about 3.6Mt/y to mostly Asian customers. The company, however, has high hopes to increase that figure. Although it has increased leased terminal space at

Coal being loaded onto rail cars; to reduce dust, the coal can be formed into an aerodynamic shape and coated with a crusting agent

“The critical thing we’ve done is to create multiple umbrellas at key locations so that the dust cannot escape”

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dust control

Spraying water over a conveyor belt to damp down coal dust

“Public opposition is rooted in fears of both climate change internationally and increased local air pollution from coal dust”

Two views of Spring Creek Mine in Montana, where most of Cloud Peak Energy’s export coal is mined

Westshore, allowing for up to 6.8Mt/y by 2019, by then the company hopes that at least one of two proposed US-based coal terminals will be in operation. “Despite current low international benchmark thermal prices, we wanted to take this rare opportunity to increase our terminal capacity so that we can grow our exports to South Korea, Japan, Taiwan and other Asian countries before new terminals are built,” explains Colin Marshall, CPE’s president and CEO. “We look forward to continuing our strong relationship with Westshore.” In 2013, CPE announced an option agreement with SSA Marine to potentially ship up to 14.5Mt/y of coal overseas through the proposed Gateway Pacific Terminal in Cherry Point, Washington. Cloud Peak followed

the example of Peabody Energy, which signed a deal with SSA Marine in 2011 to export up to 22Mt, also from Gateway Pacific. Arch Coal, another top US coal producer, has an interest in the proposed Millennium Bulk Terminals in Longview, Washington. Though markets will dictate how much coal is ultimately exported, public opposition is rooted in fears of both climate change internationally and increased local air pollution from coal dust. Just last September, a higher US court determined that Alaskan producer Usibelli Coal, along with subsidiary Aurora Energy Services, was responsible for violating the Clean Water Act at the Seward coal port. Though part of that decision was based on coal spilling from chutes and conveyors into Resurrection Bay, the judge did cite fugitive dust as part of the violation. How this will affect future shipments from there or other ports is unclear. But shippers, producers and their environmentalist opponents are definitely paying attention. Fears of coal-dust pollution have been cited numerous times by communities that would be located near to two large proposed coal terminals in Washington state. To mitigate both opposition and the potential for fouling, CPE adopted various methods to control fugitive coal dust early on. For all of the coal that CPE exports through its logistics business, it employs a voluntary three-step process. “At the final crushing at the mine, all the coal’s surfaces are sprayed with a dust suppressant in such a way as to ensure that nearly all the coal is coated,” said Rick Curtsinger, manager of media relations at CPE. From there, operators “load it into

railcars in a specific way to make sure it is more aerodynamic.” This is named the ‘breadloaf’ formation after the smoothly contoured shape of the coal load. “We also apply a topper or spray to hold the coal in place,” explains Curtsinger. “It creates a 7cm (3in)-thick crust on top of the coal that remains intact until the train gets unloaded at its final destination or is dumped at the port.” While not all customers request this amount of dust mitigation, most of the growing export coal and a large amount of domestic utilities adhere to the regimen. All the producers who are partners for the Gateway Pacific and Millennium Bulk Terminals have agreed to use some form of dust mitigation to make sure that the coal is getting to the terminal safely. Though Crown Products and Services provides all of CPE’s topper or surfactant application services, in total, rail operator BNSF allows mining companies to use five types of topper agents. The application of these agents has been shown to reduce fugitive coal dust by at least 85% compared with untreated coal piles. CPE has been adding a topper agent since 2011 and an antioxidant since 2008. The latter helps keep the coal from degrading and also from flying away, mine executives say. Keith Walters, technical services manager at the Spring Creek mine, where the majority of CPE’s export coal is mined, described the process as creating a “continuous crust”. In early partnership with CPE, GE has helped develop topping agent products that have the ability to both reduce coal dust and inhibit PRB coal’s tendency to heat or occasionally spontaneously combust – another rather large environmental negative. GE’s CoalPlus portfolio of dustcontrol binders and antioxidants enhances coal quality, reduces dust emissions and minimises spontaneous combustion, addressing operator safety and environmental compliance: two of the main challenges faced by utilities. GE claims that its technology “can reduce dusting by up to 90% during loading, unloading, stack-out and reclamation at utilities and coal terminals, and significantly decreases in-transit coal losses from rail cars”. CoalPlus technology also retards the oxidation and weathering of low-rank coals, reducing thermal unit (BTU) losses during outside storage at coal yards and terminals.

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SNAPSHOT

Inside out Nearly always pictured from the outside, the inside of an autogenous grinding mill is rarely seen. This shot captures one of two 11.6m x 13.7m autogenous grinding mills at Bolidenâ&#x20AC;&#x2122;s Aitik copper mine in Sweden while empty. The mills, which were supplied by Metso and kitted out with its Megaliner mill lining system, helped set a production record in July 2013 when 144,912t of ore passed through the plant in one day. Metso looks after all maintenance in the mineâ&#x20AC;&#x2122;s grinding circuit and has supplied most of the equipment. The companies signed a three-year extension to their life-cycle services contract in 2012 which will be reviewed next year. Photo: Fredric Alm

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SNAPSHOT

Love photography? Each month Snapshot will feature the best image sent to us by MMâ&#x20AC;&#x2122;s readers. For a chance to have your image featured, send your photo plus a 100-word caption to: carly.leonida@miningmagazine.com

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December 2014 13/11/2014 16:36

SIMULATORS

Meet the SIMS Virtual reality technology once earmarked for safety has become an essential tool for business improvement and productivity. Nadav Shemer reports Immersive’s PRO3-B advanced equipment simulators take operators into the classroom

“Demand for simulators should theoretically increase once the mining industry enters an upturn”

ourteen years have elapsed since Immersive Technologies reported that a “constant crowd, sometimes 10 deep, jostled for a view” of its newest equipment simulator at a South African trade show. Like the hamburger’s appearance in front of a mass audience at the 1904 St Louis World’s Fair, this would be a harbinger of success as simulators soon achieved mainstream recognition. Whereas in the past people would ask “why” in regards to training simulators, nowadays they ask “which” or “how many”, says Paul Olckers, chief executive of 5DT (Fifth Dimension Technologies). Presenting a user perspective, Barminco says today’s simulators provide a much more realistic experience with better graphics and motion simulation than they did five to 10 years ago. The underground mining contractor lists three main benefits to using simulators: they enable high-quality training without equipment downtime, enable quick mobilisation to projects, and ensure best-practice-tailored training. These technological improvements make a simulator an essential training tool, the Australian company says, a core reason for its decision to invest in that field. But even in virtual reality, the roads are not always completely smooth. Olckers, revealing his firm will likely

fail to match last year’s record annual sales in 2014, laments that training is usually one of the first budget items mining companies cut in a downturn. CAE, one of the largest of the firms in this sector, with a market capitalisation of almost C$4 billion (US$3.5 billion), has decided to divest its mining division in order to focus on its civil aviation, defence and healthcare businesses. Chief executive Marc Parent has painted a pessimistic picture of how long it would have taken to reach revenue and profit goals in the commodities sector. Fluctuations aside, the market for

mining simulators has matured in parallel with increasing user awareness of the products’ power, and rivals Immersive, 5DT and ThoroughTec are all confident this trend will continue. None of the three were willing to be drawn into CAE’s motives beyond the observation that mining was not one of its core businesses. Wayde Salfinger, co-founder of Immersive and its head of marketing, did, however, say that CAE had “gravely underestimated” the challenges of entering the mining industry and overestimated its ability to directly apply its expertise in this market.

Three birds with one stone ThoroughTec offers the example of Goldcorp’s Red Lake mine site in Canada to demonstrate how mining companies are using simulators to improve safety, boost productivity and reduce operating costs.

Goldcorp uses a fourth-generation CYBERMINE simulator for a Cat R1600G LHD to evaluate the way operators react to emergencies. The simulator has proved particularly useful

ThoroughTec shows off its Cybermine range of products

in assessing how equipment operators respond to fires and in teaching them how not to wear down tyres, says Greg Lew, executive vice president and director of global business development. Tyres for an LHD cost thousands of dollars each, so it is essential to ensure they are not unnecessarily worn down or damaged. “Some of their scoop operators were spinning the front wheels as they drove the bucket into the muck pile, which obviously decreases tyre life,” Lew says. “The Cybermine system allowed them to show the operators how to avoid this, [by tracking] when wheel slippage occurs and the status of all the vehicle’s sub systems. From there, the instructor can deduce how to correct this behaviour, ensuring the machine is in the correct gear and lifting the bucket at the correct time.”

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For over 50 years, CAE has been perfecting equipment simulators and their use within blended learning training programs to enable equipment operators to thrive in complex environments. Whether you are a Mine Operator looking to improve the results of your training efforts or an Original Equipment Manufacturer looking to improve your customer training support, CAE has the experience and solutions to support your commitment to excellence.

We know simulation. We know training. We know mining. cae.com/mining CAE.indd 1

13/11/2014 10:17

Simulators

Right: A Barminco employee trains on an Immersive simulator Opposite page: CAE’s core market is the Americas, as seen with this outdoor classroom at a Fresnillo mine

“Demand will increase as older operators leave the workforce and new operators enter”

Rapidly evolving market Immersive was the first mover and holds exclusive alliance arrangements with four of the largest OEMs: Caterpillar, Komatsu, Hitachi and Liebherr. It has observed three phases in the utilisation of its products. From 1998 to 2005, its simulators were used mainly to train new operators in safety or risk management. From 2005-2010, mining companies increasingly used simulation as an optimisation tool through which they could improve productivity and achieve expansion goals. More recently, there has been a greater focus on efficiency. From a sample of more than 100,000 operator training sessions, Immersive knows that less than 50% of experienced operators can recall the procedure to respond to an emergency machine failure. It boasts of delivering better than 90% pass rates through its own training solutions, and of reducing spot times by 14.2%, brake use by 62.2%, abusive shifting by 69.8%, engine over-speed by 54.5%, and fuel consumption by 6.9%. Meanwhile, the mining industry’s adoption of new technologies such as automation – Duke University automations laboratory director Missy Cummings says companies that do not invest in this now will not survive beyond 2030 – is opening new doors for standalone simulator manufacturers. In May, Immersive announced the opening of a simulation-based training centre at Codelco’s Gabriela Mistral copper mine in Chile, where the fleet consists entirely of Komatsu autonomous trucks. Personnel will undergo computerbased training, virtual classroom and

Cutting fuel consumption Cipta Kridatama, one of Indonesia’s leading mining contractors, used simulators to improve haul truck efficiency by 6.9%, earning it Immersive Technologies’ global business improvement award in 2013. “With commodity prices going down, like many sites, we are looking at ways to cut costs, and fuel consumption was identified as a problem area,” says talent development manager Gemiland Adi Perdana.We were over budget by nearly 10,000L/mth at one site and identified the contributors affecting fuel consumption. Operator skill level was the focus of the fuel efficiency efforts.” Fuel records were collected for 30 haul-truck operators over a one month period, revealing that 60% exceeded budgeted L/h consumption. All the operators were subsequently sent for simulation-based training, and the latest fuel records show the site is now operating 5.8% under budgeted L/h fuel consumption. “Production time was not affected with these improvements and we believe, with a conservative estimate, we can save US$500,000/y through this training initiative,” Perdana says.

simulator training to prepare them for autonomous haulage operations. Autonomy reduces the number of operators but increases the number of technicians, introducing a new group of employees that require training. Olckers says: “Before autonomy, the process was to train operators to operate the machine itself. Now with autonomy you need to train supervisors or handlers to understand the whole system.” Customisation is another trend. As demand for simulators grows, customers are requiring that training be tailored to their mine sites, according to Benjamin Rencoret, training portfolio manager at Sweden-based OEM Atlas Copco. CAE, despite its intention to sell its mining business, is leading the way on customisation, with a three-tiered package of low-, middle- and high-end simulators. Scott Perry, general manager of CAE Mining, simulators and training, explains that the different levels of simulators cater to different types of markets and environments around the world. “When you start with someone who may have little literacy or may have limited or no experience with machinery, putting them into a high-end simulation or the actual machine right away is not effective. It’s intimidating. It’s scary… It may be their first time on a computer. “You’d start with the lower end, you’d introduce them to machines, to [the] technology. As they get more confident you’re able to graduate them through the learning process and up the [level of] simulator fidelity and also into the actual machines, so they can be confident, safe operators.” Gina Rinehart’s Roy Hill project in Western Australia’s Pilbara region has invested in multiple Immersive PRO3-B advanced equipment simulators for haul trucks, excavators, dozers and wheel loaders. The package includes SimMentor, a training tool with three features – briefing, debriefing and live session display – which are accessible via a large touch-screen monitor situated outside the simulator. Likewise, ThoroughTec says it introduced its Computer Based Trainer e-learning modules and Operator Familiarisation Trainer in response to customer demand for a simultaneous simulator and training service. Customerspecific features such as drill rigs with mesh handling and bolting capabilities are becoming more popular, says Greg Lew, executive vice president and director of global business development. For all the positive talk, Lew admits the market is still very low in its penetration. He says experienced operators are

sometimes sceptical of simulators, and the mature markets such as North America and Australia that were early adopters of the technology have become cautious in their approach to vendors. Demand for simulators should theoretically increase once the mining industry enters an upturn, and not only because demand for labour would expand, Olckers points out. “Many operators in countries like the US and Australia have reached the diamond age, [therefore] the contraction of the industry at this point also leads to people retiring earlier than what they planned,” he says. Annette Bailey, marketing strategist for US firm Simformotion, the exclusive licensee for the smaller, mobile Caterpillar simulators that can be transported from mine site to mine site, agrees. “Demand will increase as older operators leave the workforce and new operators enter. The younger generation of operators and trainers are very comfortable with technology. Most haven’t known life without it, so it is an easy translation from simulator training to an actual machine. Ramp-up times are shorter and knowledge retention of users is better,” she adds.

Production advances Looking three to five years ahead, Immersive says its clients will view training as a driver of productivity and operational improvement rather than just a cost centre, and will show a preference for integrated solutions from single suppliers. According to Atlas Copco, there are already signs experienced operators are joining their trainee colleagues on the simulators in an effort to increase their competence on existing equipment and to learn new technologies. Simulator manufacturers continue to be aggressive on the production front in an effort to meet such end-user demands. 5DT has enlarged its catalogue by about 20% in the past two years and now offers simulators for more than 100 models from 24 OEMs.

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Simulators

ThoroughTec says it has dramatically expanded its range of simulated cabs over the past year accross the products of major OEMs such as Caterpillar, Atlas Copco and Komatsu, and has built simulators for new clients such as Fletcher, MTI (now part of Joy Global) and Taiyuan Heavy Industry. These simulators cover machines such as bolters, continuous miners, drill rigs, front end loaders, haul trucks, excavators and shovels. The South African company is also “very proud” of its new Cybermine Soft Rock Range, which includes a continuous miner, shuttle car, longwall miner and specialised bolter, and is augmented by LHD simulators from the Cybermine underground mining simulator catalogue. Expansion goes beyond just reproduction of simulators that train novice operators in basic functions such as controls familiarisation, however important they may be. One example is the advent of the machine walk-around for simulators, which most of the major players have introduced in response to customer feedback about machine maintenance issues. Bailey says of her company’s walk-arounds: “It teaches the same walk-around inspection process that Caterpillar teaches operators to perform before and after a shift. It teaches them to identify machine parts and to learn whether the part is faulty or not. “Recently we were visiting with trainers from Luminant [Texas’ largest lignite coal miner], and one of them cited a story about an operator who had been trained on our simulator walk-around. This operator caught site of a broken alligator pin before he started his shift. He reported it and saved the company thousands of dollars in downtime, lost production and maintenance costs.” Immersive lists its own walk-around alongside the Codelco training centre as one of the two most important products it has launched in the past 12 months. Using dual movement and vision systems, this product allows operators to take a virtual walk around a mine site and equipment and to see their view updated based on their head and body

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position, allowing them to peer around Operational improvements visual obstructions. Barminco uses Immersive’s worksite Companies are finding ways to use high-fidelity simulators to walk-around in its training programmes bring about operational improvement, according to Scott and believes the product will appear more Perry of CAE Mining. One CAE client used a simulator to regularly in the coming years. analyse its haul-truck speed limits. It monitored what the haul The next step being developed by truck was doing in the mine, how many km/h it was travelling, CAE (CAE Mining’s parent company) is gas consumption and rate of production. After finding that to get into the machines, “to perform the haul road was not suited to the equipment, the company virtual maintenance, to learn how to tasked its engineers with redesigning the road. “That’s really repair a pump or work on the exciting, in terms of changing the simulator from just being a transmission,” says Perry. training tool to having a more direct impact on operational He compares14-MC-645.MPS it to the use of Filter Press_Mining improvements,” Perry comments. Mag.pdf 1 11/4/14 9:04 AM simulators by CAE’s healthcare division:

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Simulators

“We can show a thousand different scenarios with a heart in a simulated environment. You can’t do that with an actual human.” The development of technology is not slowing down, a spokesperson for Barminco says. In addition to walkarounds, the company expects to make more use of touch screens, which it says can reinforce correct pre-start processes and the underground simulated environment that a person can be assessed against, and 3D technology and high-definition video, which bring the experience closer to reality. Adding depth to the simulators brings the experience one significant step closer to what it is like to operate equipment in underground mines, the spokesperson says.

Ending skills shortages The convergence of computer game-style technology with the world of mining training could assist in preventing any repeat of the skills shortage seen in the wake of the last commodities boom. Barminco argues new technologies help make its work more exciting and create added interest in working there. Giving the example of Barminco’s partnership with the Clontarf Foundation’s Kalgoorlie Academy for young indigenous Australian men, Matthew Lloyd, executive general manager of health, safety, environment and training, says: “We always know that

the highlight of the visit is going to be the simulator. They get the chance to experience underground mining first hand.” Bailey says more schools are adding operator training programmes, and companies are funding and partnering with schools to ensure there are plenty of people going into the professions so they will have good operators in the future. And Simformotion has heard anecdotally about another use for simulators – screening new hires. “No mine operation can afford a bad hire. Screening on the simulator is a sure way to find out if operators can do what they say they can before they ever get into an actual machine on site,” Bailey explains. Lew offers the view that simulators are

Customers direct R&D Simformotion formulates its R&D programme in response to feedback from Caterpillar simulator users, says marketing strategist Annette Bailey. One of the latest developments to spring from its R&D is soil layering, which can be found in Simformotion’s Small Wheel Loader simulator. “As you dig through dirt in the real world, it is not the same from topsoil to lower layers, so our team conducted the research to come up with layers of earth that the simulated machine responds to as it digs,” explains Bailey. Another is emergency response. “Our team developed a training pack for the Cat Simulators Mining Truck that teaches operators how to respond to emergency situations in the safety of the virtual environment. Better operators know what to do when a tyre blow-out happens during a simulation, rather than learning in a real world situation.”

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especially relevant in rural areas where there is traditionally a skills shortage. But Salfinger, whose involvement in mining spans 21 years since he co-founded Immersive with his brother, emphasises that simulators and other new technologies such as 3D modelling are just tools. “They can be implemented well and provide spectacular results or fail to provide any real benefit, just like most technology products. A complete solution focused on the right mining metrics with the right simulators, right complementary learning tools coupled with a curriculum tailored for the organisation, the right training personnel and management support can and will overcome any operator skills shortage.”

Simformotion is the exclusive licensee for Caterpillar mobile simulators

“Screening on the simulator is a sure way to find out if operators can do what they say they can”

5DT is one of a number of companies to introduce machine walkarounds

December 2014 14/11/2014 09:23

Underground drilling

Exploring its options Gareth Tredway spoke to Boart Longyear about the global market for exploration, demand in contract drilling and new rig features Boart Longyear’s Drill Control Interface (DCi) offers a fully electronic interface to safely and efficiently operate underground drilling equipment

escribed as its “bread and butter” income stream, the business of underground drilling has proved to be a stable moneyearner for Boart Longyear amid a large retraction in the mining sector. As commodity prices have softened, major mining companies have pulled the reins in, refocusing on existing mines and cutting costs and capital expenditure. “Usually the first thing to go is surface exploration,” says Monika Portman, director of product management, marketing and communications at Boart Longyear. “Production from existing mines continues, so that segment of the business [underground drilling] typically stays much more stable than [surface] exploration does in and out of the cycles.” According to data compiled for the upcoming edition of SNL Metals & Mining’s Corporate Exploration

Strategies study, the estimated worldwide total budget for nonferrous metals exploration dropped to US$11.36 billion in 2014 from US$15.19 billion in 2013 – a 25% decrease. SNL says that for the first time since it began the study, the proportion of overall exploration budgets dedicated to mine-site work surpassed the budget for grassroots activity. Contractors have got smaller jobs. Projects tend to be shallower, smaller in scale with less exploration overall. “Since 2012, producers have been increasingly emphasising brownfields programmes as a less capital-intensive and less risky means of replacing and adding reserves. The proportion of the annual total allocated to grassroots exploration hit a record low this year, as many junior companies, which have historically accounted for the largest portion of grassroots spending, sharply curtailed programmes to conserve cash

as the exploration sector struggles to rebound from a two-year downward trend,” says SNL.

Market demand Portman says that Boart Longyear’s primary market for contract underground drilling is in North America, which has remained extremely strong through the downturn. “In fact, we are at near capacity for underground work from a utilisation standpoint globally, and it has remained strong over the last couple of years, when the market has been depressed,” she explains. The underground production drilling side is also said to have done well along with its tooling business. Boart Longyear’s LM range of underground exploration drill rigs can be found all over the world. “Typically a rig will last 20 years easily, so the population is very large in the field,” Gregory Guillot, global product manager for capital

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Underground drilling

A Boart Longyear LM110 drilling rig

equipment for Boart Longyear tells Mining Magazine. One thing that has changed is the type of equipment demanded under current market conditions, as companies are looking less for new resources at depth but rather exploring for

nearby material to add to reserves. “What we plan to do next year is to keep on selling lots of rigs, especially in the smaller size category for jobs within the 500m depth range,” says Guillot. Contractors have also had a tough time of it given the market conditions,

and Boart Longyear says it is looking to adapt to meet the demands of its clients. As in many other parts of the mining process, productivity has become a key term in the space. “They are asking to do more with less. There is a shortage of employees at the moment because the industry has retracted. When it comes to productivity, customers expect more training and rigs that are easier to operate. It has become very difficult and very unaffordable to find skilled labour, so typically underground contractors want an easy-to-operate rig where technology is the enabler. We are bringing more and more technology to our rigs,” says Guillot. Because of this call for ‘interface friendliness’, Boart Longyear is putting a lot of effort into developing its control panels, on the rig controls in general, and on the ergonomics as well. Guillot says the company sees the industry stabilising and that underground will remain very strong, as opposed to surface drilling. In the year ahead, companies are expected to invest in modern equipment that will allow for superior efficiency gains. “Essentially, the market will move

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toward more sophistication, mostly in the sense that it is an investment for the customer, so they are going to spend more money up front for more sophisticated equipment,” he explains. “They will save lots of money as far as operating this equipment goes, because of the savings on the manpower, savings on the training, plus safety.”

Upgrades and improvements Boart Longyear’s Drill Control Interface (DCi) provides drilling contractors with a fully electronic interface to safely and efficiently operate underground drilling equipment. The DCi is a substantial step for increasing safety on site by moving the driller away from moving parts and hydraulic hoses. The DCi increases productivity by allowing the driller to operate the rig and rod handler from a distance. It is compatible with the LM75, LM90 and LM110 rig models, while existing LM-series rigs can be retrofitted. Features include one-touch rod feed and pull functionality. The rod handler utilises high-capacity springs acting on three tungsten-carbide insert jaws. It increases productivity while minimising the chances of injury associated with manual rod handling. “We see lots of customers who are still replacing their rigs, even though their turnover is limited and they are going through a downturn. Most customers see value in operating brand-new rigs,” says Guillot. “If you consider a full-spec rig with rod handling and the DCi, a very sophisticated interface, where you can even programme automatic drilling, it is a big shift from what the customers were doing in the past.”

rig from one place to the other, because customers are dependent on what the mines provide them as far as trucks or any means to move a rig. It is difficult, it is expensive and it is labour intensive,” adds Guillot.

Ready for the return As is the case with mining cycles, markets are expected to return to a growth trend eventually, at which point bigger exploration jobs will come back into fashion. “At the end of the day, reserves are almost at historic lows for the major commodities, so they are going to have to start exploring sooner or later,” says

Portman. Despite the current trend of smaller rigs, reduced job sizes and shallower projects, Boart Longyear is not resting on its laurels. “We are still maintaining and we are still investing towards a very comprehensive range. We have the solution to help the customer grow their business. “If some customers happen to be lucky and have a very big and ambitious contract, we have the right rigs to do that,” says Guillot. “Even though we are in a downturn, Boart Longyear has never stopped investing in R&D. As we speak, there are engineers around the world working on brand-new projects.”

Atlas Copco upgrades Diamec Competitor Atlas Copco has also just upgraded its range of Diamec underground core-drilling rigs. The Advanced Performance Control (APC) versions of the rigs will enable customers to capitalise on the benefits of automatic drilling, with examples showing that bit life can be increased by 400%. The upgrades have made the solutions more robust, improved the user interface and simplified the operations, according to Atlas Copco. About 20 separate hardware

improvements have been implemented. The major ones are: a new inductive water-flow meter, new water-dump valve, new water-pressure sensor and new, and more robust cables and connectors. New sensor designs also contribute to the improved ruggedness. The control panel has a 30cm display with touch-screen technology and improved brightness. The interface menus have been redesigned and reduced by 50%, simplifying the operations drastically.

New solutions Boart Longyear also plans to deliver new solutions in its product line next year; this will include solutions surrounding mobility, versatility and automation, according to Guillot. The new products are confidential, although they will address the issues mentioned above, including a lack of skilled labour. “Skilled labour is very scarce. New rigs must be sophisticated, in the sense that there needs to be lots of technology embedded so that the rig is fairly self-sufficient in many aspects. The controls for the operations are very easy to comprehend for newcomers to the drilling industry,” Guillot says. Another aspect is mobility, as contractors want to be able to move rigs around easily on site. “It is very pricey nowadays to move a

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“It has become very difficult and very unaffordable to find skilled labour, so underground contractors want an easy-tooperate rig where technology is the enabler”

An Atlas Copco Diamec underground drill rig with Advanced Performance Control

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Underground drilling

Surprises on the upside Richard Roberts asks two of the world’s biggest contractors how their businesses have fared over the past 12 months and about their plans for the future

A customised agitator, part of the Barminco fleet

“We are setting development and production records in Australia now, and I think that drives you and gives you opportunities”

rownfield exploration has been the oasis in the desert for those contractors hit hard by the mining industry’s pull-back on outsourcedservices spending. Underground work in particular, including mine-development drilling, is keeping companies such as Swick Mining Services and Barminco busy, and their outlook is positive. Barminco CEO Peter Stokes tells Mining Magazine that challenging conditions affecting the resources sector continued in the early part of Fiscal Year 2015 (to June 30 next year), but Barminco is seeing positive signs and is “well positioned to respond to the current conditions and future growth opportunities”. Barminco is currently bidding for new work in Australia, west and central Africa, and India, and investing in new fleet, including placing Australia’s largest order for new Sandvik TH663 trucks. It is also investing in high-tech development jumbos and diamond drilling rigs. “It is in decline development and mining that we are way ahead on productivity – we deliver that in our businesses in Africa, and we’re doing the same thing right across Australia. We need to keep pushing that and driving more productivity from the gear, and ensuring that we keep good people,” Stokes says.

“We are setting development and production records in Australia now, and I think that drives you and gives you opportunities. An example of that is that we’re in discussions with Hindustan Zinc in India at the moment to take on some rapid development, which is really driven by the company’s need to get to the underground orebody quickly. “They’re making the transition from a very large surface mine to a very large underground mine and, as you can imagine, that transition is quite difficult, [with the need] to not have a really big dip in production on that site, as you see in many mines. “I think there are opportunities like that in the big copper mines in South America, a number of mines in India, some of the big mines in Europe, and certainly it continues with some of the gold mines in Australia that will look to move from surface to underground over the next year or two.” Stokes adds: “Our diamond-drilling business is also very focused on brownfield work, and we’re starting to see quite an upturn in that area.”

Looking up Kent Swick, founder and managing director of Swick, says: “We have a really positive view on where things might be going over the next 12 months.”

While the underground diamond drilling market remained volatile, obscuring a view of the full year ahead, the company’s September quarter showed a modest increase in revenue year on year, and it now has 57 of its 81 rigs at work at 24 mine sites for 20 global clients. Underground diamonddrill fleet utilisation stands at 75% compared with overall fleet utilisation of 70% a year ago, with the 50 diamondcore rigs in Swick’s total fleet up from 45 units just a year ago. “Demand is expected to remain relatively steady with existing clients. However, significant tendering opportunity exists,” Swick adds. “The recovery in drilling demand has continued and indicates that our clients’ budgets, in particular for underground diamond coring, are returning to normal levels. “In addition to the organic recovery in demand, we await results for many significant contracts that have the potential to materially increase the work in hand and fleet utilisation.” Swick’s order book was worth more than US$150 million at the end of September. “It is pleasing to see that the business is operating safely and productively, with a reasonable utilisation rate considering the macro mineraldrilling market being very depressed,” Swick says. Swick is focusing heavily on its operating efficiency and the effective roll-out of significant R&D initiatives that will improve production and safety. The company has invested heavily in R&D aimed at doubling its metres per man-hour in the five years to June 2017. “Key advances in strategic R&D projects have been made during the 2014 financial year and FY2015 will see many rigs commence a major technology upgrade over the next 36 months,” Swick explains. “The new technology will allow for the introduction of commercialised automation, rod handling, telemetry, personnel identification, data logging and digital data entry at the rig. “These new initiatives will allow for major productivity advantages by allowing unattended drilling, reducing the non-productive time during the shift, recording detailed data about rig performance and improved safety.”

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Underground drilling 57

Moving forward in 2015 Swick earned A$103 million (US$89 million) from the 829,000m of underground diamond core it drilled in FY14. Total metres drilled were down 11%, the return was off by 18%, with the difference down to “rate reductions experienced during the year”. “The first half of FY2014 was probably one of the most challenging the company has seen since the introduction of its mobile underground diamond-drill rig in 2004,” Swick says. “With continuing commodity-price volatility, we saw our clients focus shift to cash conservation, and with excess drill rigs in the market price, competition intensified. “Recognising the need for customers to reduce costs, we took the view that we should work proactively with our client base to look for ways of increasing efficiency and any potential for removing costs by working closer together.” Generally, as compensation for lower rates, Swick has been able to negotiate longer terms or other contractual concessions and believes this has been a key to client retention in this extraordinarily difficult environment. The company’s continuing focus on productivity improvements to boost operational margins has the technology roll-out at its core, with “low-complexity, high-value innovations” the name of the game in future.

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The first half of FY2014 was probably the most challenging that Swick has seen for underground diamond drilling

“The company’s continuing focus on productivity improvements to boost operational margins has the technology rollout at its core”

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UNDERGROUND DRILLING

The need for speed Daniel Gleeson speaks to Douglas Morrison from CEMI about its quest for faster advance rates

Simultaneous bolting and drilling would reduce the need for personnel and equipment underground

he mining industry is not going anywhere fast when it comes to underground development. Advance rates are dropping and it is taking much longer to reach the prized orebody. The Centre for Excellence in Mining Innovation (CEMI), which is based in Sudbury, Ontario, Canada, thinks it has just the thing to reverse the trend in some of northern Ontario’s deepest operations. Douglas Morrison, president of CEMI and a Canadian mining industry veteran with 15 years of Golder Associates

experience on his CV, has gone back to basics, and work carried out in the 1990s by the Canadian Mining Industry Research Organization (Camiro), to solve this problem. Camiro came up with the idea of a canopy which would allow miners to drill, blast and install ground support at the same time, cutting valuable hours off the development process and, therefore, improving a project’s economics. The incentive to move forward with such a project 25 years ago was not as great as it is today, hence why

the research was left on the table. Morrison says: “When Camiro looked at it back then, industry was getting advance rates of more than 8m/d, but now advance rates have changed and drifts are getting bigger, and we are more safety-conscious and have more geotechnical problems. The rate of advance has been gradually declining over the last 20 or 30 years, so now we’re under a lot of pressure to improve it.” In northern Ontario, Morrison estimates that the average daily advance rate is now 3.5m, less than half of what it was when Camiro was looking at it. He notes: “If it [underground development] continues to be slow or gets progressively slower, then the net present value (NPV) of the projects will be too small for them to be approved. We’re [essentially] trying to offset the problem of going deeper and deeper.”

The canopy concept This is why Morrison and CEMI, a not-for-profit organisation funded by some of the biggest miners in Ontario, resumed work on the canopy concept two years ago when Morrison arrived at the helm. Mining Magazine heard about the project back in August 2013 at a conference in Sydney, Australia, when the company was constructing its first prototype. Back then, Morrison outlined the problem miners in northern Ontario had in reaching irregular-shaped orebodies 2km underground where temperatures could reach 40°C with humidity at 100%. In addition, the rock was 150-200MPa. This and the depth of ore meant the use of tunnel borer miners, an idea put forward at the conference and seen by many as the way forward for underground development, could not work in Sudbury mines.

Recent progress Conditions in northern Ontario haven’t changed, but progress on the canopy concept has. The C$3.7 million (US$3.3 million) project, which recently received C$783,916 from the Ontario government’s Northern Ontario Heritage Fund, has successfully been through what Morrison calls phase one. Built with hydraulic rams, the first

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UNDERGROUND DRILLING

prototype canopy can be expanded laterally and vertically to push up against the walls and ceiling of the drifts underground, which makes it easy for mining equipment to pass through the canopy while in place underground. The early-stage prototype has already surpassed expectations above ground, according to Morrison. He explains: “We designed it to take 50t of static load, which we thought is much greater than was likely to be required. We built the frame and set it up on surface with a few concrete blocks on either side to make it look like a tunnel and loaded it up with 75t of concrete blocks. It didn’t even quiver.” After running out of concrete blocks to load it with, the team eventually pushed the canopy over recreating what might happen in a mine collapse underground. “By the time we finished getting the concrete blocks off it and stood the frame back up again, it had a few kinks in it, but it was essentially undamaged. Anybody who was working within the canopy and was subject to the static load would definitely have been walking away and there would be no injury whatsoever,” says Morrison. Work has now started on a second prototype, which will consist of two canopies designed to work in tandem. The first canopy would be positioned underground close to the face, covering the drill jumbo, which with the addition of another rig, would carry out all the face drilling and load the face with explosives. This canopy would have mesh over it, which stops small rocks coming through the frame and injuring any operators during use. The second frame – identical to the one at the front – would have mesh over the surface of the frame held on by plastic clips intended to be pinned to the roof by bolters underneath, offering the ground support needed for operations. “This makes it possible to have all the face activities being executed under the protection of the front canopy, simultaneously with the ground support cycle behind,” Morrison explains. “All we’ve done there really is change the critical path. The current process is to remove the broken rock from the previous blast and then come in and install all the ground support. Then, the equipment leaves and we bring the jumbo in to drill the face. That then leaves and we bring in another unit to charge the face with explosives and then it leaves. We lose time for every equipment entry and re-entry.”

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Kathleen Wynne, Premier of Ontario, announcing the funding

Testing plans These version-two canopies will be tested underground – in a drift or decline – where conventional ground support is already in place, according to Morrison. After this, operational adjustments and static load testing – to push the structure beyond the 75t static load threshold – will occur. Morrison says: “We expect to have the next two built in the spring of 2015, hopefully by the end of April.” Third-generation canopies would then follow with testing supervised by regulators in Canada’s Ministry of Labour, after which, contractors might get their hands on them for more intense operational testing at and around the face. This phase-three version will carry out a final trial with two units driving forward in an operational setting for 100m, according to Morrison. In addition, advance rates could more than double with the use of the canopies. Morrison tells MM: “The standard cycle takes us 16 hours to complete for a 3.5m advance, so it means you’re delivering a maximum of 3.5m/d, as you can’t do anything with the remaining eight hours. It’s all in the entries, re-entries and other operational delays. What we’re trying to do is to collapse the cycle to less than 12 hours and really close to 10 hours. At the very least, we want to do two 3.5m rounds in a day.” Factor in further organisational changes which could come about with the use of the canopies, such as hot shift changes, and contractor input and rates could be further improved. Morrison says: “Using all of the operational changes as well, not just the technical, we would hope to get more than 9.5m/d on average for a 4.5m face. Our understanding is nobody can get past 6m/d with the current flow cycle.

We’re hoping for a 45-50% increase.” The use of these canopies, which in their expanded form could allow equipment such as front-end loaders to pass through it, won’t be the silver bullet needed across the whole underground mining sector though. Morrison explains: “The way the design is now, there are still some problems immediately at the face … For example, the ultra-deep mines in Ontario, below 800m to 2.5km, tend to have quite a bit of seismicity in those headings and at and around face, which presents serious risk. “We are working on an additional component which would be advanced all the way to the face and would be used in the same way to provide practical protection for the people working there. That won’t be done until we have proven out the current process we have in place now.” Additionally, the design is only meant for long, single drift headings towards new deposits. Morrison says: “It is not really designed for drifting close to the orebody, where we have lots of intersections and corners.”

Contractors These limitations aside, mining companies would welcome the technology with open arms. With Morrison keen on getting contractors on board, though, it poses an interesting question: Would contractors, who are able to bill clients more the longer a development takes, want to see advance rates increase? Morrison concludes: “You might think contractors would not necessarily want this to go faster, but unless it goes faster there will be fewer projects as the NPV of the projects will not be sufficient to justify going ahead. At greater depth, we either go faster or we don’t go at all.”

“Built with hydraulic rams, the first prototype canopy can be expanded laterally and vertically to push up against the walls and ceiling of the drifts under ground”

December 2014 14/11/2014 10:26

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BUYERS’ GUIDE 2014-15

Fluidwell Grindex Pumps Hauhinco Maschinenfabrik ITT KSB Metso Mono Pumps Paterson & Cooke Pioneer Pump Putzmeister Red Valve RF Valves Schwing Sulzer Pumps Tsurumi Pump Weir Minerals Wilfley Xylem

Safety 3M Mining Aceros Arequipa Adalet Accutron Instruments AFEX Fire Suppression Systems AFIMAC Algade Ansul Becker Mining Systems Blastcrete Equipment Co Camfil APC Caterpillar Civeo Clover Tech Cobham Surveillance Crowcon Danfoss Turbocor Davis Derby DSI Underground Systems DuPont Dust Control Technology Emerson FLIR Systems Gekko Systems Geobrugg GroundProbe Harris Caprock Hexagon Hilti Corp Hitachi Construction Machinery Honeywell Idrotech Intec Video Systems Jennmar Joy Global Kidde Fire Systems Komatsu Korfmann Metso MineARC Systems MSA Safety Northern Light Technologies Normet Paus PBE Position Partners Putzmeister Reed Pumps Riegl Laser Measurement Systems Rockwell Automation Rocvent SAFEmine Sandvik Seeing Machines Shotcrete Technologies Siemens Strata Trolex Weber Wormald Zitron

Software & simulators ARANZ Geo Bentley Systems Bretby Gammatech Carlson Software Chasm Consulting

Clover Tech Davis Derby ESRI Geosoft Geovariances Geovia Hexagon Hitachi Construction Machinery Immersive Technologies Joy Global Komatsu Leica Geosystems Maptek Micromine MineSight MinLog Modular Mining Systems Rockmate RungePincockMinarco Siemens Site Monitor Systems ThoroughTec Ventyx Wenco

General 3M Mining ABB Adalet Accutron Instruments Aggreko Air Products ALC Tournai Alvenius American Mine Door Amp Control ArrMaz Ashland Australian Scientific Instruments Axis House BASF BBE Becker Mining Systems Belshina Bel-Ray Company Bentley Systems BJM Pumps BMT WBM Bosch Rexroth BPT Components & Parts Bradken Breaker Technology Bretby Gammatech Bridgestone Bridon Brokk Brookville Bruker Camfil APC Caterpillar Cavotec Group CEMCO CESL ChemGrout Cheminova Chevron Chevron Phillips CITIC Heavy Industries Civeo CJC Clariant Cleveland Cascades Cobham Surveillance Conveyor Comp Continental Corp Continental Industrie CP Kelco Croda Intl Crowcon CTA Cummins Cyplus Cytec D-A Lubricant Co Dana Off Highway Systems Danfoss Turbocor Davis Derby Donaldson Co

Doosan Infracore DSI Underground Systems DuPont Dust Control Technology Dux Machinery Dynapower Dynaset Dyno Nobel Edmo Emerson Eriez Eurogomma Eurotire Flexco FLIR Systems Flottec Fuchs Lubricants Gardner Denver Geobrugg Geosonics GE Mining GKN Land Systems Goodyear Gridcom Enterprises GroundProbe GSE Harris Caprock Hilti Corp Hitachi Construction Machinery Honeywell Huntsman Corp Hy-Pro Filtration Hyundai Construction Equipment Idrotech Iljin Steel IMA Engineering Ingersoll-Rand Instantel Intec Video Systems Invicta Vibrators Iowa Mold Tooling Co ITT JD Neuhaus Jennmar JH Fletcher JLT Computers John Deere Power Systems Joy Global Kennametal Kinder & Co Komatsu Köppern Korfmann KRC Mining Consultants Kumera Laird Technologies Legacy Building Solutions Leica Geosystems LE Lubrication Engineers Liebherr Linear Composites LiuGong Machinery Co Magna Tyres Magni Major Wire Industries Martin Engineering Master Magnets Materion McLanahan Corp Messinger Bearings Metso Michelin Mine Site Technologies Mitsubishi Mobil Industrial Lubricants Mount Sopris Instrument Co MTG MTU NanoSteel Nexans Nokian Tyres Normet Oerlikon Oldenburg Group Optech Orica Outotec Parker Hannifin

Parsons Chain China Paus PBE Pebco Pewag Pfreundt Phillips 66 Phoenix Pintsch Bubenzer Position Partners Powerblanket PressurePro Protan Putzmeister Qualter Hall RAG Mining Solutions Reed Pumps Reliance Barker Davies Renewable Energy Group Renishaw Reutech Mining Riegl Laser Measurement Systems Rimex Robbins Rocklabs Rockwell Automation Rocvent Rösler Tyre Innovators RST Instruments Sandvik Schaeffer Oil Schneider Electric Schwing Sensefly Shell Shotcrete Technologies Siemag Tecberg Siemens Site Monitor Systems SmartWorker SNF FloMin Spectral Evolution SPX SSAB Strata Subaru Superior Industries Svendborg Brakes Tenova Thermo Scientific ThyssenKrupp Industrial Solutions Titan International Topcon Positioning Systems Toric Technologies Trazione Trimble Twiflex Valente Veekmas Victaulic Victor Vik Ørsta Voith Turbo Volvo VR Steel Wärtsilä Weber Yokohama Zest WEG Zitron

Consultants & service providers 3D Laser Mapping 3DMSI 8over8 Abitibi Geophysics Accenture AECOM AFIMAC African Mining Services Aker Solutions Alfred H Knight Algade AMC Consultants AMEC

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BUYERS’ GUIDE 2014-15 Ausenco Axis House Babcock Bechtel Behre Dolbear Bell Geospace Bentley Systems Bergteamet Bilfinger Water Technologies BioSigma BioteQ Environmental Technologies Camfil APC Caterpillar CESL CH2M Hill Civeo Clareo Partners Clover Tech CTA DMT Downer Group Dynatec Systems ESG Solutions Explotech FEI Fewzion Fischer Consulting FLSmidth Fluor G4S Geosystems Analysis Golder Associates Hatch Hexagon IHC Merwede Jacobs Joy Global Kaltech Global Kal Tire Kiewit Knight Piésold Komatsu KPMG

Leighton Holdings McKinsey & Company MDM Engineering Meridian Drilling Metal Mining Consultants Met-Chem METS Metso Micromine Monadelphous Murray & Roberts MWH Global Nalco Orway Mineral Consultants Otraco Outotec PANalytical Parsons Brinckerhoff Paterson & Cooke Pybar Redpath Rock Australia Royal HaskoningDHV RUC Cementation Sandvik Schlumberger Schramm SGS Shaft Sinkers SLR Consulting SNC-Lavalin Snowden Group Sodexo SRK Consulting Stantec St Barbara Stratalis Group Stu Blattner Target Logistics Tenova Terratec Tetra Tech ThyssenKrupp Industrial Solutions

Thyssen Schachtbau Unidata URB Mining Logistics Consulting VCI Velrada Veolia Water Solutions & Technologies Vertech Wardell Armstrong Whittle Consulting WorleyParsons Wunderlich & Gladston Zest WEG

Contract mining African Mining Services Ausdrill Barminco Deilmann Diamantina Christensen Downer Group Dumas Mining IHC Merwede Leighton Holdings Pybar

Engineering & construction Accutron Instruments AECOM Aker Solutions AKW Apparate & Verfahren Alimak Hek Alvenius American Mine Door Andritz Ausenco BBE Bechtel Behre Dolbear Bentley Systems Berco Bergteamet Blastcrete Equipment Co

Bradken Camfil APC Cavotec Group CH2M Hill ChemGrout Columbia Steel Casting Co Deilmann DRA Group DSC Dredge Dumas Mining Fluor Hatch Herrenknecht Jacobs Kiewit Knight Piésold Korfmann Leighton Holdings MDM Engineering Met-Chem METS Monadelphous Murray & Roberts Parsons Brinckerhoff Paterson & Cooke Redpath Robbins Royal HaskoningDHV RUC Cementation Schlumberger Shaft Sinkers SNC-Lavalin Stantec Stu Blattner Target Products Tata Steel Terratec Tetra Tech Thyssen Schachtbau WorleyParsons

Bells and whistles are great, but only IMT® equipment comes with a productivity promise that also walks the walk. That’s commitment. Nothing Says Commitment Like The Diamond.™ www.imt.com

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Company contacts 3D Laser Mapping – Notts, UK 3dlaser mapping.com

3DMSI – Cornwall, UK 3dmsi.co.uk 3M Mining – Minnesota, US 3m.com 8over8 – UK 8over8.com

A ABB – Zurich, Switzerland abb.com Abitibi Geophysics – Québec, Canada ageophysics.com

ALLU Group – New Jersey, US allumining.net

Becker Mining Systems – Friedrichsthal, Germany becker-mining.com

ALP Mineral Sizers – Hong Kong alpsizers.com

Bedford Steels – Sheffield, UK bedfordsteels.co.uk

ALS Minerals – International alsglobal.com

Behre Dolbear – International

Alvenius – Eskilstuna, Sweden alvenius.se

dolbear.com

AMC Consultants – Victoria, Australia amcconsultants.com

Bell Equipment – Empangeni, South Africa bellequipment.com

American Mine Door – Ohio, US minedoor.com

Bell Geospace – Texas, US bellgeo.com

Belaz – Minsk, Belarus belaz.by

Brokk – Washington, US brokk.com Brookville – Pennsylvania, US brookvillecorp.com Bruker – Karlsruhe, Germany bruker.com Brunner & Lay – Arkansas, US brunnerlay.com

C Camfil APC – US camfilapc.com

Cobham Surveillance – Dorset, UK cobham.com Columbia Steel Casting Co – Oregon, US columbiasteel.com Conveyor Comp – Michigan, US conveyorcomponents.com Continental Corp – Hanover, Germany continental-corporation.com Continental Industrie – France continental-industrie.com CP Kelco – Georgia, US cpkelco.com

AMEC – International amec.com

Belshina – Bobrusik, Belarus belshinajsc.by

Carlson Software – Kentucky, US carlsonsw.com

Aceros Arequipa – Lima, Peru acerosarequipa.com

Amp Control – NSW, Australia ampcontrolgroup.com

Bel-Ray Company – New Jersey, US belray.com

Caterpillar – Peoria, US cat.com

Accenture – International accenture.com

Andritz – Graz, Austria andritz.com

BEML – Bangalore, India bemlindia.com

Cavotec Group – Handen, Sweden cavotec.com

Adalet – Ohio, US adalet.com

Ansul – Wisconsin, US ansul.com

Bentley Systems – US bentley.com

CEMCO – New Mexico, US cemcoturbo.com

Cummins – Columbus, US cummins.com

Accutron Instruments – Ontario, Canada accutroninstruments.com

Antraquip Corp – Maryland, US antraquip.net

Berco – Copparo, Italy berco.com

CESL – Vancouver, Canada cesl.com

Cyplus – Hanau, Germany cyplus.com

AECOM – California, US aecom.com

Aramine – Aix-en-Provence, France aramine.com

Bergteamet – Boliden, Sweden bergteamet.se

CH2M Hill – Colorado, US ch2m.com

Cytec – New Jersey, US cytec.com

AEL – Jo’burg, South Africa explosives.co.za AFEX Fire Suppression Systems – North Carolina, US afexsystems.com AFIMAC – International afimacglobal.com

ARANZ Geo – Christchurch, New Zealand aranzgeo.com ArrMaz – Florida, US arrmaz.com Ashland – International ashland.com

African Mining Services – Accra, Ghana amsgh.com

Australian Scientific Instruments – Australia asi-pl.com.au

Aggreko – Scotland, UK aggreko.com

Atlas Copco – International atlascopco.com

Air Products – UK airproducts.co.uk

Ausdrill – WA, Australia ausdrill.com.au

Aker Solutions – Lysaker, Norway akersolutions.com

Ausenco – Queensland, Australia ausenco.com

AkzoNobel – Amsterdam, the Netherlands akzonobel.com

Austin Powder – Ohio, US austinpowder.com

AKW Apparate & Verfahren – Hirschau, Germany akwauv.com ALC Tournai – Tournai, Belgium alc.be Alfred H Knight – Merseyside, UK ahkgroup.com Algade – Bessines sur Gartempe, France algade.com Alimak Hek – Northampton, UK alimakhek.co.uk Alloy Steel International – Australia alloysteel.net

Axis House – South Africa axishouse.co.za

Beumer Group – Germany beumergroup.com Bilfinger Water Technologies – International bilfinger.com BioSigma – Santiago, Chile biosigma.cl BioteQ Environmental Technologies – British Columbia, Canada bioteq.ca BJM Pumps – Connecticut, US bjmpumps.com Blastcrete Equipment Co – Alabama, US blastcrete.com BMT WBM – Australia bmtwbm.com.au Boart Longyear – Utah, US boartlongyear.com Bosch Rexroth – Germany boschrexroth.com

Chasm Consulting – Queensland, Australia chasm.com.au ChemGrout – Illinois, US chemgrout.com Cheminova – International cheminova.com Chevron – International chevron.com Chevron Phillips – Texas, US cpchem.com CiDRA – Connecticut, US cidra.com CITIC Heavy Industries – Luoyang, China citic-hic.com Civeo – Texas, US civeo.com CJC – Svendburg, Denmark cjc.dk Clareo Partners – Illinois, US clareopartners.com Clariant – Muttenz, Switzerland clariant.com

Crowcon – Oxfordshire, UK crowcon.com CTA – Guatemala cta-consultoria.com

D D-A Lubricant Co – Indiana, US dalube.com Dana Off Highway Systems – Toledo, US dana.com Dando Drilling – West Sussex, UK dando.co.uk Danfoss Turbocor – Florida, US turbocor.com Davis Derby – Derby, UK davisderby.com Deilmann – Dortmund, Germany deilmann-haniel.com DEM Solutions – Scotland, UK dem-solutions.com Derrick Corp – New York, US derrickcorp.com

Babcock – London, UK babcockinternational.com

BPT Components & Parts – Sudbury, Canada bpt.on.ca

Barminco – Hazelmere, WA barminco.com.au

Bradken – NSW, Australia bradken.com

Clayton Equipment – Derbyshire, UK clayton-equipment.co.uk

Baroid Industrial Drilling Products – International baroididp.com

Breaker Technology – Ontario, Canada rockbreaker.com

Cleveland Cascades – Teesside, UK clevelandcascades.co.uk

Diamantina Christensen – Lima, Peru diamantina christensen.com

BASF – Ludwigshafen, Germany basf.com

Bretby Gammatech – Derbyshire, UK bretbygammatech.com

Clover Tech – NSW, Australia clovertechnology.com.au

Diemme – Bologna, Italy diemme-spa.com

BBE – South Africa bbe.co.za

Bridgestone – International bridgestone.com

Club Car – Georgia, US clubcar.com

Bechtel – International bechtel.com

Bridon – Yorkshire, UK bridon.com

CME – Ontario, Canada cmemining.com

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Croda Intl – E. Yorkshire, UK crodamining.com

Deutz – Germany deutz.com Devico – Melhus, Norway devico.com

DMT – Essen, Germany dmt-group.com Donaldson Co – International donaldsonfilters.com

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Doosan Infracore – Heon, Korea doosaninfracore.co.kr

Eurogomma – Bergamo, Italy eurogomma.com

Gekko Systems – Victoria, Australia gekkos.com

Hayden Diamond Bit – Richmond, Canada haydenbit.com

Doppelmayr – Wolfurt, Austria doppelmayr.com

Eurotire – Chicago, US eurotire.net

GEM Systems – Ontario, Canada gemsys.ca

Hazemag – Dulmen, Germany hazemag.de

General Kinematics – Illinois, US general kinematics.com

Heath and Sherwood – Ontario, Canada heathandsherwood64.com

Geobrugg – Romanshorn, Switzerland geobrugg.com

Herbst Smag – Braunschweig, Germany herbst-smag.de

Geometrica – Texas, UK geometrica.com

Herrenknecht – Schwanau, Germany herrenknecht.com

Dosco – Nottinghamshire, UK dosco.co.uk Downer Group – Brisbane, Australia downergroup.com DRA Group – Gauteng, South Africa drainternational.com DSC Dredge – Louisiana, US dscdredge.com DSI Underground Systems – Utah, US dsiunderground.com DT Hi-Load – Forrestfield, Australia dthiload.com Dumas Mining – Ontario, Canada dumasmining.com DuPont – Australia dupont.com

Explotech – Ontario, Canada explotech.com

F FAM – Magdeburg, Germany fam.de Famur Group – Warsaw, Poland famur.com.pl FEI – Oregon, US fei.com Feluwa Pumpen – Mürlenbach, Germany feluwa.com

Dust Control Technology – US dustboss.com Dux Machinery – Quebec, Canada duxmachinery.com Dynapower – Vermont, US dynapower.com Dynaset – Ylöjärvi, Finland dynaset.com Dynatec Systems – Ontario, Canada dynatecsystems.com Dyno Nobel – Salt lake City, US dynonobel.com

GHH Fahrzeuge – Gelsenkirchen, Germany ghh-fahrzeuge.de

Horizon Conveyor Equipment – West Midlands, UK horizonconveyors.co.uk

Flottec – New Jersey, US flottec.com Flowserve – Texas, US flowserve.com FLSmidth – Salt Lake City, US flsmidth.com Fluid Systems – Los Angeles, US fluidsystems.com Fluidwell – The Netherlands fluidwell.com

Foremost – Alberta, Canada foremost.ca Fuchs Lubricants – UK fuchslubricants.com

Emerson – Missouri, US emerson.com

Fugro – Leidschendam, the Netherlands fugro.com

Equipos Mineros – Santiago, Chile equiposmineros.cl Eriez – Pennsylvania, US eriez.com

ESCO – Portland, US escocorp.com

G4S – International g4s.com

ESG Solutions – Kingston, Canada esgsolutions.com

Gardner Denver – Illinois, US gardnerdenver.com

ESRI – California, US esri.com

Gates – Colorado, US gates.com

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GKN Land Systems – Worcestershire, UK gknlandsystems.com Golder Associates – International golder.com Goodyear – Ohio, US goodyear.com Gridcom Enterprises – BC, Canada gridcom-mining.com Grindex Pumps – Haninge, Sweden grindex.com GroundProbe – Brisbane, Australia groundprobe.com GS Analysis – Arizona, US gsanalysis.com GSE – Texas, US gseworld.com

H Harris Caprock – Houston, US harriscaprock.com Hatch – Mississauga, Canada hatch.ca Hauhinco Maschinenfabrik – Sprockhövel, Germany hauhinco.de/en Haulmax – Tasmania, Australia haulmax.com

ITT – New York, US ITTmining.com

Jennmar – Pennsylvania, US jennmar.com

Honeywell – International honeywell.com

FLIR Systems – Oregon, US flir.com

IROCK Crushers – Ohio, US irockcrushers.com

JD Neuhaus – Witten, Germany jdngroup.com

GE Mining – Atlanta, US ge.com

Gjerstad Mek Industri – Norway gjerstad.com

Iowa Mold Tooling Co – Iowa, US IMT.com

Hitachi Construction Machinery – Tokyo, Japan hitachi.com Holman-Wilfley – Cornwall, UK holmanwilfley.co.uk

Flexicon – US flexicon.com

Invicta Vibrators – Lincolnshire, UK invictavibrators.co.uk

Hilti Corp – USA us.hilti.com

Getman – Michigan, US getman.com

Flexco – Illinois, US flexco.com

Intec Video Systems – Pennsylvania, US intecvideo.com

Jacobs – International jacobs.com

Fewzion – New South Wales, Australia fewzion.com.au

Fordia – Quebec, Canada fordia.com

Eickhoff – Bochum, Germany eickhoff-bochum.de

Geovariances – France geovariances.com

Instantel – Ontario, Canada instantel.com

Hexagon – Stockholm, Sweden hexagon.com

Geovia – Vancouver, Canada gemcomsoftware.com

Fluor – International fluor.com

Edmo – Queensland, Australia edmo.com.au

Geosonics – Pennsylvania, US geosonicsvibratech.com

Fenner Dunlop – International fennerdunlop.com

Fischer Consulting – Pretoria, South Africa fischercons.com

Duratray – Victoria, Australia duratray.com

Geosoft – Ontario, Canada geosoft.com

Hoss Machinery – Irving, Texas, US hossmachinery.com Humphrey Mining Products – Mid Glamorgan, Wales humphreyint.com Huntsman Corp – Utah, US huntsman.com Hy-Pro Filtration – Indiana, US hyprofiltration.com Hyundai Construction Equipment – Georgia, US hceamericas.com

I Idrotech – Borgoricco, Italy idrotech.com Iljin Steel – Suwon, South Korea iljinsteel.com IHC Merwede – Sliedrecht, the Netherlands ihcmerwede.com IMA Engineering – Espoo, Finland ima.fi Imdex – Perth, Australia imdexlimited.com Immersive Technologies – Perth, Australia immersivetechnologies.com

JH Fletcher – Huntington, US jhfletcher.com JLT Computers – Växjö, Sweden jltmobile.com John Deere Power Systems – Iowa, US deere.com Joy Global – Milwaukee, US joyglobal.com

K Kaltech Global – US kaltechrelines.com Kal Tire – Vernon, Canada kaltire.com Kennametal – South Carolina, US kennametal.com KHD Humboldt Wedag – Cologne, Germany khd.com Kidde Fire Systems – Massachusetts, US kiddefiresystems.com Kiewit – US kiewit.com Kinder & Co – Australia kinder.com.au Knight Piésold – London, UK knightpiesold.com Komatsu – Tokyo, Japan komatsu.com Köppern – Germany koeppern-international.com Kopex – Katowice, Poland kopex.com.pl

Ingersoll-Rand – Virginia, US Ingersollrand.com

Korfmann – Witten, Germany korfmann.com

Ingetrol – Santiago, Chile ingetrol.com

KPMG – International kpmg.com

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KRC Mining Consultants – Sydney, Australia krc.com.au KSB – USA ksb.com Kumera – Riihimäki, Finland kumera.com

L Laird Technologies – North America lairdtech.com Lameter – Genoa, Italy lameter.it Larsen & Toubro – Mumbai, India larsentoubro.com Legacy Building Solutions – Minnesota, US legacybuildingsolutions.com Leica Geosystems – St Gallen, Switzerland leica-geosystems.com Leighton Holdings – NSW, Australia leighton.com.au LE Lubrication Engineers – Texas, US lelubricants.com Liebherr – Bulle, Switzerland liebherr.com Linear Composites – West Yorkshire, UK linearcomposites.com LiuGong Machinery Co – China liugong.com Longwall Associates – Virginia, US longwall.com

M MacLean Engineering – Ontario, Canada macleanengineering.com Maelgwyn – Cardiff, UK maelgwyn.com Magna Tyres – Waalwijk, the Netherlands magnatyres.com

Materion – Ohio, US materion.com MAXAM – International maxam.net Maxidrill – Montreal, Canada maxidrill.com MBE Coal & Minerals Technology – Kolkata, India mcnallybharat.com McKinsey & Company – International mckinsey.com McLanahan Corp – Pennsylvania, US mclanahan.com MDM Engineering – Johannesburg, South Africa mdm-engineering.com ME Elecmetal – Arizona, US me-elecmetal.com Melco – Germiston, South Africa melco.co.za Meridian Drilling – Bath, UK meridiandrilling.com Messinger Bearings – Philadelphia, US messingerbearings.com Metal Mining Consultants – Colorado, US metalminingconsultants.com Met-Chem – Montreal, Canada met-chem.com METS – Perth, Australia metsengineering.com Metso – Helsinki, Finland metso.com Michelin – International michelin.com Micro Impact Mill – Germany micro-impact-mill.com Micromine – Perth, Australia micromine.com Mincon Rockdrills – Shannon, Ireland mincon.com

Magni – Modena, Italy magnith.com

MineARC Systems – Perth, Australia minearc.com.au

Magotteaux – Vaux-sousChèvremont, Belgium magotteaux.com

Mine Master – Zlotoryja, Poland minemaster.eu

Major Wire Industries – Candiac, Canada majorwire.cc

MineSight – Arizona, US minesight.com

Maptek – Perth, Australia maptek.com

Mine Site Technologies – International mstglobal.com

Martin Engineering – Illinois, US martin-eng.com

MinLog – International minlog.com

Master Drilling – Fochville, South Africa masterdrilling.com Master Magnets – Worcestershire, UK mastermagnets.com

Mobil Industrial Lubricants – International mobilindustrial.com Modular Mining Systems – Arizona, US modularmining.com Monadelphous – Perth, Australia monadelphous.com.au Mono Pumps – Manchester, UK mono-pumps.com

Orica – International orica.com Orway Mineral Consultants – Perth, Australia orway.com.au Otraco – WA, Australia otraco.com Outotec – Espoo, Finland outotec.com

Mount Sopris Instrument Co – Colorado, US mountsopris.com

Padley & Venables – Sheffield, UK padley-venables.com

MSA Safety – Pennsylvania, US msasafety.com

Pajari Instruments – Ontario, Canada pajari.com

MTG – Barcelona, Spain mtg.es

PANalytical – Almelo, the Netherlands panalytical.com

MTU – Friedrichshafen, Germany mtu-online.com Multotec – Johannesburg, South Africa multotec.com Murray & Roberts – Bedfordview, South Africa murrob.com MWH Global – Denver, US mwhglobal.com

Parker Hannifin – International parker.com Parnaby Cyclones – Co Durham, UK parnaby.co.uk Parsons Brinckerhoff – International pbworld.com Parsons Chain China – Hebei, China chaincom.com

Nalco – Illinois, US nalco.com

Paterson & Cooke – Cape Town, South Africa pcce.co.za

NanoSteel – Rhode Island, US nanosteelco.com

Paus – Emsbüren, Germany paus.de

Nasaco – Geneva, Switzerland nasaco.ch Nexans – International nexans.com NILOS – Hilden, Germany nilos.de Northern Light Technologies – Ontario, Canada nltinc.com Nokian Tyres – Nokia, Finland nokiantyres.com Normet – Peltsalmi, Finland normet.fi Numa – Connecticut, US numahammers.com

PBE – International pbegrp.com Pebco – Kentucky, US pebco.com Peterstow Aquapower – Ngwenya, Swaziland peterstow.com

PR Engineering – Ontario, Canada prengineering.com PressurePro – Missouri, US pressurepro.us Protan – Drammen, Norway protan.com Putzmeister – Aichtal, Germany putzmeister.de Pybar – NSW, Australia pybar.com.au

Q Qualter Hall – Barnsley, UK qualterhall.co.uk Quantec Geoscience – Ontario, Canada quantecgeoscience.com Quinn Process Equipment – Colorado, US quinnprocess.com

R RAG Mining Solutions – Germany ragms.com Rail-Veyor – Ontario, Canada railveyor.com Rbl-Rei – Paris, France rblrei-france.com Redpath – Ontario, Canada redpathmining.com Red Valve – Pennsylvania, US redvalve.com Reed Pumps – California, US reedpumps.com

Pewag – Vienna, Austria pewag.com

Reliance Barker Davies – Ontario, Canada reliancebarkerdavies.com

Pfreundt – Südlohn, Germany pfreundt.de

Rema Tip Top – Munich, Germany rema-tiptop.com

Philippi-Hagenbuch Illinois, US philsystems.com

Renewable Energy Group – Iowa, US regi.com

Phillips 66 – Texas, US phillips66.com

Renishaw – Gloucestershire, UK renishaw.com

Phillips Machine – West Virginia, US phillipsmachine.com

Oerlikon – Switzerland oerlikon.com

Phoenix – Wisconsin, US phoenixlighting.com

Oldenburg Group – Wisconsin, US oldenburggroup.com

Pintsch Bubenzer – US pintschbubenzerusa.com Pioneer Pump – Oregon, US pioneerpump.com

Minpro – Stora, Sweden minpro.com

OMZ – St Petersburg, Russia omz.ru/eng

Mitsubishi – Tokyo, Japan mitsubishicorp.com

Optech – Ontario, Canada optech.com

Position Partners – NSW, Australia positionpartners.com.au

MMD – Derbyshire, UK mmdsizers.com

Ore-Max – US ore-max.com

Powerblanket – Utah, US powerblanket.com

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Precision Geosurveys – British Columbia, Canada precisiongeosurveys.com

Reutech Mining – Stellenbosch, South Africa reutechmining.com RF Valves – Maryland, US rfvalve.com Riegl Laser Measurement Systems – Horn, Austria riegl.com Rimex – BC, Canada rimex.com Ritchie Bros – BC, Canada rbauction.com Robbins – Ohio, US therobbinscompany.com

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BUYERS’ GUIDE 2014-15

Robertson Geologging – Gwynedd, UK geologging.com Robit Rocktools – Lempäälä, Finland robit.fi Rock Australia – Perth, Australia rockengineering.com.au Rocklabs – Auckland, New Zealand rocklabs.com Rockmate – Cheshire, UK rockmate.com Rockmore International – Oregon, US rockmore-intl.com Rockwell Automation – UK rockwellautomation.com Rocvent – Ontario, Canada rocvent.com

Sensefly – Switzerland sensefly.com

Subaru – Illinois, US subarupower.com

Sepro Mineral Systems – BC, Canada seprosystems.com

Sulzer Pumps – Winterthur, Switzerland sulzerpumps.com

SGS – Geneva, Switzerland sgs.com

Superior Industries – Minnesota, US superior-ind.com

Shaft Sinkers – Isle of Man, UK shaftsinkersgroup.com Shell – International shell.com Shotcrete Technologies – Colorado, US shotcretetechnologies.com Siemag Tecberg – Haiger, Germany siemag-tecberg.com Siemens – Erlangen, Germany siemens.com/mining SIG – Lombardy, Italy sig.it

Rösler Tyre Innovators – Dortmund, Germany roesler-tyres.com Royal HaskoningDHV – Johannesburg, South Africa royalhaskoningdhv.com RPA Process – Paris, France rpaprocess.com RST Instruments – British Columbia, Canada rstinstruments.com RUC Cementation – WA, Australia ruc.com.au

T Talbert Manufacturing – Indiana, US talbertmfg.com Target Logistics – Boston, US targetlogistics.net Target Products – British Columbia, Canada Target Products.com

SLR Consulting – London, UK slrconsulting.com

Tata Steel – International tatasteel.com

SmartWorker – Queensland, Australia smartworker.com.au Smiley Monroe – Co Antrim, Northern Ireland smileymonroe.com

SNF FloMin – Texas, US flomin.com

Russell Mineral Equipment – Queensland, Australia rmeglobal.com

Synergy Engineering – British Columbia, Canada synergy-eng.com

Site Monitor Systems – UK sitemonitorsystems.com

SNC-Lavalin – International snclavalin.com

RungePincock Minarco – Australia rpmglobal.com

Svendborg Brakes – Vejstrup, Denmark svendborg-brakes.com

Snowden Group – Perth, Australia snowdengroup.com Sodexo – Paris, France sodexo.com

Tecnicas Reunidas – Madrid, Spain tecnicasreunidas.es Telestack – Co Tyrone, Northern Ireland telestack.com Telsmith – Wisconsin, US telsmith.com

Topcon Positioning Systems – California, US topconpositioning.com Toric Technologies – Alberta, Canada torictechnologies.com Trazione – Vitoria, Spain trazione.com Trencor – Ohio, US americanaugers.com Trimble – Sunnyvale, US trimble.com TRIO – Irwindale, US trioproducts.com Trolex – Cheshire, UK trolex.com Tsurumi Pump – International tsurumi.eu Twiflex – Middlesex, UK twiflex.com

U Unidata – Western Australia, Australia unidata.com.au URB Mining Logistics Consulting – South Australia, Australia urb.net.au

V Valente – Milan, Italy valente.it VCI – WA, Australia govci.com

Tenova – International tenovagroup.com

Veekmas – Tolosenmäki, Finland veekmas.fi

Terex – International terex.com

VEI – Vicenza, Italy veigroup.com

Terratec – Tasmania, Australia terratec.co

Velrada – WA, Australia velrada.com

Terra Nova Technologies – US tntinc.com

Ventyx – Denver, US ventyx.com

SAFEmine – Baar, Switzerland safe-mine.com

Spectral Evolution – Massachusetts, US spectralevolution.com

Sandvik – Sandviken, Sweden sandvik.com

SPX – New York, US spx.com

Tesmec – Grassobbio, Italy tesmec.com

Veolia Water Solutions & Technologies – North Carolina, US veoliawaterstna.com

SRK Consulting – International srk.com

Tetra Tech – Colorado, US tetratech.com

Verco – Vorbano, Italy vercosrl.it

Thermo Scientific – Massachusetts, US thermoscientific.com

Vermeer – Iowa, US vermeer.com

SBM Mineral Processing – Oberweis, Austria sbm-mp.at Schaeffer Oil – Missouri, US schaefferoil.com Schlumberger – Texas, US slb.com Schneider Electric – International schneider-electric.com

SSAB – Stockholm, Sweden ssab.se Stantec – Alberta, Canada stantec.com St Barbara – Victoria, Australia stbarbara.com.au

Schramm – Pennsylvania, US schramminc.com

Stockholm Precision Tools – Stockholm, Sweden stockholmprecisiontools. com

Schwing – Minnesota, US schwing.com

Strata – Georgia, US strataworldwide.com

SDLG – China sdlg.com

Stratalis Group – New York, US stratalisgroup.com

Seeing Machines – Canberra, Australia seeingmachines.com

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Stu Blattner – Colorado, US stublattner.com

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ThoroughTec – Durban, South Africa thoroughtec.com Thunder Creek Equipment – Iowa, US thundercreekequipment. com ThyssenKrupp Industrial Solutions – Essen, Germany thyssenkrupp-industrial -solutions.com

VR Steel – Gauteng, South Africa vrsteel.co.za

W Wardell Armstrong – Cornwall, UK wardell-armstrong.com Wärtsilä – Helsinki, Finland wartsila.com Wassara – Stockholm, Sweden wassara.com Weba Chute Systems and Solutions – Germiston, South Africa webachutes.com Weber – Rouhling, France weber-mining.com Weir Minerals – Wisconsin, US weirminerals.com Wenco – BC, Canada wencomine.com WesTech Engineering – Utah, US westech-inc.com Western Star – Oregon, US westernstartrucks.com Westpro Machinery – British Columbia, Canada westpromachinery.com Whittle Consulting – Victoria, Australia whittleconsulting.com.au Wilfley – Colorado, US wilfley.com Wirtgen – Windhagen, Germany wirtgen.de WorleyParsons – Australia worley parsons.com Wormald – Australia wormald.com.au WS Tyler – Ontario, Canada wstyler.com Wunderlich & Gladston – Colorado, US wunderlichgladston.com

VersaDrill – Quebec, Canada versadrillcanada.com

XT – Queensland, Australia xt-t.com

Vertech – Arizona, US vertech.com

Xylem – US xyleminc.com

Victaulic – Tennessee, US victaulic.com Victor – Newcastle on Tyne, UK victor.co.uk Vik Ørsta – Ørsta, Norway vikorsta.no

Thyssen Schachtbau – The Ruhr, Germany thyssen-schachtbau.de

Voith Turbo – Crailsheim, Germany voith.com

Titan International – Illinois, US titan-intl.com

Volvo – Gothenburg, Sweden volvo.com

Y Yokohama – Tokyo, Japan yokohamatire.com

Z Zest WEG – Johannesburg, South Africa zest.co.za Zitron – Asturias, Spain zitron.com

December 2014 13/11/2014 16:57

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Annual subscription – UK and Europe £95.00 (160.00 euros) Rest of the world US$170.00. Additional current copies are available to subscribers at £12 (US$21) each

Head of production Tim Peters Senior sub editor Jim Adlam Sub editor Woody Phillips Sales director Richard Dolan T +44 (0)20 7216 6086 E richard.dolan@miningmagazine.com Advertising production Sharon Evans T +44 (0)20 7216 6075 E sharon.evans@aspermontmedia.com

Advertisement offices Head office Contact: Richard Dolan Aspermont Media, 120 Old Broad Street, London EC2N 1AR, UK T +44 (0)20 7216 6060 F +44 (0)20 7216 6050 E richard.dolan@aspermontmedia.com

Mining Magazine USPS 005-829 is published 10 times each year with combined issues in Jan / Feb and Jul / Aug – by Aspermont Media, 120 Old Broad Street, London EC2N 1AR, UK. Printed by Stephens & George Magazines, Merthyr Tydfil, UK The 2014 US annual subscription price is US$170. Airfreight and mailing in the US by Agent named Air Business, c/o Worldnet Shipping USA Inc, 149-35 177th Street, Jamaica, New York NY11434 Periodicals postage paid at Jamaica NY 11431 US Postmaster: send address changes to Mining Magazine, Air Business Ltd, c/o Worldnet Shipping USA Inc, 149-35 177th Street, Jamaica, New York NY11434

Germany & Austria Contact: Gunter Schneider GSM International, Postfach 20 21 06, D-41552 Kaast, Germany. T +49 2131 511801 E info@gsm-international.eu

Subscription records are maintained at Aspermont Media Ltd, Chancery Exchange, 10 Furnival Street, London EC4A 1YH, United Kingdom Aspermont Media, publisher and owner of Mining Magazine (‘the publisher’) and each of its directors, officers, employees, advisers and agents and related entities do not make any warranty whatsoever as to the accuracy or reliability of any information, estimates, opinions, conclusions or recommendations contained in this publication and, to the maximum extent permitted by law, the publisher disclaims all liability and responsibility for any direct or indirect loss or damage which may be suffered by any person or entity through relying on anything contained in, or omitted from, this publication whether as a result of negligence on the part of the publisher or not. Reliance should not be placed on the contents of this magazine in making a commercial or other decision and all persons are advised to seek independent professional advice in this regard.

Asia, Australia, Europe, South Africa, South America plus Canada, Ireland, UK & US Contact: Tom Peck Aspermont Media, 120 Old Broad Street, London EC2N 1AR, UK T +44 (0)20 7216 6085 F +44 (0)20 7216 6050 E tom.peck@aspermontmedia.com North America, Australia Contact: Chad Dorn 8727 E. 35th Avenue, Denver, CO 80238, US T +1 720 855 3996 E cdorn@miningadvertising.com

Subscriptions and circulation Subscription enquiries T +44 (0)20 8955 7050 E subscriptions@miningmagazine.com Aspermont Media Ltd, Chancery Exchange, 10 Furnival Street, London EC4A 1YH, United Kingdom Managing editor Richard Roberts

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